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LICENSE DATA
The following method of num bering vehicles and 5th Digit 6th Digit 7th Digit
their engines will be used on the 1970 models. Engine Ident. Year
The starting vehicle num ber will be as follows: Displacement 1970 Assembly Plant
Dart Models B—198 Cu. In. N—383 Cu. In. H.P. A—Lynch Road
Dart Series LL41A9B—100001 C—225 Cu. In. R—426 Cu. In. Hemi B—Hamtramck
E—Special 6 T—440 Cu. In. Std. C—Jefferson
Challenger Models G—318 Cu. In. U—440Cu. In. H.P. D—Belvidere
Challenger Series JH24COB- -10001 Std. V—440 3 x2 E—Los Angeles
H—340 Cu. In. Z—Special 8 F—Newark
VEHICLE NUMBER LOCATION Std. G—St. Louis
L—383 H—New Stanton
The vehicle num ber (serial number) is located on a P—Wyoming
(Export)
plate which is attached to the left top side of the dash R—Windsor
panel pad and visible through the windshield (Fig. 1).
VEHICLE NUMBERS
All vehicle numbers contain 13 digits. The vehicle BODY NUMBER LOCATION: The body num ber is
num ber is a code which tells the make of car (1st stamped on a plate which is attached to the left front
digit), model of car (2nd digit), body style (3rd and wheel house and will show trim code, paint code,
4th digit), engine displacement (5th digit), model body type and schedule date. (Fig. 2)
year (6th digit), assembly plant (7th digit) and vehicle
serial num ber (last six digits).
1st Digit 2nd Digit 3rd & 4th Digit
Car Make Model Body Style TIRE PRESSURE: A decal showing the recommended
L—Dart E—Economy tire pressure is located on the body pillar at the rea r
L— Low 23—2 Door Hardtop of the left front door opening. (“B” Post). (Refer to
M— Medium 27—Convertible Group 22 Specifications.)
J— Challenger H— High 29—2 Door Special
P— Premium 41—4 Door Sedan
K— Police
T—Taxi
S— Special
O— Super Stock
□ □ □ □ □ □ □ □ □ □ □ □ □
o & CHRYSLER
C O R P O R A T IO N
o
VEHICLE IDENTIFICATION NUMBER PLATE
INSTRUMENT PANEL LOCATED NR464 NU467
Fig. I —Vehicle N u m b er Location Fig. 2—Body N um ber Location
All information, illustrations and specifications in this manual are based on information available at the
time of publication. We reserve the right to make changes at any tim e without notice.
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CAPACITY CONVERSION TABLE
Gallons__________ 0______________1______________ 2 3 4 5
Liters Liters Liters Liters Liters Liters
0 00.0000 3.7853 7.5707 11.3560 15.1413 18.9267
10 37.8533 41.6387 45.4240 49.2093 52.9947 56.7800
20 75.7066 79.4920 83.2773 87.0626 90.8480 94.6333
30 113.5600 117.3453 121.1306 124.9160 128.7013 132.4866
40 151.4133 155.1986 158.9840 162.7693 166.5546 170.3400
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o GROUP 0
LUBRICATION AND MAINTENANCE
CONTENTS
Page Page
ALTERNATOR ................................................ 10 HYDRAULIC BRAKE SYSTEM .................... 8
BATTERY........................................................ 10 LUBRICATION AND MAINTENANCE
BODY MAINTENANCE.................................. 23 SCHEDULE
B R A K E S . . . ............................... . ..................... 8 Normal S ervice.......................................... ....... 3
CAPACITIES ........ ................................. ... . . 4 Trailer Towing and Severe Service.......... ....... 4
CARBURETOR AIR CLEANERS.................. 16 LUBRICATION AND MAINTENANCE
CARBURETOR CHOKE VALVE SHAFT . . . . 17 GUIDE Dart and Challenger.................... ....... 2
CERTIFIED CAR CARE ................................ 1 MANIFOLD HEAT CONTROL VALVES . . . . 16
CHASSIS LUBRICATION ............................ 2 MATERIALS ADDED TO ENGINE OILS . . . 11
CLASSIFICATION OF LUBRICANTS ........ 1 PARKING BRAKE M EC HA NISM ................ 8
CLUTCH LINKAGE.................... ................... 8 PARTS REQUIRING NO LUBRICATION . . . 26
COOLING SYSTEM ........................................ 9 PROPELLER SHAFT AND UNIVERSAL
CRANKCASE VENTILATION SYSTEMS . . . . 12 JO IN TS........................................................ 18
DISTRIBUTOR................................................ 10 REAR A X L E .................................................... 6
ENGINE OIL FILTE R .................................... 12 SPEEDOMETER CABLE................................ 23
ENGINE OIL— SELECTION OF .................. 10 STEERING GEAR .......................................... 19
ENGINE PERFORMANCE DIAGNOSIS . . . . 15 SUMMARY OF LUBRICATION AND
FREQUENCY OF OIL CHANGES ................ 11 MAINTENANCE SERVICES.................. ........... 1
FRONT WHEEL BEARINGS ........................ 22 ACCELERATOR LINKAGE COMPONENTS . 25
FUEL FILTER ................................................ 18 T IR E S ............................ ................................. 22
HEADLIGHTS ................................ ............ 10 TRANSMISSION (Automatic)...................... 20
HOISTING ...................................................... 2 TRANSMISSION (M anual)............................ 19
HOOD LOCKS, RELEASE MECHANISM WINDSHIELD WIPER BLADES.................. 10
AND SAFETY C ATCH ................................ 23
SUMMARY OF LUBRICATION AND Oils, lubricants and greases are classified and graded
MAINTENANCE SERVICES according to standards recommended by the Society
of Automotive Engineers (SAE), the American Petro
Maintenance and lubrication service recommenda leum Institute (API) and the National Lubricating
tions for Chrysler Corporation-built Dodge vehicles Grease Institute (NLGI).
have been compiled to provide maximum protection
for the car owner’s investment against all reasonable Engine O il
types of driving conditions. The SAE grade num ber indicates the viscosity of
Since these conditions vary with the individual car engine oils, for example, SAE 30, which is a single
owner’s driving habits, the area in which the car is grade oil. Engine oils are also identified by a dual
operated and the type of service to which the car is number, for example, SAE 10W-30, which indicates a
subjected, it is necessary to prescribe lubrication and m ultigrade oil.
maintenance service on a tim e frequency as well as The API classification system defines oil perform
mileage interval basis. ance in terms of engine usage. Only engine oils desig-
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LUBRICATION AND MAINTENANCE GUIDE
DART AND CHALLENGER
LIFT POINTS
• COOLING SYSTEM
DRAINS
PY607
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LUBRICATION AND MAINTENANCE SCHEDULE
Service
Service Cheek Inspect
Interval Item Page Replace Fluid and/or Lubricate Service
Level Clean
Every 2 Months Battery 10 X
Cooling System 9 X
3 Months or 4,000 Miles, Engine Crankcase Oil 10 X
whichever occurs first
Every Engine Manifold Heat Control Valve 16 X
Oil Change
Power Steering Fluid 19 X
Carburetor Air Filter—Paper** 16 X
Every Second Oil Change Engine Oil Filter 12 X
Tire Rotation 22 X 1
Carburetor Air Filter—Oil Bath 17 X
Carburetor Air Filter—Paper 16 X
Crankcase Ventilation System 12 X X
Carburetor Choke Shaft 17 X X
Crankcase Inlet Air Cleaner 12 X X
Transmission 20 X
Every 6 Months Rear Axle 6 X
Steerin'* Gear {Manual> 19 X
0 Linkage 6 X
Suspension Ball Joints 2 X
Universal Joints 18 X
Brake Master Cylinder 8 X
Brake Hoses 8 X
Headlight Aiming 10 X
Hood Latch and Safety Catch 23 X X
Every 12 Months Cooling System 9 X
Crankcase Ventilator Valve 12 X
Carburetor Air Filter—Oil Bath 17 X
Carburetor Ail Filter—Paper** 16 X
Accelerator Components 25 X
Every 12 Months or Engine Performance Diagnosis 15 X
12,000 Miles, which- Brakes* 8 X
ever occurs first Front Wheel Bearing Lubricant 22 X
Every 24 Months or Carburetor Air Filter 16 X
24,000 Miles, which- Fuel Filter 18 X
ever occurs first Brake Pedal Linkage Bushings 8 X X
Every 36 Months or Front Suspension Ball Joints 2 X
36,000 Miles, which- Steering Tie Rod Ends 6 X
ever occurs first Clutch torque Shaft Bearings 8 X
Distributor 10 X
Body Mechanisms 23 X
Clutch Drive Lugs, Release
Bearing Sleeve, Fork Fingers
When Necessary and Pivot 9 X
Column-Mounted Gearshift Linkage 20 X
Floor-Mounted Gearshift Controls 20 X
Parking Brake Mechanism 8 X
Speedometer Cable 23 X
Points That Should Not Be Lubricated 26
*n_i__i:_:___
‘ Replace linings:x__ ____ _
if necessary. “ .....- .......
**Vehicles equipped with Fresh Air Induction System
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LUBRICATION AND MAINTENANCE SCHEDULE
TRAILER TOWING PACKAGE AND SEVERE SERVICE
Service Check Inspect
Interval Item Page Replace Fluid and/or Lubricate Service
Level Clean
Every 3 Months or Transmission 19 X
4,000 Miles, which Rear Axle 6 X
ever occurs first Universal Joints 18 X
After first 36 Months ‘ Transmission Fluid 21 X
or 36,000 Miles, which ‘Automatic Transmission Filter 21 X
ever occurs first *Automatic Transmission Bands 21 X
Rear Axle Lubricant 6 X
**Universal Joints 18 X
*And every 12 months or 12,000 miles thereafter
**Police and Taxi
CAPACITIES
U.S. Imperial
Measure Measure
CRANKCASE
Challenger Models only when
equipped with 426 Hemi, 440
HP or 440 Three 2BBL engines. 6 qts. 5 qts.
All other engines add 1 qt.
(3/4 Imperial qt.) when filter
is replaced. 4 qts. 3-1/4 qts.
COOLING SYSTEM
Dart (198,225 Cu. In. Engine) 13 qts.** 10-3/4 qts.**
Challenger (225 Cu. In. Engine) 13 qts.** 10-3/4 qts.**
Dart (318 Cu. In. Engine) 16 qts.** 13-1/4 qts.**
Challenger (318 Cu. In. Engine) 16 qts.*** 13-1/4 qts.***
Dart (340 Cu. In. Engine) 15 qts. 12-1/2 qts.
Challenger (340 Cu. In. Engine) 15-1/2 qts. 13 qts.
(383 Cu. In. Engine) 14-1/2 qts* 12 qts.*
(440 HP or 3-2BBL and 426 Hemi) 17 qts. 14-1/4 qts.
For Maximum Cooling or Air Conditioning
Add 1/2 qt.
** Add 1 qt.
*** Add 1-1/2 qts.
TRANSMISSION (Torqueflite)
198,226 and 318 Cu. In. Engines 17 pts. 14-1/4 pts.
340,383 (4 BBL) Cu. In. Engines 16.3 pts. 13-1/2 pts.
383 (2 BBL) and 440 Cu. In. Engines 19 pts. 15-3/4 pts.
426 Hemi 16.8 pts. 14 pts.
TRANSMISSION (Manual)
3 Speed Model A-903 (6 Cyl. Dart) 6-1/2 pts. 5-1/2 pts.
3 Speed Model A-230 4-3/4 pts. 4 pts.
4 Speed Model A-833 (Dart) 7 pts. 5-3/4 pts.
(Challenger) 7-1/2 pts. 6-1/4 pts.
REAR AXLE
7-1/4" Axle 2.0 pts. 1.3/4 pts.
8- 3/4" Axle 4.4 pts. 3.5 pts.
9-3/4" Axle 5.5 pts. 4.5 pts.
FUEL TANK
All Models 18 gals. 15 gals.
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NN191B
-CHALLENGER 110"-
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Fig. 6—Steering Linkage (Dart Models)
nently lubricated with a special lubricant at the
factory.
The ball joints should be inspected every six
Fig. 4—Upper a n d Lower Ball Joints (Dart Models) months, or whenever vehicle is serviced for other
reasons, for damage to seals which can result in loss
perm it thorough inspection. Replace damaged seals
of lubricant. Clean accumulated dirt and lubricant
or joints immediately to prevent contamination of
from outside surfaces of seals to perm it thorough in
lubricant or damage to parts. Lubricate ball joints, if
spection.
necessary.
Replace damaged seals or joints immediately to
BALL JOINTS ARE DESIGNED TO OPERATE
prevent contamination of the lubricant or failure of
WITH SOME FREE PLAY. REPLACEMENT SHOULD
parts. Lubricate ball joints, if necessary.
BE MADE ONLY WHEN FREE PLAY EXCEEDS
Relubrication of tie rod ball joints is required every
THE SPECIFICATIONS SHOWN IN "FRONT SUS
36 months or 36,000 miles, whichever occurs first.
PENSION", Group 2.
When lubricating steering linkage ball joints, use
Relubrication is required every 36 months or 36,000
only the special long-life chassis greases such as
miles, whichever occurs first.
Multi-Mileage Lubricant P art Number 2525035 or
W hen lubricating control arm ball joints, use only
equivalent. Remove threaded plug from each ball
the special long-life chassis greases such as Multi-
joint and temporarily install lubrication fittings. In
Mileage Lubricant, P art Num ber 2525035 or equiva
ject lubricant until it flows freely from seal bleed
lent. Remove threaded plug from each ball joint and
area at top or base of seal. Stop when seal begins to
temporarily install lubrication fittings. Inject lubri
balloon. Remove fittings and reinstall threaded plugs.
cant until it flows freely from seal bleed areas at base
CAUTION: High pressure lubrication equipment may
of seal. Stop when seal begins to balloon. Remove
be used if time is allowed for grease to bleed from
fittings and reinstall threaded plugs.
seal base.
CAUTION: If high pressure lubrication equipment
is used, stop filling when lubricant begins to flow REAR AXLE
freely from bleed area at base or at top of seal, or if
seal begins to balloon. Stand ard a n d Sure-Grip
The lubricant installed in the rear axle at time of
Steering Linkage Ball Joints assembly is a high quality product and regularly
The four tie rod end ball joints and the steering scheduled changes of the lubricant are not recom
gear arm ball joint (Figs. 6 and 7) are semi-perma- mended in vehicles where operation is classified as
normal passenger car service.
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■
Wm
p :
FILLER HO LE
j
ND78
i %w*fc ; <
Fig. 8—Removing Rear A x le Lubricant
( 7 - 1 /4 Inch A xle)
The only exceptions, however, would be where the Fig. 9 —Removing Rear A xle Lubricant
lubricant has become contaminated with w ater or to ( 8 - 3 /4 Inch A xle)
provide the correct viscosity grade for the anticipated '--"•S * "O L E
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T railer Towing Service If necessary, add fluid to bring level to within 1/4
For vehicles equipped for trailer towing service, the inch of the top of the reservoir. With disc brakes the
axle fluid level should be checked every 3 months or fluid level can be expected to fall as the brake pads
4.000 miles, whichever occurs first. The lubricant wear. No noticeable drop in level should occur in a
should be drained and axle refilled with the specified car equipped entirely with drum brakes. Low fluid
lubricant, every 36,000 miles. level may have been caused by a leak and a checkup
If the axle is submerged in water, such as on a boat may be needed.
launching ramp where water can enter the axle vent, Only brake fluid conforming to SAE J1703 (70R3
and contamination is suspected or evident, replace the type) should be used. Chrysler Parts Brake Fluid or
lubricant immediately to avoid early axle failure. equivalent, is recommended to provide best brake
performance. Use of a brake fluid that may have a
BRAKES lower initial boiling point, such as fluid identified as
70R1 or unidentified as to specification, may result
The brakes on all models equipped with drum in sudden brake failure during hard prolonged brak
brakes, except heavy duty, are equipped with a self- ing.
adjusting mechanism which makes it unnecessary to
perform m ajor brake adjustments. Brake Hoses
Inspect brake linings for wear every 12 months or Inspect brake hoses for cracking abrasion, cuts or
12.000 miles, whichever occurs first. Replace linings, tears in the outer covering. Examine all connections
if necessary. At this time, lubricate contact areas of for fluid leakage. Correct leakage and replace hose
brake shoe supports, on models with drum brakes, where cover damage exposes the fabric braid.
with a very thin film of high-temperature lubricant
such as Chrysler Support Plate Lubricant available PARKING BRAKE MECHANISM
under Part Num ber 2932524 or equivalent.
To perform this service, first remove the brake Dart Models use a hand-operated parking brake
shoes. Next, clean the contact surfaces on the shoes lever (Fig. 12). Challenger models use a foot-operated
and supports by sanding lightly with fine sandpaper. lever (Fig. 13).
Then, carefully apply lubricant. Pivot points should be lubricated, as required, to
On models equipped with disc brakes, inspect the maintain ease of operation. Apply a film of smooth,
discs, calipers and lining every 12 months or 12,000 white body hardware lubricant conforming to NLGI
miles, whichever occurs first, as outlined under grade 1. Lubriplate, Part Number 1064768, or equiva
“Brakes”, Group 5. lent, is recommended for this purpose.
When the hand lever can be pulled to more than
HYDRAULIC BRAKE SYSTEM four inches, or the foot pedal depressed more than
four and one half inches, the brake cable should be
Every 6 m onths the fluid level in the m aster cylin adjusted. For adjusting procedure, refer to “Parking
der should be checked. (Fig. 11). Before removing the Brakes,” Group 5.
master cylinder cover wipe it clean to prevent dirt
and other foreign matter from dropping into the CLUTCH LINKAGE
master cylinder.
Clutch Torque Shaft Bearings
Inspect clutch torque shaft bearings (Fig. 14) for
...
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fork pads on sleeve, contact areas of fork fingers,
pivot contact area of fork and fork pivot (Fig. 14).
COOLING SYSTEM
The cooling system of all cars is protected against
corrosion and freezing as they leave the factory. A
perm anent type anti-freeze is added to provide pro
tection to —20°F. Higher percentages of anti-freeze
must be added w here tem peratures below —20 °F. are
anticipated.
Vehicles equipped with 383 cubic inch engines with
2 barrel carburetors and 440 cubic inch standard en
gines are equipped with 195 degree therm ostats. All
other engines are equipped with 190 degree therm o
stats and only perm anent type anti-freeze should be
Fig. 13—Foot O p e rated Parking Brake used. Alcohol base anti-freeze products should not
(Challenger Models) be used because of there low boiling point.
Inspect coolant level every two months and refill
wear and relubricate every 36 months or 36,000 miles,
as necessary. Once a year, preferably in the fall, the
whichever occurs first. To perform this service, refer
cooling system should be drained and refilled. This
to “Clutch,” Group 6. After removing torque shaft
draining and refilling procedure, however, need not
assembly, disassemble and thoroughly clean all parts
be perform ed until the fall following the vehicle’s
in a suitable solvent and inspect for wear. Damaged
first full year of operation. Drain V-8 engine cooling
bearings and/or ball studs should be replaced.
system by removing drain plugs in sides of cylinder
When reassembling shaft, coat inside surfaces at
block and opening drain cock in lower radiator tank.
ends of shaft, inside and outside surfaces of bearings
On 6-cylinder engines, remove the single drain plug
and ball studs with Multi-Mileage Lubricant, P art
in right side of engine and open drain cock in lower
Number 2525035, or equivalent.
radiator tank. Discard old solutions.
Flush the system thoroughly with water. If there
Clutch Drive Lugs, Release Bearing Sleeve, is an indication that the system contains a consider
Release Fork and Fork Pivot able amount of sediment, use a reliable cooling system
W henever effort required to depress the clutch ped
cleaner to loosen the sediment. Rinse thoroughly to
al becomes excessive, or when servicing clutch torque
remove deposits.
shaft bearings, lubricate drive lugs, sleeve, fork and
At this time, check water pump belt tension and
pivot (Fig. 14). To gain access to this area, first re check hose connections for tightness.
move inspection plate at bottom of clutch housing. In areas where protection from freezing is required,
CAUTION: Care must be taken to avoid getting lubri refill cooling system with clean, soft water and a suit
cant on clutch disc and/or pressure plate. able high quality, perm anent type anti-freeze, in suf
Fill cavity in sleeve with Multi-Mileage Lubricant, ficient quantity to provide full protection for the low
Part Number 2525035, or equivalent. Apply a film of est anticipated tem perature, but never less than 40
same lubricant to clutch drive lugs, clutch release percent of the cooling system capacity to ensure ade
quate protection against corrosion. If it becomes
BEARING necessary to add coolant during the cold weather
season, be sure the system contains sufficient anti
freeze to provide protection at least to —20 degrees
F. A suitable high quality perm anent type anti-freeze
is available under P art Number 2932531 or equiva
lent, should be used.
When vehicle is operated in areas where protection
from freezing is not required, and vehicle is not
equipped with air conditioning, refill cooling system
with clean, soft w ater and add a high quality corrosion
inhibitor, such as Chrysler Rust Resistor, P art Num
ber 2421778 or equivalent. This need not be done
until the first yearly service.
Fig. 14—Clutch Torque Shaft Bearings and Linkage If the vehicle is equipped with air conditioning,
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the cooling system must contain anti-freeze all year Lubricant, Part Number 1473595, or equivalent. At
round. This is necessary because in the reheat-cycle this time, apply 1 drop of light engine oil to felt wick
system used on all vehicles, except Dart models, cold, under rotor.
refrigerated air passes through the heater core. CAUTION: Avoid over-oiling and applying an exces
Anti-freeze is necessary to prevent coolant in the sive amount of cam lubricant to prevent lubricants
heater core from freezing in hot weather when the from getting on breaker contacts.
air conditioner is being used. For complete informa
tion refer to “Air Conditioning”, Group 24. HEADLIGHTS
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O il Viscosity Recommendations gine oils for most types of driving when MS quality
Multigrades oils are used.
SAE 20W-40 Where temperatures are consistently In some instances, such as infrequent operation or
SAE 10W-40 above +32°F. short trips only, and during break-in after a m ajor
or overhaul, addition of special materials containing
SAE 10W-30 anti-rust and anti-scuff additives is beneficial. A prod
SAE 10W-30 Suitable for year long operation in uct suitable for this purpose is Engine Oil Supple
or many parts of the U.S.; may be used
SAE 10W-40 where temperatures occasionally ment, P art Number 1879406 or equivalent.
drop as low as —10°F.
SAE 5W-30 Recommended where minimum tem- FREQUENCY OF ENGINE OIL CHANGES
or peratures are consistently below
SAE 5W-20 +10°F. The by-products of combustion, such as unburned
Single Grades fuel, condensation and carbon deposits, in addition to
SAE 30 Where temperatures are consistently dust and other abrasive materials, tend to contaminate
above +32°F. engine oil. If perm itted to rem ain in the crankcase for
SAE 10W Where temperatures range between too great a period of time, the contaminants reduce
+ 32°F. and -10°F. the lubricating qualities of the oil causing excessive
IMPORTANT: If the vehicle is to be used for maxi wear which can m aterially affect the operating effi
mum performance service (very high speeds or very ciency of the engine.
rapid acceleration), the engine requires heavier than To provide maximum protection to engine parts, it
normal lubricating oil. This is due to the high speeds, is recommended under normal operating conditions,
loads, and tem perature of moving parts developed that engine oil be drained and replenished with new
in these engines during this type of operation. oil of the proper viscosity and API classification, every
FOR BEST PROTECTION OF THE ENGINE UN three (3) months or 4,000 miles, whichever occurs
DER THESE CONDITIONS, THE HEAVIEST ENGINE first.
OIL OF MS QUALITY SHOULD BE USED THAT When draining the old oil, it is recommended that
WILL PERMIT SATISFACTORY COLD STARTING. the engine be at normal operating tem perature, as the
SAE 30 AND 40 ARE RECOMMENDED. MULTI warmed oil will drain more readily and carry with it
VISCOSITY OILS SAE 20W-40 AND 20W-50 MAY such foreign m atter which might otherwise cling to
ALSO BE USED. the sides of the crankcase and the various moving
When outside tem peratures are consistently be parts.
low 30°F, SAE 10W-30 or SAE 10W-40 are recom A greater degree of contamination of the engine
mended for ease in cold starting. However, even in oil takes place when the vehicle is operated under
cold weather, these grades should not be used if the adverse conditions, such as frequent driving in dusty
vehicle is driven in competition or other forms of areas, short trips, stop-and-go driving and w here long
maximum operation. periods of idling are experienced. For oil change
frequencies under these operating conditions, refer to
MATERIALS ADDED TO ENGINE OILS the recommendations in the paragraphs under Severe
Operating Conditions and Taxi and Police Operation.
It is not necessary to add any other products to en-
During Break-In
Cars should be driven moderately during the first
300 miles. Speeds up to 50 to 60 mph are desirable.
While cruising, brief full-throttle accelerations con
tribute to a good break-in. Wide-open throttle ac
celerations in low gear can be detrim ental and should
be avoided for at least 500 miles.
The oil installed in the engine at the factory is a
high quality lubricant, classified “For Service MS,”
and should be retained until the first regularly
scheduled three-month or 4,000 mile oil change,
whichever occurs first. If it becomes necessary to add
oil during this initial period, an oil with the “For
NK575
Service MS” classification and of the proper viscosity
grade should be used. Nondetergent or straight min
Fig. 16—Shaded A re a Cover Region W h e re M inim um
Temperatures M a y Be Consistently Below
eral oils must never be used.
+ IO°F During Some W in te r Months Oil level should be checked during each stop for
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Fig. 17—Engine O il Filter (6 Cylinder Engines) Fig. 19—Engine O il Filter (340 Cu. In. Engine)
gasoline. Oil should be added only when level on oil filtering of engine oil for maximum engine protection.
level indicator is at or below “ADD OIL” mark. The filter should be replaced every second oil
Frequently, a new engine will consume some oil change. Since filters vary widely in quality, it is rec
during its first few thousand miles of operation. This ommended that a Chrysler Corporation Engine Oil
should be considered as a norm al part of the break-in Filter, or equivalent, be used for replacem ent to
and not be interpreted as an indication of difficulty. assure most efficient service.
Severe O p eratin g Conditions CRANKCASE VENTILATION SYSTEM
Severe operating conditions, such as frequent driv
ing on dusty roads, or in sandy geographic areas, or All models are equipped with a closed crankcase
unusually short trip driving in cold weather may rea ventilating system (Figs. 21, 22, 23, 24, 25 or 26).
sonably require oil changes more frequently than This system consists of a crankcase ventilator valve
every three months. Under these conditions, consult mounted on the cylinder head cover, and a car
and follow the advice of any Chrysler Motors Corpora buretor with a hose from its base connected to the
tion Authorized Dealer’s Service Manager. ventilator valve.
A closed crankcase inlet air cleaner with a hose
T a x i and Police O p eratio n connecting it to the carburetor air cleaner housing
Severe service such as taxi and city police driving, provides the air inlet for the system.
which is principally short trip operation, including The crankcase inlet air cleaner is also provided
frequent and prolonged idling, requires oil changes with inlet fittings for a bowl vent hose and vent line
more frequently on a regular schedule. For this type hose (eight cylinder engines), or vent line only (six
of service, it is recommended that engine oil be cylinder engines), where evaporative control system
changed and the crankcase ventilation system serv (ECS) is required.
iced every two months, not to exceed 2,000 miles.
Replace filter every second oil change. VENTILATION SYSTEM OPERATION
The ventilating system operates by manifold vac
ENGINE OIL FILTER
uum. Air is drawn from the carburetor air cleaner
All engines are equipped with full-flow, throwaway through the air cleaner hose and crankcase inlet air
oil filters (Figs. 17, 18, 19 or 20) to provide efficient
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DISTRIBUTOR HOLLY VENTILATOR VALVE
CARBURETOR DISTRIBUTOR VACUUM HOSE
VACUUM ,
HOSE Y/
VENTILATOR BOWL VEN t X . ^ C VENTILATOR^
VALVE HOSE TO FUEL PUMP \ K x HOSF I fi
AIR CLEANER
REFERENCE
HOLLY
CARBURETOR
AIR CLEANER
HOSE
DISTRIBUTOR
AIR CLEANER VACUUM
HOSE BOWL VENT HOSE HOSE
LINE
ECS (IF SO EQUIPPED)
CRANKCASE INLET! PY774
AIR CLEANER
Fig. 2 3 —Crankcase V entilation System (383 Cu. In,
Bngine w ith 2 B arrel C arbm etion)
FWD
DISTRIBUTOR Qj
Servicing Frequencies
ECS VENT LINE VACUUM HOSE / y Proper maintenance of the crankcase ventilation
(IF SO EQUIPPED)
PY772 system is required to keep the system clean and
maintain good engine performance and durability.
Fig. 2 1 —Crankcase Ventilation System
(6 Cylinder Models) Periodic servicing is required to remove combustion
products from the ventilator valve, hoses, carburetor
cleaner into the crankcase, (where ECS systems are passages and crankcase inlet air cleaner.
used the fuel tank and float bowl vapors are also Every six months the system must be tested for
drawn into the crankcase through the crankcase inlet proper operation and cleaned if necessary. This in
air cleaner), circulated through the engine and drawn cludes inspecting the operation of the valve, checking
out through the ventilator valve, pass through the the hoses and carburetor passages for deposits and
ventilator valve hose and passage in the carburetor cleaning the crankcase inlet air cleaner and car
throttle body, into the combustion chamber, are buretor air cleaner.
burnt and expelled with the exhaust gasses.
VENTILATOR VALVE
AIR CLEANER VENTILATOR VALVE
VENTILATOR VALVE HOSE
v_
referenceV ' t
VENTILATORVALVE HOSE
AIR CLEANER
REFERENCE
DISTRIBUTOR
VACUUM HOSE
" W>"
► BOWL VENT HOSE
VENT LINE ECS \
VENTILATOR
(IF SO EQUIPPED)
VALVE HOSE
BOWL VENT HOSE
AIR CLEANER -CARTER
ECS (IF SO EQUIPPED)
HOSE ECS CARBURETOR
VENT LINE
(IF SO EQUIPPED) BOWL VENT HOSE
VENT LINE
CRANKCASE INLET AIR CLEANER
ECS (IF SO EQUIPPED)
PY773 PY775
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VENTILATOR VALVE VENTILATOR VALVE
HOSE
AIR CLEANER
REFERENCE
AID
CLEANER
HOSE
ECS (IF SO
EQUIPPED)
CRANKCASE
INLET AIR CLEANER PY776 Fig. 2 7 —Checking Vacuum at V e n tilato r Valve Inlet
Fig. 2 5 —Crankcase Ventilation System 440 Cu. In. will be heard as air passes through the valve,
Engine w ith three 2 BBL. and a strong vacuum should be felt when a
The crankcase ventilator valve must be replaced finger is placed over the valve inlet (Fig. 27).
with a new one every year. The carburetor air cleaner 2. Reinstall the ventilator valve, then remove
filter elem ent must be replaced every year on High the crankcase inlet air cleaner. Loosely hold
Perform ance Vehicles equipped with “Fresh Air In a piece of stiff paper, such as parts tag, over
duction System”, and every 2 years for vehicles the opening in the rocker cover (Fig. 28).
equipped with standard air cleaner.
After allowing about a minute for the crank
If the car is used extensively for short trips with
case pressure to reduce, the paper should be
frequent idling, the ventilation system may require
sucked against the opening in the rocker
servicing more frequently. cover with a noticeable force.
Inspection a n d Service Procedure: NOTE: For 6 cylinder 198 and 225 CID en
a. With engine idling— gines, it will be necessary to clamp, off or plug
1. Remove ventilator valve from rocker cover. the carburetor bowl vent to fuel pump hose
If the valve is not plugged, a hissing noise (Fig. 21) in order to perform this check.
LINES A
ra fARisTAG1- . ^ .
^ECS (IF SO
v EQUIPPED)
AIR CLEANER v"'
HOSE CRANKCASE INLET AIR CLEANER
PY777
Fig* 2 6 —Crankcase V e n tilatio n System Fig • 28—Checking Vacuum a t Crankcase Inlet Mir
(426 Cu. In. Hem i) Cleaner O pening
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necessary. Remove the crankcase inlet air cleaner
and wash it thoroughly in kerosene, or similar sol
vent. Lubricate or wet the filter, by inverting the
crankcase inlet air cleaner and filling with SAE-30
engine oil. Position the air cleaner to allow excess
oil to drain thoroughly through the vent nipple lo
cated on the top of the air cleaner.
Hoses
Clean hoses by immersing in C arburetor Cleaner,
Part Num ber 2933500 or equivalent, followed by
drying with compressed air. Hoses should not remain
in solvent more than one-half hour.
, PY780 |
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■lU.
SHAFT
COUNTERWEIGHT
NR87
PY781
UMZi+.i Figo 32—M a n ifo ld Heat C ontrol V alve
(34 0 Cu. In . Engine)
Fig. 3 0 —M an ifo ld H ea t Control Valve (6 Cylinder)
idle rough after the above services have been per
formed, adjust the valve lash to specifications. See
“Engine” Group 9 for lash specifications. Idle ad
justm ents of the carburetor should be rechecked
after setting lash.
COUNTERWEIGHT
\ -t
VALVE
SHAFT
/
r*
ill!
M l
■HI■
COUNTERWEIGHT
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COVER
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1 v:j.
t -
HHGBGB i i m
v\\\ ;.\3r. FUEL FILTER
\; a ;
"4l
•’ Y320;
HHBbHSHEh
X?3lV I
NK580 NN240
Fig. 4 0 —Fuel Filter (3 1 8 , 3 4 0 Cu. In. Engines) Fig. 4 3 —Rear Universal Joint
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Severe Service Requirements
When the vehicle is operated under the severe
conditions as in police and taxi service the uni
versal joints should be disassembled, cleaned, and
relubricated every 36,000 miles or 3 years. The
units should be disassembled, cleaned, and relubri
cated with Multipurpose Grease, NLGI Grade 2,
E.P., such as Multi-Mileage Lubricant part num ber
2525035, or equivalent.
:...i £ . ND83B.
M anual
The lubricant installed in the steering gear at time Fig. 4 5 —Pow er Steering Pump Reservoir
of assembly is a high quality product and regularly (1.0 6 Pump)
scheduled changes are not required. fluid is checked when hot, the fluid level will be ap
Every six months, remove plug in steering gear proximately 1/2 to 1 inch below the top of the filler
housing (Fig. 44) and check lubricant level. Lubri neck.
cant should cover worm gear. At room tem perature (approximately 70°F) the
If lubricant is below prescribed level, replenish fluid level should be above the joint of the filler
with Multi-Purpose Gear Oil SAE 90, as defined by neck and reservoir (between 1-1/2 to 2 inches below
MIL-L-2105B. This is suitable for all tem peratures. the top of the filler neck).
Special Sure-Grip Lubricant, P art Number 2585318 If necessary, add fluid to restore these levels.
and Chrysler Hypoid Lubricant, part num ber Units equipped with a dipstick should be filled to
2933565, or their equivalent, are lubricants of this the required indicated oil level. Only petroleum
type and are recommended. fluids specially formulated for minimum effect on
CAUTION: When filling, do not use a pressure gun as the rubber hoses should be used. Power Steering
high pressure may damage the seals. Fluid part num ber 2084329, or its equivalent, is
recommended.
Pow er Steering CAUTION: Before removing the reservoir cover,
At every engine crankcase oil change, the power wipe outside of cover and case so that no dirt can
steering fluid level should be checked at the power fall into the reservoir.
steering pump reservoir (Figs. 45 or 46). When the
TRANSMISSION (Manual)
Three-Speed
The lubricant installed in the transmission at the
time of assembly is a high quality product and regu
larly scheduled changes are not required for vehicles
FILLER CAP. OVAL SHAPED
FILLER TUBE
NP168
Fig. 4 6 —Pow er Steering Pump Reservoir (.94 Pump)
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Multi-Purpose Gear Lubricant SAE 140 in warm
weather. No other lubricants should be used.
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W H H W ***' NU90
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(b) Frequent towing of trailers.
(c) Continuous operation at higher than normal
loading.
For transmission fluid draining and refilling serv
ice, filter replacem ent and band adjustm ent proce
dures, see “TorqueFlite Transmission” , Group 21.
Fig. 5 1—Front W heel Bearing Lubrication Fig. 5 3 —Tire Rotation D ia g ram —5 Tires
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LEFT FRONT RIGHT FRONT
NP158
Fig. 5 4 —Tire Rotation D ia gram —4 Tires
A decal showing the recommended tire pressure is
located on the body pillar at the rear of the left front
door opening (“B” post). Refer to “Tires”, Group 22,
for additional information. sary to maintain ease of operation and to provide pro
tection against rust and wear.
SPEEDOMETER CABLE Prior to applying any lubricant, wipe the parts
To service a noisy speedom eter cable, disconnect clean to remove dust and grit. A fter lubricating parts,
housing at speedom eter head. Remove shaft and clean remove excess oil or lubricant.
it thoroughly. Apply a very thin film of speedometer Relubricate mechanisms as outlined in the follow
cable lubricant on the shaft. Such a lubricant is avail ing paragraphs. Where Lubriplate is specified, use a
able under P art Number 1243632, Speedometer Cable smooth, white body hardware lubricant conforming to
Lubricant, or equivalent. Wipe excess lubricant from NLGI grade 1. Chrysler Parts Lubriplate, Part Num
the top one-foot of the shaft and from the ferrule. ber 1064768 or equivalent, is a suitable lubricant.
CAUTION: Excessive lubricant may cause malfunc Where Door Ease Lubricant is specified, use a stain
tion of the speedometer. less wax type lubricant such as Chrysler Parts Door
Ease, Part Number 774512 or equivalent.
HOOD LOCK, RELEASE MECHANISM AND
SAFETY CATCH Lock Cylinders
Lubrication of the hood latch release mechanisms When necessary, apply a thin film of Lubriplate or
and safety catch is of vital importance and should be equivalent, directly to key. Insert key into lock and
inspected, cleaned and lubricated every 6 months to actuate several times. Wipe excess lubricant from
assure ease of operation and freedom from binding.
»PIVOT AREA
STRIKER
All Models
Apply Multi-Purpose Lubricant NLGI grade 2 EP,
such as Multi-Mileage Lubricant, P art Number
2525035 or equivalent, sparingly to all sliding con
tact areas of latch and release lever, and ends of
hood lock release links, if so equipped. (Figs. 55 or
56).
W ork lubricant into the lock mechanism until all
frictional surfaces are covered. Also apply a film of
the same lubricant to the pivot contact areas of the
HOOD LOCK
safety catch. SUPPORT
BODY MAINTENANCE
Body and other operating mechanisms should be PY816
inspected, and relubricated as needed. This is neces Fig. 5 6 —Hood Lock Lubrication (Challenger Models)
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PIN ENDS
TORSION
SPRING
CONTACT
POINTS
Door Hinges
On all hinges, apply engine oil to hinge pin ends
(Figs. 59 or 60).
On lower hinges, in addition, apply engine oil to
torsion spring contact points and all pivot contact
points. Fig. 6 0 —Door Hinge Lubrication (Challenger Models)
RATCHET
V .
|H E ~ j
PIVOT . / -
AND
LINK
CONTACT DOOR LOCK
AREAS
PY814 1STRIKER BOLT NP328A
Fig. 5 8 —Hood Hinge Lubrication (Challenger Models) Fig. 6 1 —Door Lock Ratchet and Striker Bolt
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Lubriplate or equivalent, to all pivot and sliding con Fig. 6 4 —Deck Lid Hinge Lubrication
tact areas. (Challenger Models)
Door Remote Control Link (All Models) Deck Lid Latch (All Models)
Apply Lubriplate or equivalent, sparingly, to all
If necessary to inspect operation of and relubricate
pivot and sliding contact surfaces (Fig. 62).
these parts, remove door trim panel. Apply a film of
Lubriplate or equivalent, to all link end pivots.
Deck Lid Hinges (All Models)
Apply Lubriplate or equivalent, sparingly, to all
W in d o w Regulator ,Glass Lower Frame (All torsion bar support bearing areas and interior sur
Models) face of torsion bar slide (Figs. 63 and 64).
If necessary to inspect operation of and lubricate
Also, apply same lubricant sparingly, to contact
these parts, remove door or quarter trim panel.
surface of hinge cam slide.
Apply Lubriplate or equivalent, sparingly, to regu
lator sector gear teeth, assist spring and pivots. Apply
ACCELERATOR LINKAGE COMPONENTS
same lubricant sparingly, to glass lower frame roller
slide tracks and roller and bracket assembly pivot Every 12 months the accelerator linkage compo
points. nents should be lubricated with Multi-Purpose Grease,
NLGI grade 2 EP, such as Multi-Mileage Lubricant,
Part Number 2525035 or equivalent, as described in
NP177C
Fig. 6 6 —Throttle Linkage Lubrication
Fig. 6 3 —Deck Lid Hinge Lubrication (Dart Models) (6 Cylinder Models)
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DASH PANEL
CABLE ASSEMBLY CABLE BALL END
INSULATOR
PLUG
WASHER
i ANTI-RATTLE SPRING
v J i ^ ^ ' ( S H O W N INSTALLED) PEDAL
VIEW IN DIRECTION
PLUG OF ARROW A
ANTI-RATTLE SPRING
PEDAL
SPRING
PIVOT PIN
I
PIVOT PIN SPRING
CHALLENGER
DART PAD
VIEW IN DIRECTION OF ARROW A
VIEW IN DIRECTION OF ARROW B (SHOWN SPRING INSTALLED)
SHOWING SPRING INSTALLED PY740
BELLCRANK PIN-UPPER
(AUTOMATIC TRANSMISSION)
BELLCRANK PIN-LOWER
(AUTOMATIC TRANSMISSION)
PY737
Fig. 6 7 —Throttle Linkage Lubrication (Dart Models Fig. 69—Throttle Linkage—Challenger Models (318
w ith 3 1 8 Cu. In. Engines) or 3 8 3 Cu. In. Engines w ith 2 Barrel Carburetors)
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BELLCRANK PIVOT POINT-UPPER
(AUTOMATIC TRANSMISSION ONLY)
ACCELERATOR
SHAFT
BELLCRANK PIVOT
POINT-LOWER
(AUTOMATIC
TRANSMISSION ONLY)
NP4I3B
% 70—T hrottle Linkage Lubrication (Challenger Models w ith 383 o r 440 Cm In *Engines
w ith 4 B arrel C arburetors)
PY739
Fig. 71—T h rottle Linkage Lubrication (Models w ith 426 Hem i & 440 Three 2 BBL Carburetors)
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BELLCRANK PIVOT POINT—UPPER CABLE
(AUTOMATIC TRANSMISSION ONLY)
BALL END
— it
Fig. 6 8 —Throttle Linkage Lubrication (Dart, Challenger Models with 3 4 0 Cu. In. Engines)
operating characteristics, and some because lubri
cants will cause component failures. In any event,
rubber bushings should not be lubricated, not only
because lubricants will cause rubber to fail, but also
will destroy their necessary friction characteristics.
The following parts should not be lubricated.
All Rubber Bushings Drive Belts
A lternator Bearings Fan Belt Idler Pulley
Automatic Transmission Rear Springs
Controls and Linkage Rear Wheel Bearings
C arburetor Air Cleaner Starting Motor Bushings
(Paper Element Type) Throttle Linkage Ball
Clutch Pedal Push Joints
Rod Ends Throttle Control Cable
Clutch Adjustm ent Upper and Lower Control
Rod Ends Arm Bushings
Clutch Release Bearing W ater Pump Bearings
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O GROUP 1
ACCESSORIES
CONTENTS
Page Page
DEFOGGER ................................................... 6 RADIO AND A N T E N N A ................................ 1
ELECTRIC CLOCK ........................................ 1 SPEED CONTROL .. .................... ............... 6
ELECTRIC CLOCK
GENERAL INFORMATION
The electric clocks have a self-regulating mecha to the correct time. Push in the time set shaft.
nism for automatically correcting time gain or lag (2) If the clock runs slow, pull the tim e set shaft
when the hands are reset to the correct time. Clocks out and reset the hands in a “clockwise” direction to
should be reset as follows: the correct time. Push in the time set shaft.
(1) If the clock runs fast pull the time set shaft out (3) Repeat steps (1) a n d /o r (2) frequently for sev
and reset the hands in a “counterclockwise” direction eral days until the correct rate of time is achieved.
SERVICE DIAGNOSIS
__________ Condition _______ ______ Possible Cause____________________________ Correction__________
CLOCK DOES NOT (a) Wire l oose or off terminal. (a) Install connector on terminal.
OPERATE (b) Internal short. (b) Repair or replace the clock as neces-
sary.
(c) Faulty ground. (c) Tighten clock retaining screws on
cluster housing and/or cluster.
SERVICE PROCEDURES
CLOCK Rem oval—Challenger (Rallye Cluster)
(1) Disconnect battery ground cable.
Rem oval—Challenger (Standard Cluster) (2) Remove radio. See “Radio Removal”.
(1) Disconnect battery ground cable.
(3) Remove clock reset from rear of clock.
(2) Remove radio. See “Radio Removal”.
(4) Disconnect clock lead.
(3) Disconnect lead. Remove the two clock m ount
(5) Remove clock from rear of cluster (three
ing screws.
screws).
(4) Carefully remove clock assembly from panel.
Installation Installation
(1) Position clock assembly in panel. (1) Position clock assembly in panel, install three
(2) Install mounting screws and connect electrical mounting screws and electrical lead.
lead. (2) Install clock reset at rear of clock.
(3) Install radio. See “Radio Installation”. (3) Install radio. See “Radio Installation”.
(4) Connect battery ground cable and check clock (4) Connect battery ground cable and check clock
operation. operation.
Page Page
Antennas ..................................................................... 5 Radio ........................................................................... ..... 5
Antenna Trim m ing...................................................... 4 Radio S p e a k e r ........................................................... ......5
General Information .................................................. 2 Service Diagnosis ........................................................... 3
Fader Control .............................................................. 2 Stereo Multiplex......................................................... ..... 6
Interference Elimination ........................................... 4 Stereo Speakers ............................................................... 5
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GENERAL INFORMATION
PY716
Fig. 1—Radio Interference Capacitor to Cluster Fig. 2—Radio Interference Capacitor to Cluster
Installation (Standard Cluster) Installation (Rallye Cluster)
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COIL
PRIMARY BATTERY POST
-A N TE N N A
MAST
MOUNTING
BRACKET
UPPER ADAPTER,
MOUNTING
I0 L J
/ ^
CAPACITOR KP 4 3 9 B GASKET--------- - NR490A
SERVICE DIAGNOSIS
Condition Possible Cause Correction
RADIO INOPERATIVE (a) Blown fuse. (a) Replace fuse, check for short or open
in wiring harness.
(b) Antenna open or shorted. (b) Test with an auxiliary antenna with
lead-in plugged into the receiver set
and test antenna lead outside of car.
If radio plays with test antenna, use
original antenna and check antenna
mostly for shorts to ground while
rocking antenna slightly. Unplug an
tenna lead from radio and use ohm-
meter to check from center contact of
antenna to outside of case. If reading
on ohmmeter is less than 500,000
ohms, replace antenna,
(c) Receiver or Speaker connections (c) Test the voltage at the fuse and tight
loose or faulty. en all connections. With speaker con
trol tuned to either stop, rotate con
trol to other stop. If radio plays, re
place faulty speaker. If radio does not
play, remove radio receiver for servic
ing.
RADIO RECEPTION (a) Unbalanced antenna trimmer. (a) Carefully adjust the antenna trimmer.
WEAK See “Service Procedures”.
(b) Shorted antenna lead-in. (b) Turn on radio and wiggle antenna. If
speaker static is heard, check for an
tenna mounting tightness. If speaker
static is still heard after tightening,
disassemble antenna and test for
faulty insulators or presence of mois
ture. Make an ohmmeter check step
(b) under “Radio Inoperative. If no
static is heard, test for faulty or loose
receiver or antenna connections at
receiver. Also check antenna lead-in
at antenna. If antenna checks OK, re
move radio receiver for servicing.
RADIO NOISY (a) Outside electrical interferences. (a) Move the car or eliminate interfer
ence.
(b) Insufficient or faulty interference sup- (b) Install effective capacitor in ignition
pression. system or at fuel gauge on instrument
panel.
(c) Faulty antenna. (c) Turn on radio and wiggle antenna
lead and listen for speaker static. If
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static is heard, disassemble antenna
and check for faulty insulators or
presence of moisture. Make an ohm
meter test, Step (b) “Radio Inopera
tive”. if no static is heard, check for
a loose or faulty capacitor. If capaci
tor is OK, remove antenna plug from
radio receiver and bump receiver with
heel of hand. If no static is heard,
start engine, turn on headlights and
slowly, accelerate engine speed. If a
whining noise is heard, turn off head
lights and if whining noise is still
present, tune in AM to a weak station
at left end of dial. Run antenna up
and down; if a loud whirring noise is
present in the radio unit, the antenna
cable connection is loose and should
be tightened to 20 to 40 inch pounds.
Check alternator for burned out di
odes, and voltage regulator setting.
If O.K. remove radio receiver for
servicing.
RADIO RECEPTION (a) Speaker voice coil leads rubbing on (a) Install an auxiliary speaker and com-
DISTORTED speaker cone. pare. Replace if improved.
(b) Torn speaker cone. (b) Replace the speaker.
(c) Faulty radio. (c) Send radio to authorized radio service
station for repair.
(d) Foreign material in speaker. (d) Clean or replace speaker.
(e) Torn cover. (e) Replace speaker.
INTERMITTENT (a) Broken or shorted antenna lead-in (a) Test with a substitute antenna and re
RECEPTION wire. place if necessary.
(b) Faulty radio. (b) Send radio to authorized radio service
station for repair.
SERVICE PROCEDURES
INTERFERENCE ELIMINATION whenever a radio is being installed after repair, or if
verification of trim m er adjustment is desired, proceed
Three capacitors are used to suppress engine inter as follows:
ference. The alternator is equipped with an internal (1) Extend antenna to 40 inches.
capacitor integral with the output stud. A second (2) Manually tune radio to noise or a weak signal
capacitor is m ounted on the back of the instrum ent between 1400 and 1600 K.C.
cluster with a self tapping screw (Fig. 1 and 2). The (3) Increase radio volume.
lead wire of this capacitor is connected to the input (4) Using a short screwdriver under instrum ent
term inal of the voltage lim iter (center term inal of fuel panel locate antenna trim m er in bottom right hand
gauge). A third capacitor is installed on the ignition corner of radio chassis.
coil with the lead connected to the positive prim ary (5) Adjust antenna trim m er by carefully turning it
term inal of the coil (Fig. 3). Radio resistance type back and forth until position is found that gives a
wires in the high tension circuit of the ignition sys peak response in volume. Maximum output indicates
tem complete the interference suppression. proper point of antenna trim m er adjustment.
If radio noises are evident, be sure the capacitor
lead wires are making good contact on their respec Push Buttons
tive term inals and are securely mounted. Faulty or (1) Extend the radio antenna fully.
deteriorated spark plug wires should be replaced. (2) Turn the radio ON and allow a warm-up period
of 15 minutes.
ANTENNA TRIMMING (3) Unlock the push button by pulling it out toward
the rear of the vehicle.
All radios are trim m ed at the factory and should (4) Using the manual tuning control, tune in the
require no fu rth er trim m er adjustm ent. However, desired station.
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(4) Install inner fender shield and attaching screws.
(5) Install antenna mast into antenna body until
sleeve bottoms on antenna body.
(6) Reroute antenna lead through hole in dash
panel and behind fresh air duct hose to radio receiver
(Fig. 6).
RADIO
CAUTION: Do not operate the radio with speaker
leads detached since damage to the transistors may;
result.
Rem oval
(1) Disconnect battery ground cable at battery.
(2) Remove channel selector shaft and knobs (if so
equipped).
(3) Remove the two radio mounting bolts at lower
fig . S—Antenna (Disassembled) front of radio.
(5) Relock the push button by pushing it all the (4) Disconnect electrical leads and antenna lead at
way in toward the front of the vehicle. radio.
(5) While holding radio in position, remove rear
ANTENNAS support bracket and remove radio.
Removal Installation
(1) Unplug antenna lead from radio receiver. (1) Carefully enter radio into position on the in
(2) Remove antenna by unscrewing mast from an strum ent panel.
tenna body (Fig. 4). (2) Install two mounting screws at lower front of
(3) Remove capnut (Figs. 5 and 6). radio and rear support bracket and connect electrical
(4) Remove the screws attaching inner fender leads and anenna lead.
shield and remove shield. (3) Install channel selector shaft and knobs.
(5) Remove the antenna snap-on fender adapter (4) Connect battery ground cable at battery and
and gasket. test operation of radio and controls.
(6) From under fender remove the mounting col
lar and antenna lead. RADIO SPEAKER
Rem oval
Installation (1) From top of instrum ent, remove the four speak
(1) Assemble mounting collar to antenna body (Fig. er grille mounting screws and remove grille.
4). (2) Remove the two speaker mounting screws.
(2) Enter antenna body from underneath fender (3) Lift speaker from instrum ent panel and discon
and insert through fender mounting hole. nect leads.
(3) Install gasket, adapter and capnut. Tighten
capnut to 155 inch pounds plus or minus 25 inch Installation
pounds with Tool C-4085, (Fig. 5). (1) Connect leads, position speaker in panel and
install screws.
(2) Position grille on panel, install mounting screws
and check operation of speaker.
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Installation Installation
(1) Position grille on speaker and install the two (1) Connect electrical leads and position crossover
mounting screws. under panel.
(2) Connect electrical leads. Position assembly on (2) Install mounting screws.
panel and install the two mounting screws. (3) Connect battery ground cable and check cross
(3) Check operation. over operation.
REAR WINDOW DEFOGGER
STEREO SPEAKER CONTROL
To service the blower motor or fan, the assembly
Rem oval—Challenger m ust be removed from the shelf panel from inside the
(1) Disconnect battery ground cable. luggage compartment.
(2) Remove knob, mounting nut and bezel from A fter disconnecting the outlet hose and wire con
panel. nector, remove the mounting screws from the m ount
(3) Remove radio. See “Radio Removal”. Discon ing clips and remove the assembly from the vehicle
nect control connector and remove control from bezel. for service.
Disassembly
Installation (1) Remove the blower motor adapter plate to
(1) Position control in bezel and connect electrical
housing mounting screws and withdraw motor and
connector.
fan assembly from housing.
(2) Install radio. See “Radio Installation”. Install
(2) Loosen fan set screw on fan hub and slide fan
bezel mounting nut and knob.
from motor shaft.
(3) Connect battery ground cable and check con
(3) Remove the motor adapter late mounting nuts
trol operation.
and separate motor from plate.
STEREO CROSSOVER Assembly
(1) Position adapter plate on motor studs and in
Rem oval—Challenger stall the mounting nuts.
(1) Disconnect battery ground cable. (2) Install fan on motor shaft and insert assembly
(2) Open glove box. Remove crossover mounting in housing. Check fan to housing clearance and ad
screws. just if necessary.
(3) From under panel disconnect leads and remove (3) Install the blower motor adapter plate to hous
crossover. ing mounting screws.
GENERAL INFORMATION
The speed control system (Fig. 1) is electrically memory and engaging system. Remove foot from ac
actuated and vacuum operated. The turn signal lever celerator. Speed will be maintained at this level.
on the steering column incorporates a CONTROL Turning the control ring from “OFF” to “ON” while
RING which when rotated, turns the system “OFF”, the vehicle is in motion establishes memory without
“ON” or “RESUME SPEED”. A SPEED SET button is system engagement at that speed.
located in the end of the lever. This device is designed TO DISENGAGE: Normal brake application or a soft
to operate at speeds above approximately 30 M.P.H. tap on the brake pedal will disengage control units
WARNING: The use of "Speed Control" is not recom without erasing speed memory. Fully rotating the
mended when driving conditions do not permit main control ring in the “OFF” direction or turning the
taining a constant speed, such as heavy traffic or on ignition “OFF” also disengages the system and in
roads that are winding, icy, snow-covered or slippery. addition erases the speed memory.
TO ENGAGE: Rotate control ring to the “ON” posi TO RESUME: Rotate control ring fully in the “RE
tion, attain desired speed then momentarily depress SUME” direction. Vehicle will resume to the previous
and release “SPEED SET” button establishing speed ly memorized speed.
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INTAKE INTAKE MANIFOLD
MANIFOLD VACUUM FITTING VACUUM
CONNECTOR
CABLE TO SPEEDOMETER
CABLE
SERVO TO TRANSMISSION
HOSE
(WITH POWER BRAKE)
SERVICE DIAGNOSIS
Condition Possible Cause Correction
NO SPEED CONTROL (a) Control ring in “OFF" position. (a) Turn ring to “ON” position.
WHEN BUTTON PRESSED. (b) Fuse blown. (b) Replace fuse.
(c) Vacuum leak. (c) Check vacuum lines.
(d) Speed control throttle cable discon (d) Disconnect and adjust control cable.
nected. See “Tests and Adjustments."
(e) Improper stop lamp and speed con (e) Adjust stop lamp and speed control
trol switch adjustment. switch. See “Tests and Adjustments.”
(f) Faulty electrical circuit. (f) See "Electrical Tests”.
NO RESUME WHEN (a) Insufficient rotation of control ring. (a) Rotate ring fully toward “Resume”.
CONTROL RING IS (b) Faulty electrical circuit (b) See "Electrical Tests”.
ROTATED.
NO SYSTEM DISEN (a) Improper adjustment of stop lamp (a) Adjust switch. See “Tests and Adjust-
GAGEMENT WHEN BRAKE and speed control switch, ments”.
PEDAL IS DEPRESSED. (b) Faulty electrical circuit. (b) See “Electrical Tests”.
SPEED CONTROL (a) Faulty electrical circuit. (a) See “Electrical Tests”.
ENGAGES WITHOUT
ACTUATING SWITCH.
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CARBURETOR DOES NOT (a) Speed control thrott l e cable m a l ad (a) Adjust speed control throttle cable.
RETURN TO NORMAL justed. See “Tests and Adjustments".
IDLE. (b) Speed control throttle cable kinked (b) Repair or replace cable.
or damaged.
(c) Standard throttle linkage faulty. (c) Repair or replace linkage.
SPEEDOMETER NOISE, (a) Speedometer cable kinked or dam (a) Align cables to avoid sharp bends or
EXCESSIVE NEEDLE aged. replace cable.
WAIVER OR ERRATIC (b) Cable core bent or too long. (b) Replace core.
SERVO LOCK-IN (c) Cable ferrule nut loose at speed (c) Tighten cable ferrule nuts.
PERFORMANCE. ometer head, transmission or speed
control servo.
(d) No lubricant on speedometer cable (d) Lubricate cables
core.
(e) Noisy speedometer head assembly. (e) Repair or replace the speedometer as
necessary.
SPEED SETTING AFTER (a) Improper adjustment of speed control (a) Adjust speed control throttle cable.
LOCK-IN, TOO HIGH OR throttle cable.
TOO LOW. (b) Vacuum leak. (b) Check all vacuum hose connections.
(c) Improper speed control servo lock-in (c) See “Servo Lock-in Screw Adjust
adjustment. ment”.
UNIT DISENGAGES (a) Improper adjustment of stop lamp (a) Adjust as necessary. See “Tests and
ON ROUGH ROAD. and speed control. Adjustments”.
RESUME SPEED IS (a) Faulty low speed inhibit switch in (a) Replace servo unit.
POSSIBLE BELOW servo unit.
20 M.P.H. (b) Faulty electrical circuit. (b) See “Electrical Tests”.
SPEED CONTROL (a) Faulty electrical circuit. (a) See “Electrical Tests”.
ENGAGES WHEN ENGINE
IS STARTED, OR DOES
NOT DISENGAGE WHEN
BRAKE PEDAL IS
DEPRESSED.
SERVICE PROCEDURES
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CAUTION: This adjustment must not exceed two (b) Connect a twelve volt positive source to the
turns in either direction or damage to unit may occur. black wire term inal in the speed control harness con
nector (male).
Speed Control Throttle Cable Adjustment (c) With the lever rotary switch in the ON position,
Optimum servo perform ance is obtained with a attach one lead of a test lamp to the connector
given amount of free play in the throttle control yellow wire, other lead to a good ground; test lamp
cable. To obtain proper free play, insert a 1/16 inch should light and should go off when the Speed Set
diam eter pin between forward end of slot in cable button is depressed.
end and carburetor linkage pin. Use hair pin clip re (d) Move the test lamp lead to the connector blue
moved from carburetor linkage pin as a gauge (Fig. 3). wire; test lamp should light and should go off when
With choke in full open position and carburetor at the rotary switch is turned to the OFF position.
curb idle, pull back on cable (toward dash panel) with (e) With the rotary switch in the ON position,
out moving carburetor linkage until all free play is move test lamp lead to the connector white wire; test
removed. Tighten cable clamp bolt to 45 inch-pounds, lamp should light by either depressing the Speed Set
remove 1/16 inch diam eter pin and install hair pin button or by rotating the rotary switch fully toward
clip if removed. the “Resume” position.
(f) Reconnect speed control lever harness connec
Stop Lamp a nd Speed Control Switch tor to harness connector.
Adjustment (3) Stop lamp and speed control switch test:
Refer to Figure (4), for proper switch adjustm ent as (a) Disconnect the double connector at the switch
follows: pigtail and connect a twelve volt source to either te r
(1) Loosen switch bracket. minal and connect a test lamp from other term inal to
(2) Insert proper spacer gauge between brake push a good ground: test lamp should light when brake
rod and switch with pedal in free position. pedal is in the normal position and should go off
(3) Push switch bracket assembly toward brake when the brake pedal is depressed to a maximum of
push rod until plunger is fully depressed and switch approximately one half inch after proper adjustm ent
body contacts spacer. as outlined under “Stop Lamp and Speed Control
(4) Retighten switch bracket bolt to 100 inch- Switch A djustm ent”.
pounds. (b) Remove test lamp and reconnect pigtail con
(5) Remove spacer. nector to harness conductor.
(4) Servo unit tests:
(a) Locking coil test; turn ignition switch to the
Electrical Tests:
Accessory or ON position and rotate the speed control
Refer to “Speed Control Wiring Diagram”, (Fig. 5).
rotary switch to the ON position.
It is suggested that the electrical tests be made in the
(b) Momentarily disconnecting and connecting the
following sequence:
double connector at the servo term inals should pro
(1) Check accessory fuse for continuity.
duce a clicking sound in the servo. Replace the servo
(2) Speed control switch (turn signal lever) test.
if no clicking sound is heard.
(a) Disconnect the four wire electrical connector
(c) Holding coil and Low Speed switch test; with
at the steering column.
out removing either connector at servo, place a test
lamp probe to the black (with tracer) wire terminal of
servo, other probe to a good ground. Block front
wheels; raise rear wheels and drive rear wheels to
35 miles per hour; with speed control lever rotary
switch in the ON position and ignition switch in the
ON position, depress and release Speed Set button.
The speed should increase above 35 miles per hour
and the test lamp should rem ain ON until the brake
pedal is depressed to disengage the system and test
light should go off.
(d) Remove test lamp.
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1-10
SPEED
CONTROL
SYSTEM
Fig. 4 —Stop Lamp and Speed Control Switch Adaptation—Challenger o
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STOP LAMP A ND PUSH BUTTON
SPEED BRAKE SWITCH ACTUATOR
!8DBL r ~ T ~ X30B-20DBL-
TURN SIGNAL
a
18DBL Lj™ X30A-20DBL - AND SPEED
CONTROL SWITCH
LEVER
TO ACCESSORY
FEED (SEE ACCESSORY
WIRING DIAGRAM)
GROMMET
\ -X30B-20DBL-
— X32-20BK -
—X33-20BK—
RTI
O
o
-22D B L -
— 22BK -
— 22W* ’
— X31-18Y*- — 22Y -
K DASH LINE
-X33-20BK*-
X31-18Y*
*X30A-20DBL ■
c OLOR CODE
BK BLACK
Lq J DBL DARK BLUE
Y YELLOW
-TO SPEED CONTROL UNIT- # WITH TRACER
(ENGINE COMPARTMENT)
PY246
Fig. 5 —S p e e d C ontrol W i r in g D ia g r a m
from servo to expose cable retaining clip (Fig. 6) and (3) Disconnect cable at servo (Fig. 6) and remove
remove clip attaching cable to servo diaphragm pin. cable assembly.
(2) Disconnect speedom eter and transmission drive
cables at the servo housing. Installation
(3) Disconnect vacuum hoses at servo housing (Fig. (1) Locate cable through routing brackets on dash
7) and electrical connectors. panel and on brake booster studs, (so equipped).
(4) Remove servo from mounting bracket (2 self (2) Connect cable at servo housing.
locking nuts). (3) Route cable through retaining clamp and con
nect at carburetor lost motion link lever pin.
Installation (4) Adjust cable free play as described under
(1) Position servo on mounting bracket studs and “Speed Control Throttle Control Cable Adjustm ent”.
install attaching nuts. Tighten to 95 inch-pounds.
(2) Install vacuum hose and clamp. Make sure the Speed Control Switch (Turn Signal Lever)
hose clamp is locked securely. Rem oval
(3) Connect speedometer and transmission drive (1) Disconnect battery negative term inal at battery
cables at servo.
(4) With choke in full open position, align throttle
cable to servo pin and install retaining clip.
(5) Install cable cover on servo studs and install
attaching nuts. Tighten nuts securely.
(6) Install electrical connectors at servo.
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Fig. 7 —Removing or Installing Servo Hose
negative post and speed control connector at lower
end of column.
(2) Remove steering wheel. See Group 19 “Steer Fig. 8—Removing W ire Terminals w ith Tool C-4135
ing”. In s ta lla tio n
(3) Remove turn signal switch and lever attaching (1) Make a guide wire and thread the harness
screw. through the opening in column. Make guide wire long
(4) Remove steering column cover plate and sup enough so that it can be reached at bottom of column
port steering column while clamp is removed to pre before harness is attached to the upper hook. When
vent column from sagging. harness has been pulled through, install term inal
(5) Remove wire harness trough to facilitate reach clips into switch connector and connect to harness
ing the lower end of speed control switch lead wires connector (be sure wires are connected to proper
(Figs. 4 through 5) and remove wires and term inals cavity (Fig. 4).
from connector with Wire Harness Tool C-4135 (Fig. (2) Install harness trough, steering column cover
8). plate and column support clamp.
CAUTION: Check co lor coding of wires to insure they (3) Install turn signal lever (speed control lever
are installed in the proper connector at reassembly. switch) and turn signal switch attaching screw.
See Figures 4 and 5. (4) Install steering wheel, steering column cover
(6) Tape terminals, then turn direction indicator plate. See Group 19 “Steering” .
lever sideways and pull lever up and wires out (5) Connect battery negative term inal at battery
through opening between column and tube. negative post.
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o- GROUP 2
GENERAL INFORMATION
The torsion bar rear anchors are integral with the Service replacement ball joints are equipped with a
engine rear support member and the front anchors, "Knock-Off" type lubrication fitting. After lubrica
which are part of the lower control arms, provide the tion, knock off that portion of the fitting over which
m eans of adjusting vehicle front height. The lower the lubrication gun was installed. A ball check is in
ball joints are integral with the steering arms. Com stalled in the remaining portion of the fitting to pre
pression type lower balljoints are used on all Models. vent foreign materials from passing through.
All ball joints and the torsion bars at the front of The tie rod ends are serviced separately and
the rear anchors are effectively sealed against road should be inspected for damage at all oil change
splash by tightly fitted balloon type flexible seals. The periods.
ball joints and tie rod ends are of the semi-permanent Caster and camber adjustm ents are controlled by
lubricated type. cams on the upper control arm pivot bolts.
When re-lubrication of the ball joints and tie rod All front suspension points that contain rubber
end assemblies is required remove the plugs and should be tightened while the suspension is at the
install a lubrication fitting. A fter the lubrication is specified height (see specifications), with full weight
completed reinstall the plugs. of vehicle on its wheels.
Lower ball joints, steering arm assemblies, should Rubber bushings should not be lubricated at any
not be replaced for looseness if the axial end play (Up time.
and Down movement) is under .070 inch. Looseness ON MODELS EQUIPPED WITH DISC BRAKES, RE
of this nature is not detrimental and will not affect FER TO GROUP 5 FOR BRAKE DISC REMOVAL
front wheel alignment or vehicle stability. AND INSTALLATION PROCEDURES.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
FRONT END NOISE (a) Ball joint needs lubrication. (a) Lubricate ball joint.
(b) Shock absorber inoperative or bush (b) Replace bushings, shock absorber or
ings worn, or loose shock absorber tighten shock absorber mounting nuts.
mounting.
(c) Worn strut bushings. (c) Replace bushing.
(d) Loose struts. (d) Inspect bushings and tighten strut
nuts.
(e) Loose steering gear on frame. (e) Tighten steering gear mounting bolts.
(f) Worn upper control arm bushings. (f) Replace worn bushings.
(g) Worn lower control arm shaft bush (g) Replace worn bushings.
ings.
(h) Excessively worn upper ball joint. (h) Replace ball joint.
(i) Excessively worn lower ball joint. (i) Replace ball joint.
(j) Worn tie rod ends. (j) Replace tie rod end.
(k) Loose or worn front wheel bearings. (k) Adjust or replace bearings as neces
sary.
(I) Steering arm contacting the control (I) Smooth off contacting areas and lu
arm wheel stops. bricate with a water resistant grease.
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POOR DIRECTIONAL (a) Low or uneven tire pressure. (a) Inflate tires to correct pressure.
STABILITY (b) Loose wheel bearings. (b) Adjust wheel bearing.
(c) Improper steering cross shaft adjust (c) Adjust steering cross shaft.
ment.
(d) Steering gear not centered. (d) Adjust steering gear.
(e) Worn idler arm bushing. (e) Replace bushing or idler arm as
necessary.
(f) Loose or failed front strut bushings. (f) Replace bushings.
(g) Weak or broken rear spring. (g) Replace spring.
(h) Incorrect front wheel alignment or (h) Measure and adjust front wheel
suspension heights. alignment and suspension heights.
(i) Shock absorber inoperative. (i) Replace shock absorber.
(j) Un-horizontal center link (cocked) (j) Align steering gear or replace cross
member.
HARD STEERING (a) Ball joints need lubrication. (a) Lubricate ball joints.
(b) Low or uneven tire pressure. (b) Inflate tires to the recommended
pressures.
(c) Low power steering fluid level. (c) Fill power steering pump reservoir to
correct level.
(d) Lack of assist of power steering (d) Inspect and test power steering pump
system. and gear. Service as required.
(e) Low front suspension height. (e) Adjust heights to specifications.
(f) Incorrect front wheel alignment (Par (f) Replace bent parts and adjust front
ticularly caster) resulting from a bent wheel alignment.
control arm steering knuckle or steer
ing knuckle arm.
(g) Steering gear not adjusted properly. (g) Adjust steering gear.
(h) Idler arm binding. (h) Replace idler arm.
EXCESSIVE PLAY (a) Worn or loose front wheel bearings. (a) Adjust or replace wheel bearings as
IN STEERING necessary.
(b) Incorrect steering gear adjustment. (b) Adjust steering gear.
(c) Loose steering gear to frame mount (c) Tighten steering gear to frame bolts.
ing bolts.
(d) Worn tie rod ends. (d) Replace tie rods as necessary.
(e) Worn steering gear parts. (e) Replace worn steering gear parts and
adjust steering gear as necessary.
(f) Worn upper control arm ball joints. (f) Replace ball joints.
(g) Worn lower control arm ball joints. (g) Replace ball joints.
(h) Worn idler arm bushing. (h) Replace bushing.
FRONT WHEEL (a) Tire and wheel out of balance. (a) Balance wheel and tire assembly.
SHIMMY (b) Unever tire wear, or excessively worn *(b) Rotate or replace tires as necessary.
tires.
(c) Worn or loose wheel bearings. (c) Replace or adjust wheel bearings.
(d) Worn tie rod ends. (d) Replace tie rod ends.
(e) Strut mounting bushings loose or (e) Replace strut mounting bushings.
worn.
(f) Incorrect front wheel alignment and (f) Adjust front wheel alignment and car
car height (particularly caster). height.
(g) Upper ball joints loose or excessively (g) Tighten to specifications or replace
worn. as necessary.
VEHICLE PULLS TO (a) Low or uneven tire pressure. (a) Inflate tires to the recommended pres
ONE SIDE sure.
(b) Front brake dragging. (b) Adjust brakes.
(c) Grease, lubricant or brake fluid leak (c) Replace brake shoe and lining as
ing onto brake lining. necessary and eliminate all leaks.
(d) Loose strut bushings. (d) Inspect bushings and replace as
necessary.
(e) Power steering control valve out of (e) Adjust steering gear control valve.
adjustment.
(f) Incorrect front wheel alignment (par (f) Adjust front wheel alignment.
ticularly caster).
(g) Broken or sagging front or rear (g) Replace spring.
spring.
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(h) Excessively worn suspension pivot (h) Replace bushings,
bushings.
SERVICE PROCEDURES
WHEEL ALIGNMENT tire wear factor; negative camber causes wear on
the inside of the tire, while positive cam ber causes
Front wheel alignment is the proper adjustm ent of
wear to the outside.
all the interrelated suspension angles affecting the
Toe-in is m easured in inches and is th e distance
running and steering of the front wheels of the ve
the leading edges of the tires are closer than the
hicle. The importance of wheel alignment and wheel
trailing edges. Toe-in is considered the most serious
balancing is considered essential in order to main
cause for excessive tire wear. Toe-in is the last of
tain ease of steering, good directional stability and
the alignm ent angles to be set in the front wheel
to prevent abnormal tire wear.
alignm ent operation.
Under every day driving conditions the front wheel
Steering Axis Inclination is m easured in degrees
alignment angles change and therefore it becomes
and is the amount the spindle support center line is
necessary that every vehicle should have an align
tilted from tru e vertical. It has a fixed relation
ment check at least once a year. Such an inspection of
ship with cam ber settings and does not change except
the front suspension and steering components is a
when a spindle or ball joint is damaged or bent.
preventative maintenance service and also has a
This angle is not adjustable and damaged parts must
definite bearing on the safe operation of the vehicle.
be replaced.
The method of checking front wheel alignment
Toe-out on Turns (Turning Radius) is measured in
will vary depending on the type of equipm ent being
degrees and is the amount one front wheel turns
used. The instructions furnished by the m anufacturer
sharper than the other on a turn. This angle is
of the equipment should always be followed, with the
designed into the steering arm s in relationship to
exception that the specifications recommended by
the wheelbase of the vehicle and is not adjustable.
the Chrysler Motors Corporation be used.
When checking the turning radius and it is found not
There are six basic factors which are the founda
tion to front wheel alignment; height, caster, camber,
toe-in, steering axis inclination and toe-out on turns
(Fig. 1). All are mechanically adjustable except steer
ing axis inclination and toe-out on turns. The latter
two are valuable in determining if parts are bent or
damaged particularly when the camber and caster
adjustments cannot be brought within the recom
mended specifications.
Do not attempt to modify any suspension or steer
ing components by heating or bending. STEERING AXIS INCLINATION
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to be within the recommended specifications, look Height
for possible bent or damaged components. Front suspension heights must be held to specifica
tions for a satisfactory ride, correct appearance,
PRE-ALIGNMENT INSPECTION proper front wheel alignment and reduced tire wear.
The heights should only be m easured after the ve
Before any attem pt is made to change or correct hicle has the recommended tire pressures, a full
the wheel alignment factors the following inspection tank of fuel, no passenger or luggage com partm ent
and necessary corrections must be made on those load and is on a level floor or alignment machine rack.
parts which influence the steering of the vehicle. (1) Clean all foreign m aterial from bottom of steer
(1) Check and inflate tires to recommended pres ing knuckle arm assemblies and from lowest area of
sure. All tires should be same size and be in good the height adjusting blades directly below center of
condition and have approximately same wear. Note lower control arm inner pivots.
type of tire tread wear which will aid in diagnosing (2) Jounce vehicle several times releasing it on
(Group 22). downward motion.
(2) Check and adjust front wheel bearings (Group (3) Measure distance from lowest point of one ad
22 ). justing blade to floor (Measurement A) and from low
(3) Check front wheel and tire assembly for radial est point of steering knuckle arm, at the centerline,
and lateral runout (follow the Equipment Manu on same side (Measurement B) to floor (Fig. 2). Meas
facturers Instructions (Group 22). ure only one side at a time.
(4) Check wheel and tire for unbalance conditions The difference between A and B (A always being
both static and dynamic which could affect steering. greater than B) is the front suspension height.
(5) Inspect ball joints and all steering linkage pivot (4) Refer to Specifications and adjust if necessary
points for excessive looseness. by turning torsion bar adjusting bolt clockwise to in
(6) Check shock absorbers for leaks and jounce crease height and counterclockwise to decrease
vehicle to determ ine if shock absorbers have proper height.
control. (5) After each adjustment, jounce vehicle before
(7) Check steering gear for roughness, binding or remeasuring. Both sides should be measured even
sticking condition and adjust as necessary. though only one side has been adjusted.
(8) Check rear springs for cracks or broken leaves (6) Measure other side in same manner. The maxi
and “U” bolts for proper tightness and m easure mum allowable difference in suspension height from
height differential between left and right sides of side to side is 1/8 inch on all Models.
vehicle. (Vehicle should be on level floor or on align
m ent rack) with a full tank of fuel and no luggage or Cam ber and Caster
passenger load. Access holes to loosen upper control arm cam bolt
(9) Front suspension heights must only be checked nuts have been provided for in the fender side shields
after the vehicle has the recommended tire pres (Fig. 3) of the Challenger model vehicles. The front
sures, full tank of fuel, no passenger load and is on access hole is made available by removing splash cov
a level floor or alignment rack. er tapping screws and cover.
To obtain accurate readings, vehicle should be (1) Prepare vehicle for measuring wheel alignment.
jounced in following m anner just prior to taking each
(2) Remove all foreign m aterial from exposed
m easurem ent (Height - Caster - Camber and Toe):
threads of cam adjusting bolts.
Grasp bum pers at center (rear bum per first) and
jounce up and down several times. Always release (3) Record initial camber and caster readings be
bum pers on the down cycle after jouncing both rear fore loosening cam bolt nuts.
and front ends an equal num ber of times.
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.BUSHING
ACCESS OPENINGS
NUT
RETAINER
LOCK RING
MD32S
-BOLT NR360
Rem oval
(1) Remove upper control arm rebound bumper.
(2) If vehicle is to be raised on a hoist, make sure it
is lifted on body only so that front suspension is in
i ' ■ 'A D IU lV nN O S B
: ■ BOi.l
TOOL
full rebound (under no load). If vehicle is to be raised
on jacks, placed under center of crossmember it will . J
be necessary that, a support first be placed between
the crossmember and the jack.
(3) Release all load from torsion bar (Fig. 4) by
turning anchor adjusting bolt (Fig. 5) counterclock
wise.
(4) Remove lock ring from torsion bar rear an
chor (Fig. 4). 6 VS? 'JNC
(5) Using Tool C-3728, remove torsion bar (Fig. 5)
from its anchors. It is advisable to place Tool C-3728
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if any corrosion or other damage is noted. Lubricate prevent damage to brake hose when lower bolts are
for easy operation. removed.
Installation Installation
(1) Insert torsion bar through rea r anchor. (1) Position steering knuckle on brake support and
(2) Slide balloon seal over torsion bar (cupped end install upper mounting bolts and nuts. Tighten nut
toward rear of bar). finger tight only.
(3) Coat both hex ends of torsion bar with Multi- (2) Position steering knuckle arm on steering
Mileage Lubricant or equivalent. knuckle and install mounting bolts and nuts finger
(4) Slide torsion bar into hex opening of lower con tight only.
trol arm. (3) Install upper ball joint stud in steering knuckle
(5) Install lock ring in rear anchor. and tighten ball joint stud nut 55 foot-pounds (Dart)
(6) Pack the annular opening in rear anchor com and 100 foot-pounds (Challenger). Install cotter pin.
pletely full of Multi-Mileage Lubricant or equivalent. (4) Tighten steering knuckle upper bolt nuts 55
(7) Position balloon seal on rea r anchor so lip of foot-pounds. Tighten lower bolt nuts 100 foot-pounds
seal engages with groove in anchor. (Dart) 120 foot-pounds (Challenger models).
(8) Turn adjusting bolt clockwise to place a load on (5) Place a load on the torsion bar by turning ad
torsion bar. justing bolt clockwise.
(9) Lower vehicle to floor and adjust front suspen (6) Install tie rod end in steering knuckle arm and
sion height. install nut, tighten 40 foot-pounds and install cotter
(10) Install upper control arm rebound bum per and pin.
tighten nut 200 inch-pounds. (7) Install wheel, tire and drum assembly and ad
just front wheel bearings (Group 22).
STEERING KNUCKLES (8) Lower vehicle to floor and install upper control
arm rebound bumper. Tighten nut 200 inch-pounds.
ON MODELS EQUIPPED WITH DISC BRAKES, RE (9) Measure and adjust front suspension heights
FER TO GROUP 5 FOR BRAKE DISC REMOVAL and wheel alignment as necessary.
AND INSTALLATION PROCEDURES.
STEERING LINKAGE (Figs. 6, 7)
R em oval
(1) Remove upper control arm rebound bumper. The tie rod end seals should be inspected for
(2) Raise vehicle so front suspension is in full re damage at all oil change periods.
bound (under no load).
(3) Remove wheel, tire and drum as an assembly. Rem oval
Removal of tie rod ends from the steering knuckle
(4) Remove all load from torsion bar by turning
arm or center link by methods other than using Tool
adjusting bolt counterclockwise.
C-3894 will damage tie rod end seal.
(5) Remove tie rod end from steering knuckle arm
When removing tie rod ends, idler arm or steering
using Tool C-3894.
(6) Remove upper ball joint stud from steering
knuckle using Tool C-3711. It may be necessary to
add approximately 7/16 inch of flat washers over
lower ball joint stud to allow the use of Tool C-3711
without damaging threads on lower ball joint stud.
Place Tool C-3711 over stud. Turn threaded portion of
tool locking it securely against the upper stud (Fig.
17). To use Tool C-3711 as outlined, it may be neces
sary to modify the tool (Fig. 19). Spread tool enough
to place upper stud under a load, then strike steering
knuckle sharply with a ham m er to loosen stud. Do not
attem pt to force stud out of steering knuckle with
tool alone.
(7) Remove two upper bolts attaching steering
knuckle to brake support.
(8) Remove two lower bolts attaching steering arm
to steering knuckle and remove steering knuckle.
Support the brake assem bly during this operation to Fig. 6 —Steering Linkage (Dart)
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KNUCKLE
ARM
TIE
ROD
\_E N D
11
l£ 9 E H ^
U N H R il
NK387
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The sway bar cushions are not serviced separately.
If replacement is necessary, install a new sway bar
assembly.
Installation—D a rt
(1) Position link with retainer and rubber insula
tor in lower control arm bracket, followed by rubber
insulator and retainer (concave side toward rubber
insulator) and nut. Tighten nut to 100 inch-pounds.
(2) Position sway bar assembly in vehicle and in
stall attaching bolts and nuts and tighten to 200 inch-
pounds.
(3) Install retainer on link, followed by rubber
insulator and sway bar. Using a screwdriver or pinch
bar between strut and sway bar, if necessary apply
INSULATOR------ pressure and install upper rubber insulator, retainer
RETAINER------- ^ and nut, tighten nuts 100 inch-pounds.
NUT------►©
NN43C
Rem oval—Challenger
Fig. 9 —Sw ay Bar Assembly (Dart) (1) Loosen and remove upper link nut retainer and
rubber insulator on both sides of car.
SWAY BAR (Figs. 9,10) (2) Loosen and remove bolts and nuts attaching
both retainer brackets to front crossmember.
Rem oval—D a rt (3) Remove sway bar link bolt from sway bar fol
(1) Loosen and remove upper link nut, retainer and lowed by rubber insulators, retainers, sleeve spacer.
rubber insulator on both sides. (4) Remove the center rubber insulator bracket and
(2) Loosen and remove bolts attaching both brack turn sway bar toward front of car and remove by slid
ets to front crossmember. ing out thru opening in front crossmember.
(3) Remove sway bar from vehicle. (5) If the rubber insulator bushings show excessive
(4) Loosen and remove nuts, retainers and rubber wear or deterioration of rubber, install new bushings.
insulators and remove links from lower control arm The sway bar cushions are serviced separately.
bracket.
(5) If the rubber insulator bushings show exces Installatio n—Challenger
sive wear or deterioration of rubber, install new
(1) With sway bar ends pointed toward front of car,
bushings. insert sway bar thru hole in front crossmember into
its correct position.
INSULATOR
(2) Install sway bar cushion retainer brackets and
attaching bolts and nuts and tighten to 200 inch-
pounds.
(3) Position link bolt with retainer and rubber in
sulator thru sway bar mounting hole. Install other
LOWER
CONTROL mounting components in correct sequence (Fig. 11).
ARM (Always making sure the concave side of retainers are
toward the rubber insulators).
(4) Position the link bolt, sway bar and the stack
up of parts thru mounting bracket hole in lower con
trol arms. Install upper rubber insulator, retainer and
RETAINER
nut. Tighten link nut to 100 inch-pounds.
INSULATOR
NUT RETAINER
SLEEVE LOWER CONTROL ARM AND SHAFT
RETAINER (Figs. 11, 12)
SWAY BAR
INSULATOR
Removal
RETAINER ON MODELS EQUIPPED WITH DISC BRAKES, RE
LINK----- --------- H PY84
FER TO GROUP 5 FOR BRAKE DISC REMOVAL
AND INSTALLATION PROCEDURES.
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CROSS MEMBER CONTROL
SHAFT ARM
SPRING
PIN
FWD. ^
-tf'WK"). SWIVEL
ADJUSTING BOLT
^3S
KNUCKLE ARM
NR362
Fig. 11 —Lower Control Arm (Dart)
(1) Remove the wheel, tire and drum as an as
sembly.
(2) Remove lower shock absorber attaching bolt and
push up and out of way, and remove torsion bar from Fig. 13 —Removing L o w e r Ball Joint Stud (Dart)
lower control arm.
(3) Remove tie rod end from steering knuckle arm vise and remove stru t nut.
using Tool C-3894 (Fig. 8). Use care not to dam age (2) Remove stru t from control arm.
seal. (3) Remove torsion bar adjusting bolt and swivel.
(4) Remove sway bar link from lower control (4) Place lower control arm assembly in an arbor
arm. press with torsion bar hex opening up and with a
(5) Remove steering knuckle arm to brake support support under outer edge of control arm.
bolts and remove steering knuckle arm. Move brake (5) Place a brass drift into hex opening and press
support assembly out of way. shaft out of lower control arm. The bushing inner
(6) Remove ball joint stud from lower control arm shell will rem ain on shaft.
using Tool C-3964 (Fig. 13). The bottom portion of (6) Cut and remove rubber portion of bushing from
tool must be positioned between seal and control control arm shaft.
arm to avoid seal damage. (7) Remove bushing outer shell by cutting with a
(7) Remove strut spring pin, front nut and bushing chisel. Use care not to cut into control arm.
retainer (Fig. 11) from forward end of cross-member. (8) Remove bushing inner shell from pivot shaft.
(8) Remove nut and washer from lower control arm Cut off if necessary.
shaft.
(9) Tap end of lower control arm shaft with a “soft
Assembly
end” hammer to aid in removal of shaft from cross (1) Position new bushing on shaft (flange end of
member. bushing first) press shaft into inner sleeve until bush
(10) Remove lower control arm, shaft and strut as
ing seats on shoulder of shaft.
an assembly.
(2) Press shaft and bushing assembly into lower
(11) Remove stru t bushing from crossmember only
control arm using Tool C-3848 and an arbor press.
if damaged; replace bushing. All models (except Dart)
use a two piece bushing and sleeve arrangem ent (Fig. In some instances it may be necesssary to reduce the
14). diam eter of shaft shoulder to facilitate use of tool.
(12) Remove stru t bushing inner retainer from (3) Install torsion bar adjusting bolt and swivel.
strut. (4) Position stru t in lower control arm and tighten
nut 100 foot-pounds.
Disassembly
(1) Place stru t portion of control arm assembly in a FRONT BUSHING REAR BUSHING RETAINER
CROSS MEMBER,
_ \ o H A rI w
<^p CONTROL
,!?- 1
SPRING \ \
/
/ /
sw,vel
ADJUSTING BOL’s • ,
RETAINER
\ N N 47
NR361 STRUT KNUCKLE ARM
Fig. 12—Lower Control Arm (Challenger) Fig. M —Strut Crossmember Bushings (Challenger)
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o
Installation Installation
(1) On Dart models, install new strut bushing in (1) Install new strut bushings, if necessary.
crossmember with a twisting motion. Water may be (2) Position strut into control arm and tighten nut
used as a lubricant to aid in installation. Do not use 100 foot-pounds.
oil or grease. (3) Position strut bushing inner retainer and strut
(2) Place strut bushing inner retainer on strut and rear bushing on strut and position lower control arm
install lower control arm, shaft, and strut assembly. shaft and strut assembly into crossmember. Install
Install strut bushing outer retainer and nut finger strut front bushing, sleeve and retainer. Tighten nut
tight only. finger tight only.
(3) On Challenger models, position front strut bush (4) Install control arm pivot shaft washer and
ing half and sleeve into crossmember. Place rear re nut finger tight only.
tainer and rear strut bushing on strut and position (5) Connect shock absorber to lower control arm
control arm, shaft and strut assembly into cross and tighten nut finger tight only.
member. Install strut bushing outer retainer and (6) Lower vehicle to floor so full weight is on its
nut finger tight only. wheels.
(4) Install lower control arm shaft washer and nut (7) Adjust front suspension heights to specifica
finger tight only. tions.
(5) Position lower ball joint stud into lower control (8) Tighten front strut nut to 45 foot-pounds Dart,
arm and tighten nut 85 foot-pounds, and install cotter (52 foot-pounds Challenger), and install spring pin.
pin. Tighten pivot shaft nut 145 foot-pounds. Tighten
(6) Position brake support on steering knuckle and shock absorber nut 50 foot-pounds.
install two upper bolts and nuts finger tight only. (9) Adjust front wheel alignment as necessary.
(7) Position steering knuckle arm on steering
knuckle and install two lower bolts and nuts. LOWER BALL JOINTS
(8) Tighten upper bolt nuts 55 foot-pounds. Tighten ON MODELS EQUIPPED W ITH DISC BRAKES, RE
lower bolt nuts 100 foot-pounds (Dart) 120 foot FER TO GROUP 5 FOR BRAKE DISC REMOVAL
pounds (Challenger). AND INSTALLATION PROCEDURES.
(9) Inspect tie rod end seal and replace if damaged.
Connect tie rod end to steering knuckle arm and Inspection
tighten nut 40 foot-pounds and install cotter pin. (1) Raise the front of vehicle and install safety floor
(10) Connect shock absorber to control arm and stands under both lower control arms as far outboard
tighten finger tight only. (Dart install bolt from rear as possible. The upper control arms must not contact
only). the rubber rebound bumpers.
(11) Install wheel, tire and drum assembly and ad (2) With the weight of vehicle on the control arm,
just front wheel bearing (Group 22). install dial indicator and clamp assembly to lower
(12) Lower vehicle to floor, adjust front suspension control arm (Fig. 15).
(3) Position dial indicator plunger tip against ball
heights and tighten strut nut, at crossmember 45 foot
joint housing assembly and zero dial indicator.
pounds and install strut pin Dart (52 foot-pounds
(4) Measure axial travel of the ball joint housing
Challenger). Tighten shock absorber nut 50 foot
pounds.
(13) Tighten lower control arm shaft nut 145 foot
pounds, and tighten shock absorber lower bushings
to 50 foot-pounds.
(14) Measure and adjust front wheel alignment as
necessary.
Removal
(1) Remove lower control arm, shaft and strut as
an assembly.
(2) Remove nut holding strut to lower control arm
and remove strut from control arm.
(3) Inspect strut bushings (Fig. 14). If bushings are
worn or deteriorated, install new bushings.
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arm with respect to the ball joint stud, by raising and
lowering the wheel using a pry bar under the center
of the tire.
(5) If during m easurem ent you find the axial travel
of the housing arm is .070" or more, relative to the
ball joint stud, the ball joint should be replaced.
Rem oval
The lower ball joint is integral with the steering
arm and is not serviced separately. Compression type
lower ball joints are used on all models.
(1) Remove upper control arm rebound bumper.
(2) Raise vehicle so front suspension is in full re
bound. Remove all load from torsion bar by turning
adjusting bolt counterclockwise. If jacks are used to
raise vehicle it is essential that a support be used
between the crossmember and jack. UPPER CONTROL ARM (Figs. 16,17)
(3) Remove wheel, tire and drum as an assembly. It
R em oval a n d Disassembly
may be necessary to back-off the brake shoes to facili (1) Place a jack under lower control arm as close to
tate removal of drum assembly. wheel as possible and raise vehicle until wheel clears
(4) Remove two lower bolts from the brake support floor.
attaching steering arm and ball joint assembly to (2) Remove wheel and tire as an assembly.
steering knuckle. (3) Remove upper and lower ball joint stud using
(5) Remove tie rod end from steering arm using Tool C-3711. On Dart models, it may be necessary to
Tool C-3894. Use care not to damage seal. add approximately 7/16 inch of flat washers over
(6) Using Tool C-3964 remove ball joint stud from lower ball joint stud to allow the use of Tool C-3711
lower control arm (Fig. 13), and remove steering arm without damaging threads on lower ball joint stud.
and ball joint assembly. Place Tool C-3711 over stud. Turn threaded portion
of tool locking it securely against the upper stud (Fig.
Installation 18).
(1) Place a new seal over ball joint and using Tool To use ToolC-3711 as outlined, it may be necessary
C-4039 press retainer portion of seal down on ball to modify the tool (Fig. 19).
joint housing until it is securely locked in position. (4) Spread tool enough to place upper stud under a
(2) Position steering arm and ball joint assembly on load, then strike steering knuckle sharply with a
steering knuckle and install two mounting bolts. hammer to loosen stud. Do not attempt to force stud
Tighten nuts 100 foot-pounds (Dart), 120 foot-pounds out of steering knuckle with tool alone.
(Challenger). (5) Remove nuts, lockwashers, cams and cam bolts
(3) Insert ball joint stud into opening in lower con
trol arm.
(4) Install stud retaining nut and tighten 85 foot
pounds. Install cotter pin and lubricate ball joint, see
Lubrication Section Group “ O”.
(5) Inspect tie rod seal for damage and replace if
damaged. Connect tie rod end to steering knuckle
arm, tighten nut 40 foot-pounds, and install cotter pin.
(6) Place a load on torsion bar by turning adjusting
bolt clockwise.
(7) Install wheel, tire and drum assembly and ad
just front wheel bearing (Group 22).
(8) Lower vehicle to floor, install upper control arm
rebound bum per and tighten nut 200 inch-pounds.
(9) Measure front suspension height and adjust if
necessary.
(10) Measure front wheel alignment and adjust if
necessary.
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'M,'
Fig. 18—Removing Upper Ball Joint Stud (Dart) adaptor SP-3827 in place of SP-3233A cup on tool and
install support sleeve on rear bushing only (Fig. 22).
attaching upper control arm and bushings (Figs. 16,
17), to support brackets. Lift control arm up and (2) Install ball joint into arm using Tool C-3714
away from support. (Tool C-3560 Challenger). Tighten until seated (125
(6) Remove ball joint (Fig. 20) using Tool C-3714 foot-pounds minimum). The ball joint will cut threads
(Tool C-3560 Challenger). The seal w ill come off as ball into a new arm during tightening operations.
joint is removed. (3) Install a new ball joint seal using a 2" socket,
(7) Assemble Tool C-3710A over bushing and press making sure it is seated fully on ball joint housing.
bushing out of arm (from inside out) (Fig. 21). To On Dart Models install seal using Tool C-4039.
remove upper control arm rear bushing support
sleeve (used on Dart models with 10 inch front brakes Installation
and police and taxi application) assemble Tool C- (1) Slide control arm into position and install cam
3710A, using adaptor SP-3826 in place of adaptor bolts, cams, washers and nuts (Figs. 16 and 17).
SP-3088, over bushing and press bushing out of arm Tighten nuts in preparation for final adjustments.
(Fig. 21). (2) Slide upper ball joint stud into position in steer
ing knuckle and install nut. Tighten nut 100 foot
Assembly pounds, (Dart 55 foot-pounds). Install cotter pin and
When installing new bushings, be sure control arm
is supported squarely at point where bushing is being
pressed in. Do not use oil or grease to aid in instal
lation.
(1) Position flange end of new bushing in Tool C-
3710A, support control arm squarely, and press bush
ings into control arm (from outside) until tapered m . \
portion of bushing seats on the arm. On Dart models \
with 10 inch front brakes and police and taxi applica u p t
tion, (using bushing support sleeve) remove Tool C- v iti i
3710A after bushing has been installed and install \ W > \
k \ : v .
H h
■'V- f llt k | s.
HHa
x
P m " ■■r
v»
J %
-B-
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Place Tool C-3711 over studs. Turn threaded portion
SLEEVE- of tool locking it securely against upper stud (Fig. 18).
To use Tool C-3711 as outlined it will be necessary to
modify it, as shown in Figure 19.
(4) Spread tool enough to place upper stud under a
load, then strike steering knuckle sharply with a
ham m er to loosen stud. Do not attempt to force stud
out of steering knuckle with tool alone.
(5) Remove tool, then remove ball joint stud from
steering knuckle.
(6) Using Tool C-3560, (Tool C-3714 Dart) unscrew
ball joint from upper control arm (Fig. 20). The
seal will come off as ball joint is being removed.
Installation
When installing a ball joint, make certain the ball
joint threads engage those of the control arm square
ly if original arm is being used. Balloon type seals
is;- should always be replaced once they have been re
\ NH153A moved.
(1) Screw ball joint squarely into control arm as far
Fig. 2 2 —Installing Support Sleeve on Bushing as possible by hand.
(2) Using Tool C-3560 (Tool C-3714 Dart) tighten
lubricate ball joint. Tighten lower stud nut 85 foot
ball joint until it bottoms on housing. Tighten to a
pounds.
minimum of 125 foot-pounds.
(3) Install wheel and tire. Adjust wheel bearing
If ball joint cannot be torqued to 125 foot-pounds,
(Group 22).
inspect threads on ball joint and also in control arm
(4) Measure and adjust vehicle height and wheel
and replace as necessary.
alignment. Tighten cam bolt nuts 65 foot-pounds.
(3) Position a new seal over ball joint stud and in
UPPER BALL JOINTS stall using a 2" socket making sure it is seated fully
on ball joint housing. On Dart Models, install seal
ON MODELS EQUIPPED WITH DISC BRAKES, RE
FER TO GROUP 5 FOR BRAKE DISC REMOVAL using Tool C-4039.
AND INSTALLATION PROCEDURES. (4) Position ball joint stud in steering knuckle and
install a retaining nut.
Rem oval
(1) Raise vehicle by placing a jack under lower con (5) Tighten nut 100 foot-pounds, (Dart 55 foot
trol arm as close as possible to wheel. pounds). Install cotter pin, lubricate ball joint.
(2) Remove wheel, tire and drum. (6) Install lower ball joint stud nut and tighten
(3) Remove upper and lower ball joint stud nuts 85 foot-pounds.
using Tool C-3711. On Dart models, it will be neces (7) Install wheel, tire and drum assembly and
sary to add approximately 7/16" of flat washers over adjust front wheel bearings (Group 22).
lower ball joint stud to allow the use of Tool C-3711 (8) Lower vehicle and adjust front suspension
without damaging threads on lower ball joint stud. height.
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2-14 TIGHTENING REFERENCE-
SPECIFICATIONS
Dart __________ Challenger
CAMBER—Left ..................... .................................................................... + 1/4° to + 3/4° (+ 1 /2 ° preferred)
—Right .............. ............................................................................ 0° to + 1/2° (+ 1 /4 ° preferred)
CASTER—Manual S te e rin g .......................................... ............................ 0° to —1° ( —1/2° preferred)
—Power Steering ......................... ............................................... + 1/4° to +1-1/4° (+ 3/4° preferred)
HEIGHT (inches) Standard & Heavy D u ty ........................................... 2 - l/ 8 ± l/ 8 l-3 /1 6 ± l/8
Side to Side Difference (M aximum )..................... ................... 1/8
STEERING AXIS INCLINATION 7-1/2°
TOE-IN ............................ ............................................................................. 3 /3 2 t o 5 /3 2 inch (1 /8 preferred)
TOE-OUT ON TURNS
When Inner Wheel is 20° outer wheel i s .................................. ......... 17.6° 17.8°
TORSION BARS—Length (inches) ............................. ............................ 35.8 41
—Diameter (inches)
Std. Suspension (6 c y l.) ........................................ 0.83 0.86
W/Air Conditioning ................................................ 0.85 0.86
318, 340 C. I. E n g in e .............................................. 0.87 0.88
383 C. I. E ngine........................................................ 0.89 0.88
Police, 426 & 440 E n g in e ....................................... — 0.92
Heavy Duty Suspension ......... ............................. 0.87 0.90
TREAD (inches)—F r o n t................... ......................................................... 57.4 59.7
—Rear ............................................................................... 55.6 58.7
WHEEL BASE (in c h e s ) ............................................................................... Ill 110
TIGHTENING REFERENCE
Foot Inch Foot Inch
Pounds Pounds
Ball Joint—Upper ........................... 125 (Min.) (Dart) ......................................... 100
Nut—Lower .................................. 85 (Disc Brakes) ........................... 120
—Upper (Challenger) .......... 100 U p p e r .................................................... 55
(Dart) ............... 55 Strut Nuts
Control Arm Front (Dart) ....................................... 45
Pivot Shaft N u t ............................. 145 (Challenger) ............................. 52
Rebound B um pers....................... 200 105
Crossmember Bolts ........................ 150 Sway Eliminator Shaft
Engine Mounting Bolts ................. ..... 85 Frame Bracket Bolt Nut (D a rt)........ 200
Idler Arm Bolt N u t ......................... 65 Link Insulator Retainer Bolt Nuts . . . 100
Shock Absorber Nuts—Front Tie Rod Ends
Lower ............................................ 50 Sleeve Clamp Bolt N u t ..................... 115
Upper ............................................ 25 Stud N u t s ..................................... . 40
Steering Gear Mounting B o lts ___ . . . , 80 Wheel Nuts
Steering Knuckle Bolt Nuts C hallenger............................................ 65
Lower (Challenger) ..................... 120 55
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o- GROUP 3
REAR AXLE
CONTENTS
Page Page
REAR AXLE ASSEMBLY {VA") RING GEAR 4 SERVICE DIAGNOSIS ..................................... 1
REAR AXLE ASSEMBLY (83/4") RING GEAR 14 SPECIFICATIONS........................................... 51
REAR AXLE ASSEMBLY (93/4") RING GEAR 32 SURE-GRIP DIFFERENTIAL........................... 48
REAR AXLE NOISE DIAGNOSIS 2 TIGHTENING REFERENCE ........................... 53
SERVICE DIAGNOSIS
Condition Possible Cause Correction
REAR WHEEL NOISE (a) Wheel loose. (a) Tighten loose wheel nuts.
(b) Spalled wheel bearing cup or cone. (b) Check rear wheel bearings. If spalled
or worn, replace.
(c) Defective, brinelled wheel bearing. (c) Defective or brinelled bearings must
be replaced. Check rear axle shaft
end play.
(d) Excessive axle shaft end play. (d) Readjust axle shaft end play.
(e) Bent or sprung axle shaft flange. (e) Replace bent or sprung axle shaft.
SCORING OF (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
DIFFERENTIAL GEARS on the pressure face of gear teeth
AND PINIONS or in the bore are caused by instan
taneous fusing of the mating surfaces.
Scored gears should be replaced. Fill
rear axle to required capacity with
proper lubricant.
See Specification section.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
gears and bearings for possible dam
age. Clean out and refill axle to re
quired capacity with proper lubricant.
See Lubrication section.
(c) Excessive spinning of one wheel. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
scoring, or bearings for possible dam
age. Service as necessary.
TOOTH BREAKAGE (RING (a) Overloading. (a) Replace gears. Examine other gears
GEAR AND PINION) and bearings for possible damage.
Replace parts as needed. Avoid Over
loading.
(b) Erratic clutch operation. (b) Replace gears, and examine remain
ing parts for possible damage. Avoid
erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustment. (d) Replace gears. Examine other parts
for possible damage. Make sure ring
gear and pinion backlash is correct.
REAR AXLE NOISE (a) Insufficient lubricant. (a) Refill rear axle with correct amount
of the proper lubricant. See Specifica
tion section. Also check for leaks and
correct as necessary.
(b) Improper ring gear and pinion adjust (b) Check ring gear and pinion tooth
ment. contact.
(c) Unmatched ring gear and pinion. (c) Remove unmatched ring gear and
pinion. Replace with a new matched
gear and pinion set.
(d) Worn teeth on ring gear or pinion. (d) Check teeth on ring gear and pinion
for contact. If necessary, replace with
new matched set.
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(e) End play in drive pinion bearings. (e) Adjust drive pinion bearing preload.
(f) Side play in differential bearings. (f) Adjust differential bearing preload.
(g) Sure-Grip Differentia l moan and chat- (g) Drain and flush lubricant. See proce
ter. dure in Sure-Grip section of Group 3.
LOSS OF LUBRICANT (a) Lubricant l evel too high. (a) Drain excess lubricant by removing
filler plug and allow lubricant to level
at lower edge of filler plug hole.
(b) Worn axle shaft oil seals. (b) Replace worn oil seals with new ones.
Prepare new seals before replacement.
(c) Cracked rear axle housing. (c) Repair or replace housing as required.
(d) Worn drive pinion oil seal. (d) Replace worn drive pinion oil seal
with a new one.
(e) Scored and worn companion flange. (e) Replace worn or scored companion
flange and oil seal.
(f) Clogged vent. (f) Remove obstructions.
(g) Loose carrier housing bolts or hous- (g) Tighten bolts or cover screws to
ing cover screws. specifications and fill to correct level
with proper lubricant.
OVERHEATING OF UNIT (a) Lubricant level too low. (a) Refill rear axle.
(b) Incorrect grade of lubricant (b) Drain, flush and refill rear axle with
correct amount of proper lubricant.
See Specification Section.
(c) Bearings adjusted too tightly. (c) Readjust bearings.
(d) Excessive wear in gears. (d) Check gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear to pinion clear- (e) Readjust ring gear and pinion back
ance. lash and check gears for possible
scoring.
REAR AXLE NOISE DIAGNOSIS tires, road surfaces, wheel bearings, engine, transm is
sion, exhaust, propeller shaft vibration, universal joint
Most rear axle failures are relatively simple to noise or body drumming. A thorough and careful
locate and correct, although rear axle noise is a little check should be made to determine the source of the
more difficult to diagnose and make the necessary noise before any disassembly and teardown of the
repairs. The most essential part of the rear axle serv rear axle is attempted.
ice is proper diagnosis of the problem. The complete isolation of noise in any one unit re
All rear axles are noisy to a certain degree. Gear quires considerable skill and previous experience.
noise is usually associated with older axles, but this Eliminating certain type noises often baffle even the
is not always true. New axles can also be noisy if they most experienced personnel. Often such practices as
are not properly adjusted or lack lubrication. Usually raising tire pressures to eliminate tire noise, listening
when new improperly set gears are noisy; the disturb for the noise at varying speeds under different load
ing noise cannot be “adjusted out” once the gears are conditions such as; drive, float and coast, and under
broken in. Recent experience has shown that axle certain highway conditions, turning the steering wheel
gears can often be readjusted to reduce excessive gear from left to right to detect wheel bearing noise, will
noise, if they have been operated at normal break-in aid even the beginner in detecting certain alleged axle
speeds for less than 500 miles. Regardless of what noises. Axle noises normally fall into two categories:
you’ve heard to the contrary, noisy gears will not get gear noise and bearing noise.
quieter with added mileage . . . they will stay the To make a good diagnostic check for rear axle noise
same or get worse. a thorough road test is necessary. Select a level smooth
Slight axle noise heard only a certain speeds or blacktop or asphalt road. This will reduce tire noise
under rem ote conditions must be considered normal. and body drumming. Drive the car far enough to
Axle noise tends to “peak” at varying speeds and the thoroughly warm up the axle to normal operating
noise is in no way indicative of trouble in the axle. tem perature.
If axle noise is present in an objectionable form, Drive the car and note speed at which noise occurs.
loud or at all speeds, an effort should be made to Then stop car and, with clutch disengaged or auto
isolate the noise as being in one particular unit of the matic transmission in neutral, run engine slowly up
vehicle. Many noises, reported as coming from the rear and down through engine speeds, corresponding to
axle actually originate from other sources such as car speed at which noise was most pronounced, to de
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term ine if it is caused by exhaust roar, or other engine GEAR NOISE
conditions. Repeat, while engaging and disengaging
clutch (transmission in neutral), to determine if noise Abnormal gear noise can be recognized easily be
can only be isolated by removing propeller shaft and cause it produces a cycling tone and will be very
operating transmission in high). pronounced through the speed range in which it oc
curs. Gear noise may be developed under one or more
TIRE NOISE of the following conditions, “drive”, “road load”,
“float” or “coast”. Gear noise usually tends to peak in
Tire noise is often mistaken for rear axle noise even a narrow speed range or ranges. Gear noise is more
though the noisy tires may be located on the front prom inent between 30 to 40 mph and 50 to 60 mph.
wheels. Tires that are unbalanced or worn unevenly Abnormal gear noise is quite rare and if present it
or have surfaces of non-skid type design, or worn in a usually originates from scoring of the ring and drive
saw tooth fashion are usually noisy and often produce pinion gear as a result of insufficient or improper
noises that seem to originate in the rear axle. lubrication of the axle assembly. The differential side
Tire noise changes with different road surfaces, but gears and pinions very seldom cause trouble as they
rear axle noise does not. Inflate all tires to approxi are only under loads when the rear wheels travel at
mately 50 pounds pressure (for test purposes only). different speeds; such as when turning corners.
This will materially alter noise caused by tires, but When objectionable axle noise is heard, note the
will not affect noise caused by rear axle. Rear axle driving condition and speed range. Remove the hous
noise usually ceases when coasting at speeds under ing cover on the 7-1/4" and 9-3/4" axles or remove
30 miles per hour; however, tire noise continues but the differential and carrier from the axle housing on
with lower tone, as car speed is reduced. Rear axle the 8-3/4" axle. Perform a tooth contact pattern check
noise usually changes when comparing drive and to determine if the best possible pattern has been ob
coast, but tire noise remains about the same. tained. If pattern is found to be unacceptable, reshim
Distinguish between tire noise and differential noise and adjust to obtain the best possible tooth pattern.
by noting if noise varies with various speeds or sudden If after readjustm ent noise still persists, replace with
acceleration and deceleration; exhaust and axle noise new gear set.
show variations under these conditions while tire noise
remains constant and is more pronounced at speeds of PRE-DISASSEMBLY INVESTIGATION
20 to 30 miles per hour. Further check for tire noise
by driving car over smooth pavements or dirt roads A close examination of the rear axle assembly prior
(not gravel) with tires at normal pressure. If noise is to disassembly can often reveal valuable information
caused by tires, it will noticeably change or disappear as to the extent and type of repairs or adjustm ents
and reappear with changes in road surface. necessary. This information coupled with the road
test results will provide a basis for determ ining the
FRONT WHEEL BEARING NOISE degree of disassembly required. Since the most fre
quent causes of axle noise are improper backlash or
Loose or rough front wheel bearings will cause noise differential bearing preload, or both a few simple ad
which may be confused with rear axle noises; however, justm ents may be all that is necessary to correct the
front wheel bearing noise does not change when com complaint.
paring drive and coast. Light application of brake Therefore, before disassembly the following checks
while holding car speed steady will often cause wheel should be made; drive gear and pinion backlash,
bearing noise to diminish, as this takes some weight pinion bearing preload, and tooth contact pattern and
off the bearing. Front wheel bearings may be easily these results recorded and analyzed. It is felt that
checked for noise by jacking up the wheels and spin these measurements and their results will aid you in
ning them, also by shaking wheels to determ ine if making the necessary repairs to the axle assembly.
bearings are loose.
Rear suspension rubber bushings and spring insula BEARING NOISE (DRIVE PINION AND
tors help to dampen out rear axle noise when properly DIFFERENTIAL)
and correctly installed. Check to see that no metallic
interference exists between the springs and springs Defective or damaged bearings generally produce a
hangers, shackles or “U” bolts. Metal to m etal contact rough growl or grating sound, that is constant in pitch
at these points may result in telegraphing road noise and varies with the speed of the vehicle. This fact will
and normal axle noise which would not be objection allow you to diagnose between bearing noise and gear
able if properly installed and tightened to specifica noise.
tions. Drive pinion bearing noise resulting from defective
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or damaged bearings can usually be identified by a must be reset to original settings upon reinstallation.
constant rough sound. Front pinion bearing noise is
usually most pronounced on “coast”, whereby rea r BACKLASH CLUNK
pinion bearing is loudest on “drive”. Pinion bearings Excessive clunk on acceleration and deceleration
are rotating at a higher rate of speed than the differ can be caused by anyone of the following items or a
ential side bearings or the axle shaft bearings. These combination; (excessive clearance between) (1) Differ
particular noises can be picked up best by road test ential pinion shaft to differential case, (2) Axle shaft
ing the vehicle in question on a smooth road (black to differential side gear splines, (3) Differential side
top). However, extreme caution should be taken not gear hub to differential case counterbore, (4) Differen
to confuse tire noise with bearing or gear noise. If tial side gear to pinion, (5) Worn thrust washers, (6)
doubt should exist tire treads should be examined for Drive gear backlash. Measure and inspect components
irregularities that will often produce such noise. and replace as required an d /o r adjust to proper speci
Differential bearing noise will usually produce a fications.
constant rough tone which is much slower than the
noise caused by the pinion bearings. ENGINE AND TRANSMISSION NOISE
Sometimes noises which seem to originate in the
REAR WHEEL BEARING NOISE rear axle are actually that of the engine or transm is
Defective or damaged rear wheel bearings produce sion. To diagnose which unit is actually causing the
a vibration or growl which continues with car coasting noise, observe the approximate vehicle speed and con
and transmission in neutral. A brinneled rear wheel ditions under which the noise is most pronounced; stop
bearing causes a whirring noise. Spalled rear wheel the vehicle in a quiet place to avoid any interfering
bearings normally produce a noise similiar to a growl, noises. With engine running and transmission in neu
created from either flaked or pitted rollers or bearing tral, run engine slowly up and down through engine
races. Unless the damage is severe, rear axle bearing speeds corresponding to approximate car speed at
noise is seldom heard above 30 mph. which the noise was most pronounced. If a noise simi
To differentiate between wheel bearings and gear lar is produced in this m anner it usually can be as
noise, road test the vehicle on a smooth road (black sumed that the noise was caused by the engine or
top) at medium and low speed. With traffic perm itting, transmission and not that of the rear axle.
swerve the vehicle sharply right to left. If the noise in
question is caused by wheel bearings, it will usually PROPELLER SHAFT VIBRATION
increase when the vehicle is swerved and will probably Objectionable vibrations at high speed (65 MPH or
be coming from the bearing on the loaded side. If the higher) may be caused by a propeller shaft that is out
noise in question cannot be isolated an inspection of of balance or worn universal joints. Out of balance
bearings will be necessary. may be due to a damaged or bent shaft.
To determ ine whether propeller shaft is causing
KNOCK AT LOW SPEEDS the vibration in question; road test the vehicle through
Low speed knock is usually caused by brinneled speed range and note speed at which vibration is most
universal joints or differential side gear hub to coun pronounced. Shift transmission into lower gear range
terbore clearance being too great. Inspect and replace and drive car at same engine speed as when vibration
universal joint or differential case and side gear as was most pronounced in direct drive and note any
required. effect on vibration.
If the vibration is still present at the same engine
DRIVE-LINE SNAP speed, whether in direct drive or in the lower gear,
A snap on a sudden start, either forward or reverse, since the propeller shaft speed varies, this cannot be
may be caused by a loose companion flange. Remove the fault. If the vibration decreases or is eliminated
the flange and reinstall 180 degrees from original posi in the lower gear, then propeller shaft is at fault and
tion. Pinion bearing preload and pinion nut torque should be rebalanced or replaced.
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GENERAL INFORMATION
The 7-1/4" Rear Axle Assembly shown in (Fig. 1), axle. Refer to the Sure Grip Differential Section of the
is a semi-floating type which incorporates a unitized Axle Group for the Servicing procedure.
rear axle housing assembly. The drive pinion and the A hooded breather is attached to the left leg of the
differential case with drive gear are mounted directly axle housing approximately 15" inboard of the flange
into the center section of the rear axle housing as face. Gear ratio identification is stamped on the front
sembly. Access to the differential, drive gears and face of the pad at the bottom of housing.
bearings is obtained by removal of the carrier cover. SHOULD THE REAR AXLE BECOME SUBMERGED
Axle shaft bearings, oil seals and drive pinion oil seal IN WATER, THE LUBRICANT MUST BE CHANGED
can be removed and serviced without removing the IMMEDIATELY TO AVOID THE POSSIBILITY OF
complete axle assembly from the vehicle, but the unit EARLY AXLE FAILURE RESULTING FROM CON
should be removed for any additional operations. TAMINATION OF THE LUBRICANT BY WATER
A Sure Grip Differential is available in the 7-1/4" DRAWN INTO THE VENT HOLE.
Axle Assembly, similar to those used in the 8-3/4"
SERVICE PROCEDURES
AXLE SHAFTS AND BEARINGS (3) Using access hole in axle shaft flange, remove
retainer nuts.
CAUTION: It is absolutely necessary that anytime an (4) Attach axle shaft rem over tool C-3725 to axle
axle assembly is serviced, and the axle shaft is loos shaft flange and remove axle shaft. Remove brake
ened and removed, both brake support plate gaskets assembly (Fig. 2).
and the inner axle shaft seal must be replaced. (5) Remove axle shaft oil seal from housing.
CAUTION: Under no circumstances should axle
Rem oval and Disassembly shaft collars or bearings be removed using a torch.
(1) With wheels removed, remove clips holding The use of a torch in the removal of the axle shaft
brake drum on axle shaft studs and remove brake collars or bearings is an unsafe practice, because
drum. heat is fed into the axle shaft bearing journal and,
(2) Disconnect brake lines at wheel cylinders. thereby weakens this area.
SHAFT RETAINER NUT
WASHER
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TOOL
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C -3926
C -3725 PARTS
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Fig. 6 —Installing Rear A xle Shaft Bearing Fig. 8 —Measuring D riv e G e ar Runout
To m aintain proper drive line balance when reas THERE SHOULD BE NO SIDE PLAY.
sembling, make scribe marks on the propeller shaft (4) In preparing to m easure drive gear runout on
universal joint and the pinion flange before removal. differential case, (provided no side play was found)
(6) Disconnect propeller shaft at differential pinion mount a dial indicator tool C-3339 on pilot stud C-
yoke and secure in an upright position to prevent 3288, and load the indicator stem slightly when
damage to front universal joint. plunger is at right angles to back face of drive gear
(7) Remove shock absorber from spring plate studs (Fig. 8).
and loosen rea r spring “U” bolt nuts and remove “U” (5) Measure drive gear runout by turning drive
bolts. gear several complete revolutions and reading dial
(8) Remove axle assembly from vehicle. indicator. Mark drive gear and differential case at
point of maximum runout. The m arking of differential
DIFFERENTIAL case will be very useful later in checking differential
case runout. Total indicator reading should be no
Removal and Disassembly more than .005 inch. If runout exceeds .005 inch the
Side play and runout checks taken during disas differential case may be damaged. A test for case
sembly will be very useful in reassembly. runout will be described later.
(1) Remove drain plug in cover assembly and (6) Remove drive pinion nut and washer. Using
drain lubricant from housing. Tool C-452 and holding Tool C-3281, remove drive
(2) Remove cover and with a suitable cleaning sol pinion flange (Fig. 9).
vent, clean inside the axle housing and differential (7) Using Tool C-748 remove drive pinion oil seal
case and drive gear assembly. (Fig. 10). Remove front pinion bearing cone and pre
(3) Measure for differential side play. Position a load shim.
screwdriver or pinch bar between left side of axle
housing and differential case flange, then using a TOOLS
I
prying motion determ ine if side play is present.
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N Y 1023 , N Y 1037
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TOOL
__ -J*A>
STUD'
NY I036 NY-1034
Fig. 10—Removing Pinion O il Seal Fig. 12—Spreading Rear A xle Housing
(8) Mark axle housing and differential bearing (14) Using a flat end brass drift, remove front and
caps for location in reassembly (Fig. 11). rear bearing cups from housing.
(9) Remove differential bearing caps and locate (15) Mount differential case and ring gear assem
spreader Tool C-3721 with tool dowel pins seated bly in a vise equipped with soft jaws (brass).
in locating holes of axle housing. Turn tool screw (16) Remove drive gear bolts. BOLTS ARE LEFT
finger tight at this time. HAND THREAD. With a non-metallic hamm er tap
(10) Install pilot stud, Tool C-3288, on left side of drive gear loose from differential case pilot and
axle housing. Attach dial indicator and load indicator remove.
stem slightly against opposite side of axle housing (17) If a drive gear runout exceeded .005 inch in
(Fig. 12). step 4, differential case flange runout should be re
(11) Tighten spreader tool nut sufficiently to obtain measured. Install differential case with appropriate
.012 to .015 inch movement of dial indicator to per bearing cups and shims in axle housing. Loosen nut
mit removal of differential case assembly. (Do not of spreader tool and remove, mount dial indicator in
spread over .020 inch.) contact with drive gear flange face to take runout
(12) Remove dial indicator and remove differential readings as in steps 3, 4 and 5. Total allowable run
and ring gear assembly from axle housing. A light out should not exceed .003 inch. It is often possible to
prying action m ust be used to unseat the differential reduce high runout by positioning drive gear 180°
assembly from the housing (Fig. 13). Differential from point of maximum runout when re-assembling
bearing cups and preload adjusting spacers must be ring gear on differential case.
kept with respective bearing cones. Do not remove (18) W ith small drift remove differential pinion
spreader tool. shaft lock pin from drive gear side of case.
(13) Remove drive pinion and rear bearing assem (19) With a brass drift remove differential pinion
bly from axle housing. shaft.
PUNCH MARKS
PUNCH MARKS
N Y 1O 3 5
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(20) Rotate differential side gears until differential
pinions appear at differential case windows and re
roo«_
move.
(21) Remove differential side gears and thrust \
washers.
(22) Remove differential bearings using Tool C-293 :ry.)
and #44 plates (Fig. 14). M r
(23) Remove rear pinion bearing cone from pinion
stem using Tool C-293 and #40 plates (Fig. 15). \; y
r.
Cleaning and Inspection
(1) Clean all parts except axle shaft bearings with
a suitable cleaning solvent. With oil dampened cloth
wipe axle shaft bearing outer race. Clean off all rust
NY1031
and corrosion. To clean axle housing tubes insert a
stiff wire into tube, attach a clean cloth to wire at Fig. 15—Removing Rear Pinion Bearing Cone
center section and withdraw from center outward. bearing cone and cup assemblies should have a
(2) All machined contact surfaces in the axle hous smooth appearance with no broken or dented sur
ing and differential bearing caps should be smooth faces on rollers or roller contact surfaces. The bearing
and free of any raised edges. Front and rear pinion roller retainer cages m ust not be distorted or cracked.
bearing cup bore machined surfaces should be (7) Differential side gears and pinions should have
smooth. Raised metal on shoulders of bores incurred smooth teeth with a uniform contact pattern without
in removal of cups should be flattened by use of a excessive wear or broken surfaces. The differential
flat nosed punch. side gear hub surfaces and thrust washer contact sur
(3) The axle drive shaft bearing and oil seal bores faces should be smooth and free from any scoring or
at both ends of housing should be smooth and free of metal pickup.
rust and corrosion. This also applies to the brake sup (8) The machined thrust washer surface areas in
port plate and housing flange face area. side the differential case should be polished and with
(4) The axle shaft splines should be smooth and no surface imperfections. The pinion shaft bore in
free of excessive wear. The axle shaft oil seal journal differential case should be round and smooth. The
should be smooth and free of nicks, scratches or differential pinion shaft should be round and without
blemishes. To remove any imperfections polish with excessive wear in areas of contact with either differ
#600 crocus cloth (without reducing diam eter of axle ential case or differential pinions.
shaft oil seal surface). (9) The ring gear and drive pinion teeth should
(5) If axle shaft bearings, collars and retainers are have a uniform contact pattern with smooth and un
removed from shafts they are unfit for further use broken surfaces without excessive wear. Machined
and MUST BE REPLACED. Refer to axle shaft assem surfaces of the pinion stem (at points of contact with
bly procedure. either rear pinion bearing contact journal or rear pin
(6) Differential bearings and front and rear pinion ion bearing mounting shim surface) should be smooth.
TOOL
Assembling the Differential
Lubricate all parts when assembling and adjusting.
(1) Install thrust washers on differential side gears
PLATES (TOOL) and position gears in case.
V , (2) Place thrust washers on both differential pinion
gears and mesh the pinion gears with the side gears,
mm having pinion gears exactly 180° apart.
(3) Rotate side gears to align pinion gears and
washers with differential pinion shaft holes in case.
$ (4) Install differential pinion shaft with care not to
damage thrust washers. Hole in pinion shaft m ust
align with lock pin hole in differential case.
(5) Install lock pin in differential case from drive
gear tooth side.
' .... NY 1032 (6) Position drive gear on differential case to sepa
Fig* 1 4 —R e m o v i n g Differential B e a rin g Cone rate the points of maximum runout 180° apart and
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start all bolts through case into drive gear. Finger MAIN TOOL CENTRALIZING
tighten. (LEFT HAND THREAD.) WASHER
CROSS BORE ARBOR
(7) Tap drive gear against differential case flange
with non-metallic mallet. Tighten bolts to 55 foot GAUGE BLOCK
C COMPRESSION
pounds. \ NUT
(8) Install differential bearing cones with Tool COMPRESSION
C-4107 (Fig. 16). SLEEVE
CENTRALIZING
PINION BEARING CUP INSTALLATION SLEEVE
REAR SPACER
ARBOR
ti
TOOL-
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TOOL
OIL SEAL .
''SIDE PLAY’
NYT:G25A§ NK368B
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MEASURE BACKLASH
f o u r TEETH r ~-n
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DRIVE GEAR AND PINION BACKLASH (10) Tighten spreader tool nut sufficiently to obtain
.012" to .015" movement of dial indicator to perm it
(1) With drive pinion and bearings installed and installation of differential case assembly. Do not
bearing preload set, install differential case and ring spread over .020 inch.
gear assembly, and cups. Insert a .254 inch preload (11) Remove dial indicator.
adjusting spacer on ring gear side (Fig. 22) of axle (12) Holding differential assembly with bearing
housing. Do not install bearing caps. cups on respective bearing and selected preload
(2) Install a preload spacer on right side of housing
spacers, carefully install differential and ring gear
that will fit snugly but still leave a slight amount of
assembly into axle housing.
end play.
(3) To measure, move differential to the left side (13) Loosen spreader tool nut and remove spread
or ring gear side of rear axle housing. Using two sets er.
of feeler gauges, insert feeler gauges between the (14) Install differential bearing caps on respective
spacer and the right side of the axle housing above sides and alternate tightening bolts to 40 foot
the center line of the case (Fig. 23). Insert the same pounds.
thickness of feeler gauges between the spacer and (15) Install dial indicator to axle housing with indi
the axle housing below center line of case. Increase cator parallel to drive gear. With pointer of indicator
thickness of gauges until heavy drag is felt. contacting the drive side of ring gear tooth, m easure
(4) Rotate differential and ring gear assembly sev drive gear backlash. At least four readings should be
eral times in both directions to seat bearings and cups taken on teeth approximately 90° apart to find the
and re-check feeler gauge drag. point of least backlash, and m ark the tooth.
(5) Install a spacer totaling the combined thickness (16) At point of minimum backlash, dial indicator
of spacer and feeler gauge. This will provide zero should read .004 to .007 inch. If reading is not within
end play. this tolerance, it will be necessary to refer to chart
(6) Measure drive gear backlash at 4 positions at and Install Differential Spacers and re-check backlash
approximately 90 degrees intervals (Fig. 24). Refer to to bring within proper specifications.
“Differential Preload Spacer Chart” for selection of
(17) Apply a thin film of red or white lead on both
proper spacers to provide .004" to .007" backlash.
the drive and coast side of the drive gear teeth. Ro
(7) Remove differential case and ring gear assem
bly from axle housing. tate drive gear one complete revolution in both direc
(8) With proper spacers selected for left and right tions while prying with a round bar or screwdriver
sides of assembly as specified by “Differential Pre between the casting and differential case flange. This
load Spacer C hart”, attach spreader Tool C-3721 with action creates a load and produces a distinct tooth
tool dowel pins seated in locating holes of axle hous contact pattern on the drive gear teeth.
ing. Tighten tool screw only finger tight at this time. (18) Observe the contact pattern on the drive gear
(9) Install pilot stud Tool C-3288 on left side of teeth and compare with those in (Fig. 25) to deter
axle housing. Attach dial indicator and load indicator mine if pattern is properly located. If pinion depth
stem slightly against opposite side of axle housing of mesh and gear backlash are correct, the heaviest
(Fig. 12). most distinct part of contact pattern should be cen-
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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 + .010 -.000
.018 + .022 -.0 1 2 .008 + .008 + .002
.017 + .022 -.0 1 2 .007 + .0d8 + .002
.016 + .020 -.010 .006 + .006 + .004
.015 + .020 -.0 1 0 .005 + .004 + .006
.014 + .018 -.008 .004 + .002 + .008
.013 + .016 -.006 .003 + .002 + .008
.012 + .014 -.004 .002 + .000 + .010
.011 + .014 -.004 .001 + .000 + .012
aximum 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 recommended procedure.
tered on both drive and coast sides of the drive gear clean, install cover with new gasket on housing and
teeth. insert cover bolts and tighten to 20 foot-pounds.
If your tooth contact resembles that in (Fig. 26),
the drive pinion is too far away from centerline of REAR AXLE ASSEMBLY
the ring gear, the contact pattern will appear high on
the heel on drive side and high on toe on coast side. Installation
To correct this type tooth contact pattern, increase Refer to Paragraph "Axle Shaft Assembly" when
the thickness of the rear pinion bearing mounting installing the rear axle shafts.
spacer (Fig. 27), which will cause the high heel con (1) With body supported at front of rear spring,
tact on drive side to lower and move toward the toe; position rear axle assembly spring seats over the
the high toe contact on coast side will lower and move spring center bolts.
toward the heel. (2) Install spring “U” bolts and tighten nuts to 45
If the tooth contact pattern resembles that in (Fig. foot-pounds and install shock absorbers on spring
28), the drive pinion is too close to the ring gear, the plate studs.
pattern will appear low on the toe on drive side and (3) Connect hand brake cable.
low heel contact on the coast side. To correct this (4) Install propeller shaft (match scribe marks on
type tooth contact pattern, decrease the thickness of propeller shaft universal joint and pinion flange).
the rear pinion bearing mounting spacer (Fig. 29), Tighten clamp screws to 15 foot-pounds.
which will cause the low toe contact on drive side to (5) Connect brake lines to rear wheel cylinders and
raise and move toward the heel; low heel contact on connect hydraulic flexible line and bleed wheel cyl
coast side will raise and move toward the toe. inder.
(19) When correct tooth contact pattern is ob (6) Install brake drums, and rear wheels and tight
tained, and cover and gasket surface is thoroughly en to 55 foot-pounds and adjust brakes.
\ toe
h
END /
Fig. 2 5 —Desired Tooth Contact Pattern Fig. 2 6 —Incorrect Tooth Contact Pattern
Under Light Load (Increase Spacer Thickness)
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PATTERN MOVES TOWARD CENTER
AND D O W N PATTERN MOVES INWARD A ND UP
Fig. 2 7 —Effect on Tooth Contact Pattern as Spacer Fig. 2 9 —Effect on Tooth Contact Pattern as Spacer
Thickness is increased Thickness is Decreased
Chrysler Hypoid Lubricant part num ber 2933565 is an
THINNER SPACER NEEDED oil of this type and is recommended or an equivalent
be used.
In Sure-Grip axles on all 1970 Vehicles it is recom
mended that only Chrysler Hypoid Lubricant part
num ber 2933565 or an equivalent be used. This lubri
cant, recommended for conventional differentials too,
contains special additives to provide proper differen
tial durability and performance
Anticipated Temperature Viscosity Grade
Above —10°F. SAE 90
HEEL END—DRIVE As low as —30°F. SAE 80
SIDE (CONVEX) SIDE (CONCAVE) NR201 Below —30°F. SAE 75
Fig . 28 —Incorrect Tooth Contact Pattern "SHOULD THE REAR AXLE BECOME SUBMERGED
(Decrease Spacer Thickness) IN WATER, THE LUBRICANT MUST BE CHANGED
IMMEDIATELY TO AVOID THE POSSIBILITY OF
LUBRICATION EARLY AXLE FAILURE RESULTING FROM CON
Refill axle assembly with Multipurpose Gear Lubri TAMINATION OF THE LUBRICANT BY WATER
cant, as defined by MIL-L-2105B (API GL-5) should be DRAWN INTO THE VENT HOLE."
used in all rear axles with conventional differentials;
Page Page
Axle Shafts and B e a rin g s......................................... 15 Pinion Bearing Preload and Pinion
Axle Shaft End P l a y .................................................. 18 Setting Using Tool C-758-D-4.................................. 23
Differential and Carrier (Removal) ......................... 19 Small Stem Step Pinion ...................................... ... 24
Differential and Carrier (Installation) . . .................. 30 Large Stem Step P in io n........................................ ... 25
Differential Case ........................................................ 20 Large Stem Pinion With Collapsible S p a c e r ____27
Drive Gear and Pinion Backlash ...... ...................... 29 Pinion Bearing Preload and Pinion
Gear Tooth Contact Pattern ..................................... 30 Setting Without Using Tool C-758-D4................. ... 28
Lubrication .................................................................. 31 Rear Ax le Housing ................................. ...................... 18
Pinion Bearing Cup Installation ............................. 23 Removal and Replacement of Drive Pinion
Flange and Oil Seal in V ehicle................................ 31
GENERAL INFORMATION
The 8-3/4" Rear Axle Assembly shown in (Fig. 1), is with carrier, and the axle housing. Servicing of the
a semi-floating type and may be divided into four sub- above mentioned subassemblies, with exception of the
assemblies; flanged axle drive shafts with related axle housing may be performed without removing the
parts (Fig. 2.) differential with drive gear, drive pinion complete rear axle assembly from the vehicle.
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Gear ratio identification num bers will be stamped A new Sure-Grip Differential is available as optional
on a metal tag and attached by means of the rear equipm ent in both the 7-1/4" and 8-3/4" rea r axle
axle housing-to-carrier bolt. assembly. The Sure-Grip Differential is of a two
Some 8-3/4" large stem differential and carrier as piece construction sim ilar to the old type and is com
semblies have incorporated a collapsible spacer which pletely interchangeable with the previous type and
bears against the inner races of the front and rear will be serviced as a complete assembly only. Refer
bearing. This collapsible spacer is used to establish to the “Sure Grip Differential” Section of the Axle
preload on the pinion bearings. Group for the servicing procedure.
Adjustment of pinion depth of mesh is obtained by SHOULD THE REAR AXLE BECOME SUBMERGED
placing a machined shim between the pinion head and IN WATER, THE LUBRICANT MUST BE CHANGED
the rear bearing cone. IMMEDIATELY TO AVOID THE POSSIBILITY OF
The differential bearings are larger on both the con EARLY AXLE FAILURE RESULTING FROM CON
ventional and Sure-Grip Differentials and are not in TAMINATION OF THE LUBRICANT BY WATER
terchangeable with previous years bearings. DRAWN INTO THE VENT.
SERVICE PROCEDURES
AXLE SHAFTS AND BEARINGS retainer plate will have a lock under one of the studs
that should be removed at this time.
CAUTION: It is absolutely necessary that anytime an (3) Remove parking brake strut.
axle assembly is serviced, and the axle shafts are (4) Attach axle shaft rem over Tool C-3971 (Fig. 3)
loosened and removed, the axle shaft gaskets and to axle shaft flange and remove axle shaft. Remove
inner axle shaft oil seals must be replaced. brake assembly and gaskets.
(5) Remove axle shaft oil seal from axle housing
Removal using Tool C-637 (Fig. 4).
(1) With wheels removed, remove clips holding (6) Wipe axle housing seal bore clean and install a
brake drum on axle shaft studs and remove brake new axle shaft oil seal using Tool C-839 (Fig. 5).
drum.
(2) Using access hole in axle shaft flange, remove Disassembly
retainer nuts, the right shaft with threaded adjuster in CAUTION: To prevent the possibility of damaging
RIGHT
> / n bolt
^G ASKET
SHAFT
NUT
STUD
'CARRIER A N D CAP
FLANGE
OIL SEAL
RETAINER' NK967B
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TOOl
NK59A
ADAPTER
f ! x / "^*^4 WASHERS SP-5015 OR SP-5168
V SP-320
SLEEVE
SP-5041
II
SLEEVE RING-BLOCK
SP-5041 HOLDING SP-5017 NK360A • ■>. .N K 127A
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sleeve
SP-50'.;';
MK356
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BEARING
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NK558 (I
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NK362
Fig. 13—Installing N e w Bearing And Collar Fig. 14—Measuring A xle Shaft End Play
(4) Inspect axle shaft seal journal for scratches and TERCLOCKWISE APPROXIMATELY FOUR NOTCH
polish with #600 crocus cloth if necessary. ES TO ESTABLISH AN AXLE SHAFT END PLAY
OF .008-.018 INCH.
Installation (2) Tap end of left axle shaft lightly with a non-
(1) Clean axle housing flange face and brake sup metallic mallet to seat right wheel bearing cup
port plate thoroughly. Install a new rubber asbestos against adjuster, and rotate axle shaft several revolu
gasket on axle housing studs, followed by brake sup tions so that a true end play reading is indicated.
port plate assembly on left side of axle housing. (3) Remove one retainer plate nut, install adjuster
(2) Apply a thin coating of Multi-Purpose Grease, lock. If tab on lock does not mate with notch in ad
NLGI grade 2 E.P. or equivalent to the outside diam juster, turn adjuster slightly until it does. Install nut
eter of the bearing cup prior to installing in the and tighten 30-35 foot-pounds.
bearing bore. This operation is necessary as a corro (4) Recheck axle shaft end play. If it is not within
sion preventative. the tolerance of .008-.018 inch, then repeat adjust
(3) Install foam gasket on the studs of axle housing m ent procedure.
and carefully slide axle shaft assembly through oil (5) Remove dial indicator and install brake drum,
seal and engage splines in differential side gear. drum and wheel.
(4) Tap end of axle shaft lightly with a non-
metallic m allet to position axle shaft bearing in hous REAR AXLE HOUSING
ing bearing bore. Position retainer plate over axle
Removal
housing studs. Install retainer nuts and tighten 30-35 Should it become necessary to remove rear axle
foot-pounds. Start by tightening bottom nut. assembly for repair proceed as follows:
(5) Repeat step (1) for right side of axle housing. (1) Raise vehicle and support body at front of rear
(6) Back off threaded adjuster of right axle shaft springs.
assembly until inner face of adjuster is flush with (2) Block brake pedal in the up position using a
inner face of retainer plate. Carefully slide axle shaft wooden block.
assembly through oil seal and engage splines in dif (3) Remove rear wheels.
ferential side gears. (4) Disconnect hydraulic brake hose at connection
(7) Repeat step (4). on left side of underbody.
(5) Disconnect parking brake cable.
AXLE SHAFT END PLAY To maintain proper drive line balance when reas
sembling, make scribe marks on the propeller shaft
CAUTI ON: When setting axle shaft end play, both universal joint and the pinion flange before removal.
rear wheels must be off the ground, otherwise a false (6) Disconnect propeller shaft at differential yoke
end play setting will occur. and secure in an upright position to prevent damage
(1) Using a dial indicator m ounted on the left to front universal joint.
brake support (Fig. 14), TURN THE ADJUSTER (7) Remove shock absorber from spring plate studs
CLOCKWISE UNTIL BOTH WHEEL BEARINGS ARE and loosen rear spring “U” bolt nuts and remove “U”
SEATED AND THERE IS ZERO END PLAY IN THE bolts.
AXLE SHAFTS. BACK OFF THE ADJUSTER COUN- (8) Remove the assembly from vehicle.
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Installation
(1) With body of vehicle supported at front of rear
springs, position the rear axle assembly spring seats
over the spring center bolts.
(2) Install spring “U” bolts and tighten nuts to 45
foot-pounds and install shock absorbers on spring
plate studs. (DO NOT OVER TIGHTEN “U” BOLT
NUTS.)
(3) Install propeller shaft (match scribe marks on
propeller shaft universal joint and pinion flange).
Tighten clamp screws to 15 foot-pounds.
(4) Connect parking brake cable.
(5) Connect hydraulic brake hose, bleed and adjust
brakes.
(6) Install rear wheels.
I KP19
(7) If carrier was removed from axle housing dur Fig. IS —Cheeking fo r Runout and Zero End Play
ing the removal operation, fill axle with proper
exceeds .005 inch the differential case may be dam
amount and type of lubricant; see “Specifications” in
aged, and a second reading will be required after
Lubrication section Group “0 ”.
drive gear has been removed. This operation is cov
ered during “Differential Disassembly”. Remove dial
W elding Rear A x le Housing indicator.
The axle housing should be completely disassem
(3) With Tool C-3281 hold companion flange and
bled if it is to be welded with arc welding equip
remove drive pinion nut and Belleville washer.
ment. It is also possible to weld the assembled hous
(4) Install companion flange remover Tool C-452
ing with gas welding equipment, if precaution is
and remove flange (Fig. 16).
taken to protect gaskets and heat treated parts.
(5) Using a screwdriver and hammer, remove the
drive pinion oil seal from the carrier.
DIFFERENTIAL AND CARRIER (6) While holding one hand over nose end of car
rier, invert carrier in stand. The front pinion bearing
Removal cone, shim pack and bearing spacer (where used) will
(1) Remove flanged axle drive shafts.
drop from carrier.
(2) Disconnect rear universal joint and support
(7) Apply identifying punch marks on differential
propeller up and out of the way to prevent damage
bearing pedestals of carrier, differential bearing caps
to the front universal joint.
and bearing adjusters for reassembly purposes (Fig.
(3) Remove the rear axle lubricant.
17).
(4) Loosen and remove the carrier-to-housing at
(8) Remove both differential bearing adjuster lock
taching nuts and lift the carrier assembly from axle
screws and locks.
housing.
(9) With a 3 /4 inch socket, loosen bearing cap bolts
(one on each side) and back off bearing adjusters
Disassembly
Side play and runout check taken during disassem slightly using spanner wrench Tool C-406A; to re
bly will be very useful in reassembly. move differential bearing preload. Remove bearing
(1) Mount carrier in Stand DD-1014 and attach dial cap bolts, caps and bearing adjusters.
indicator Tool C-3339 to differential carrier flange in
a position so pointer of indicator squarely contacts
back face of ring gear (Fig. 15). With a screw driver
positioned between bearing cap and differential case
FLANGE
TOOL P
flange, then using a prying motion determ ine if side
play is present. If side play is evident, remove adjuster
lock and loosen adjuster slightly and retighten ad
juster sufficiently to eliminate side play.
(2) Rotate drive gear several complete revolutions
while noting total indicator reading. Mark drive gear
and differential case at point of maximum runout. The iP »
TOOL'"*’
marking of differential case will be very useful later
KP5B
in checking differential case runout. Total indicator
reading should be no more than .005 inch. If runout
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SCRIBE MARKS
(3) If drive gear runout exceeded .005 inch in
PUNCH MARKS
step 2 (under “Carrier Disassembly”), recheck the case
/
as follows: Install differential case and respective
bearing cups in carrier.
(4) Install bearing caps, cap bolts and bearing ad
justers. Tighten bearing cap bolts down tightly and
screw in both adjusters with spanner wrench Tool
C-406A.
(5) Tighten cap bolts and adjusters sufficiently to
prevent any side play in bearings.
WtMm (6) Attach a dial indicator Tool C-3339 to carrier
flange so pointer of indicator squarely contacts drive
gear surface of differential case flange between outer
edge flange and drive gear bolt holes (Fig. 19).
(7) Rotate differential case several complete revo
KP2 lutions while noting total indicator reading. This
reading must not exceed .003 inch runout. If runout
Fig. 17—M ark in g Bearing Caps and Adjusters is in excess of .003 inch, differential case must be re
(10) Remove differential and ring gear assembly placed. In a case where the runout does not exceed
with bearing cups. Differential bearing cups m ust be .003 inch it is often possible to reduce the runout by
kept with respective bearing cones. positioning the drive gear 180° from point of maxi
(11) Remove drive pinion and rea r bearing assem mum runout when reassembling drive gear on dif
bly from carrier. ferential case.
(8) With a flat nose drift and hammer, remove dif
Rear Pinion Bearing Rem oval ferential pinion shaft lock pin from back side of drive
(1) Remove drive pinion rear bearing from small gear flange. (The hole is reamed only part way
stem pinion with Tool C-293 and four (4) No. 36 plates, through, making it necessary to remove lock pin from
or four (4) No. 37 plates on large stem step pinion or one direction.)
large stem pinion using a collapsible spacer (Fig. 18). (9) With a brass drift and hammer, remove dif
(2) Using a flat end brass drift, remove front and ferential pinion shaft and axle drive shaft thrust
rear pinion bearing cups. block.
(10) Rotate differential side gears until each dif
DIFFERENTIAL CASE ferential pinion appears at large opening of case.
Remove each pinion and thrust washer at that time.
Disassembly (11) Remove both differential side gears and thrust
(1) Mount differential case and ring gear assembly washers.
in a vise equipped with soft jaws (brass).
(2) Remove drive gear bolts. BOLTS ARE LEFT Cleaning a nd Inspection (Figs. 2 0 ,2 1 and 22).
HAND THREAD. W ith a non-metallic hammer, tap (1) Clean all parts in a fast evaporating m ineral
drive gear loose from differential case pilot and
remove.
V ;
V, _
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N*§ I ..Ai'-m
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KP7A
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T HRUST
WASHER BOLT AND LOCKWASHER
SHAFT
DIFFERENTIAL CASE SPACER
BEARING
CONE PIN
/ BEARING CONE
CUP
WASHER.
SIDE GEAR
ADJUSTING WASHER
THRUST WASHER
BEARING CONE
PINIO N BOLT A ND LOCICWASHER
THRUST BLOCK ADJUSTER
SIDE GEAR
fHRUST WASHER THRUST WASHER KP2B
GUARD
& ■■■. \ X- >1 ""''-P l.UG \
/€r ■' i ... CUP
CAP
7 / j J ^ -A D JU S T E R
j SIDE GEAR
THRUST WASHER \ x THRUST BLOCK j B° Lf V\ ^ L O C K
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SHAFT
THRUST WASHER S O U AND LOCKWASHER
DIFFERENTIAL CASE
LOCK BEARING CONE
PIN COLLAPSIBLE
BEARING CONE ADJUSTER SPACER
CARRIER
CUP CAP
:a p I ^ /
V, 'YS\ ✓ J > DRIVE GEAR
AND PINION
WASHER
GUARD
PLUG
-CAP WASHER
'ADJUSTER
I SIDE GEAR WASHER
-LOCK
THRUST WASHER NTHRUST BLOCK
PINION THRUST WASHER BEARING CONE "BOLT AND LOCKWASHER
SIDE GEAR
THRUST WASHER KP1D
J
" ■ m .'
spacer. Replace if necessary during establishment of
pinion bearing preload.
ASSEMBLY
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(5) Install thrust block through side gear hub, so GAUGE BLOCK SP-528 OR SP-3250 8Y4" SLEEVE SP-2920
that slot is centered between the side gears. AND 9%if AXLE
(6) While keeping all of these parts in proper
*
WRENCH Ik CROSSBORE ARBOR
SP-561 8%" AXLE
alignment, push pinion shaft into case until locking p a * ~ SP-5183 9 3/4" AXLE
pin hole in pinion shaft is in exact alignment with its
respective hole in case. Install pinion shaft lock pin SCREW COMPRESSION
SLEEVE SP-535
through hole in case from pinion shaft side of drive SP-538
MAIN BODY
gear flange. The contacting surfaces of the drive gear SP-526
and differential case flange must be clean and free of ~ SPACER SPACER
all burrs. ^WASHER
HER (V -W A S H E R
SP-1371
371 SP-3639
(7) Using an Arkansas stone, relieve the sharp edge SLEEVE
_ ^CENTRALIZING
of the chamfer on the inside diam eter of the ring gear SM 370 _ SP-2921 OR 5 3 8 7 C? WASHER
(Fig. 24). This is very important otherwise during the 8%" AXLE SP-534
SJ SP-5184 9%" AXLE
installation of ring gear on differential case, the sharp COMPRESSION
edge wil l remove metal from the pilot diameter of PINION
•'^ .L O C A T IN G NUT SP-533
case and can get imbedded between differential case SLEEVE SPACER W SPACER SPACER
SP-2919 SP-539
flange and gear; causing gear not to seat properly. SP-1682 SP’ 1 7 3 0 NU418A
(8) Position drive gear on differential case pilot, Fig. 2 5 —Rear A x le Setting Gauge Tool C-758-D4
aligning threaded holes of drive gear with those in
differential case flange. ing spacer SP-2919 followed by rea r pinion bearing
(9) Insert drive gear screws (LEFT HAND cone over main screw of tool and inserting it into
THREADS) through case flange and into drive gear. carrier from gear side.
After all cap screws are properly started, tap drive (2) Place front pinion bearing cone over main
gear against differential case flange with a non- screw of tool followed by compression sleeve SP-535,
metallic mallet. centralizing washer SP-534, and main screw nut SP-
(10) Position unit between brass jaws of a vise and 533. Hold compression sleeve with the companion
alternately tighten each cap screw to 55 foot-pounds. flange holding Tool C-3281 and tighten nut (Fig. 26),
(11) Position each differential bearing cone on hub allowing tool to rotate as nut is being tightened in
of differential case (taper away from drive gear) and order not to brinnel bearing cone or cups. Do not
with installing Tool C-4086, install bearing cones. remove tool after installing cups.
An arbor press may be used in conjunction with in
stalling tool. PINION BEARING PRELOAD AND DEPTH OF
CAUTION: Never e x ert pressure against the bearing MESH SETTING USING TOOL C-758-D4
cage, since this would damage the bearing.
The 8-3/4" axle incorporates three types of pinions.
The method of determ ining pinion depth of mesh and
PINION BEARING CUP INSTALLATION
bearing preload are the same for the small and large
(1) Position pinion bearing cups squarely in bores stem step pinions; however, the sequence of making
of carrier. Assemble Tool C-758-D4 (Fig. 25), by plac- the two adjustments change. Small stem pinions re
quire the bearing preload adjustm ent first while large
stem step pinions require the depth of mesh adjust
ment first. The large stem pinion using a collapsible
■ '■-*r-.-' • - ..............
Fig. 2 4 —Stoning C ham fer o f Ring G e ar Fig. 2 6 —Seating Bearing Cups in Carrier Housing
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spacer for bearing preload requires the depth of mesh
setting first also.
The position of the drive pinion with respect to the
drive gear (depth of mesh) is determ ined by the loca
tion of the bearing cup shoulders in the carrier and
by the portion of the pinion in back of the rear bear
ing. The thickness of the rear pinion bearing m ount
ing shim suitable for the carrier can be determ ined
by using Tool C-758-D4.
Bearing Preload
(1) W ith tool installed in carrier, remove main
screw nut, centralizing washer, compression sleeve
and front pinion bearing cone.
(2) Install the pinion bearing spacer, larger bore of Fig. 2 8 —Installing Gauge Block on Tool
spacer next to rear bearing. wrench is moving through several complete revolu
(3) Position sleeve (SP-1730) in front bearing cone tions. Correct preload setting is 20-30 inch-pounds
making sure sleeve is flush with rear of bearing. for a new bearing and 0-15 inch-pounds for orig
(4) Position original shims, previously removed inal bearing. Bearing preload should be uniform
from drive pinion stem, over the sleeve and slide the during complete revolution. A reading that varies
sleeve, bearing and shims over main screw of tool considerably during rotation of pinion indicates a
until shims rest against spacer (Fig. 27). binding condition which requires correction. Use a
(5) Install tool compression sleeve (SP-535) (square thinner shim pack to increase preload and a thicker
end out), centralizing washer (SP-534) and main screw shim pack to decrease preload. Preload shims are
nut (SP-533). Turn carrier in stand to bring nut on top. available in two thousandths of an inch increments
(6) Tighten tool nut to 240 foot-pounds with a from .014-.026 inch.
torque wrench, using holding Tool C-3281 on the After correct pinion bearing preload is set, DO
compression sleeve to hold the assembly in several NOT REMOVE THE TOOL.
positions to make a complete revolution while tight
ening. Remove holding tool and rotate the pinion
Depth of Mesh
several revolutions in both directions to seat the
(1) Reverse carrier in stand and install gauge block
bearing rollers. Recheck torque to 240 foot-pounds
SP-528 on end of tool and securing it to tool with
(torque may have diminished as bearing rollers were
Allen screw. The flat portion of gauge block should
seated by rotating). Correct bearing preload reading
be facing differential bearing pedestals (Fig. 28).
can only be obtained with nose of carrier up.
Tighten screw with Allen wrench.
(7) Using inch-pound torque wrench C-685, m eas
(2) Position arbor SP-561 (part of Tool C-758-D4)
ure pinion bearing preload by rotating pinion with
in differential bearing pedestals of carrier (Fig. 29).
handle of wrench floating, read the torque while
Center the arbor so that an approximate equal dis
tance is maintained at both ends. Position differential
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bearing caps and attaching bolts on carrier pedestals, (10) Using installing Tool DD-996 press bearing on
and insert a piece of .002 inch shim stock between pinion stem. An arbor press may be used in conjunc
arbor and each cap. Tighten cap bolts to 10 foot tion with tool.
pounds. (11) Install bearing tubular spacer on pinion stem
(3) Select a rear pinion bearing mounting shim (large bore facing rear bearing cone).
which will fit between cross arbor and gauge block. (12) Install selected shim pack.
This fit must be snug but not too tight (similar to the (13) Lubricate front and rear pinion bearing cones
pull of a feeler gauge) (Fig. 30). This shim is then with lubricant as specified in (Lubrication Group
used in determining the correct thickness shim for “ O ” ).
installation. (14) Position front pinion bearing cone in its cup in
(4) To select a shim for installation, read the m ark carrier.
ing on end of pinion head (—0, — 1, —2, + 1 , + 2 etc.). (15) Apply a light coat of sealer in seal bore of
When marking is —(minus), add that amount to the carrier and install drive pinion oil seal into carrier
thickness of shim selected in step (3). When the m ark using Tool C-4109 or C-3980 (double lip synthetic rub
ing is + (plus), subtract that amount. Example: With ber oil seal) or Tool C-3656 (single lip leather oil seal).
a shim .086 inch thick and a pinion m arked — 2, The proper tool must be used in order to position the
install a shim .088 inch thick. (.086 + .002 = .088). seal the proper depth into the carrier casting.
Example: With a shim .086 inch thick and a pinion (16) Insert drive pinion and bearing assembly up
m arked + 2 , install a washer .084 inch thick, (.086 through carrier. While supporting pinion in carrier,
— .002 = .084) or when a shim .086 inch thick is too install companion flange with installing Tool C-496 or
loose and .088 inch too tight, use .086 inch shim. DD-999 and holding Tool C-3281.
Treat other pinion markings in a similar manner. (17) Remove tools and install Belleville washer
Shims are available in two thousandths of an inch (convex side of washer up) and pinion nut.
increments. Mounting shims differ in diameter, de (18) Hold companion flange with holding Tool C-
pending on which pinion they are used on. 3281 and tighten pinion nut to 240 foot-pounds. Ro
(5) Remove tool arbor from carrier. tate pinion several revolutions in both directions to
(6) Remove tool and bearings out of carrier. seat bearing rollers. Recheck torque to 240 foot
(7) Remove shims, spacer, tool sleeve and rear pounds (torque may have diminished as bearing
bearing cone from tool main screw. rollers were seated by rotating).
(8) With stem of pinion facing up, install correct
shim on pinion stem. Shims are chamfered on one PINION BEARING PRELOAD
side and must be installed on the pinion stem with (Large Stem Step Pinion)
chamfered side toward pinion head.
(9) Position rear bearing cone on pinion stem Inspect bearing cups and carrier for grit and dirt or
other foreign material. Clean all parts in a fast evapo
(small side away from pinion head). Make certain that
rating mineral spirits or a dry cleaning solvent and
the contacting surfaces of correct shim, pinion head
with the exception of bearing cones, dry with com
shim contact surface and rear bearing cone are per pressed air.
fectly clean and free of any foreign particles. (1) Assemble spacer SP-2921 to main section of
tool followed by spacer SP-1730. Install rear pinion
bearing cone over spacer SP-1730 and against spacer
Jfe SP-2921 (Fig. 31).
$$"• SP-561 PINION LOCATING WASHER
1 / SP-3250
N O WASHER OR SPACER
_SP-1730
4 ,
■
S P -5387 ASSEMBLY OF S P -526 NU419
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(2) Insert assembly into carrier and install front (11) Remove rear pinion bearing cone from tool.
pinion bearing cone over tool shaft and in its proper (12) Remove front pinion bearing cone from carrier
position in bearing cup. Install tool spacer, tool thrust housing.
washer and tool nut on shaft. (13) With stem of drive pinion facing up, add rear
(3) With nose of carrier up, place flange holding pinion bearing mounting shim you selected on pinion
Tool C-3281 on compression sleeve. Allow assembly stem. Shims are cham fered on one side and must be
to rotate while tightening nut to not more than 25-50 installed on the pinion stem with chamfered side to
foot-pounds. Always make sure bearing cones are ward pinion head.
lubricated with hypoid gear lubricant. (14) Position rear pinion bearing cone on pinion
(4) Turn tool several complete revolutions in both stem (small side away from pinion head). Make cer
directions to permit bearing rollers to seat. After tain that the contacting surfaces of correct shim,
bearing rollers are properly seated, check bearing pinion head shim contact surface and rear bearing
preload by rotating tool with an inch-pound torque cone are perfectly clean and free of any foreign par
wrench. The correct bearing preload should be from ticles.
20-30 inch-pounds for new bearings and 0-15 inch- (15) Lubricate front and rear pinion bearing cones
pounds for the original bearings. with hypoid gear lubricant. Install rear bearing cone
(5) With proper bearing preload set, invert carrier onto pinion stem, using Tool DD-996, press bearing
in stand and install gauge block SP-528 or SP-3250 cone into place. An arbor press may be used in con
to the main screw attaching it with Allen screw se junction with tool.
curely (Fig. 28). The flat portion of gauge block should (16) Insert pinion and bearing assembly up through
be facing differential bearing pedestals. carrier and install the original preload shim pack on
(6) Position tool arbor SP-561 in differential bear pinion stem.
ing pedestals of carrier (Fig. 29). Center the arbor so (17) Install front pinion bearing cone on pinion
that an approximate equal distance is maintained at stem followed by drive pinion flange, bellville wash
both ends. Position differential bearing caps and at er and nut. Using flange holding Tool C-3281 and
taching bolts on carrier pedestals, and insert a piece torque wrench, tighten pinion nut to 240 foot-pounds.
of .002 inch shim stock between arbor and each cap. Hold the assembly in several positions to make a com
Tighten cap bolts to 10 foot-pounds. plete revolution while tightening.
(7) Select a rear pinion bearing mounting shim (18) Remove holding tool and rotate tool several
which will fit between cross arbor and gauge block. complete revolutions in both directions to permit
This fit must be snug but not too tight (similar to the bearing roller to seat. Recheck torque to 240 foot
pull of a feeler gauge. (Fig. 30). This shim is then pounds (torque may have diminished as bearing roll
used in determining the correct thickness shim for ers seated).
installation. (19) Measure pinion bearing preload by rotating
(8) To select a shim for installation, read the mark pinion using an inch-pound torque wrench. The cor
ing on end of pinion head (—0, — 1, —2, + 1, +2, rect preload specifications are 20-30 inch pounds for
etc.). When marking is — (minus), add that amount to new bearing and 0-15 for original bearings. Correct
the thickness of shim selected in step (7). When the bearing preload readings can only be obtained with
marking is + (plus), subtract that amount. Example: nose of carrier in up right position. Bearing preload
With a shim .086 inch thick and a pinion marked —2, should be uniform during complete revolution. A
install a shim .088 inch thick (.086 -f .002 = .088). reading that varies during rotation indicates a bind
Example: With a shim .086 inch thick and a pinion ing condition which should be corrected. Use a thin
marked + 2, install a washer .084 inch thick, (.086 ner shim pack to increase preload and a thicker shim
— .002 = .084) or when a shim .086 inch thick is too pack to decrease preload. Preload shims are available
loose and .088 inch too thick, use .086 inch shim. in two thousandths of an inch increments from .014-
Treat other pinion markings in a similar manner. .026 inch.
Shims are available in two thousandths of an inch (20) Loosen and remove drive pinion nut, washer
increments. Mounting shims differ in diameter, de and flange after proper bearing preload has been
pending on which pinion they are used on. established.
(9) Remove differential bearing caps and remove (21) Apply a light coat of sealer in seal bore of
tool arbor from carrier. carrier and install drive pinion oil seal into carrier
(10) Reverse carrier in stand so nut of tool is in up using Tool C-4109 or C-3980 (double lip synthetic rub
right position. Loosen compression nut, and support ber oil seal) or Tool C-3656 (single lip leather oil seal).
lower portion of tool in carrier with one hand, re The proper tool must be used in order to position the
move tool nut, centering washer and compression seal the proper depth into the carrier casting.
sleeve. Lower tool down and out of carrier. (22) While supporting pinion in carrier, install
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companion flange with installing Tool C-496 or DD- used in determ ining the correct thickness shim for
999 and holding Tool C-3281. installation.
(23) Remove tools and install Belleville washer (8) To select a shim for installation, read the m ark
(convex side of washer up) and pinion nut. ing on end of pinion head (— 0, — 1, —2, + 1 , + 2 ,
(24) Hold universal joint flange with holding Tool etc.). When m arking is — (minus), add that amount to
C-3281 and tighten pinion nut to 240 foot-pounds. the thickness of shim selected in step (7). When the
Rotate pinion several revolutions in both directions to marking is + (plus), subtract that amount. Example:
seat bearing rollers. Recheck torque to 240 foot With a shim .036 inch thick and a pinion m arked — 2,
pounds (torque may have diminished as bearing install a shim .038 inch thick (.036 + .002 = .038).
rollers were seated by rotating). Example: With a shim .036 inch thick and a pinion
marked + 2, install a washer .034 inch thick, (.036
DEPTH OF MESH — .002 = .034) or when a shim .036 inch thick is too
loose and .038 inch too thick, use .036 inch shim.
(Large Stem Pinion With Collapsible Spacer) Treat other pinion markings in a similar manner.
Inspect differential bearing cups and cones, carrier Shims are available in one thousandths of an inch
for grit and dirt or other foreign material. Clean all increments.
parts in fast evaporating mineral spirits or a dry (9) Remove differential bearing caps and remove
cleaning solvent and with the exception of bearing tool arbor from carrier.
cones, dry with compressed air. Front Pinion Bearing (10) Reverse carrier in stand so nut of tool is in up
Cone and Cup Must Never Be Reused Under Any right position. Loosen compression nut, and support
Circumstances. lower portion of tool in carrier with one hand, re
(1) Assemble spacer SP-5387 to main section of move tool nut, centering washer and compression
tool followed by spacer SP-1730. Install rear pinion sleeve. Lower tool down and out of carrier.
bearing cone over spacer SP-1730 and against spacer (11) Remove front pinion bearing cone from carrier
SP-5387 (Fig. 31). housing.
(2) Insert assembly into carrier and install front (12) With stem of drive pinion facing up, add rear
pinion bearing cone over tool shaft and in its proper pinion bearing mounting shim you selected on pinion
position in bearing cup. Install tool spacer, tool thrust stem.
washer and tool nut on shaft.
(3) With nose of carrier up, place flange holding PINION BEARING PRELOAD
Tool C-3281 on compression sleeve. Allow assembly (Large Stem Pinion With Collapsible Spacer)
to rotate while tightening nut to not more than 25-50
foot-pounds. Always make sure bearing cones are (1) Position rear pinion bearing cone on pinion stem
lubricated with hypoid gear lubricant. (small side away from pinion head). Make certain that
(4) Turn tool several complete revolutions in both the contacting surfaces of selected shim, rear bearing
directions to perm it bearing rollers to seat. After cone and pinion head are perfectly clean and free of
bearing rollers are properly seated, check bearing any foreign particles.
preload by rotating tool with an inch-pound torque (2) Lubricate front and rear pinion bearing cones
wrench. The correct bearing preload should be from with hypoid gear lubricant. Install rear pinion bearing
20-30 inch-pounds for new bearings. cone onto pinion stem, using Tool C-3095, press bear
(5) With proper bearing preload set, invert carrier ing cone into place. An arbor press may be used in
in stand and install gauge block SP-528 or SP-3250 conjunction with tool.
to the main screw attaching it with Allen screw se (3) Insert drive pinion and bearing assembly up
curely (Fig. 28). The flat portion of gauge block should through carrier and install collapsible spacer followed
be facing differential bearing pedestals. by front pinion bearing cone on pinion stem. Install
(6) Position tool arbor SP-561 in differential bear companion flange using Tool C-496 or DD-999 and
ing pedestals of carrier (Fig. 29). Center the arbor so holding Tool C-3281. This is necessary in order to
that an approximate equal distance is m aintained at properly install front pinion bearing cone on stem
both ends. Position differential bearing caps and at due to interference fit. Remove tool from pinion stem.
taching bolts on carrier pedestals, and insert a piece CAUTION: During the installation of the front pinion
of .002 inch shim stock between arbor and each cap. bearing be careful not to collapse the spacer.
Tighten cap bolts to 10 foot-pounds. (4) Apply a light coat of sealer in seal bore of car
(7) Select a rear pinion bearing mounting shim rier casting and install drive pinion oil seal into car
which will fit between cross arbor and gauge block. rier using Tool C-4109 or C-3980 (double lip synthetic
This fit must be snug but not too tight (similar to the rubber oil seal) or Tool C-3656 (single lip leather oil
pull of a feeler gauge. (Fig. 30). This shim is then seal). The proper tool must be used in order to position
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the seal the proper depth into the carrier casting. stem pinion with collapsible spacer).
(5) With pinion supported in carrier, install anti To select the proper thickness shim, proceed as fol
clang washer on pinion stem. Install companion flange lows: It will be noted that the head of the drive pinion
with installing Tool C-496 or DD-999 and holding Tool is marked with a plus (+) or minus (—) sign followed
C-3281. by a number ranging from 1 to 4, or zero (0) marking.
(6) Remove tools and install Belleville washer (con
vex side of washer up) and pinion nut. D epth o f M esh
(7) Hold universal joint flange with holding Tool If the old and new pinion have the same marking
C-3281 and tighten pinion nut to remove end play in and if the original bearing is being reused, use a
pinion, while rotating the pinion to insure proper bear mounting shim of the same thickness. But if the old
ing seating. pinion is marked zero (0) and the new pinion is
(8) Remove holding tool and rotate pinion several marked +2, try a .002 inch thinner shim. If the new
complete revolutions in both directions to permit bear pinion is marked —2, try a .002 inch thicker shim.
ing rollers to seat.
(9) Tighten pinion nut to 100 foot-pounds and meas P inion B e a rin g P re lo a d
ure pinion bearing preload by rotating pinion using an If the bearings are being replaced, place the new
inch-pound torque wrench. The correct preload speci bearing cup in position in the carrier and drive the
fications are 20-35 inch-pounds for new bearings or cups in place with a suitable drift. After properly
10 inch-pounds over the original if the old rear pinion positioning the bearing cups in the carrier, assemble
bearing is being reused. Correct bearing preload read the drive pinion mounting shim (chamfered side
ings can only be obtained with nose of carrier in up down toward gear) on the drive pinion stem. Install
right position. Continue tightening of pinion nut in the tubular spacer (if so equipped) and the preload
small increments and checking pinion bearing preload shims on the pinion stems. Insert the pinion assembly
until proper preload is obtained. Bearing preload into the carrier. Install the front pinion bearing cone,
should be uniform during complete revolution. A pre universal joint flange, Belleville washer (convex side
load reading that varies during rotation indicates a of washer up) and nut. DO NOT INSTALL THE OIL
binding condition which has to be corrected. The as SEAL. Rotate the drive pinion after tightening the
sembly is unacceptable if final pinion nut torque is flange nut to 240 foot-pounds, to properly seat the
below 170 foot-pounds or pinion bearing preload is not bearing rollers in the bearing cups. The preload
within the correct specifications. torque required to rotate the pinion with the bearings
NOTE: UNDER NO CIRCUMSTANCES SHOULD THE oiled should be 20-30 inch-pounds for new bearing
PINION NUT BE BACKED OFF TO LESSEN PRE and 0—15 inch-pounds for used bearings. Use a
LOAD. IF THIS IS DONE A NEW COLLAPSIBLE thinner shim pack to increase preload and a thicker
SPACER MUST BE INSTALLED AND NUT RE shim pack to decrease preload. After the correct pin
TIGHTENED UNTIL PROPER PRELOAD IS OB ion depth of mesh has been established and correct
TAINED. bearing preload obtained, remove the drive pinion
flange. Apply a light coat of sealer to drive pinion oil
PINION BEARING PRELOAD AND PINION seal and carrier casting bore and install drive pinion
SETTING (Without Using Tool C-758-D4) oil seal with Tool C-4109 or C-3980 (synthetic rubber
If the differential assembly was satisfactorily quiet seal) or Tool C-3656 (leather seal). Install the pinion
before being disassembled, the drive pinion may be flange, washer and nut and tighten nut to 240 foot
assembled with the original components. If replace pounds.
ment parts are installed, a complete readjustment is
necessary; the proper thickness shim must be selected P inion B e arin g P re lo a d (Large Stem Pinion
and installed. The drive gear and pinion are manu w it h C o llap sib le Spacer)
factured and lapped in matching sets and are avail After selecting the correct pinion bearing mounting
able in matched sets only. The adjustment position in shim and installing it behind the rear pinion bearing
which the best tooth contact is obtained is marked on cone proceed as follows: Install the pinion assembly
the end of the pinion head. into the carrier. Install the new collapsible spacer fol
To obtain the proper pinion setting in relation to lowed by new front pinion bearing cone on pinion
the drive gear, the correct thickness mounting shim stem. Press front pinion bearing cone on pinion stem,
must be selected before the drive pinion is installed being careful not to collapse the spacer.
in the carrier. The pinion bearing mounting shims are Apply a light coat of sealer to drive pinion oil seal
available in two thousandths increments from .084 to and carrier casting bore and install drive pinion oil
.100 inch, (small stem or large stem step type pinions) seal with Tool C-4109 or C-3980 (synthetic rubber seal
or .020-.038 inch in increments of .001 inch (large or Tool C-3656 (leather seal). Install anti-clang washer
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and universal joint flange, Belleville washer (convex properly set is .006 to .008 inch at point of minimum
side of washer up) and nut. Tighten the pinion nut to backlash. Rotate drive gear and ring gear several
170 foot-pounds and using an inch-pounds torque revolutions in both directions in order to seat the
wrench rotate the pinion to determ ine preload. The bearing rollers. This is necessary before setting back
correct preload specifications are 20-30 inch-pounds lash.
for new bearings or 10 inch pounds over the original (1) Attach a dial indicator Tool C-3339 to carrier
if the old rear pinion bearing is being reused. If pre flange so pointer of indicator is squarely contacting
load is not correct, continue to tighten pinion nut in one drive gear tooth (drive side) (Fig. 33).
small increm ents and checking preload until preload (2) Measure backlash between drive gear and pin
on pinion bearings is correct. A minimum of 170 foot ion at four positions, approximately 90 degrees apart.
pounds of torque is required on pinion nut. Under no After point of least backlash has been determined,
circumstances should the pinion nut be backed off to m ark drive gear. Do not rotate drive gear from point
lessen preload. If this is done a new pinion bearing of least backlash until all adjustments have been
collapsible spacer must be installed and nut retight completed.
ened until proper preload is obtained. (3) Using Tool C-406A (spanner wrench) tu rn both
bearing adjusters equally (in same direction) until
installation ©# D ifferen tial a n d Ring G ear in backlash between drive gear and pinion is .0005 to
C arrier .0015 inch. This backlash variation is given to permit
(1) Holding differential and ring gear assembly alignment and installation of the bearing adjuster
with bearing cups on respective bearing cones, care lock, lockwasher and attaching screw. The adjuster
fully install the assembly into carrier. must only be turned in a clockwise direction and
(2) Install differential bearing caps, on respective under no circumstances should be backed off.
sides, making certain that identification m arks on (4) Install adjuster lock on bearing cap, back-face
caps correspond with those on carrier. Install cap bolts side of drive gear. Tighten lock screw to 15 to 20
and tighten bolts of each cap by hand. foot-pounds.
(3) Install differential bearing adjusters, on respec
tive sides, making certain that identification marks
D ifferen tial Bearing Preload
correspond. Screw adjuster in by hand. No attem pt (1) Turn bearing adjuster (tooth side of drive gear)
should be made to apply any excessive pressure at (Fig. 33) in a notch at a time (notch referred to is the
this time. adjuster lock holes) until backlash between drive gear
(4) Using spanner wrenches Tool C-406A to square
and pinion is a minimum of .006 to .008 inch. This
bearing cups with bearing cone, turn adjusters “IN”
until cups are properly square with bearings and end will preload differential bearings and establish cor
play is eliminated with some backlash existing be rect backlash.
tween the drive gear and pinion (Fig. 32). (2) Tighten the remaining two differential bearing
(5) Tighten one differential bearing cap bolt on cap bolts to 85-90 foot-pounds.
each side to 85-90 foot-pounds. (3) Install remaining adjuster lock, lockwasher and
attaching screw. Tighten to 15-20 foot-pounds.
DRIVE GEAR AND PINION BACKLASH
\ t
| 0 |
■m B
KP21
K P20A
Fig. 3 3 —Measuring Backlash Between Drive
Gear and Pinion
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GEAR TOOTH CONTACT PATTERN THICKER SPACER NEEDED
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PATTERN 'MOVES INWARD A N D UP
propeller shaft universal joint, drive pinion flange
and end of pinion stem.
(2) Disconnect propeller shaft at pinion flange and
secure in an upright position to prevent damage to
front universal joint.
(3) Remove the rea r wheels and brake drums to
prevent any drag or a possible false preload reading
could occur.
(4) Using inch-pound torque wrench C-685 measure
111 pinion bearing preload by rotating pinion with handle
of wrench floating, read the torque while wrench is
HEEi END—DRIVE HEEL END— COAST
SIDE (CONVEXI SIDE (CONCAVE) NR202 moving through several complete revolutions and re
cord. This operation is very important because pre
Fig . 3 8 —Effect on Tooth Contact Pattern as Spacer load must be careful ly reset when reassembling.
Thickness Is Decreased (5) With Tool C-3281 hold companion flange and
into the axle housing. Tighten the carrier to axle hous remove drive pinion nut and Belleville washer.
ing nuts to 45 foot-pounds. (6) Install companion flange rem over Tool C-452
(3) Refer to “Installation of Rear Axle Shaft,” when and remove flange. Lower rear of vehicle to prevent
installing and setting axle shaft end play. lubricant leakage.
(4) Install propeller shaft (match scribe marks on (7) Using a screwdriver and hammer, remove the
propeller shaft universal joint and pinion flange). pinion oil seal from the carrier and clean the oil seal
Tighten clamp screws to 15 foot-pounds. seat.
(5) Remove wooden block from under brake pedal (8) Check splines on pinion shaft stem to be sure
and bleed and adjust brakes. they are free of burrs or are not worn badly. If burrs
(6) Install rear wheel and tighten to 65 foot-pounds. are evident remove them using crocus cloth by work
ing in a rotational motion. Wipe the pinion shaft clean.
LUBRICATION (9) Inspect companion flange for cracks, worn
splines, pitted, rough or corroded oil seal contacting
Refill axle assembly with Multipurpose Gear Lubri surface. Repair or replace companion flange as neces
cant, as defined by MIL-L-2105B (API GL-5) should be sary.
used in all rear axles with conventional differentials; (10) Apply a light coat of sealer in seal bore of car
Chrysler Hypoid Lubricant part num ber 2933565 is rier and install drive pinion oil seal into carrier using
an oil of this type and is recommended or an equiva Tool C-4109 or C-3980 (Double lip synthetic rubber oil
lent be used. seal) or Tool C-3656 (single lip leather oil seal). The
In Sure-Grip axles on all 1970 Vehicles it is recom proper tool must be used in order to properly position
mended that only Chrysler Hypoid Lubricant part the seal the correct depth into the carrier casting.
number 2933565 or an equivalent be used. This lubri (11) Position companion flange on pinion stem be
cant, recommended for conventional differentials too, ing careful to match scribe marks made previously
contains special additives to provide proper differen before removal.
tial durability and performance. (12) Install companion flange with installing Tool
Anticipated Temperature Range Viscosity Grade C-496 or DD-999 and holding Tool C-3281.
(13) Remove tool and install Belleville washer (con
Above — 10° F. SAE 90
As low as — 30° F. SAE 80 vex side of washer up) and pinion nut.
Below — 30°F. SAE 75 (14) Hold universal joint flange with holding Tool
C-3281 and tighten pinion nut to 170 foot-pounds. Ro
REMOVAL AND REPLACEMENT OF DRIVE tate pinion several complete revolutions to assure
PINION FLANGE AND OIL SEAL IN VEHICLE that bearing rollers are properly seated. Using an
inch-pound torque wrench C-685 m easure pinion bear
On large stem carriers which use the collapsible
spacer to obtain pinion bearing preload, the following ing preload. Continue tightening pinion nut and check
procedure for the removal and replacem ent of the ing preload until preload is at the original established
drive pinion flange and pinion oil seal m ust be fol setting you found in step 4. Under no circumstances
lowed to assure that the proper bearing preload is should the preload be more than 5 inch-pounds over
maintained in the axle assembly. If this procedure is the established setting found at time of checking in
not followed it could result in a prem ature failure of step 4 of procedure.
the axle. Bearing preload should be uniform during a com
(1) Raise vehicle on hoist and make scribe m arks on plete revolution. A preload reading that varies during
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rotation indicates a binding condition which has to be (15) Install propeller shaft (match scribe marks on
corrected. The assembly is unacceptable if final pinion propeller shaft untiversal joint and pinion flange).
nut torque is below 170 foot-pounds or pinion bearing Tighten clamp screws to 15 foot-pounds.
preload is not within the correct specifications. (16) Install the rear brake drums and wheels and
CAUTION: Never back off the pinion nut to l essen tighten nuts 65 foot-pounds.
pinion bearing preload. If the desired preload is ex (17) Raise the vehicle to a level position so axle
ceeded a new collapsible spacer must be installed and assembly is at correct running position and check
nut retightened until proper preload is obtained. I n lubricant level. Add the correct type of lubricant re
addition, the universal joint flange must never be ham quired to bring lubricant to proper level.
mered on, or power tools used.
Page Page
Axle Shafts and B e a rin g s........................................ 34 Drive Pinion Depth Of Mesh Setting
Differential (Removal and Disassem bly)............... 37 (Using Pinion Depth Gauge Tool DD 1244)........... 43
Differential (Cleaning and Inspection) ................. 40 Drive Pinion Depth Of Mesh Setting
Differential Bearing Preload and Drive Gear (Using Tool C-758-D4) ...................................... ......44
and Pinion Backlash ............................................ 46 Gear Tooth Contact P a tte r n .................................... 46
Differential Case and Drive Gear (Installation) . . . 42 Lubrication ................................................................. 48
Differential Case (Sure-Grip) ................................... 38 Pinion Bearing P re lo a d ..................... ...................... ...46
Differential Noise ...................................................... 33 Rear Axle Assembly (Removal)................................. 37
Rear Axle Assembly (Installation) ......................... ...47
GENERAL INFORMATION
With the increased torque output of the 440 cubic and ring gear, and by dividing the larger num ber
inch engine with Power Pak and the 426 cubic inch (ring gear teeth) by the smaller num ber (drive pin
Hemi engine in vehicles equipped with 4-speed man ion) the axle ratio can be determined.
ual transmission, the 9-3/4" rear axle assembly will The drive pinion is supported by two preloaded
appear on Challenger and Dart models that are so taper ro Je r bearings. The rear pinion bearing cone is
equipped (Fig. 1). a tight press-fit on the pinion stem. The front pinion
The standard differential case used in both in bearing is a light-press fit to a close sliding fit on
stances will be of the plate clutch type Sure-Grip Dif the pinion stem. The front and rear bearing cups are
ferential. In some instances where a high numerical a press-fit against a shoulder recessed in the carrier.
ratio gear set is installed, a new differential case will The drive pinion depth of mesh adjustm ent is con
have to be purchased and installed due to the differ trolled by locating shims, which are installed between
ence in ring gear mounting dimensions. The standard the rear pinion bearing cup and the carrier casting.
ratio gear set used with both the 440 and 426 engines Drive pinion bearing preload is maintained by
will be 3.54 ratio. Optional matched gear sets with using different thicknesses of shim packs between
ratios of 4.10, 4.56 and 4.88 will be available for deal the drive pinion bearing shoulder and front pinion
er installation on models equipped with the 9-3/4" bearing cone.
diam eter axle assembly. The differential case is supported by two taper
The rear axle is of the integral carrier-housing, roller bearing cones which are a press-fit on the dif
hypoid gear type in which the centerline of the drive ferential case hubs. Shims installed between the bear
pinion is m ounted below the centerline of the ring ing cone and shoulder of hub of differential case, per
gear. form three functions: They eliminate the differential
The rear axle housing is an iron casting with tubu case side play; they adjust and maintain the backlash
lar legs pressed into and welded to the carrier to between the ring gear and drive pinion; and establish
form a carrier and tube assembly. A removable a means of obtaining differential bearing preload.
stam ped steel cover is bolted to the rear of the carrier The rear axle shafts are mounted on taper roller
to perm it visual inspection of the differential without bearings which are located at the outer ends of the
removing the complete rear axle from the vehicle. axle housing tubes. The bearings are pressed onto
A small m etal tag is attached beneath one of the the shoulder of the shaft and held in place by a collar
cover screws to identify the axle ratio. This tag is th at has a very tight interference fit. The bearings are
stamped with the num ber of teeth on the drive pinion lubricated with Multi-Purpose Grease NLGI Grade
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BEARING C ON E
GASKET CASE HALF
CLUTCH PLATES |
A ND DISCS
RING GEAR
SIDE GEAR
r - .
/ DIFFERENTIAL
BOLT ADJUSTING
SHIMS
CASE HALF # ''’'"SinF
SIDE GEAR RING
BEARING CONE
CUP
SLINGER
ASKET
SEAL
^FLANGE
RETAINER GASKET jp >WASHER
SHAFT FLANGE
'*J ^ N U T
NN1019A
fig . I—9-3/4" Rear A x le Assembly
2 E.P. or equivalent. Oil seals are pressed into the also clamps the brake support plate to the studs of the
outer ends of the housing tubes to prevent oil leakage housing tube. Axle shaft end play is adjusted by
from the center section of the axle into the wheel bear- means of a threaded adjuster located in the right
ings and onto the brake assembly. The outer retainer axle shaft bearing retainer. Axle shaft end play must
clamps the bearing and cup into the housing bore and be maintained at ,008"-.012".
SERVICE PROCEDURES
CAUTION: When servicing cars equipped with 9-3/4" (1) With lubricant of rear axle assembly at operat
axles, DO NOT use the engine to rotate axle com ing tem perature raise car on hoist so rear wheels are
ponents unless both wheels are clear. These axles can free to turn.
exert significant driving force with one wheel. (2) Loosen and remove drain plug and drain out as
much of the old lubricant as possible.
DIFFERENTIAL NOISE (3) Fill to proper level with special Sure-Grip Lubri
(Chatter-Moan) cant P art Number 2585318 or equivalent. Reinstall
It is suggested that before the axle assembly is fill plug and tighten.
disassembled for any type noise complaint, that the (4) Start engine of vehicle and engage in gear and
lubricant be changed. An im proper lubricant can run on hoist with rear wheels free to turn at ap
cause such noises as chatter and moan as well as proximately 40 (MPH) for ten (10) minutes. This
scoring of the differential clutch plates and discs re thoroughly circulates the lubricant and brings it to
sulting in a possible failure of the unit. operating tem perature.
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(5) Stop vehicle and remove drain plug and drain
BLOCKS BEARING ADAPTER
as much of the old lubricant as possible. SP-5021
REMOVING SP-5020
(6) Refill axle to proper level with new Sure-Grip
Lubricant Part Number 2585318 or equivalent. Rein SCREWS X ,
SP-5026
stall fill plug and tighten.
(7) Lower car on hoist and return to customer to (
drive and evaluate for approximately 100 miles to
determ ine if lubricant corrects the noise condition.
If after driving vehicle approximately 100 miles
and the differential noise is still evident, remove the
axle assembly and service the differential with the
necessary parts.
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SLEEVE
SP-5041
NK57
f
SLEEVE
SP-5041 m SLEEVE
SP-5041'
WKm
BEARING
• ROLLER
N K 1 27A
SLEEVE
SP-5041
S1.ZEV-
SP-5041
\
\
\
■H ,vlK356 NX359
I
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-.005 SHIM STOCK
-------~ - . NK362
NN'i 24 A
■■I
%
NK361
NX 128
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(2) Tap end of left axle shaft lightly with a non-
metallic mallet to seat right wheel bearing cup
against adjuster, and rotate axle shaft several revolu
tions so that a true end play reading is indicated.
(3) Remove one retainer plate nut, install adjuster
lock. If tab on lock does not mate with notch in ad
juster, turn adjuster slightly until it does. Install nut
and tighten 30-35 foot-pounds.
(4) Recheck axle shaft end play. If it is not within
the tolerance of .008-.012 inch, then repeat adjust
m ent procedure.
(5) Remove dial indicator and install brake drum
and wheel.
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and locate spreader Tool W-129 with tool dowel pins
seated in locating holes of axle housing. Turn tool
screw finger tight at this time.
(9) Install pilot stud on left side of axle housing.
Attach dial indicator and load indicator stem slightly
against opposite side of axle housing (Fig. 16).
(10) Tighten spreader tool nut sufficiently to ob
tain .015 inch movement of dial indicator to perm it
removal of differential case and ring gear assembly.
DO NOT SPREAD OVER .020 INCH AS IT WILL
RESULT IN PERMANENT DAMAGE TO CARRIER
CASTING.
(11) Remove dial indicator and remove differential
case and ring gear assembly from axle housing. A
light prying action with a screwdriver or pinch bar
Fig. 17—Removing Differential and Drive
will loosen assembly for easy removal (Fig. 17). Pry G ear Assembly
up differential case and ring gear as straight up as
possible using leverage against differential case and (15) Using Tool C-748, remove drive pinion oil seal.
carrier to prevent damage. Keep respective bearing Remove slinger, gasket, front pinion bearing cone
cups with bearing cones, if they are not worn or dam and preload shim pack. Record the thickness of the
aged and are to be reassembled. shims in case they should be lost.
(12) Place the differential case between the soft (16) Position the carrier and tube assembly on an
jaws of a vise and remove the drive gear screws and arbor press, then press out the drive pinion stem and
discard. Using a fiber mallet, tap the drive gear loose rea r bearing cone assembly.
from the differential case pilot and remove. (17) With the aid of a brass drift and hammer, drive
(13) If the drive gear runout exceeded .006 inch out the front and rear pinion bearing cups from hous
in step 5 differential case flange runout should be re ing. Remove the shim from behind the rear bearing
measured. Install differential case with respective cup and record the thickness of shim pack.
bearing cups into axle housing. Loosen nut of spreader (18) Remove rear bearing cone from drive pinion
tool and remove. Install bearing caps and tighten stem using Tool DD-914C or Tool C-293 and adapters
snugly. Mount dial indicator in contact with flange No. 37.
face of differential case (Fig. 18), and m easure runout (19) Remove differential bearing cones from dif
as described in Step 5. Total allowable runout should ferential case hubs using Tool DD-914C or Tool C-
not exceed .003 inch. It is often possible to reduce 293 and adapters No. 62 (Fig. 19). Care must be taken
excessive runout by positioning drive gear 180 degrees to insure that bearing remover adapters are located
from point of maximum runout when reassembling so as not to pull on bearing cage.
ring gear on differential case. (20) Remove the shims located behind each bear
(14) Position carrier and tube assembly in vise ing and record thickness to aid in reassembly.
with nose of carrier in the up position. Remove drive
pinion nut and washer. Using Tool C-452 and holding DIFFERENTIAL CASE
Tool C-3281, remove drive pinion flange. The sure-grip differential (Figs. 20, 21 and 22) is
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AXLE DRIVE GEAR AXLE DRIVE PINION
DIFFERENTIAL CASE
AXLE SHAFT
AXLE SHAFT
DIFFERENTIAL
SIDE GEAR
NN 1025
DIFFERENTIAL PINION
KR260A
Fig. 22 —Pow er Flow A x le Shafts Turning a t
Different Speeds
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CLUTCH
BELLEVILLE PLATES
PLATE
SCRIBE
SIDE GEAR
MARKS
A ND RETAINER
.. a A
*2* “V”
“V" GROOVE
GROOVE
^ -M *
r\,
KR720B
KR718
Fig. 2 5 —Removing Installing Clutch Plates (Cap Side)
Fig. 2 3 —Case Halves Scribed fo r Proper Reassembly
Disassembly
(1) Remove axle drive gear. Measure runout of the
drive gear mounting flange. Replace both case halves
if runout exceeds .003 inch.
(2) Before disassembling case halves, place scribe
marks on each half to aid in aligning the case when
reassembling (Fig. 23). Remove case cap attaching
bolts and remove case cap (Fig. 24). Remove clutch
plates (Fig. 25).
(3) Remove side gear retainer (Fig. 26), and side
gear (Fig. 27).
(4) Remove pinion shafts with pinion gears (Fig.
28).
(5) Remove remaining side gear (Fig. 29), side gear
retainer (Fig. 30), and clutch plates (Fig. 31).
.
Fig 2 6 —R e m o vin g o r In s ta llin g Side G e a r R e ta in e r
CLEANING AND INSPECTION (Cap Side)
(1) Wash and clean all parts in a suitable cleaning insert a stiff wire into tube, attach a clean cloth to
solvent and with the exception of bearing cones, dry wire at center section and withdraw from center
with compressed air. To clean axle housing tubes, outward.
- w
— SIDE GEAR
AXLE SHAFT
CASE CAP ^ f ^ T H R U S T SPACER
CLUTCH
PLATES
I r/- fK - .
SIDE GEAR
RETAINER
V 1 ;
KR719 KR722
Fig. 2 4 —R e m o v in g o r In s ta llin g D iffe re n tia l Case Cap Fig. 2 7 —R em ovin g or In s ta llin g Side G e ar (Cap Side)
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PINION PINION
SHAFTS \ ' GLARS SIDE GEAR.,
A N D RETAINER
CLUTCH
DIFFERENTIAL PLATES
CASE vit f
\
B&i
mm
PPgB
1CR726A
Fig. 29-Rem ovm g ©r IInstalling Side G ear from Fig, 3 1 —R em ovin g or in s ta llin g Clutch P lates a n d
D ifferential Case Pfscs
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broken, damaged or distorted shims. Replace, if nec
essary, during establishment of pinion bearing pre
load.
(10) Clean all differential parts and inspect parts
for wear, nicks and burrs. The inner and outer flat
clutch plates and outer flat clutch disc should be re
placed if they are worn or distorted. If either case
half is worn, it will be necessary to replace both
halves.
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— PRESS
TOOL-
mm i m ? -DRIVE PINION
■N N 1M 7 ■; -
Fig. 3 4 —D e te rm in in g Shims to O b ta in " O " End
KD 3 82
Clearance KD382
(8) Remove dial indicator, loosen bearing cap bolts Fig. 3 6 —Installing Rear Pinion Bearing Cone
and remove bearing caps. Remove differential as
between the rear cup and carrier can be determ ined
sembly from housing. ■
from the shims removed and the etched m arking on
DRIVE PINION DEPTH OF MESH SETTING the pinion. The + or — figure indicates the variation
(Using Pinion Depth Gauge Tool DD1244) from the nominal distance between the front of the
pinion and the center line of the carrier. For example,
Note the figures etched on the head of the drive if a pinion m arked + 2 was originally installed with a
pinion and observe (Fig. 35). One figure is found on shim pack .035 inch and the new pinion is m arked
both the drive pinion and ring gear and indicates a — 1, the shim pack should be increased .003 inch to
matched gear set. Directly opposite this figure will bring the new pinion to its correct position and the
be one with a -f or — before it, or if not a + or — , new shim pack would be .038 inch. This will give an
the figure will be 0. This num ber must be positively approxim ate setting of the pinion. A pinion depth
identified before continuing with the assembly pro gauge should be used for final setting of the pinion,
cedure. Midway between the two sets of figures de see steps 6 through 14. Shims are available in .003,
scribed above are numbers and letters. These num bers .005 and .010 inch thickness.
and letters are etched for m anufacturing purposes (2) Install front pinion bearing cup in carrier.
only, but as one of these num bers may be 0, it might (3) Lubricate rear drive pinion bearing cone with
be confused with the num ber needed for assembly Sure-Grip Lubricant, Part Number 2585318, or equiva
procedure. A rule to follow would be to first examine lent, and install bearing cone on pinion stem with
the shaft end for a + or — number. If a + or — num Tool C-3095 (Fig. 36).
ber is not etched on the pinion head, then the num (4) Position drive pinion and bearing assembly in
ber will be 0. carrier and install front pinion bearing cone on pinion
(1) Install rear drive pinion bearing cup and shim stem. Do not install preload shims behind front pinion
pack in carrier. The starting shim pack to be placed bearing at this time.
PINION DEPTH
(5) Install universal joint pinion flange followed
r ADJUSTMENT by washer and nut. Tighten nut just enough to obtain
PRODUCTION
FIGURE 10-30 inch-pounds of preload. Rotate drive pinion
while tightening to seat bearing rollers.
(6) The pinion depth gauge Tool DD-1244 (Fig. 37),
is a direct reading precision micrometer, mounted in
an arbor and is calibrated to show the distance from
the end of the anvil to the centerline of the gauge set.
To check the accuracy of the gauge, install the micro
m eter and arbor in the m aster gauge. Install the
checking block and read the micrometer, it should be
accurate within less than .0005 inch (Fig. 38).
GEAR MATING MARK (7) Select the proper adapters from the gauge set
(SAME AS O N DRIVE GEAR)' NY425A that fits the differential bearing cup bores. Install the
adapters on the arbor and position in carrier housing.
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o
Fig. 3 7 —Pinion Depth Gauge Tool DD-1244
N N 1028
AXLE PINION
NUS97
Fig. 38—Checking Gauge in M aster Gauge Assembly Fig. 4 0 —Pinion Setting Dimension
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(2) Assemble Tool C-758-D4 by positioning spacer the m arkings on the end of pinion head (— 0, — 1,
SP-5184 on main screw of tool. Position rear pinion —2, + 1, + 2, etc.). When marking is — (minus), add
bearing cone on tool screw and insert into axle hous that amount to the thickness of shim pack selected
ing. in step (9). When the m arking is + (plus), subtract th at
(3) Position front pinion bearing cone over main amount. T reat other pinion m arkings in a similar
screw of tool followed by compression sleeve SP-535, manner. Shims are available in .003, .005, and .010
centralizing washer SP-534, and main screw nut inch thickness.
SP-533. (11) Remove the tool arbor and tool from axle
(4) Lubricate drive pinion bearing cones with Sure- housing.
Grip Lubricant, P art Number 2585318, or equivalent. (12) Using a brass drift or soft punch and hammer,
(5) To install pinion bearing cups, hold compres remove rea r pinion bearing cup from casting.
sion sleeve from turning with Tool C-3281, tighten (13) Position the correct shim pack in axle hous
nut, thereby drawing pinion bearing cups into axle ing cup bore and install rear bearing cup as de
housing bearing cup bores. Permit tool to turn several scribed previously in steps (1 thru 5). W hen cup is
revolutions during tightening operation to perm it properly seated, remove tool and pinion bearing
bearing rollers to align and prevent brinnelling of cones.
bearing cups. Do not remove tool after installing (14) Lubricate rear drive pinion bearing cone with
cups. Pinion depth of mesh will be determined next. Sure-Grip Lubricant, P a rt Number 2585318 or equiva
(6) With main tool left in axle housing after in lent and install bearing cone on pinion stem using
stalling drive pinion bearing cups, loosen tool nut Tool C-3095. An arbor press may be used in conjunc
and re-tighten nut to produce 10-30 inch-pounds of tion with tool (Fig. 36).
preload. Rotate while tightening to align bearing (15) Install drive pinion and bearing assembly in
rollers. carrier and install the original front pinion bearing
(7) Install gauge block SP-528 on main tool and shim pack followed by the bearing cone. Do not install
tighten screw with an Allen wrench securely. oil seal at this time.
(8) Position cross bore arbor SP-5183 in axle hous (16) Install universal joint flange, washer and nut.
ing differential bearing seats. Center the arbor so th at Tighten nut 250-270 foot-pounds. Rotate pinion sev
an approximate equal distance is maintained at both eral complete revolutions to seat bearing rollers.
ends. Correctly position differential bearing caps (17) Using an inch-pound torque wrench C-685,
and insert bolts and tighten to 10 foot-pounds. measure pinion bearing preload by rotating pinion
(9) Using a feeler gauge select the proper thick with handle of wrench floating (Fig. 42). Take read
ness of shims that will snugly fit between arbor and ing while handle is moving through several complete
gauge block. This fit m ust be snug but not too tight revolutions. Accurate reading can be made only
(similar to the pull of a feeler gauge). This m easure with nose of axle in upright position. Correct preload
m ent is then used in determining the correct thick is 10-20 inch-pounds. Add shim to decrease preload
ness shim pack for installation behind the rear pin and Subtract shims to increase preload. Shims are
ion bearing cup and carrier casting (Fig. 41). available in the following thicknesses: .003, .005,
(10) To select a shim pack for installation, read .010, and .030 inch.
(18) A fter the correct pinion bearing preload has
NP414
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been established, remove the universal joint flange, point against back face of ring gear. Move the differ
nut and washer. ential and ring gear assembly tight against the drive
(19) Install oil slinger and gasket. Using pinion pinion, set the dial indicator on 0. Move the differen
seal installing Tool C-3719, install drive pinion oil tial and ring gear assembly in the opposite direction
seal. as far away from pinion as possible and note the read
(20) Install universal joint flange washer and nut. ing on dial indicator.
Tighten nut 250-270 foot-pounds. This reading represents the thickness of shim pack
necessary to take up the clearance between the bear
PINION BEARING PRELOAD ing cup and the case on the ring gear side of the dif
ferential assembly. Subtract this reading from the
(1) Remove universal joint flange, washer, nut previously recorded total reading to obtain the
and front pinion bearing cone. amount of shims necessary to take up the clearance
(2) Install the original front pinion bearing shim between the bearing cup and the case at the pinion
pack followed by the bearing cone. Do not install oil side of the differential.
seal at this time. (3) Remove differential and ring gear assembly
(3) Install universal joint flange washer and nut. from carrier.
Tighten nut 250-270 foot-pounds. Rotate pinion sev (4) Remove differential bearing cones. Install the
eral complete revolutions to align and seat bearing correct thickness shim pack as determined in step 2
rollers. between bearing cone and differential case hub
(4) Using an inch-pound torque wrench C-685, shoulder using Tool C-4025. Add an additional .015
m easure pinion bearing preload by rotating pinion inch shims to the drive gear side of differential and
with handle of wrench floating (Fig. 42). Take reading install the differential bearing cones. This additional
while handle is moving through several complete .015 inch shim pack provides the correct bearing pre
revolutions. Accurate reading can be made only with load and backlash.
nose of axle in upright position. Correct preload is (5) Position spreader Tool W-129 in locating holes
10-20 inch-pounds. Add shims to decrease preload and of carrier and tighten screw finger tight. Install dial
subtract shims to increase preload. Shims are avail indicator and spread carrier .015 to .020 inch Do not
able in the following thicknesses: .003, .005, .010, and exceed this limit to perm it placing of differential
.030 inch. and ring gear assembly in carrier.
(5) After the correct bearing preload has been es (6) Install the bearing caps in their respective
tablished, the pinion depth setting should be re positions as indicated by identification marks on caps
checked. and carrier. Remove the spreader tool. Coat the bear
(6) Remove universal joint flange nut and washer. ing cap bolt threads with sealing compound and install
(7) Install oil slinger and gasket. Using Tool C- and tighten bolts snugly.
3719, install drive pinion oil seal. (7) Tap the drive gear lightly with a rawhide ham
(8) Install universal joint flange, washer and nut. m er to properly seat the differential bearing and cups.
Using Tool C-3281 to hold flange, tighten pinion nut Care must be taken in this operation to prevent nick
250-270 foot-pounds. Recheck pinion bearing pre-load. ing the teeth of ring gear or drive pinion as they are
meshed together. Tighten the bearing cap bolts to 70-
DIFFERENTIAL BEARING PRELOAD AND 90 foot-pounds.
DRIVE GEAR AND PINION BACKLASH (8) Attach a dial indicator to carrier and with in
dicator contact point contacting ring gear tooth (Fig.
(1) With drive pinion and bearings installed and 43), measure the backlash between the ring gear and
bearing preload set, install differential case and ring drive pinion.
gear assembly with their respective bearing cups. In (9) Check backlash at four equally spaced points
stall bearing caps in their positions, align identifica around circumference of ring gear. Backlash must be
tion marks and tighten cap bolts finger tight. held between .004-.009 inch and cannot vary more
Refer to the m easurem ent taken previously in step than .002 inch between the four positions checked.
(7) of “Installation-Differential Case and Drive Gear”. If backlash does not fall within these specifications,
This reading taken before the drive pinion was
change shim pack thickness on both differential bear
installed represents the total clearance between the ing hubs to maintain proper bearing preload and
differential bearing cups and the carrier casting. Per backlash.
form the following steps to determ ine the thicknesses
of shims required behind each bearing cone to take up GEAR TOOTH CONTACT PATTERN
the clearance and establish the correct bearing pre
load and backlash. The gear tooth contact pattern will disclose whether
(2) Install a dial indicator and position the contact the correct rear pinion bearing mounting shim has
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THICKER SPACER NEEDED
/ ”\ TOE
TDK r
END
m*.
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THINNER SPACER NEEDED PATTERN MOVES INWARD A ND UP
Fig. 47—Incorrect Tooth Contact Pattern Fig. 48—Effect on Tooth Contact Pattern as Shim
(Decrease Shim Pack Thickness) Pack Thickness is Decreased
bolts, install the ratio identification tag. Tighten universal joint clamps to 170-200 inch pounds.
(2) For correct procedure when installing axle (8) Install rear wheel and tighten nuts to 65 foot
shafts and bearings and setting axle shaft end play, pounds in the proper tightening sequence.
see “Axle Shafts and Bearings”.
(3) With body supported at front of rear springs, LUBRICATION
position rear axle assembly spring pads over the Refill axle housing and carrier assembly with 5-1/2
spring center bolts. pints of lubricant. Sure-Grip differentials, use only
(4) Install spring “U” bolts and tighten nuts to 45 the special multi-purpose gear lubricant intended for
foot-pounds and install shock absorbers on spring axles equipped with plate-clutch Sure-Grip differen
plate studs. tials. Such a lubricant is available under P art Number
(5) Connect parking brake cables. 2585318, Special Sure-Grip Lubricant or equivalent.
(6) Connect hydraulic brake lines at wheel cyl “SHOULD THE REAR AXLE BECOME SUBMERGED
inders and bleed brakes, install brake drums and IN WATER, THE LUBRICANT MUST BE CHANGED
adjust brakes. IMMEDIATELY TO AVOID THE POSSIBILITY OF
(7) Install rear universal joint of propeller shaft EARLY AXLE FAILURE RESULTING FROM CON
in same position as removed (match scribe m arks on TAMINATION OF THE LUBRICANT BY WATER
propeller shaft universal joint and pinion flange). DRAWN INTO THE VENT HOLE."
SURE-GRIP DIFFERENTIAL
INDEX
Page Page
Installing Sure Grip Differential and Sure Grip Differential ................................................ 50
Carrier Assembly . . . s.......................................... 51 R em oval................................................................... 50
Lubrication ................... ......................../.................... 51 Cleaning & Inspection .......................................... 50
Sure Grip Differential Identification . / ................... 49 Assemb l y ................................................................. 51
Sure Grip Differential N o is e ..................................... 49 Testing Sure Grip Differential ................................. 49
GENERAL INFORMATION
A new Sure-Grip differential being offered as a is ordinarily desirable and satisfactory. However, the
special equipm ent option in the 7-1/4" and 8-3/4" total driving torque can be no more than double the
rear axles only (Fig. 1). torque at the lower-traction wheel. When traction con
The Sure-Grip differential design is basic and sim ditions are not the same for both driving wheels, a
ple and consists of a two piece case construction and portion of the available traction cannot be used.
is completely interchangeable with the conventional The SURE-GRIP differential allows the driving
differential and also the previous type Sure-Grip dif wheel with the better traction condition to develop
ferential (Fig. 2). more driving torque than the other wheel, so that the
A conventional differential allows the driving total driving torque can be significantly greater than
wheels to rotate at different speeds while dividing the with a conventional differential.
driving torque equally between them. This function SURE-GRIP is not a locking differential. In normal
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cones that clutch the side gears to the differential
case. The grooves assure maximum lubrication of the
clutch surface during operation. The cones and side
gears are statically spring preloaded to provide an
internal resistance to differential action within the
differential case itself. This internal resistance pro
vides pulling power while under extremely low trac
tive conditions such as mud, snow or ice when en
countered at one of the rear wheels.
During torque application to the axle, the initial
spring loading of the cones is supplem ented by the
gear separating forces between the side gears and
differential pinions which progressively increases the
friction in the differential. It should be rem embered
NU404
that the Sure-Grip differential is not a positive lock
ing type and will release before excessive driving
Fig. 1 -S u re-G rip D ifferential force can be applied to one wheel.
driving conditions the controlled internal friction is
easily overcome during cornering and turning so that SURE-GRIP DIFFERENTIAL IDENTIFICATION
the driving wheels can turn at different speeds. Ex
trem e differences in traction conditions at the driving Identification of sure-grip differential assembly can
wheels may perm it one wheel to spin. easily be made by lifting both rear wheels off the
SURE-GRIP has been engineered to perform its ground and turning them. If both rear wheels turn in
specialized functions with minimum effect on normal the same direction simultaneously, the vehicle is
vehicle operations. equipped with a Sure-Grip Differential. Another
The cone clutch SURE-GRIP differentials are simi means of identification is by removing the filler plug
lar to corresponding 8-3/4" conventional differentials and using a flashlight to look through the filler plug
except for the incorporation of the helix-grooved hole to identify the type of differential case.
SERVICE PROCEDURES
SURE-GRIP DIFFERENTIAL NOISE lent. Reinstall fill plug and tighten.
(Chatter-Moan) (4) Start engine and engage in gear and run on
hoist with rear wheels free to turn at approximately
Noise complaints related to rear axles equipped 40 MPH for ten (10) minutes. This thoroughly cir
with cone-clutch SURE-GRIP should be checked to culates the lubricant and brings it to operating tem
determ ine the source of the noise. If a vehicle ride perature.
check produces the noise in turns but not straight (5) Stop vehicle and remove the fill plug and using
ahead, the probable cause is incorrect or dissipated a suction gun remove as much of the lubricant as pos
rear axle lubricant. The following draining and flush sible.
ing procedure has been established for the Sure-Grip (6) Refill axle to proper level with multi-Purpose
Differential before it is removed from the vehicle and Hypoid Gear Lubricant P art Number 2933565 or
replaced. equivalent. Reinstall fill plug and tighten.
CAUTION: When servicing vehicles equipped with (7) Lower vehicle on hoist and return to owner to
Sure-Grip differentials do not use the engine to rotate drive and evaluate for approximately 100 miles to de
axle components unless both rear wheels are off the term ine if lubricant corrects the noise complaint.
ground. Sure-Grip equipped axles can exert a signifi If after the vehicle is driven approximately 100
cant driving force if one whee l is in contact with floor miles and the noise condition is still evident, remove
and could cause the vehicle to move. the differential and carrier assembly and replace the
(1) With lubricant of rear axle assembly at oper Sure-Grip Differential. The Sure-Grip Differential and
ating tem perature raise car on hoist so rear wheels are the internal parts are serviced as an assembly only.
free to turn.
(2) Loosen and remove fill plug and using a suction TESTING SURE-GRIP DIFFERENTIAL
gun remove as much of the old lubricant as possible.
(3) Fill axle to proper level with Multi-Purpose Hy The Sure-Grip differential can be checked to deter
poid Gear Lubricant Part Number 2933565 or equiva mine if its performance is satisfactory without remov
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ing the differential and carrier assembly from the Removal
vehicle. Follow the same procedure outlined under conven
(1) Position vehicle on a hoist with engine off and tional differential removal.
the transmission selector lever in park if automatic
or in low gear if manual. Cleaning and Inspection
(2) Attem pt to rotate wheel by applying turning (1) Clean the Sure-Grip differential assembly in a
force with hands gripping tire tread area (Fig. 3). fast evaporating m ineral spirits or a dry cleaning sol
(3) If you find it extrem ely difficult, if not impos vent and with exception of bearings, dry with com
sible to manually turn either wheel, you can consider pressed air.
the sure-grip differential to be perform ing satisfac (2) Inspect differential bearing cones, cups and roll-
torily. If you find it relatively easy to continuously
turn either wheel the differential is not perform ing
properly and should be removed and replaced. The
Sure-Grip Differential and internal parts are serviced
as a complete assembly only. Under no circumstances
should the differential be removed and disassembled
and reinstalled.
SURE-GRIP DIFFERENTIAL
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ers for pitting, spalling or other visible damage. If (6) Position differential case unit between brass
replacem ent is necessary, remove bearing cones from jaws of a vise and alternately tighten each cap screw
differential case using Tool C-293 and adapter plates to 55 foot-pounds.
No. 43. NOTE: Before installation of differential case into car
(3) Visually inspect differential case for cracks or rie r lubricate the inside of differential assembly with
other visible damage which might render it unfit for Multi-Purpose Hypoid Gear Lubricant Part Number
further service. 2933565 or equivalent. Do not use any other lubricant
other than this special lubricant.
Assembly (7) Follow procedure outlined in conventional axle
If during cleaning and inspection the differential assembly for setting drive pinion depth of mesh, drive
bearings were found to be unfit for further use and gear backlash adjustm ent and bearing preload adjust
were removed follow this procedure for installation ment.
of new bearings.
(1) Position each differential bearing cone on hub INSTALLING SURE-GRIP DIFFERENTIAL
of differential case (taper away from drive gear) and AND CARRIER ASSEMBLY
with installing Tool C-4086, install bearing cones. An
arbor press may be used in conjunction with installing (1) Using a new gasket install carrier assembly in
tool. CAUTION: Never exert pressure against the axle housing. Tighten mounting nuts to 45 foot
bearing cage, since this would damage the bearing. pounds.
(2) If the ring gear was removed from the sure- (2) Refer to “Installation of Rear Axle Shaft”, when
grip differential case or is being replaced with a new installing axle shafts.
ring gear for any reason, new nylok drive gear screws (3) Connect the rear universal joint.
must be installed. (4) Before lowering the rear wheels of the vehicle
IMPORTANT: The procedure for installing the ring to the floor, adjust rear brakes. CAUTION: Both rear
gear on differential case for the 8-3/4" axle differs wheels must be raised off the floor when adjusting
from that of the 7-1/4" axle. This procedure must be brakes.
followed so the ring gear seats on the differential case
properly. LUBRICATION
(3) Using an Arkansas stone, relieve the sharp edge
of the chamfer on the inside diam eter of the ring gear Every six months check the fluid level in the axle
(Fig. 24), in 8-3/4" Axle section of this group). This is through the filler plug hole. When checking the level,
very important, otherwise during the installation of be sure the vehicle is in a level position on an axle or
ring gear on differential case, the sharp edge will re drive on type hoist. “See Lubrication Section” for
move metal from the pilot diam eter of case and can proper level of specific axle assembly.
get imbedded between differential case flange and In Sure-Grip Differentials, use only the Multi-Pur-
gear; causing gear not to seat properly. pose Hypoid Gear Lubricant P art Number 2933565 or
(4) Position ring gear on differential case pilot equivalent. Do not use any other lubricant other than
aligning threaded holes of ring gear with those in dif this special lubricant.
ferential case flange. Viscosity Grade
Anticipated Temperature Range
(5) Insert drive gear screws (left hand threads) SAE 90
Above — 10° F.
through case flange and into ring gear. A fter all cap As low as — 30° F. SAE 80
screws are properly started, tap ring gear against dif Below — 30° F. SAE 75
ferential case flange with a non-metallic mallet.
SPECIFICATIONS
______________7-1/4" Axle____________
TYPE .................................................................................................................... Semi-Floating Hypoid
Ring Gear D ia m e te r....................................................................................... 7.250
Number of Differential P in io n s ............................................ ...................... 2
DIFFERENTIAL BEARINGS
Adjustment b y ...............................................................................................
Spacer Washer
.254-.284 inch in .002 inch graduations
Carrier Bearing Preload Spread ............................................................. .003-.006
PINION AND DRIVE GEAR BACK LA SH ..........................................................004-.007"at point of minimum back lash
PINION BEARING PRELOAD ADJUSTMENT B Y ......................................... Spacer Washers
.074-.106 inch in .001 variations
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PINION BEARING DRAG TORQUE ........................................................... 15-25 inch-pounds
PINION DEPTH OF MESH ADJUSTMENT B Y .............................................. Spacer Washers
.084-.100 inch in .002 inch graduations
RUNOUT-CASE AND DRIVE GEAR.................................................................. .005 inch Maximum
WHEEL BEARING TYPE ................................................................................... Single Row Sealed Ball
LUBRICATION
C apacity............................................................................................................ 2 pints (1-3/4 Imperial)
T y p e .......... Multi-Purpose Gear Lubricant as defined by MIL-L-2105B (API GL-5) should
be used on all rear axles; such a lubricant is available under Part No.
2933565 Chrysler Hypoid Gear Lubricant or an equivalent be used.
9-3/4" Axle
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Type ................................................................................................................. Taper Roller
Adjustment ...................................................................................................... Threaded Adjusting Nut
End Play ......................................................................................................... .008-.012
Lubrication ..................................................................................................... Automotive Multi Purpose
Grease NLGI grade 2
LUBRICATION
C apacity................................................................... ........................................ 5- 1/2 Pts. (4-1/2 Imperial)
Type...................Use only the special multi-purpose lubricant intended for use in Plate-
Clutch Sure-Grip differentials. Such a lubricant is available under Part
No. 2585318, Special Sure-Grip Lubricant or an equivalent be used.
T I GHTEN I NG REFERENCE
7-1/4" Axle
Pounds
Foot I nch
Differential Bearing Cap B o lts ................................................................................................... 40
Ring Gear to Differential Case Bolts (Left Hand T h re a d )....................................................... 55
Drive Pinion Flange N u t ............................................................................................ 240 (Min.)
Carrier Cover B o lts ........................................................................................................................ 20
Axle Shaft Retainer N u t s .......................................................................................... ...................35
Propeller Shaft Bolts (Rear) ....................................................................................................... 15
Spring Clip (U Bolt) N u t s .......................................................................................... ...................40 (Max.)
Wheel Stud N u t s ....................................................................................... .................................... 55
Shock Absorber Stud Nuts (Lower)......................................................................... .................. 50
8-3/4" Axle
Pounds
Foot Inch
Differential Bearing Cap B o lts .................................................................................. 90
Ring Gear to Differential Case Bolts (Left Hand T h re ad ).................................... 55
Drive Pinion Flange Nut (Small Stem or Large Stem Step P inions)................. 240 (Min.)
(Large Stem Tapered Pinions) ......................... ........... 170 (Min.)
Carrier to Axle Housing Bolt N u t s ........................... .............................................. 45
Axle Shaft Retainer Nuts .......................................................................................... 35
Propeller Shaft Bolts (R e a r)..................................................................................... 15
Spring Clip (U Bolt) Nuts .......................................................................................... 45
Wheel Stud N u t s ......................................................................................................... 65
Shock Absorber Stud Nuts (Lower) ......................................................................... 50
9-3/4" Axle
Pounds
Foot Inch
Differential Bearing Cap B o lts ................................................................................. 70-90
Differential Case Half Retaining Bolts ................................................................. 35-45
Ring Gear To Differential Case B o l t s ..................................................................... 100-120
Drive Pinion Flange N u t ............. ............................................................................... 250-270
Carrier Cover B o lts .................................................................................................... 15-25
Axle Shaft Retainer Nuts ........................................................................................ 30-35
Propeller Shaft Bolts (R e a r)................................................................................. . 170-200
Spring Clip (U-Bolts) N u t s ............................... ...................................................... 45
Wheel Stud N u t s ........................................................................................................ 65
Shock Absorber Stud N u t s ....................................................................................... 50
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BRAKES
CONTENTS
Page Page
KELSEY-HAYES DISC BRAKES POWER BRAKES (B E N D IX ).................... 20-21
(FOUR P IS T O N )............. 22 POWER BRAKES (MIDLAND-ROSS).. . . 18
KELSEY-HAYES DISC BRAKES SERVICE BRAKES ................................... 1-5
(FLOATING CALIPER) . . . . . . ........ 37 SERVICE DIAGNOSIS .................... . . . . 1
GENERAL INFORMATION ............ . 1 SPECIFICATIONS........ ................... 54
MASTER CYLINDERS .. .................. 9-33-49 WHEEL CYLINDERS ................................ 13
PARKING BRAKES.............................. . . . . . 16
GENERAL INFORMATION
The new Models are equipped with servo contact, adjusters. The lower ends of the brake shoes are con
two shoe, internal expanding brakes with application nected by a tubular star wheel adjusting screw (Fig. 1).
SERVICE BRAKES
SERVICE DIAGNOSIS
Condition Possibl e Cause Correction
PEDAL GOES TO (a) Fluid low in reservoir. (a) Fill and bleed master cylinder.
FLOOR (b) Air in hydraulic brake system. (b) Fill and bleed hydraulic brake system.
(c) Improperly adjusted brake. (c) Repair or replace self-adjuster as re
quired.
(d) Leaking wheel cylinders. (d) Recondition or replace wheel cylinder
and replace both brake shoes.
(e) Loose or broken brake lines. (e) Tighten all brake fittings or replace
brake line.
(f) Leaking or worn master cylinder. (f) Recondition or replace master cyl
inder and bleed hydraulic system.
(g) Excessively worn brake lining. (g) Reline and adjust brakes.
SPONGY BRAKE PEDAL (a) Air in hydraulic system. (a) Fill master cylinder and bleed hy
draulic system.
(b) Improper brake fluid (low boiling (b) Drain, flush and refill with brake fluid.
point).
(c) Excessively worn or cracked brake (c) Replace all faulty brake drums.
drums.
(d) Broken pedal pivot bushing. (d) Replace nylon pivot bshing.
BRAKES PULLING (a) Contaminated lining. (a) Replace contaminated brake lining.
(b) Front end out of alignment (b) Align front end.
(c) Incorrect brake adjustment. (c) Adjust brakes and check fluid.
(d) Unmatched brake lining. (d) Match primary, secondary with same
type of lining on all wheels.
(e) Brake drums out of round. (e) Grind or replace brake drums.
(f) Brake shoes distorted. (f) Replace faulty brake shoes.
(g) Restricted brake hose or line. (g) Replace plugged hose or brake line.
(h) Broken rear spring. (h) Replace broken spring.
SQUEALING BRAKES (a) Glazed brake lining. (a) Cam grind or replace brake lining.
(b) Saturated brake lining. (b) Replace saturated lining.
(c) Weak or broken brake shoe retaining (c) Replace retaining spring.
spring.
(d) Broken or weak brake shoe return (d) Replace return spring.
spring.
(e) Incorrect brake lining. (e) Install matched brake lining.
(f) Distorted brake shoes. (f) Replace brake shoes.
(g) Bent Support Plate. (g) Replace support plate.
(h) Dust in brakes or scored brake drums. (h) Blow out brake assembly with com
pressed air and grind brake drums.
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5-2 BRAKES — o
CHIRPING BRAKES (a) Out of round drum or eccentric axle (a) Repair as necessary, and lubricate
flange pilot. support plate contact areas (6 places).
DRAGGING BRAKES (a) Incorrect wheel or parking brake ad (a) Adjust brakes and check fluid.
justment.
(b) Parking brakes engaged. (b) Release parking brakes.
(c) Weak or broken brake shoe return (c) Replace brake shoe return spring.
spring.
(d) Brake pedal binding. (d) Free up and lubricate brake pedal and
linkage.
(e) Master cylinder cup sticking. (e) Recondition master cylinder.
(f) Obstructed master cylinder relief port. (f) Use compressed air and blow out re
lief port.
(g) Saturated brake lining. (g) Replace brake lining.
(h) Bent or out of round brake drum. (h) Grind or replace faulty brake drum.
HARD PEDAL (a) Brake booster inoperative. (a) Replace brake booster.
(b) Incorrect brake lining. (b) Install matched brake lining.
(c) Restricted brake line or hose. (c) Clean out or replace brake line or
hose.
(d) Frozen brake pedal linkage. (d) Free up and lubricate brake linkage.
WHEEL LOCKS (a) Contaminated brake lining. (a) Reline both front or rears of all four
brakes.
(b) Loose or torn brake lining. (b) Replace brake lining.
(c) Wheel cylinder cups sticking. (c) Recondition or replace wheel cylinder.
(d) Incorrect wheel bearing adjustment. (d) Clean, pack and adjust wheel bear
ings.
BRAKES FADE (a) Incorrect lining. (a) Replace lining.
(HIGH SPEED) (b) Overheated brake drums. (b) Inspect for dragging brakes,
(c) Incorrect brake fluid (low boiling (c) Drain, flush, refill and bleed hydraulic
temperature). brake system.
(d) Saturated brake lining. (d) Reiine both front or rear or all four
brakes.
PEDAL PULSATES (a) Bent or out of round brake drum. (a) Grind or replace brake drums.
BRAKE CHATTER AND (a) Out of round brake drum. (a) Grind or replace brake drums.
SHOE KNOCK (b) Loose support plate. (b) Tighten support plate bolts to proper
specifications.
(c) Bent support plate. (c) Replace support plate.
(d) Distorted brake shoes. (d) Replace brake shoes.
(e) Machine grooves in contact face of (e) Grind or replace brake drum.
brake drum. (Shoe Knock).
(f) Contaminated brake lining. (f) Replace either front or rear or all four
linings.
BRAKES DO NOT (a) Adjuster screw frozen in thread. (a) Clean and free-up all thread areas.
SELF ADJUST (b) Adjuster screw corroded at thrust (b) Clean threads and replace thrust
washer. washer if necessary.
(c) Adjuster lever does not engage star (c) Repair, free up or replace adjuster as
wheel. required.
(d) Adjuster installed on wrong wheel. (d) Install correct adjuster parts.
SERVICE PROCEDURES
ADJUSTING SERVICE BRAKES then back off parking brake cable adjustment so there
is slack in cable.
Normally self adjusting brakes will not require (4) Insert adjusting tool C-3784, into star wheel of
manual adjustment but in the event of a brake reiine adjusting screw. Move handle to tool upward until
it may be advisable to make the initial adjustment a slight drag is felt when road wheel is rotated.
manually to speed up the adjusting time. (5) Insert a thin screwdriver into brake adjusting
(1) Jack up vehicle so all wheels are free to turn. hole and push adjusting lever out of engagement with
(2) Remove rear adjusting hole cover froin brake star wheel. (Care should be taken so as not to bend
supports of vehicle. adjusting lever (Fig. 1), while holding adjusting lever
(3) Be sure parking brake lever is fully released. out of engagement, back off star wheel to insure a
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BLEEDING BRAKE SYSTEM
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fective flaring seats. The steel tubing is equipped with
a double flare or inverted seat to insure more positive
seating in the fitting. To repair or reflare tubing pro
ceed as follows:
(1) Using Tool C-3478, or equivalent, cut off dam
aged seat or damaged tubing (Fig. 3).
(2) Ream out any burred or rough edges showing
on inside edges of tubing. This will make the ends of
tubing square and insure better seating of flared end
tubing. Place compression nut on tubing prior to flar
ing tubing.
(3) To flare tubing open handles of flaring Tool
C-3838 and rotate jaws of tool until the mating jaws
of tubing size are centered in area between vertical
NK105 posts.
(4) Slowly close handles with tubing inserted in
Ffg« 2 —W h e e l Stud N u t Tightening Sequence jaws but do not apply heavy pressure to handle as this
BRAKE HOSE AND TUBING will lock tubing in place.
(5) Place gauge “Form A” on edge over end of
The flexible hydraulic brake hose should always be tubing and push tubing through jaws until end of
installed in the vehicle by first tightening the male tubing contacts the recessed notch of gauge matching
end of the hose in the wheel cylinder or rea r axle the size of tubing (Fig. 3).
housing tee. The hose is then clipped to the hose (6) Squeeze handles of flaring tool and lock tubing
bracket in a m anner to give minimum twist. Exces in place.
sive twist can result in hose interference problems (7) Place proper sized plug of gauge “A ” down in
with possible hydraulic system failure. end of tubing. Swing compression disc over gauge and
Inspection of brake hose and tubing should be center tapered flaring screw in recess of disc.
included in all brake service operations. The hoses (8) Lubricate taper of flaring screw and screw in
should be checked for: until plug gauge has seated on jaws of flaring
(1) Correct length, severe surface cracking, pulling tool. This action has started to invert the extended
scuffing or worn spots. (Should the cotton fabric cas end of the tubing.
ing of the hose be exposed by cracks or abrasions in (9) Remove gauge and apply lubricant to tapered
the rubber hose cover, the hose should be replaced. end of flaring screw and continue to screw down until
Eventual deterioration of the hose can take place with
possible burst failure).
(2) Faulty installation to cause twisting, wheel, tire
or chassis interference.
Always use factory recommended hose to insure
quality, correct length and superior fatigue life. Care
should be taken to make sure that the tube and hose
mating surfaces are clean and free from nicks and
burrs. New copper seal washers should be used and
the tube nuts and connections should be properly
made and tightened. Double wall steel tubing should
always be used to insure superior fatigue life. Care
should be taken when replacing brake tubing, to use
the proper bending and flaring tools and to avoid
routing the tubes against sharp edges, moving com
ponents or in hot areas. All tubes should be properly
attached with recommended retaining clips.
Steel tubing is used to conduct hydraulic pressure
to the front and rear brakes. Flexible rubber hose is
used at both front brakes and at a rear axle junction
block. Steel tubing is used from the junction block to
NY 1371A
both rear wheel cylinders. All fittings, tubing and
hoses should be inspected for rusted, damaged or de
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tool is firmly seated in tubing. (11) Clean seat and tube of any lubricant before
(10) Remove tubing from flaring tool and inspect connecting to hydraulic system.
seat.
SERVICE BRAKES
INDEX
Page Page
Brake Drum Removal Grinding Recom m endations................................... 8
Front Brake D ru m s ........................................ ....... 5 Brake Shoe Installation
Rear Brake Drums ................................................ 5 Front Brake Shoes ........... ........ ............................ 8
Brake Shoe Removal Rear Brake S h o e s .................................................. 8
Front Brake S h o e s .................................................. 6 Brake Drum Installation
Rear Brake S h o e s .................................................. 6 Front Brake D ru m s .......................................... . 9
Cleaning and Inspection ......................................... 7 Rear Brake D ru m s ................................................ .. 9
SERVICE PROCEDURES
Illustrations of the various service procedures will (4) Remove wheel cover, grease cap, cotter pin,
not always show any one specific brake. lock, adjusting nut, outer wheel bearing and remove
wheel and drum assembly from spindle to expose
BRAKE DRUM REMOVAL brake linings. (Figs. 1, 2 or 3).
(5) Inspect brake lining for wear, shoe alignment,
Removing Front Brake Drums or contamination from grease or brake fluid.
To aid in brake drum removal loosen brake star
adjusting wheel. Removing Rear Brake Drums
(1) Remove rear plug from brake adjusting access (1) Remove rear plug from brake adjusting access
hole. hole.
(2) Insert a thin screwdriver into brake adjusting (2) Insert a thin screwdriver into brake adjusting
hole and push adjusting lever away from star adjust hole and hold adjusting lever away from notches of
ing wheel. Care should be taken not to bend adjusting adjusting screw.
lever. (3) Insert Tool C-3784 into brake adjusting hole
(3) Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw. Release
and engage notches of brake adjusting star wheel. brake by prying down with adjusting tool.
Release brake adjustment by prying down with adjust (4) Remove rear wheel and clips from wheel studs
ing tool. that holds drum on axle. Discard clips. Remove drum.
ANCHOR ANCHOR
PLATE
WHEEL CYLINDER WHEEL CYLINDER
SHOE TABS (3)
DUST BOOT PRIMARY w
/
SECONDARY SHOE
PRIMARY RETURN S P R I N G W ” ■ RETURN SPRING
y SHOE A N D
RETURN SPRING
LINING STRUTs . / • > ,-'v - A . .CABLE
ANTI-RATTLE^ . i % GUIDE
SUPPORT P L A T E m
SPRING "I ^
CABLE ' - \ ^ SHOE TABS (3)
GUIDE RETAINER^,!* m
SHOE RETAINER
\ I ADJUSTER CABLE
SPRING W
SPRING (2)
\ SHOE RETAINER '\ \ % .? * /
I
*'
' SHOE
RETAINING NAIL
PRIMARY S H O E -^ ,
A N D LINING
SHOE / f
r (2)
A U T O M A T IC X
ADJUSTER
‘ OVERLOAD
RETAINING NAIL j ADJUSTER SPRING ^ SPRING
SHOE RETAINER LEVER LEVER; S P R IN G -
(2 ) SPRING
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W H E EL 'CYLINDER
DUST BOOT
PRIMARY RETURN
A NC HOR SPRING '
PUSH ROD LOCK
A~ iSPRING WASHER
SECONDARY SHOE \ ^ DUST BOOT
RETURN SPRING \
SECONDARY
\ f.t, ■
PRIMARY LINING
A ^ D SHOE STRUT, ** SHOE RETURN
SECONDARY SHC3
SPRING
A N D LINING ANTI-RATTLE
SPRING- 1 |~ * P U S H ROD
CABLE GUIDE
SHOE 1I"" SHOE TABS (3).
SHOE RETAINER
RETAINER'S^
SPRING (2) sp r in g V ; ‘ r . p x ’f f - SHOE RETAINING
ADJUSTER \ ' % \ J NAIL (2)
CABLE SHOE RETAINER (4) \ > „ , ' j f ' PARKING BRAKE
ADJUSTER
OVERLOAD S P R IN G " X s
■■LEVER SPRING"
\
SUPPORT PLATE
PRIMARY SHOE
A N D LINING
SHOE TABS ( 3 /
'/
\
ADJUSTER SCREW ASSEMBLY
.
LEVER
A N D LINING
ADJUSTING LEVER
SHOE
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PRIMARY SHOE SECONDARY SHOE PRIMARY SHOE SPECIAL TOOL
RETURN SPRI N G V _ RETURN SPRING RETURN FMOVING A ND
SPRIN G > INSTALLING)
5 •$&, % ADJUSTER
^ .V ,; M - i w CABLE ' :A ^ ' SECONDARY
TAB OF ^
ANTI-RATTLE-.
SPRING ~ B
*' S Q L SHOE RETURN
■ ;>|j| A
:**K >
SPECIAL TOOL
(REMOVING
AND
INSTALLING)
ADJUSTER,
SPRING \A D JU S T IN G LEVER
LEVER t!„ .......'/:--SPR!NG
SPRING NU241A
ADJUSTER,- ADJUSTING
Fig. 4 —Removing or installing Shoe Return Springs SPRING NU243A
(Left Front) Fig. 6 —Removing or installing Shoe Return Springs
Remove drum. (Left Rear)
(2) Using Tool C-3785, remove brake shoe return push rods (if so equipped) and remove from support.
springs (Fig. 6). (Note how secondary spring overlaps Remove adjusting star wheel assembly from shoes.
prim ary spring). (Fig. 1).
(3) Slide eye of automatic adjuster cable off anchor CLEANING AND INSPECTION
and then unhook from adjusting lever. Remove cable, Wipe or brush clean (dry) the metal portions of the
overload spring, cable guide and anchor plate. brake shoes. Examine the lining contact pattern to
(4) Disengage adjusting lever from spring by slid determ ine if the shoes are bent. The lining should
ing forward to clear pivot, then working out from show contact across the entire width, extending from
under spring. Remove spring from pivot. Remove heel to toe. Shoes showing contact only on one side
automatic adjuster spring from prim ary shoe web and should be replaced. Shoes having sufficient lining but
disengage from secondary shoe web. Remove spring. lack of contact at toe and heel should be measured for
(5) Remove brake shoe retainers, springs and nails. proper grind.
Using Tool C-4070, (Fig. 7). Clean the support, using a suitable solvent, then
(6) Spread anchor ends of prim ary and secondary inspect for burrs. Remove if necessary. Clean and
shoes and remove parking brake lever strut and anti inspect the adjusting screws for pulled or stripped
rattle spring (Fig. 8). threads, then apply a thin film of lubricant to the
(7) Disengage parking brake cable from parking threads.
brake lever. New brake shoe return springs and hold down
(8) Disengage prim ary and secondary shoes from springs should be installed where the old springs
SECONDARY TAB O f ANTI-
PRIMARY SHOE SECONDARY 5 - O r .,*• RATTLE SPRING
SHOE AND AND LINING
LINING A N D L 'l-iifiG iB-HIND SHOE
\ * WEB)
SPECIAL
SPECIAL.
y /T O O L
T O O ,\
% , A i ? ’.....
SPRING^C1 %«„.. ... SPRING
WAIL
/W
RETAINER
M /m PRIMARY SHG:
5ZTAINER
Fig. 5 —Removing o r Installing Shoe Retainers, Fig • J —R em oving or In s ta llin g Shoe R etainers,
S p rin gs a n d N a ils (R ig ht Front) Springs a n d N a ils (R ight Rear)
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5-8 BRAKES o
PRIMARY SHOE ^ a n w n w ii^ ANCHOR PLATE tion on vehicle). The left side star wheel is cadmium
RETURN SPRING'S.
N T & C ADJUSTER plated. The right is black, and the adjusting stud end
TAB OF ANTI *' 4*.-' ‘ v .-r fu lf e * '-'C A B L E is not stamped.
RATTLE
SPRING (3) Install adjuster spring in secondary shoe and
STRUT hook other end in web of primary. Install adjusting
lever spring over pivot pin on shoe web. Install adjust
ing lever under spring and over pivot pin. Slide lever
slightly rearw ard to lock in position (Fig. 1).
(4) Spread anchor ends of brake shoes to hold star
adjusting wheel assembly in position.
(5) Holding brake shoes firmly, place assembly on
support plate, and at the same time engage shoe webs
with push rods (if so equipped). (Fig. 9).
PARKING
(6) Using Tool C-4070, install shoe retaining nails,
BRAKE springs and retainers. (Fig. 5).
CABLE
PRIMARY SHOE (7) Install anchor plate over anchor.
AND LINING NU245 (8) Slide “eye” of adjusting cable over anchor and
against anchor plate. Engage end of primary shoe re
Fig. 8 —R em o v in g o r In s ta llin g P a rk in g B ra k e Strut
a n d S prin g (Left R ear) turn spring in shoe web and install other end over
anchor, using Tool C-3785.
have been subjected to overheating or if their strength (9) Install cable guide in secondary shoe web. Hold
is questionable. Spring paint discoloration or distorted ing in position, engage secondary shoe return spring
end coils would indicate an overheated spring, through guide and into web. Install other end over
GRINDING RECOMMENDATIONS anchor, using Tool C-3785. (Be sure cable guide re
mains flat against shoe web, and that secondary spring
Brake Shoe Lining—New lining should be meas
overlaps primary). (Fig. 1). Using pliers, squeeze ends
ured and ground .060" to .080" (maximum under the
of spring loops (around anchor) until parallel.
drum diameter). When replacing brake shoe and lin
(10) Thread adjuster cable over guide and hook
ing assemblies, always check them in the drum they
end of overload spring in lever (Fig. 1). (Be sure “eye”
are to be used with to insure that they have the
of cable is pulled tight against anchor and in a straight
recommended radius grind. This grind, which should
provide at least .004 inch heel and toe clearance, is line with guide).
necessary for proper lining to drum contact during
brake application. Installing Rear Brake Shoes
Drum Refacing—Measure the drum runout with Lubricate with a thin film the shoe tab contact area
an accurate gauge. Drum runout should not exceed (6 places) on support plate with Chrysler support plate
.006 inch out of round. If the drum runout is in excess lubricant, Part Number 2932524 or equivalent (Fig.
of .006 inch, (total indicator run-out) the drum should 11).
be refaced. Remove only as much m aterial as is nec (1) Install parking brake lever on inner side of sec
essary to clean up the drum. It is recommended the ondary shoe web after lubricating pivot with support
front drums be refaced with the wheel and tire
PRIMARY SHOE SECONDARY SHOE
mounted. Do not reface more than .060 inch over the AND LINING AND LINING
standard drum diameter.
BRAKE SHOE INSTALLATION
Installing Front Brake Shoes
Lubricate with a thin film the shoe tab contact area
(6 places) on support plate with Chrysler support plate
lubricant, P art Number 2932524 or equivalent (Fig.
11).
(1) Match a prim ary with a secondary brake shoe
and place them in their relative position on a work
bench.
(2) Install adjusting star wheel assembly between
prim ary and secondary shoes, with a star wheel next ADJUSTING' .......
WHEEL ^
to secondary shoe (Fig. 1). (The left star wheel adjust
ing stud end is stamped “L” which indicates its posi
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PRIMARY SHOF -A . nTHO;^ PLATE
RETURN .'WAVE WASHER
SPRING STOf»
X >{ i IORSESHOE
^ s'CLIP
SUPPORT
TAB’ OF
ANTI-RATTI E .
SPRi.VG '• '
9
(ADJUSTER
\ CABLE
&> i'SHOE V t T A iN I N G
HAIL
„ SECONDARY
V 4^f, "'S H O E A N D
LINING
PRIMARY SHOr.
AND LINING NU 247
SHOE CONTACT
Fig. 10—Installing Brake Shoes (Left Rear) NR107
AREA (6 )
plate lubricant. Secure with wave washer and horse Fig. 1 1—Shoe Contact A rea on Support
shoe clip.
(2) Engage parking brake lever with cable, then prim ary and secondary shoe, with star wheel next to
slide secondary shoe against support plate, and at the secondary shoe. (Fig. 1). The left star wheel adjusting
same time engage shoe web with push rod (if so stud end is stamped “L” which indicates its position
equipped), and against anchor. on vehicle. The left side star wheel is cadmium plated.
(3) Slide parking brake strut behind hub and into The right is black, and the adjusting stud end is not
slot in parking brake lever. Slide anti-rattle spring stamped. Install adjuster spring between shoes (Fig.
over free end of strut. (Fig. 8). On ten inch brakes, be 1). (Engage secondary shoe first).
sure spring tab is pointing rearw ard and up on outside (8) Install adjusting lever spring over pivot pin on
of shoe web (Left Brake), and pointing frontward and shoe web. Install adjusting lever under spring and
down behind shoe web (Right Brake) (Fig. 8). On over pivot pin. Slide lever slightly rearw ard to lock in
eleven inch brakes, be sure spring tab is pointing for position.
ward and down and outside of shoe web (Left Brake), (9) Using Tool C-4070, install shoe retaining nails,
and pointing frontward and down behind shoe web retainers and springs. (Fig. 7).
(Right Brake) (Fig. 3). (10) Thread adjuster cable over guide and hook end
(4) Slide prim ary shoe into position and engage of overload spring in lever. (Fig. 1). (Be sure eye of
with push rod (if so equipped), and free end of strut. cable is pulled tight against anchor and in a straight
Install anchor plate over anchor, then install eye of line with guide).
adjuster cable over anchor. (Fig. 10).
(5) Engage prim ary shoe return spring in web of Installing Front Brake Drums
shoe and install free end over anchor, using Tool C- (1) Lubricate wheel bearings and install brake
3785. (Fig. 6). drum and adjust wheel bearing to proper preload.
(6) Install cable guide in secondary shoe web. Hold (2) Adjust brakes as described under “Service
ing in position, engage secondary shoe return spring Procedures” at front of this Section.
through guide and into web. Install other end over
anchor, using Tool C-3785. (Be sure cable guide re Installing Rear Brake Drums
mains flat against shoe web and that secondary spring (1) Install brake drum, reinstallation of retaining
overlaps primary). (Fig. 1). Using pliers, squeeze ends clips is not necessary. Install wheel and tire assembly.
of spring loops (around anchor) until parallel. (2) Adjust brakes as described under “Service
(7) Install adjusting star wheel assembly between Procedures” at front of this Section.
MASTER CYLINDER
(Drum Brakes)
INDEX
Page Page
Bleeding Master C y lin d er........................................ 12 Installing Master Cylinder............... ........................ 12
Cleaning and Inspection .......................................... 11 Master Cylinder Removal ........................................ 10
Disassembling Master Cylinder............................... 10 Reassembling Master C ylinder............................... 11
General Information ............... .................................. 10 Testing Master Cylinder .......................................... 12
Hydraulic System Safety Switch ........................... 12
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GENERAL INFORMATION
The tandem m aster cylinder (Fig. 1) is of the com to the safety switch and the front brakes.
pensating type with the reservoirs cast integrally. The m aster cylinder used on vehicles not equipped
The m aster cylinder consists of a front and rear pis with power brake units is serviced in the same man
ton (in tandem) two outlets, each contain a residual ner as the m aster cylinder with power brakes, with
pressure valve and spring (Fig. 4). one exception, the m aster cylinder for power brakes
The front outlet tube from the m aster cylinder is does not include the push rod.
connected to the hydraulic system safety switch The disc brake master cylinder is different than
(Figs. 8 and 9) and thence to the rear brakes. The rear the standard drum brake master cylinder and is cov
outlet tube from the m aster cylinder is also connected ered in the disc brake section of the brake group.
SERVICE PROCEDURES
MASTER CYLINDER REMOVAL (4) Retnove front piston compression spring from
bore.
(1) Disconnect front and rear brake tubes from (5) Remove rubber cups from pistons, after noting
m aster cylinder (residual pressure valves will keep positions of cup lips.
cylinder from draining).
Do riot remove the primary cup of the rear piston.
(2) Remove nuts that attach m aster cylinder to
If cup is damaged or worn, install a new rear piston
cowl panel an d /o r power brake unit (if so equipped).
assembly.
(3) Disconnect pedal push rod (manual brakes)
from brake pedal.
(6) Using Tool T109-178 (or an easy out) remove
(4) Slide m aster cylinder straight out from cowl tube seats by threading tool firmly into seat, tap tool
panel an d /o r power brake unit (if so equipped). and seat out of cylinder body. (Fig. 2).
(7) Remove two residual pressure valves and
DISASSEMBLING MASTER CYLINDER springs (Fig. 3).
To disassemble the m aster cylinder, (Figs. 1 and SPECIAL TOOL
4) clean outside of m aster cylinder thoroughly.
(1) Remove cover retaining bolt, and clamp then
remove cover and gasket. Empty brake fluid from
reservoirs.
(2) Loosen piston retainer screw then press in on
rear piston and flip retainer down to release rear
piston assembly (Fig. 3). Slide rear piston assembly
out of cylinder bore.
(3) Remove screw and gasket that retains front TUBE SEAT
piston; then, upending m aster cylinder, tam p (open
end down) on bench to remove front piston. If front
TUBE SEAT NP18A
piston sticks in bore of cylinder, use air pressure
to force piston out of cylinder. New cups must be Fig. 2—Removing Tube Seats
installed at reassembly if air pressure is used.
RESIDUAL PRESSURE PISTON RETAINER
CLAMP ID DOW N CLAMP VALVE AND SPRING SCREW
RETAINING------ -4 .. COVER GASKET
BOLT
------- —■ TAB
p :s ” CN
COVER RETAINER V
SCREW
/
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COVER: COVER RETAINING
BOLT
PISTON RETAINING
SET SCREW AND
GASKET
PISTON SPRING
CUP RETAINER
SECONDARY CUP
FRONT PISTON
REAR PISTON
PRIMARY CUP
'ASSEMBLY
SECONDARY
CUP
RETAINER
/ SCREW
TUBE SEAT RESIDUAL "O” RING
MASTER CYLINDER
PRESSURE SECONDARY CUP
BODY PISTON RETAINER NP20B.
VALVE
Fig. 4 —T a n d e m M a s te r C y lin d e r (E x p lo d e d V ie w )
CLEANING AND INSPECTION (3) Carefully work front piston secondary cup (Fig.
4) into rear land, with the cup lip away from piston.
Clean m aster cylinder thoroughly, using a suitable (4) Slide cup retainer over front end of piston,
solvent and dry with compressed air. Wash the cyl followed by piston spring (Fig. 4).
inder bore with clean brake fluid and inspect for (5) Install piston spring, piston cup retainer, piston
scoring or pitting. Master cylinder bore walls that and cups into bore of master cylinder (Fig. 5).
have light scratches or show signs of corrosion, can Be sure the lip of cups enter bore evenly in order
usually be cleaned with crocus cloth. However, cyl not to damage sealing qualities of cups. (Keep well
inder bores that have deep scratches or scoring may lubricated w i t h brake fluid.)
be honed, providing diam eter of bore is not increased
more than .002 inch. If m aster cylinder bore does not
Rear Piston
clean up at .002 inch when honed, the m aster cylinder (1) Carefully work secondary cup over rear end of
should be discarded and a new m aster cylinder in rear piston with lip of cup toward piston (Fig. 4).
stalled.
(2) Center spring retainer of rear piston assem
If m aster cylinder pistons are badly scored or
bly over shoulder of front piston. Push piston as
corroded, replace them with new ones. The piston
semblies into bore up to center piston cup. Carefully
cups and seals should be replaced when recondition
ing a m aster cylinder. work cup into bore then push piston in up to the
When overhauling a m aster cylinder, use all parts rea r cup. Carefully work lip of rear cup into bore,
furnished in repair kit. Discard all used rubber then push in on piston until seated (Fig. 6).
parts. (3) Holding piston in seated position, move piston
PISTON SPRING
“ O " RING
REASSEMBLING MASTER CYLINDER /
Front Piston
Before assembling the m aster cylinder, dip all
component parts in clean brake fluid and place on a
clean shop towel or paper (assembling seals dry,
can ruin them).
(1) Carefully work prim ary cup on end of front FRONT PISTON
/ PISTON CU."
piston with the lip away from piston (Fig. 4). RETAINING SCREW
PISTON CUP
A ND GASKET FRONT PISTON NP21A
(2) Slide “ 0 ” ring over the rear end of front pis
ton and into correct land.
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FRONT PISTON REAR PISTON push rod with cowl panel opening (manual brakes)
4
^ I SPRING or power brake push rod with cylinder piston.
(2) Slide over mounting studs. Install attaching
nuts and tighten to 9 foot-pounds. Connect push rod
to brake pedal.
(3) Connect front and rear brake tubes and tighten
PISTON CUP
to 150 inch-pounds.
(4) Bleed brakes at wheel cylinders using regular
'« € ' ' X-
procedure, being sure fluid level is maintained. (See
*/j r t• I^
Bleeding the Brake System.)
X FRONT PISTON /
RETAINING'SCREW REAR P I S T O N / TESTING MASTER CYLINDER
AND GASKET ASSEMBLY NP22A
Be sure that the m aster cylinder compensates at
Fig* 6 —Installing Rear Piston Assembly
both ports. This can be done by applying the pedal
retainer over piston and tighten screw securely. lightly with the engine running (power brakes) and
(4) Install front piston retaining set screw and gas observing for a gyser of fluid squirting up in the
ket in cylinder body and tighten securely (Fig. 1). reservoirs. This may only occur in the front chamber
(5) Install residual pressure valves and springs in and so to determ ine if the rear compensating port
outlet ports and install tube seats, firmly. is open, it will be necessary to pump up the brakes
rapidly and, then, hold the pedal down. Have an ob
BLEEDING MASTER CYLINDER server watch the fluid in the rear reservoir while
the pedal is raised. A disturbance in the fluid indi
Before installing the m aster cylinder on vehicle, it cates that the compensating port is open.
m ust be bled on the bench as follows:
(1) Clamp m aster cylinder in a vise and attach HYDRAULIC SYSTEM SAFETY SWITCH
bleeding tubes Tool C-4029 (Fig. 7).
(2) Fill both reservoirs with approved brake fluid. The hydraulic system safety switch (Figs. 8 and 9)
(3) Using a wooden stick or dowel (power brake is used to warn the vehicle operator that one of the
equipped vehicles) or depress push rod slowly and hydraulic systems has failed. A failure in one part
allow the pistons to return under pressure of springs. of the brake system does not result in failure of the
Do this several times until all air bubbles are ex entire hydraulic brake system. As an example, failure
pelled. (Fig. 7). of the rear brake system will leave the front brake
(4) Remove bleeding tubes from cylinder and in system still operative.
stall cover and gasket. (As tubes are removed, fluid FROM MASTER CYLINDER
rem aining in tubes will syphon out.) PORT STAMPED "F"
(5) Install cover retaining clamp and clamp screw. SPRING > SWITCH BODY
(6) Remove from vise and install m aster cylinder OUTLET TO
y ^-OUTLET TO LEFT
FRONT BRAKE TUBE
on vehicle as follows: RIGHT _
FRONT
PISTON SEAL “O ” RING
BRAKE TUBE
INSTALLING MASTER CYLINDER SWITCH SEAL "O ” RING
r %i
AIR BUBBLES
/ W O O DEN DOWEL
PISTON ASSEMBLY
FROM MASTER CYLINDER
PORT STAMPED "R"
OUTLET TO
REAR BRAKE TUBE
NP16A
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As pressure falls in one system, the other system’s
SAFETY SWITCH
normal pressure forces the piston to the inoperative
side contacting the switch terminal, causing a red
warning light to come on in the instrum ent panel, SAFETY SWITCH
thus, warning the operator of the vehicle that one 'BODY ASSEMBLY
of the systems has failed and should be repaired. SEAL-
The safety, switch is mounted on the fram e in a
vertical position, with the brake tubes connected.
(Fig. 8).
If a malfunction occurs within the switch, dis •PLUG
connect tubes from body assembly and install a new
assembly. The component parts of the switch body MOUNTING
BRACKET'
are not serviced. However, the term inal unit can NP24
be removed if a malfunction occurs and a new term i Fig. 9 —Hydraulic System Safety Switch
nal unit installed. (Exploded V ie w )
If a new body is installed, bleed the brake system.
WHEEL CYLINDERS
INDEX
Page Page
Assembling Wheel C ylinders.................................... 13 Installing Wheel Cylinders........................................ 14
Disassembling Wheel C ylinders..................... ........ 13 Removing Brake S u p p o rts ........................................ 15
Installing Brake S u p p o rts ........................................ 15 Removing Wheel C ylinders...................................... 13
GENERAL INFORMATION
A piston stop (Fig. 4) is welded to the support plates (front or rear), then slide wheel cylinder assembly out
to prevent the pistons from moving out far enough to of support.
lose brake fluid. The piston boots are of the press-on
DISASSEMBLING WHEEL CYLINDERS
type and prevents moisture from entering the wheel
cylinder. Front or Rear
To perform service operations or inspections of the To disassemble the wheel cylinders, (Figs. 1 or 2)
wheel cylinders, it will be necessary to remove the proceed as follows:
cylinders from the support plate and disassemble on (1) Using a suitable tool, pry boots away from cylin
the bench. ders and remove. Remove push rods (if so equipped).
(2) Press in on one piston and force out piston, cup,
REMOVING WHEEL CYLINDERS spring cup and piston.
(3) Wash wheel cylinder, pistons and spring in
Front or Rear clean brake fluid or alcohol; clean thoroughly and
With all the brake drums removed, inspect the blow dry with compressed air. Inspect cylinder bore
wheel cylinder boots for evidence of a brake fluid leak. and piston for scoring or pitting. (Do not use a rag as
Visually check the boots for cuts, tears, or heat cracks, lint from the rag will adhere to bore surfaces.)
and if any of these conditions exist, the wheel cylin Wheel cylinder bores and pistons that are badly
ders should be completely cleaned, inspected and new scored or pitted should be replaced. Cylinder walls
parts installed. (A slight amount of fluid on the boot that have light scratches, or show signs of corrosion,
may not be a leak, but may be assembly fluid used can usually be cleaned with crocus cloth, using a cir
during assembly. cular motion. Black stains on the cylinder walls are
(1) In case of a leak, remove brake shoes, (replace caused by piston cups and will not impair operation
if soaked with grease or brake fluid.) of cylinders.
(2) Disconnect brake hose from brake tube at fram e
bracket (front wheels) or disconnect brake tube from ASSEMBLING WHEEL CYLINDERS
wheel cylinder (rear wheels). Front or Rear
(3) Disconnect brake hose or tube from wheel cyl To assemble the wheel cylinders (Figs. 1 or 2,) pro
inder (front). Remove wheel cylinder attaching bolts ceed as follows:
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REAR-HOUSING
/
JP
CUP
1
/
v 1
5 /16" BLEED SCREW
PISTON 1
PRESS O N -B O O T
FRONT-HOUSING-
NR4
REAR-HOUSING
FRONT-HOUSING
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Fig. 4 —W h eel Cy linder Piston Stops
support attaching nuts and washers.
(2) Remove rear axle shaft and retainer.
(3) Disconnect hydraulic brake line from wheel
Fig. 3 —Removing Brake Cable from Support cylinder.
(front or rear). Install mounting screws and torque to (4) Disengage brake cable from parking brake lever.
(5) Using a suitable tool compress three flared legs
110 inch pounds. (9 inch brakes) or 220 inch pounds
(10 and 11 inch brakes). of cable retainer and pull brake cable out of support
(2) Connect brake tube to rear wheel cylinder and (Fig. 3).
torque to 115 inch pounds. (6) Remove brake support from rear axle housing.
(3) Challenger Only—Connect brake hose to front
wheel cylinder, using a new gasket. Torque to 25 foot
INSTALLING BRAKE SUPPORT
pounds, before attaching brake hose to fram e bracket. (Front)
Should hose be connected to w heel cylinder last, tight (1) Dart only—Place support on spindle and install
ening of the hose into wheel cylinder will tw ist hose attaching bolts, nuts and washers. Torque the top at
and can result in suspension or tire interference. taching bolts to 55 foot pounds. The bottom attaching
Dart Only—Connect jum per tube into wheel cylin bolts are to be torqued to 100 foot pounds.
der and torque to 105 inch pounds. Attach brake hose Challenger only— Place support on spindle and in
to fram e bracket and connect brake line to hose and stall attaching bolts, nuts, and washers. Torque the
torque to 105 inch-pounds. Thread jum per tube into bottom attaching bolts 55 foot pounds. The bottom at
brake hose. Attach brake hose to stand off bracket taching bolts are to be torqued to 120 foot pounds.
and then torque jum per tube to 105 inch-pounds. (2) Connect brake hose to wheel cylinder and
(4) Connect brake line to hose and torque to 115 torque to 25 foot-pounds, before connecting brake
inch pounds. hose to fram e bracket. Should hose be connected to
w heel cylinder last, tightening of hose into w heel cyl
REMOVING BRAKE SUPPORT inder will twist hose, which can result in suspension
or tire interference problems.
(Front)
(1) Disconnect brake line from brake hose at fram e (Rear)
bracket. (1) Install support onto rear axle housing.
(2) With wheel and brake drum removed, remove (2) Insert rear axle shaft and retainer into housing
four support attaching nuts and washers. and install axle retainer nuts and washers. Tighten
(3) Remove support and brake assembly from retainer nuts to 35 foot-pounds.
spindle. (3) Attach brake line to wheel cylinder and tighten
to 115 inch-pounds.
(Rear) (4) Insert parking brake cable into support plate
(1) W ith wheel and brake drum removed, remove and attach cable to parking brake lever.
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PARKING BRAKES
INDEX
Page Page
Adjusting Parking B rak e ............. ............................ . 16 Removing Front Parking Brake C a b l e ................... 17
General Information ....................... .......................... 16 Removing Rear Parking Brake C a b le ..................... 16
Installing Front Parking Brake C a b le ................... . 18 Service Diagnosis ...................................................... 16
Installing Rear Parking Brake Cable ..................... 17
GENERAL INFORMATION
The rear wheel service brakes also act as parking The wheel brake cables are joined together by a for
brakes. The brake shoes are mechanically operated by ward brake cable and equalizer extending to the park
a lever and strut connected to a flexible steel cable. ing brake pedal or release handle (Figs. 1, 2, 3 and 4).
SERVICE DIAGNOSIS
Condition Possible Cause Correction
DRAGGING BRAKE (a) I mproper cable or brake shoe adjust (a) Properly adjust the service brakes
ment. then adjust the parking brake cable.
(b) Broken brake shoe return spring. (b) Replace any broken return spring.
(c) Broken brake shoe retainer spring. (c) Replace the broken retainer spring.
(d) Grease or brake fluid soaked lining. (d) Replace the grease seal or recondi
tion the wheel cylinders and replace
both brake shoes.
(e) Sticking or frozen brake cable. (e) Replace cable.
(f) Broken rear spring. (f) Replace the broken rear spring.
(g) Bent or rusted cable equalizer. (g) Straighten, or replace and lubricate
the equalizer.
(h) Heat set parking brake cable spring. (h) Replace parking brake cable.
BRAKE WILL NOT HOLD (a) Broken or rusted brake cable. (a) Replace cable.
(b) Improperly adjusted brake or cable, (b) Adjust brakes and cable as necessary.
(c) Soaked brake lining. (c) Replace the brake lining.
(d) Ratchet or pedal mechanism worn. (d) Replace pedal assembly.
SERVICE PROCEDURES
ADJUSTING PARKING BRAKE (Fig. 3) Wheel Cylinders.
(1) With vehicle jacked up or on a suitable hoist,
The service brakes must be properly adjusted be remove rear wheels.
fore adjusting the parking brake. (2) Disconnect brake cable from equalizer.
(1) Release parking brake lever and loosen cable
adjusting nut to insure cable is slack, (Figs. 1 or 2). RIGHT REAR CABLE ASSEMBLY,
Before loosening cable adjusting nut, clean threads LEFT REAR
CABLE ADJUSTING CABLE ASSEMBLY
with wire brush and lubricate with grease. A
NUT
(2) Tighten cable adjusting nut until a slight drag
is felt while rotating wheel, loosen cable adjusting nut PARKING BRAKE
. ASSEMBLY.
until both rea r wheels can be rotated freely, then
EQUALIZER
back off cable adjusting nut two full turns.
(3) Apply parking brake several times, then release f t CABLE ASSEMBLY
SCREW & WA. ASSY.
and test to see that rear wheels rotate freely without
dragging. ^ R I G H T REAR
CABLE BRACKET ,
RETAINER /
REMOVING REAR PARKING BRAKE CABLE ^FRONT
k<f
CABLE RIGHT REAR
CABLE ASSEMBLY
The independent rear brake cables are attached to FRAME TO SILL ASSEMBLY
REAR EXHAUST
REINFORCEMENT
an equalizer (Fig. 1). The front cable is adjusted at HANGER BRACKET VIEW B
the equalizer. REAR ENGINE'
CROSSMEMBER V IE W A NN558^
Should it become necessary to remove the parking
brake cable (rear) for installation of a new cable, see
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EQUALIZER PY365
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N H 310A
Fig. 4 —Parking Brake Lever (Dart)
attaching clip out of body crossmember. down through cable routing hole in floor pan.
(4) Fold back left front edge of floor m at and re (2) Engage upper end of cable and housing assem
move rubber cable cover from floor pan. bly up through pedal assembly bracket and firmly
(5) Depress parking brake pedal and work brake attach housing and clip into bracket.
cable up and out of brake pedal linkage, (Figs. 3 or 4). (3) Depress parking brake pedal and insert end of
(6) Using a screwdriver force upper end of cable cable into parking brake pedal clevis.
housing and clip down out of pedal assembly bracket. (4) Insert cable through body crossmember and
(7) Remove cable to floor pan clip and work cable firmly press into housing and attaching clip.
and housing assembly up through floor pan. (5) Attach front cable to equalizer bar.
(6) Adjust service brakes and parking brake cable.
INSTALLING FRONT PARKING BRAKE CABLE (7) Apply brakes several times and test for free
wheel rotation when parking brake is in “off” posi
(1) Insert rear end of brake cable and housing tion.
Page Page
Installing Power B r a k e ............................................. 20 Service Diagnosis . 19
Removing Power Brake ............................................ 20
GENERAL INFORMATION
The tandem diaphragm power brake (Fig. 1) is a unit provides lighter pedal effort.
vacuum unit which utilizes engine intake manifold This lighter effort is obtained in combination
vacuum and atmospheric pressure to provide power with a reduced pedal travel, which makes it possible
assisted application of the vehicle brakes. The power to bring the pedal down to the approximate height of
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the accelerator pedal when at closed throttle condi The power brake is externally connected to the
tion. Thus, the driver, after closing the throttle, can brake system. The unit is connected by a pedal link
shift his toe from one pedal to the other without to the brake pedal, by a vacuum line to the intake
lifting his heel from the floor. manifold (through a vacuum check valve) and hy
The power brake, which is a self contained unit, draulic tubes from the m aster cylinder to the wheel
eliminates all external rods and levers, and mounts units.
on the engine side of the cowl panel.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
DRAGGING BRAKES (a) Brake shoes improperly adjusted. (a) Adjust brakes.
(ALL WHEELS) (b) Brake pedal linkage binding. (b) Free up linkage.
(c) Excessive hydraulic seal friction. (c) Lubricate seal.
(d) Compensator port plugged. (d) Clean out master cylinder.
(e) Fluid cannot return to master cylinder. (e) Inspect pedal return.
(f) Parking brake not returning. (f) Free up as required.
(g) Disc brake metering valve mal-func- (g) Replace valve.
tioning.
GRABBING BRAKES (a) Grease or brake fluid on linings. (a) Inspect for a leak and replace lining
as required.
PEDAL GOES TO FLOOR (a) Self-adjusters not operating. (a) Inspect self-adjuster operations.
(OR ALMOST TO FLOOR) (b) Air in hydraulic system. (b) Bleed brakes.
(c) Hydraulic leak. (c) Locate and correct leak.
(d) Fluid low in master cylinder. (d) Add brake fluid.
(e) Shoe hanging up on rough platform. (e) Smooth and lubricate platforms.
HARD PEDAL (POWER (a) Faulty vacuum check valve. (a) Replace check valve.
UNIT TROUBLE) (b) Collapsed or leaking vacuum hose. (b) Replace hose.
(c) Plugged vacuum fittings. (c) Clean out fittings.
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SERVICE PROCEDURES
REMOVING POWER BRAKE (3) Using lubriplate, coat the bearing surface of
bolt that connects power brake pedal link with brake
(1) Remove nuts attaching m aster cylinder to brake pedal linkage. Install bolt and nut. Tighten to 30 foot
unit. Remove m aster cylinder from unit. pounds.
(2) Disconnect vacuum hose from power brake (4) Connect vacuum hose to unit.
check valve. (5) Attach brace and support, secure with nut and
(3) Remove nut attaching brace and support to tighten to 150 inch pounds.
power unit (Fig. 1). (6) Install m aster cylinder to front cover mount
(4) Remove nut and bolt that attach power brake ing studs and tighten nuts to 100 inch-pounds.
pedal link to pedal. (Under instrum ent panel.) Be sure power brake output push rod is set to cor
(5) Remove nuts and washers that attach power rect length. With power brake attached to dash panel
brake unit to dash panel and remove unit. and vacuum supplied to unit, the m aster cylinder
should compensate (force jet of fluid up through front
INSTALLING POWER BRAKE chamber compensation port.)
(1) Install new dash panel to power brake gasket. (7) Check stop light operation.
(2) Position power brake unit on dash panel, then CAUTION: Do not attempt to disassemble brake
install attaching nuts and washers and tighten to 150 booster as this unit will be serviced by Manufacturer's
inch-pounds. Service Station.
POWER BRAKE—BENDIX
(Large Single Diaphragm )
GENERAL INFORMATION
The single diaphragm type power brake (Fig. 1) ance with the foot pressure applied to the valve
is a self contained vacuum hydraulic power braking operating rod through the brake pedal linkage.
unit. It is of the vacuum suspended type which utilizes The control valve is of a single poppet type valve
engine intake manifold vacuum and atmospheric with the atmospheric port and a vacuum port. The
pressure for its power. This type of units does not vacuum port seat is a part of the valve body attached
require a vacuum reservoir. to the diaphragm assembly. The atmospheric port is a
The Bendix Power Brake Unit can be identified by part of the valve plunger which moves within the
the twist lock method of attaching the housing and valve housing and vacuum power diaphragm as
cover together. sembly.
The basic elem ents of the vacuum unit are as fol A hydraulic m aster cylinder which contains all
lows: of the elements of the standard brake m aster cylinder
_ A mechanically actuated control valve integral except for the special hydraulic push rod which is a
with the vacuum power diaphragms, controls the de part of the power brake.
gree of power brake application or release in accord
SERVICE PROCEDURES
REMOVING POWER BRAKE equipped) into dash panel. Install attaching nuts and
washers. Tighten nuts to 150 inch-pounds.
(1) Remove nuts attaching m aster cylinder to brake
(2) Using lubriplate, coat the bearing surface of
unit. Remove m aster cylinder from unit.
bolt that connects power brake pedal link with brake
(2) Disconnect vacuum line from check valve.
pedal. Install bolt and nut. Tighten to 30 foot-pounds.
(3) From under instrum ent panel, remove n u t and
Install lower pivot bolt (if so equipped).
bolt from power brake link and brake pedal. (On link
(3) Attach vacuum hose to check valve.
age type power brake, remove lower pivot bolt).
(4) Install m aster cylinder on power brake. Tighten
(4) From under instrum ent panel remove four
mounting nuts to 100 inch pounds. Be sure power
brake unit attaching nuts and washers.
brake output push rod is set to correct length. With
(5) W ithdraw brake unit assembly from vehicle.
power brake attached to dash panel and vacuum sup
plied to unit, the m aster cylinder should compensate
INSTALLING POWER BRAKE
(force jet of fluid up through front chamber compen
sation port).
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V IE W IN DIRECTION O F
ARROW A
POWER BRAKE-BENDIX
(Tandem Diaphragm )
GENERAL INFORMATION
The tandem diaphragm type power brake (Fig. 1), with the vacuum power diaphragms, controls the de
is a self contained vacuum hydraulic power braking gree of power brake application or release in accord
unit. It is of the vacuum suspended type which utilizes ance with the foot pressure applied to the valve
engine intake manifold vacuum and atmospheric pres operating rod through the brake pedal linkage.
sure for its power. This type of unit does not re The control valve is of a single poppet type valve
quire a vacuum reservoir. with the atmospheric port and a vacuum port. The
The Bendix Power Brake Unit can be identified by vacuum port seat is a part of the valve body attached
the crim ped edge method of attaching the housing to the diaphragm assembly. The atmospheric port is a
and cover together. part of the valve plunger which moves within the
The basic elements of the vacuum unit are as fol valve housing and vacuum power diaphragm as
lows: sembly.
(a) The vacuum power chamber consists of a front (c) A hydraulic m aster cylinder which contains all
and rea r shell, a center plate, front and rear dia of the elements of the standard brake m aster cylinder
phragm, hydraulic push-rod and a vacuum diaphragm except for the special hydraulic push rod which is a
retu rn spring. part of the power brake.
(b) A mechanically actuated control valve integral
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(DRUM BRAKE) NP293
SERVICE PROCEDURES
REMOVING POWER BRAKE (2) Using lubriplate, coat the bearing surface of
bolt that connects power brake pedal link with brake
(1) Disconnect m aster cylinder from power brake pedal linkage. Install bolt and nut. Tighten to 30 foot
unit. pounds.
(2) Disconnect vacuum line from check valve. (3) Attach vacuum hose to check valve.
(3) From under instrum ent panel, remove push rod (4) Install m aster cylinder on power brake. Tighten
nut and bolt from power brake and brake pedal. mounting nuts to 100 inch-pounds. Be sure power
(4) From under instrum ent panel remove four brake output push rod is set to correct length. With
brake unit attaching nuts and washers. power brake attached to dash panel and vacuum sup
(5) Withdraw brake unit assembly from brake sup plied to unit, the m aster cylinder should compensate
port bracket. (force jet of fluid up through front chamber compen
sation port).
INSTALLING POWER BRAKE
(5) Inspect adjustm ent of stop light switch.
(1) Install power brake and linkage assembly (if so CAUTION: Do not attempt to disassemble brake
equipped) into dash panel. Install attaching nuts and booster as this unit will be serviced by Manufacturer's
washers. Tighten nuts to 150 inch-pounds. Service Station.
Page Page
Assembling C a lip e r............. .............................. .. . . . 30 Disassembling Master Cylinder.............................. 33
Assembling Master Cylinder..............................., . . . 34 Disc Brake Service P re ca u tio n s............ ............... 26
Bleeding Disc B ra k e ............................................ . . . . 32 General Information ............................... ............... 23
Brake Shoe Installation ................................... . . . . 28 Installing Brake Disc and H u b ............... ............... 31
Brake Shoe Removal ......................................... . . . . 28 Installing C a lip e r...................................... ............... 31
Cleaning and Inspection (Master Cylinder) .. . . . . 29 Installing Master C ylinder....................... ............... 35
Disassembling Caliper ............................... .... 29 Proportioning Valve .............................. ............... 33
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Page Page
Removing Braking Disc and H u b ............................. 31 Routine M aintenance............................................. 24
Removing Caliper ...................................................... 28 Service Diagnosis ...................................................... 26
Removing Master C ylinder......................................... 33
GENERAL INFORMATION
The disc brake (Fig. 1) is a fixed caliper, opposed 6) and are supported radially by “ears” on th e outer
piston, non-energized, ventilated disc type, actuated ends of the shoe assemblies. The shoes slide axially in
by the hydraulic system. There is no lateral move the abutm ents and ride on machined ledges (bridges)
m ent of either the disc or the caliper. The caliper as when hydraulic pressure is applied to the pistons. The
sembly consists of two caliper housings, bolted to lining assembly consists of organic friction m aterial,
gether. Each half contains two cylinder bores of 1-5/8 bonded to a m etal plate called the shoe, and is re
inch diam eter. Each cylinder contains a seal, piston placed as a unit. Brake torque is absorbed by the
and externally attached molded rubber dust boot to reaction of the shoe end against the caliper abutments.
seal the cylinder more from contamination. The pis Two spring clips bolted in the top opening of the
tons are sealed by “rectangular section” rubber piston caliper act as shoe retaining springs. The caliper is
seals, positioned in grooves machined in the cylinder m ounted directly to the front wheel spindle and at
bores, which provide hydraulic sealing between the the rear of the wheel’s vertical centerline (Fig. 4).
pistons (Fig. 2), and the cylinder bores. The cast iron braking disc is of the ventilated type
The cylinders are connected hydraulically by and incorporates forty cooling fins. This increases the
means of internal passages in the caliper housings cooling area and perm its circulation of air through
and by an external transfer tube between the two the disc, resulting in more rapid cooling of the brake.
halves of the caliper assembly. A bleeder screw and a The disc is attached to the wheel hub by five flathead
fluid inlet fitting are provided on each caliper assem serrated bolts. The outside diam eter of the disc is
bly (Fig. 1). 11.04 inches and the inside is 6.91 inches. A splash
The shoe and lining assemblies are located between shield bolted to the spindle is used to prevent road
parallel machined abutm ents within the caliper, (Fig. contaminates from contacting the inboard side of the
WHEEL
BRAKING DISC
NUT LOCK
EXTERNAL TRANSFER
TUBE
COTTER PIN
GREASE CAP
CALIPER
ASSEMBLY
STEERING ARM
SPECIAL WHEEL
1 4 x 4 .5 0 J
DISC HUB
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disc and lining surfaces (Fig. 4). The wheel, itself, wheel cylinders which provides balanced braking ac
provides protection for the outboard surface of the tion between the front and rear brakes under a wide
disc. range of braking conditions. The valve regulates the
Braking action begins immediately upon applica hydraulic pressure applied to the rear wheel cyl
tion of the brake pedal as hydraulic pressure from the inders, thus limiting rear braking action when high
m aster cylinder to the system applies pressure to the pressures are required at the front brakes. In this
co-axially aligned caliper pistons forcing the linings m anner, prem ature rear wheel skid is prevented.
against both sides of the braking disc, thus applying An additional feature of this disc brake system is a
the brakes. During brake application, the piston seals “tell-tale” tab sounding device which indicates when
are deflected by the hydraulic pressure (Fig. 5). W hen replacem ent of the shoe and lining assemblies are
the pressure is released, the seals relax or retract, required (Fig. 3). The tabs located on the shoes create
pulling the pistons back from the shoe and lining as an audible metallic scraping noise from the brake by
semblies approximately .005". (This reaction is called m etal to m etal contact on the braking disc. This
“seal retraction” and provides the required running warns the driver that the lining has worn to a mini
clearance as the linings relieve their force on the mum thickness and the vehicle should be returned to
disc.) Inherent disc runout also contributes to main the dealer for relining of the brakes. This device is not
taining running clearance. Automatic adjustm ent is detrim ental to the function of the braking disc.
achieved by the pistons sliding outward from the cyl
inder bore as the lining wears. The piston assumes ROUTINE MAINTENANCE
a new position relative to the seal and maintains the
correct adjustm ent location at all times (Fig. 5). Check Brake Lines and Linings
There is no residual pressure in the disc brake Raise all four wheels. Remove one of the front
hydraulic system since the residual pressure valve wheel and tire assemblies and inspect the braking
normally used in drum brake system is located only in disc, caliper and linings. (The wheel bearings should
the front outlet port of the m aster cylinder. (See be inspected at this time and repacked if necessary.)
Master Cylinder Section of this Group). The caliper must be removed to inspect and pack the
The hydraulic system contains a proportioning inner wheel bearing.
valve between the m aster c y lii^ ^ ^ n d the re^ -Jg ^ k e Do not get oil or greasgj^ the disc or the linings. If
SEAL BOOT
BLEED
SCREW
VENTILATED \
DISC
CALIPER
(OUTER)
BRAKE TUBE
INLET
LOCKWASHER
CALIPER
(INNER)
BRIDGE
BOLT
TRANSFER TUBE FITTING
SHOE A N D
(WITH TUBE SEAT!
LINING ASSEMBLY
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PISTON v CYLINDER BORE CALIPER
“ TELL i.'J x HOUSING
PISTON TAVA~’ PISTON SEAL
BRAKE
PRESSURE
ON
BRAKE,*. •
Lh i!i JG
SHOE #***
DUST BOOT NN427B
PISTON BOOT
GROOVE NN425
Fig. 5 —Piston Seal Function fo r Automatic
Adjustment
Fig. 3 —Disc Brake Piston, Shoe a n d Lining Assembly
“scraping” noise from the front brakes will be heard.
the linings are worn to within .030 inch of the surface This noise is metal-to-metal contact between the tabs
of the shoe, replace both sets of shoe and lining as on the shoe assemblies and the braking disc. When
semblies (inboard and outboard) on the front wheels. the noise becomes audible to the driver, the lining has
It is recommended that both front wheel sets be re worn to the m etal tabs and the brakes must be re
placed whenever a respective shoe and lining is worn lined. The contact between the m etal tab and disc will
or damaged. not affect the functioning of the disc brake system,
If the caliper is cracked or fluid leakage through but continued use until lining is completely worn
the casting is evident, it must be replaced as a unit.
away will cause disc damage.
Shoe a n d Lining W e a r
If a visual inspection does not adequately deter Running Clearance
To check the shoe and lining assembly to the brak
mine the condition of the lining, a physical check will
ing disc clearance, remove the wheel and tire assem
be necessary.
bly. Insert a feeler gauge between the lining and the
To check the amount of lining wear, remove the
braking disc. Ordinarily, the clearance should be .003
wheel and tire assembly, the spring clips and the
to .006 inch. However, if the vehicle was stopped by a
shoe and lining assemblies (see “Brake Shoe Removal”
brake application just prior to checking the clearance,
paragraph). Three (3) thickness m easurem ents with
it is considered normal for the brakes to drag slightly.
a micrometer should be taken across the middle sec
tion of the shoe and lining; one reading at each side
and one reading in the center. When an assembly has B rake Roughness
worn to a thickness of .180 inch, it should be replaced. The most common cause of brake chatter on disc
If shoes do not require replacement, reinstall making brakes is a variation in thickness of disc. If rough
sure to replace to their original inner and outer ness or vibration is encountered during highway
positions (see “Brake Shoe Installation” paragraph). operation or if pedal pumping is experienced at low
When shoe and lining replacem ent is required, a speeds, the disc may have excessive thickness varia
tion. To check for this condition, measure the disc at
CALIPER TRANiili-tR j i. r-i i.W A !U - 12 (twelve) points with a micrometer at a radius
TUBL
*»* approximately one inch (1") from edge of disc. If
SHOE H Q LD D O W M ^S ''-: . SHOCK BOLT MUST IS!. !r IS IA IIW : thickness measurements vary by more than .0005
CLIP S y ,; WITH iI IF H t A.D AS SHOW N inch the disc should be replaced with a new one.
BRAKE HOSfc
MOUNTING X M Braking Disc Runout
Excessive lateral runout of the braking disc will
C A U K R M O U N TIN G I cause a “knocking back” of the pistons, which will
BOLTS I create increased pedal travel and vibration when the
brakes are applied.
tAUPCR V • ./ * 'f S '-
Before checking the runout, the wheel bearing end
-AS3Y x * play should be eliminated by tightening the adjusting
ViSJUMP'-iJ \f 'T'51N ’.:MP I'5.'- •£&■''* ' "K
v; iub' W f jfe^piASH % nut. The readjustment is very important and will be
required at the completion of the test to prevent bear
••if ' W •# ing failure. After tightening the adjusting nut, be
NN426B sure that the braking disc can still be rotated.
Dial indicator C-3339 should be clamped to the
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steering knuckle so that the stylus contacts the brak (3) During removal and installation of a wheel and
ing disc at a point approximately one (1) inch from tire assembly, exercise care so as not to interfere with
the outer edge, (Fig. 15). Rotate the disc and check or damage the bleeder screw or the transfer tube.
the indicator reading. The maximum total indicator (4) The front wheel bearing end play is im portant
reading on the gauge should not exceed .0025 inch. If and must be within specifications.
the reading exceeds this specification, the disc should (5) Be sure vehicle is centered on the hoist before
be replaced. Do not attempt to refinish a disc that servicing any of front end components to avoid
indicates runout in excess of the specification. bending or damaging disc splash shield on full right
or left wheel turns.
DISC BRAKE SERVICE PRECAUTIONS (6) Before vehicle is moved after any brake serv
(1) Grease or any other foreign m aterial must be ice work, be sure and obtain a firm brake pedal .
kept off the caliper assembly, surfaces of the braking (7) The assembly bolts of two caliper housings
disc and external surfaces of the hub, during service should not be disturbed, unless servicing of caliper
procedures. Handling the braking disc and caliper assembly is required.
should be done in a way to avoid deformation of the (8) Riding brake pedal (common left foot applica
braking disc and nicking or scratching the brake tion) should be avoided during vehicle operation.
linings. (9) The wheel, tire, hub and disc assembly cannot
(2) If inspection reveals the square sectioned be removed as an assembly. The caliper assembly
rubber piston seals are worn or damaged, they should must be removed before removal of hub and disc as
be replaced immediately. sembly.
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(f) Out-of-round rear drums. (f) Check and regrind drums if neces
sary.
(g) Incorrect tire pressure. (g) Inflate tires to recommended pres
sures.
(h) Brake fluid, oil or grease on linings. (h) Install new shoe and linings.
(i) Restricted hose or line. (i) Check hoses and lines and correct as
necessary.
(j) Rear brakes out of adjustment. (j) Adjust rear brakes.
(k) Unmatched linings. (k) Install correct lining.
(I) Distorted brake shoes. (I) Install new brake shoes.
NOISE Groan- •Brake noise emanating when slowly releasing brakes (creep—groan)
(a) Not detrimental to function of disc brakes—no corrective action re
quired.
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SERVICE PROCEDURES
BRAKE SHOE REMOVAL shoe is fully seated and lining is facing disc.)
(3) Slide remaining shoe and lining into caliper,
To remove the disc brake shoe and lining assembly, using same procedure as described above.
(Fig. 1), proceed as follows: (4) Place shoe retainer spring assemblies in position
(1) Raise vehicle on a hoist or jackstands. on caliper.
(2) Remove wheel covers, and wheel and tire as (5) Pump brake pedal several times until a firm
sembly. pedal has been obtained and shoe and lining have
(3) Remove shoe retainer spring assemblies. been properly seated.
(4) Using two pair of pliers, grasp tabs on outer (6) Install wheel and tire. Tighten wheel stud nuts
ends of shoes, remove shoe and lining by pulling out to 55 foot-pounds. Install wheel cover.
ward (Fig. 6). Due to a ridge of rust that may build up (7) Check and refill m aster cylinder reservoir with
on rotor surface outside of lining contact area, it may brake fluid as required.
be necessary to force piston back slightly into bores. CAUTION: Road test the vehicle and make several
Pistons can be forced back into bores by forcing shoe stops to wear off any foreign material on the brakes
back with a water pump pliers placed on corner of the and to seat the linings. The vehicle may pull to one
shoe and caliper housing (Fig. 6). side or the other if this is not done.
Check the caliper for seal leaks (evident by fluid
moisture around the cavity) and for any damage to REMOVING CALIPER
the piston dust boot. Wipe the cavity clean (between
the inner and outer caliper housings) with a shop Should it become necessary to remove the caliper
towel. Check the piston dust boot for proper seating for installation of a new piston seal or boot, (Fig. 4),
in the piston bore and the caliper housing. If exces proceed as follows:
sive fluid moisture is evident, it will be necessary to (1) Raise car on hoist or jackstands.
install a new piston seal and piston dust boot. (Refer (2) Remove wheel cover and wheel and tire as
to “Disassembling the Caliper” paragraph.) sembly.
(3) Disconnect front brake flexible hose from brake
BRAKE SHOE INSTALLATION tube at fram e mounting bracket. (Plug brake tube to
prevent loss of fluid.)
(1) Push all pistons back into their bores until (4) Remove bolts that attach caliper assembly to
bottomed to allow for installation of new thick shoes. steering knuckle. Should it become necessary to in
This can be done by placing a flat sided m etal bar or stall a new flexible brake hose on a disc brake
tool against piston and exerting a steady force until equipped vehicle, scribe a m ark on hose bracket on
bottomed. This will cause fluid to rise in the reservoir side where hose enters, and position of hose retaining
so be sure and remove a quantity of fluid from the clip underneath (Fig. 4). Be sure at reassembly, that
reservoir before hand. open end of retaining clip is facing out and away
(2) Slide new shoe and lining into caliper with ears from caliper.
of shoe resting on bridges of caliper (Fig. 7). Be sure (5) Slowly slide caliper assembly up and away from
. 'w r “7 ~
v '- .. f t - - - * ; .■
if"' DISC
• *
BRAKE SHOE INSTALL LINING
AND LINING ASSY' TOWARD DISC
"hr•'
ca up ~;c C A V ? Z R
v;0 !'“ Or-r\ RONT OF r \
I v e k ;c l " v VEHICLE V
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CALIPER (3) Remove shoe and lining assemblies.
ASSEMBLY : j (4) Remove bridge bolts that hold two halves of
^lblSC SPLASH caliper together. (Make sure at reassembly that these
’h
M —
BY SHIELD two bolts are used and tightened to correct torque.)
Separate assemblies.
\ Mmmm (5) Peel dust boot out and away from caliper hous
\ m
wmMMMU ing retainer and out of piston groove (Fig. 10). Re
■ — WH move rem aining dust boots in same manner.
(6) Using Tool C-3999, remove each of pistons (Fig.
11). Care must be used so as not to scratch, burr or
otherwise damage piston on outside diameter. To do
so effects sealing qualities of piston. Draw piston
DISC BRAKE ■ straight out of its bore. If a piston becomes cocked,
HUB
removal is more difficult and piston or bore may be
BRAKING - FRONT OF i \
DISC
damaged.
VEHICLE ! /
NN431A (7) Using a small pointed wooden or plastic tool,
remove piston seals from groove in cylinder bore (Fig.
Fig. 8—Removing or Installing Disc Brake Caliper 12). Discard old seals. (Use care so as not to scratch
bore or the seal groove.)
brake disc (Fig. 8) and remove to bench for disas
sembly.
CLEANING AND INSPECTION
DISASSEMBLING CALIPER Clean all parts in brake fluid and wipe dry, using
To disassemble the caliper for the installation of clean, lint free, shop towels. Using an air hose, blow
new parts (Fig. 9), proceed as follows: out the drilled passages and bores. Check the dust
(1) Remove shoe retainer spring assemblies. Re boots for punctures or tears. If punctures or tears are
move jum per tube (armored) at caliper. evident, new boots should be installed at reassembly.
(2) Mount caliper assembly in a vise equipped with Inspect the piston bores in both housings for scoring
protector jaws. (Use caliper mounting lugs.) Remove or pitting. Install a new piston if it is pitted, scored or
transfer tube. the chrome plating is worn off. Bores that show
PISTON |
r / \ ^ B° lT
BLEEDER SCREW
PISTON SEAL
PISTON SEAL
w DUST BOOT
*PISTON
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CALIPER
. :.n
— i w
1% •!
/
/ / FiF.i?E
Ca UP cR PISTON SiiCK
ASSEMBLY SEAL
NN434B
Fig. 10—Removing Dust Boot from Piston and Caliper Fig. 12 —Removing Piston Seals from Caliper
light scratches or corrosion, can usually be cleaned (1) Clamp inner caliper half in a vise (with protec
with crocus cloth. However, bores that have deep tor jaws) by mounting lugs.
scratches or scoring may be honed, using Tool C-3993, (2) Dip new piston seals in clean brake fluid and
providing the diam eter of the bore is not increased install in caliper grooves. The seal should be posi
more than .002 inch. If the bore does not clean up tioned at one area in groove and gently worked
within this specification, a new caliper housing should around cylinder bore with a finger until properly
be installed. (Black stains on the bore walls are caused seated. Never use an old piston seal. (Be sure seals are
by the piston seals and will do no harm.) not twisted or rolled.)
When using hone C-3993 (Fig. 13) be sure and in (3) Coat outside diam eter of pistons with clean
stall the hone baffle before honing bore. The baffle is brake fluid and install them in cylinder bores (Fig. 14),
used to protect the hone stones from damage. After with open end of piston and boot retaining groove
honing the bore carefully, clean the seal groove with facing out of cylinder.
a stiff non-metal lie rotary brush. (4) Position piston squarely in bore and apply slow
Use extreme care in cleaning the caliper after hon steady pressure until piston is positioned. If piston
ing. Remove all dust and grit by flushing the caliper will not position itself, remove piston and check posi
with brake fluid; wipe dry with a clean lintless cloth tion of seal for proper position in groove.
and then clean a second time in the same manner. (5) Install a new dust boot in position in groove in
caliper and in piston. Be sure dust boot is properly
ASSEMBLING CALIPER seated. Install new remaining dust boots in same
manner.
To reassemble the disc brake caliper, (Fig. 9), (6) Install caliper half on one clamped in vise, then
proceed as follows:
install assembly bolts (bridge bolts) and tighten from
SPECIAL
TOOL
70 to 80 foot-pounds. (Under no condition should
these bolts be substituted or replaced by an inferior
bolt. The use of bolts other than those specified for
this purpose, could cause a caliper failure resulting
■-K- in an accident).
/•
(7) Install transfer tube and tighten securely. (Be
PISTON sure tube is under protective eyebrow.)
(8) Install bleeder screw but do not tighten.
SPECIAL
TOOL
CALIPER
- r ASSEMBLY N N 433A
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be a minimum of .050 inch from either disc face to
machined groove in outboard caliper.
(2) Install shoe and lining assemblies between cali
per and braking disc.
(3) Install shoe retainer springs in position on cali
per.
(4) Open bleeder screw, then reconnect brake line
at caliper housing. Allow caliper to fill with brake
fluid; then, close bleeder screw. (Be sure all air bub
bles have escaped; bleeding caliper.) Replenish brake
fluid in m aster cylinder.
(5) "Pump" brake pedal several times to actuate
piston seals and position shoe and lining assemblies.
(6) A fter assembling caliper unit be sure and check
for fluid tightness under maximum pedal pressures.
NN4361
(Recheck m aster cylinder reservoir level.) Check and
Fig. 14—In s ta llin g Pistons in C a lip e r be sure that lower shock absorber mounting bolt has
been installed from rear and nut toward front of ve
INSTALLING CALIPER
hicle. This is important. (Fig. 4).
Before installing the caliper assembly over the (7) Install wheel and tire assembly and tighten
brake disc, check the disc for runout and thickness wheel stud nuts to 55 foot-pounds. This is important.
variation. Mount a dial indicator (Fig. 15) and check Install wheel cover.
the lateral runout. Runout should not exceed .0025 (8) Remove jackstands or lower hoist.
inch. If runout exceeds the specified figure, remove CAUTION: Road test the vehicle and make several
the disc and install a new one. (Be sure the wheel stops to wear ofF any foreign material on the brakes
bearings are adjusted to zero lash during this check.) and to seat the linings. The vehicle may pull to one
Readjust wheel bearings after check. side or the other if this is not done.
Thickness variation of the disc, measure the disc
at 12 (twelve points) with a m icrometer at a radius
REMOVING BRAKING DISC AND HUB
approximately one inch (1") from edge of disc. If
thickness m easurem ents vary by more than .0005 Should it become necessary to remove the braking
inch, the disc should be replaced with a new one. disc for installation of a new disc, proceed as follows:
(1) Install caliper assembly over disc and align (1) Remove wheel cover and wheel and tire as
mounting holes. Install mounting bolts and tighten sembly.
from 50 to 80 foot-pounds. A check should be made to (2) Remove caliper assembly as described under
be sure that braking disc runs squarely and centrally “Removing Caliper” paragraph, (but do not discon
within caliper opening. There should be approximate nect brake line). Suspend caliper from wire hook or
ly .090 to .120 inch clearance between outside dia loop to avoid strain on hose and damage to transfer
meter of braking disc and caliper. There should also tube.
(3) Remove grease cup, cotter pin, nut lock, nut,
thrust washer and outer wheel bearing.
(4) Pull disc and hub off wheel spindle.
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check runout of disc on both sides. The runout should (3) Reinstall braking disc and hub assembly. Install
not exceed .0025 inch. Readjust wheel bearing clear outer bearing, thrust washer and nut. Tighten front
ance after checking braking disc runout. wheel bearing as described previously. Install nut
(7) Clean grease cap, coating inside with wheel lock, cotter pin and grease cap.
grease (do not fill) and install cap. (4) Install caliper assembly as described under “In
(8) Install caliper assembly as described in “Install stalling Caliper” paragraph.
ing the Caliper” paragraph. (5) Install wheel and tire. Tighten wheel stud nuts
(9) Install wheel and tire assembly and wheel (in a star pattern) to 30 foot-pounds, then to 55 foot
cover. pounds. Install wheel cover.
(10) Remove jackstands or lower hoist. (6) Remove jackstands or lower hoist.
(11) Road test vehicle as described in “Brake Shoe
Installation” paragraph. BLEEDING DISC BRAKE
REMOVING SPLASH SHIELD The disc brake hydraulic system can be bled
(preferably) with pressure bleeding equipment. On
Should it become necessary to remove the braking disc brake equipped vehicles, the brake pedal will
disc splash shield because of damage or the installa require more pumping, and frequent checking of the
tion of the steering knuckle, proceed as follows: fluid level in the m aster cylinder during the bleeding
(1) Raise vehicle on a hoist or jackstands. operation, if pressure bleeding equipm ent is not used.
(2) Remove wheel cover and wheel and tire as It will be necessary to remove the front wheel and
sembly. tire assemblies in order to gain access to the bleeder
(3) Remove caliper assembly, as described under screw, located on the outboard caliper housing at the
“Removing Caliper” paragraph. Do not disconnect top. (Fig. 1).
brake line. Never use brake fluid that has been drained from
(4) Remove grease cup, cotter pin, nut lock, nut, the hydraulic system, when bleeding the brakes.
thrust washer and outer wheel bearing. On vehicles equipped with disc brakes, be sure that
(5) Pull braking disc and hub off wheel spindle. the disc brake pistons are returned to their normal
(6) Remove bolts that attach splash shield (Fig. 16) positions and that the shoe and lining assemblies are
to steering knuckle. properly seated.
Before driving the vehicle, check the operation of
INSTALLING SPLASH SHIELD the brakes to be sure that a firm pedal has been ob
tained.
To install the braking disc splash shield, (Fig. 16), (1) Remove wheel covers, then raise vehicle using a
proceed as follows: hoist or jackstands.
(1) Position styrafoam gasket and install splash (2) Remove wheel and tire assemblies.
shield in position on steering knuckle, with cutout (3) Bleed the front brakes first, then proceeding
section toward rear. to the right rear and left rear in order.
(2) Align mounting holes and install attaching After bleeding the brakes, proceed as follows:
bolts. Tighten to 17 inch-pounds. (1) Install wheel and tire assemblies, tightening
REAR BRAKE U N E * * ^ ' 'W " F R OM-/ '■
/ ... % v ‘ ; - ■ FRAME "T " A N D MASTER %
■f ' ' -V'-'-.., ™.NDERJJN!BfiS3%^:
. * INLET PRESSURE^'- , 6
~"v~;
fANDEM M ASTER^
PROPORTIONING . /<V f P ' ' I y jC Y L IN D E R '
VALVE \
: ' v
“ V
K
v
:
OUTLET
Pkt:5>SUrtE t LINE T O ^
imMW-:■■: FRONT BRAKES
?FRONT OF f4\
linT t o f r a m e *
I VEHICLE
T " A N D REAR BRAKES®
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wheel stud nuts to 55 foot-pounds. (1) Install one of Gauge Set C-4007 and “T” in
(2) Install wheel covers. brake line between m aster cylinder and proportioning
(3) Remove jackstands or lower hoist. valve and rem aining Gauge and “T” at output end of
valve and brake line. (Fig. 17). Be sure all joints are
TESTING PROPORTIONING VALVE fluid tight.
(2) Have a helper exert pressure on brake pedal
When a prem ature rear wheel slide is obtained on (holding pressure). Obtain a reading on m aster cylin
brake application, it usually is an indication that the der output of approxim ately 500 p.s.i.
fluid pressure to the rear brakes is above the reduc (3) While pressure is being held as above, reading
tion ratio for the rear line pressure and that a mal on valve outlet Gauge should be 360-405 p.s.i.
function has occurred within the proportioning valve, If the proportioning valve pressure readings do not
which should be tested. m eet the specifications, the valve should be removed
To test the proportioning valve, proceed as follows: and a new valve installed.
MASTER CYLINDER
Kelsey-Hayes Disc Brakes (Four Piston)
INDEX
Page Page
Bleeding Master Cylinder 35 Installing Master Cylinder ...................................... ... 35
Cleaning and Inspection 34 Master Cylinder Removal ........................................ ... 33
Disassembling Master Cylinder 33 Reassembling Master Cylinder ................................ 34
General Information ................... 33 Testing Master Cylinder .......................................... ... 36
Hydraulic System Safety Switch 36 Testing Hydraulic System Safety Switch ............. ....36
GENERAL INFORMATION
The tandem m aster cylinder (Fig. 1) is of the to the safety switch and the front brakes.
compensating type with the reservoirs cast integrally. The m aster cylinder used on vehicles not equipped
The m aster cylinder consists of a front and rear pis with power brake units is serviced in the same man
ton (in tandem) two outlets, with 1 containing a ner as the m aster cylinder with power brakes with
residual pressure valve and spring (rear brake line one exception, the m aster cylinder with power brakes
outlet only), (Fig. 3). does not include the push rod.
The front outlet tube from the m aster cylinder is The drum brake m aster cylinder is different than
connected to the hydraulic system safety switch (Figs. the disc brake m aster cylinder and is covered in the
8 or 9) and thence to the rear brakes. The rear out service brake section of this group.
let tube from the m aster cylinder is also connected
SERVICE PROCEDURES
MASTER CYLINDER REMOVAL 4) clean the outside of the m aster cylinder thoroughly.
(1) Press bail to one side and remove cover and
Should it become necessary to service the m aster gasket. Empty brake fluid from reservoirs.
cylinder, remove from the vehicle as follows: (2) Remove piston retaining screw and gasket (Fig.
(1) Disconnect front and rear brake tubes from 2), then slide rear piston assembly out of cylinder
m aster cylinder and install a plug in rear outlet. bore.
(The residual pressure valve in front outlet will (3) Upend m aster cylinder and tamp (open end
keep cylinder from draining). down) on bench to remove front piston and spring. If
(2) Disconnect pedal push rod (drum type brakes) front piston sticks in bore of cylinder, use air pres
from brake pedal. sure to force piston out of cylinder. New cups must
(3) Remove nuts that attach m aster cylinder to
be installed at reassembly if air pressure is used.
cowl panel an d /o r power brake unit, (if so equipped).
(4) Slide m aster cylinder straight out from cowl (4) Remove front piston compression spring from
panel an d /o r power brake unit, (if so equipped). bore.
(5) Using Tool T109-178 (or an easy out) remove
DISASSEMBLING MASTER CYLINDER tube seats by threading tool firmly into seat, tap tool
To disassemble the m aster cylinder, (Figs. 1 and and seat out of cylinder body. (Fig. 2). Discard seats.
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BAIL COVER TO FRONT BRAKE
GASKET TUBE ONLY
RESERVOIRS
PISTON
BRAKES
TO FRONT
PISTON RETAINING
SCREW «AND
, n u ^GASKET
« o i s CI
PISTON
Np28
(4) Install residual pressure valve and spring (Fig.
3) in front outlet then install tube seats firmly.
(When the bleeding tubes are attached, the tube seats
will be positioned correctly.)
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GASKi^
■ COVER
RESIDUAL PRESSURE
VALVE SPRING
-BAIL-
RETAINER
PRIMARY CUP
FRONT PISTON SECONDARY CUP
REAR PISTON
^ SEAL CUP 'ASSEMBLY •
TUBE SEAT
CUP
GASKET SECONDARY CUP
PRIMARY PISTON
RETAINER SCREW
if
W /
NP30A
BLEEDING MASTER CYLINDER (5) Place cover and gasket over reservoirs and
secure with bail.
Before installing m aster cylinder on vehicle, it (6) Remove m aster cylinder from vise and install
must be bled on the bench as follows: on vehicle as follows:
(1) Clamp m aster cylinder in a vise and attach
bleeding tubes Tool C-4029 (Fig. 7). INSTALLING MASTER CYLINDER
(2) Fill both reservoirs with approved brake fluid.
(3) Using a wooden stick or dowel (power brake (1) Install m aster cylinder on vehicle, aligning
equipped vehicles) depress push rod slowly. (Note push rod with cowl panel opening (manual) or power
air bubbles.) Allow pistons to return under pressure brake push rod with m aster cylinder piston.
of springs. Do this several times or until bubbles (2) Slide over mounting studs. Install attaching
cease to appear (Fig. 7). nuts and tighten to 9 foot-pounds.
(4) Remove bleeding tubes from cylinder and install (3) Connect front and rear brake tubes and tighten
plug in rear outlet. (As tubes are removed, fluid re to 150 inch-pounds.
(4) Bleed brakes at wheel cylinders, using regular
maining in tubes will syphon out.)
procedure, being sure fluid level is maintained. (See
NOTE FLUTES Bleeding the Brake System).
| O N PRIMARY
# seal FRONT PISTON
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BUBBLES
of the brake system does not result in failure of the
entire hydraulic brake system. As an example, failure
W O O D E N STICK of the rear brake system will leave the front brake
OR DOWEL system still operative.
As pressure falls in one system, the other system’s
normal pressure forces the piston to the inoperative
side; contacting the switch terminal, causing a red
warning light to come on in the instrum ent panel,
thus warning the operator of the vehicle, that one of
the systems has failed and should be repaired.
The safety switch is mounted on the frame in a
*BLEEDING TUBES - NP33A
vertical position, with the brake tubes connected,
as shown in (Fig. 8).
Fig. 7 —Bleeding M aster Cylinder If a malfunction occurs within the switch, discon
TESTING MASTER CYLINDER nect tubes from body assembly and install a new as
sembly. The component parts of the switch body are
Be sure that the m aster cylinder compensates at not serviced. However the switch unit can be re
both ports. This can be done by applying the pedal moved if a malfunction occurs, and a new switch unit
lightly with the engine running (power brakes) and installed.
observing for a gyser of fluid squirting up in the If a new safety switch or body assembly is installed,
reservoirs. This may only occur in the front chamber be sure and bleed the brake system.
and so to determ ine if the rear compensating port is
open, it will be necessary to pump up the brakes TESTING HYDRAULIC SYSTEM SAFETY
rapidly and then hold the pedal down. Have an ob SWITCH
server watch the fluid in the rear reservoir while
the pedal is raised. A disturbance in the fluid indi The brake warning light flashes only when the
cates that the compensating port is open. parking brake is applied with the ignition key turned
“ON” . The same light will also illuminate should one
of the two service brake systems fail when the brake
HYDRAULIC SYSTEM SAFETY SWITCH
pedal is applied. To test the system turn the ignition
The hydraulic system safety switch (Figs. 8 and 9) key “ON”, and apply the parking brake. If the light
is used to warn the vehicle operator that one of the fails to light, inspect for a burned out bulb, discon
nected socket, a broken or disconnected wire at the
hydraulic systems has failed. A failure in one part
switch.
FROM MASTER CYLINDER To test the service brake warning system, raise the
PORT STAMPED "F" car on a hoist and open a wheel cylinder bleeder
SPRING > SWITCH BODY while a helper depresses the brake pedal and observes
y ^O UTLET TO LEFT the warning light. If the light fails to light, inspect
OUTLET TO FRONT BRAKE TUBE
RIGHT for a burned out bulb, disconnected socket, a broken
FRONT
BRAKE TUBE
PISTON SEAL "O" RING or disconnected wire at the switch. If the bulb is not
SWITCH SEAL “O" RING
‘ BODY ASSEMBLY
PISTON ASSEMBLY
FROM MASTER CYLINDER PLUG'
PORT STAMPED "R"
OUTLET TO
REAR BRAKE TUBE i
MOUNTING Sswi
BRACKET / NP34
PLUG NP16A
Fig. 9 —Hydraulic System Safety Switch
Fig. 8 —Hydraulic System Safety Switch (Sectional) (Exploded V iew )
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burned out and the wire continuity is proven, re fitting m ounted on the fram e rail in the engine com
place the brake warning switch in the brake line Tee partm ent below the m aster cylinder.
Page Page
Assembling C a lip e r......................... .......................... 45 Installing Brake Disc and H u b ................................. 47
Bleeding Disc B ra k e ................................................. 48 Installing C a lip e r........................................................ 45
Brake Shoe Installation........................... ................. 43 Metering V a lv e ............................................................ 41
Brake Shoe Removal ................................................ 42 Refinishing (Refacing) Braking D is c ....................... 47
Cleaning and Inspection..................... ................... 42-44 Removing Braking Disc and H u b ............................. 47
Checking Braking Disc for Run-out Removing Caliper from V ehicle............................... 43
and Thickness ..................................... .................. 46 Routine Maintenance—30,000 M ile s....................... 41
Disassembling Caliper . . ................. ........................ 43 Service D iagnosis...................................................... 37
Disc Brake Service Precautions............................... 42 S p e c ific a tio n s.................................................. .. 56
General Information .................................................. 38
SERVICE DIAGNOSIS
Condition Possible Cause Correction
EXCESSIVE PEDAL (a) Air, leak, or insufficient fluid in sys (a) Check system for leaks and bleed.
TRAVEL tem or caliper.
(b) Warped or excessively tapered shoe (b) Install new shoe and linings.
and lining assembly.
(c) Excessive disc runout. (c) Check disc for runout with dial in
dicator. Install new disc.
(d) Rear brake adjustment required. (d) Check and adjust rear brakes.
(e) Loose wheel bearing adjustment. (e) Readjust wheel bearing to specified
torque.
(f) Damaged caliper piston seal. (f) Install new piston seal.
(g) Improper brake fluid (boil). (g) Drain and install correct fluid.
(h) Power brake malfunction. (h) Check and correct power unit.
BRAKE ROUGHNESS OR (a) Excessive thickness variation of brak (a) Check disc for thickness variation
CHATTER (PEDAL ing disc. using a micrometer.
PUMPI NG) (b) Excessive lateral runout of braking (b) Check disc for lateral runout with dial
disc. indicator. Install new disc.
(c) Rear brake drums out-of-round. (c) Regrind rear drums and check for
out-of-round.
(d) Excessive front bearing clearance. (d) Readjust wheel bearings to specified
torque.
EXCESSIVE PEDAL (a) Brake fluid, oil or grease on linings. (a) Install new shoe linings as required.
EFFORT (b) Incorrect lining. (b) Remove lining and install correct lin
ing.
(c) Frozen or seized pistons. (c) Disassemble caliper and free up pis
tons.
(d) Power brake malfunction. (d) Check and correct power unit.
PULL (a) Brake fluid, oil or grease on linings. (a) Install new shoe and linings.
(b) Unmatched linings. (b) Install correct lining.
(c) Distorted brake shoes. (c) Install new brake shoes.
(d) Frozen or seized pistons. (d) Disassemble caliper and free up pis
tons.
(e) Incorrect tire pressure. (e) Inflate tires to recommended pres
sures.
(f) Front end out of alignment. (f) Align front end and check.
(g) Broken rear spring. (g) Install new rear spring.
(h) Rear brake pistons sticking. (h) Free up rear brake pistons.
(i) Restricted hose or line. (i) Check hoses and lines and correct as
necessary.
(j) Caliper not in the proper alignment (j) Remove caliper and reinstall. Check
to braking disc. alignment.
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NOISE Groan— Brake noise emanating when slowly releasing brakes (creep-groan)
(a) Not detrimental to function of disc brakes—no corrective action re
quired. (Indicate to operator this noise may be eliminated by slightly
increasing or decreasing brake pedal efforts.)
Rattle— Brake noise or rattle emanating at low speeds on rough roads, (front
wheels only).
(a) Shoe anti-rattle spring missing or not (a) Install new anti-rattle spring or po
properly positioned. sition properly.
(b) Excessive clearance between shoe (b) Install new shoe and lining assem
and caliper. blies.
Scraping- (a) Mounting bolts too long. (a) Install mounting bolts of correct
length.
(b) Loose wheel bearings. (b) Readjust wheel bearings to correct
specifications.
FRONT BRAKES HEAT UP (a) Operator riding brake pedal. (a) Instruct owner how to drive with disc
DURING DRIVING AND brakes.
FAIL TO RELEASE (b) Stop light switch improperly adjusted. (b) Adjust stop light to allow full return
of pedal.
(c) Sticking pedal linkage. (c) Free up sticking pedal linkage.
(d) Frozen or seized piston. (d) Disassemble caliper and free up pis
ton.
(e) Residual pressure valve in master (e) Remove valve. (See Fig. 15).
cylinder.
(f) Power brake malfunction. (f) Check and correct power unit.
LEAKY WHEEL (a) Damaged or worn caliper piston seal. (a) Disassemble caliper and install new
CYLINDER seal.
(b) Scores or corrosion on surface of (b) Disassemble caliper and hone cylin
cylinder bore. der bore. Install new seal
GRABBING (a) Causes listed under “Pull.” (a) Corrections listed under “Pull."
OR UNEVEN (b) Power brake malfunction. (b) Check and correct power unit.
BRAKING ACTION
BRAKE PEDAL CAN BE (a) Air in hydraulic system or improper (a) Bleed system.
DEPRESSED WITHOUT bleeding procedure.
BRAKING EFFECT (b) Leak past primary cup in master cyl (b) Recondition master cylinder.
inder.
(c) Leak in system. (c) Check for leak and repair as required.
(d) Rear brakes out of adjustment. (d) Adjust rear brakes.
(e) Bleeder screw open. (e) Close bleeder screw and bleed entire
system.
GENERAL INFORMATION
The Kelsey-Hayes single piston, floating caliper disc the outboard portion of the caliper and two on the
brake assembly (Fig. 1), consists of the hub and disc inboard side (Fig. 3). Four machined abutm ents on
assembly, the caliper, shoes and linings, splash shield the adaptor, position and align the caliper, fore and
and adaptor. aft. Two positioners installed over the guide pins, con
The cast iron braking disc has 40 (forty) cooling trol the movement of the caliper along with the piston
fins (or louvres) that are cast integrally between the seal, and assists in maintaining proper shoe clearance
two machined braking surfaces (Fig. 2). When the and are also required to hold the inner bushing in
wheel is in motion, the rotation of the disc cooling place.
fins supplies air circulation between the braking sur The guide pins are also used to radially locate and
faces for efficient cooling of the disc and prolonged restrain both shoes, while all of the braking force is
lining life. The braking disc is protected from road taken by the caliper on the outboard shoe and ma
splash (inboard side) by a shield bolted to the steering chined lug (Fig. 9) on the adapter for the inboard
knuckle and by the wheel and tire on the outboard shoe.
side. The caliper is a one piece casting with the inboard
The single piston caliper assembly floats through side containing the single piston cylinder bore. The
four rubber bushings on two steel guide pins threaded steel piston is 2-3/4 inches in diam eter and is nickle
into the adaptor. Two of the bushings are inserted in and chrome plated for anti-corrosion and long wear.
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SHOE AND LINING COO LIN G FINS
\\
■/( L O U V E R S )
CALIPER ** - / BO O T
x / SEAL
BUSHING ' j N / BUSHING
BRAKE LINING v -CALIPER (i n c a l i p e r ;
SHOE V 'v
ADAPTOR /
PIN ■ !---\
* /
\ V
r\
i
JW & -PIN
v>
M; G u : o :■
ADAPTOR
!j \ ?!K *PISTON
INNER POSITIONER
BUSHING SLUED SCREW NU1 \ qleed s c r e w
/
Fig. I—Floating Caliper Assembly (Single Piston) ADAPTOR
’N POSITIONER
The square cut rubber piston seal is located in a ma NU2A
chined groove in the cylinder bore and provides a
Fig. 2—Floating C a l i p e r A s s e m b ly (Sectional)
hydraulic seal between the piston and the cylinder
wall (Fig. 4). The adaptor is m ounted to the steering bore area.
knuckle by two special nylock bolts (Fig. 5). As the brake pedal is depressed, hydraulic pressure
A moulded rubber dust boot installed in a groove in is applied against the piston. This force is transm itted
the cylinder bore and piston, keeps contamination to the inboard brake shoe and lining and the inboard
from the cylinder wall and piston. The boot has a braking surface of the disc. As force increases against
viping lip (Fig. 6) that prevents contamination in the the disc from the inner lining, the caliper assembly
WASHER
LINING
POSITIONER BLEEDEr SCREW (PART OF BUSHING)
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PISTON
WHEEL STUD
SPINDLE
OUTER
BEARING
BRAKING DISC
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moves inboard, sliding on the guide pins, thus provid PISTON v CYLINDER BORE CALIPER
ing a clamping force on the disc. PISTON SEAL \ PISTON SEAL
HOUSING
When the brake pressure is released, the piston BRAKE BRAKE PRESSURE !
seal (distorted by applied pressure) returns to its PRESSURE OFF
ON I -
normal position, pulling the piston back to released c£>
position, while the two positioners force the caliper V
outboard to create a slight running clearance between J
outer shoe and the disc.
Automatic adjustm ent is obtained by outward relo
cation of the piston as the inboard lining wears and
the inward movement of the caliper as the outboard DUST BOOT NN427B
lining wears, thus maintaining correct adjustm ent at
Fig. 6 —Piston Seal Function fo r Automatic
all times. Adjustment
METERING VALVE Do not get oil or grease on the braking disc or lin
ings. If the linings (pads) are worn to within .030 inch
All Kelsey-Hayes Floating Caliper disc brake of the shoe, replace both sets of shoe and lining as
equipped vehicles are equipped with a pressure m eter semblies, (inboard and outboard) on the front wheels.
ing valve. The valve is located on the left frame rail. It is necessary that both front wheel sets be replaced
The use of the m etering valve is to better match the whenever a respective shoe and lining is worn beyond
front disc brakes with the rear drum brakes on the specifications or damaged.
vehicle. This results in improved braking and steer Check all brake tube connections for possible leaks.
ing control on icy surfaces. Install new flexible hoses as required.
Check adapter plate to knuckle bolts for specified
ROUTINE MAINTENANCE— 30,000 Miles torque (75 to 100 Foot Pounds).
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or salt air may incur rust on the disc which could (4) The front wheel bearing end play is im portant
cause a tem porary brake surge and roughness. Nor and must be within specifications.
mally however, this condition should correct itself (5) Be sure vehicle is centered on the hoist before
after a short period of usage. If rust is severe enough servicing any of the front end components to avoid
roughness will not clear up and the disc must be re bending or damaging disc splash shield on full right
surfaced or replaced. or left hand turns.
(6) Before vehicle is moved after any brake service
DISC BRAKE SERVICE PRECAUTIONS work, be sure and obtain a firm brake pedal.
(7) Dragging the brakes (common result of left foot
(1) Grease or any other foreign m aterial must be application) should be avoided during vehicle opera
kept off the caliper assembly, surfaces of the braking tion.
disc and external surfaces of the hub, during service (8) The wheel, tire, hub and disc assembly cannot
procedures. Handling the braking disc and caliper be removed as an assembly. The caliper assembly must
should be done in such a way as to avoid deformation be removed before removal of the hub and disc as
of the disc and scratching or nicking the brake linings sembly.
(pads). (9) As lining wears, reservoir level will go down.
(2) If inspection reveals that the square sectioned If fluid has been added between relines, then reser
caliper piston seal is worn or damaged, it should be voir overflow may occur when the piston is pushed
replaced immediately. back into the new lining position. Overflowing can be
(3) During removal and installation of a wheel and avoided in this case by removal of a small amount of
tire assembly, use care not to strike the caliper. fluid before overflow occurs.
SERVICE PROCEDURES
BRAKE SHOE REMOVAL
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through bushing, caliper, adaptor, inboard and out
board shoes, into outer bushings in caliper and anti
rattle spring.
(6) Press IN on end of guide pins and thread pin
into adaptor, USING EXTREME CARE SO AS NOT TO
CROSS THREADS. Tighten from 30 to 35 foot-pounds.
Be sure tabs of positioners are over machined surfaces
of caliper (Fig. 1).
(7) Pump brake pedal several times until a firm
pedal has been obtained.
(8) Check and refill m aster cylinder reservoirs (if
necessary) with approved brake fluid as required. (It
should not be necessary to bleed the system after
shoe and lining removal and installation). However,
if a firm pedal cannot be obtained bleed the brake
ii s -:c e a ^ -: system as described in “Bleeding Brake System” para
graph. It may have been necessary to remove fluid to
put in new linings as fluid is pushed back into master
j'OJ.NG cylinder.
■ f t ) l $ C ‘..
(9) Install wheel and tire assemblies and wheel cov
ers.
(10) Remove jackstands or lower hoist.
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PIN
INNER
tv / BUSHING
BLEEDER SCREW
POSITiONER-^^^
ANTI-RATTLE SPRING
OUTER BUSHING
SEAL
POSITIONER BOOT
/
ADAPTER» f
SHOE AND
LINING
c
r
NU5A
SEAL PISTON
• PISTON
PISTON BORE
PISTON
NU324 DUST BOOT NU28
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WOODEN OR PLASTIC STICK SPECIAL H O NEv CALIPER
,x ,
PISTON SEAL.
Fig. 12—Removing Piston Seal side of boot. Install in caliper by working into outer
groove, using fingers only. (Boot will seem larger than
Tool C-4095, providing the diam eter of the bore is not
diam eter of groove, but will snap into place when
increased more than .002 inch. If the bore does not
properly positioned in groove) (Fig. 16). Using a fore
clean up within this specification, a new caliper hous
finger, slide around inside of boot to be sure it is
ing should be installed. Black stains on the piston are
seated, or correctly installed.
caused by the piston seal and will do no harm.
(4) Plug high pressure inlet to caliper and bleeder
When using Hone C-4095, coat the stones and bore
screw hole, then coat piston with a generous amount
with brake fluid. After honing the bore, carefully clean
of lubricant (as specified above). With fingers spread
the seal and boot grooves with a stiff non-metalic
ing boot, work piston into boot and press down on
rotary brush (Fig. 14).
piston. (The entrapped air below piston will force boot
Use extreme care in cleaning the caliper after hon
around piston and into its groove as piston is de
ing. Remove all dirt and grit by flushing the caliper
pressed). (Fig. 17). Remove plug, then carefully push
with brake fluid; wipe dry with a clean, l intless cloth
piston down the bore until bottomed. Caution: Force
and then clean a second time in the same manner or
must be applied uniformly to avoid cocking.
until clean cloth shows no signs of discoloration.
(5) Install new inner guide pin bushings in caliper
ASSEMBLING CALIPER with flanged end on inboard side (Fig. 3). Compress
flanges of outboard bushing in with fingers and work
(1) Clamp caliper in vise (with protector jaws), (Fig.
into position in hole from the outboard side of the
10). Caution: Excessive vise pressure will cause bore
caliper (Fig. 18). Press IN on bushing, using finger tips
distortion and binding of piston.
or small plastic stick (Fig. 18) until seated. Be sure
(2) Dip new piston seal in lubricant (supplied with
flanges extend over caliper casting evenly on both
kit) Ucon #LB1145Y24 (or equivalent) and install in
groove in bore. Seal should be positioned at one area sides. Install bleeder screw.
Before installing caliper assembly on vehicle, in
in groove and gently worked around the groove, using
clean fingers, until properly seated. NEVER USE AN spect braking disc. Conditions as described in “Check
ing Braking Disc for Runout and Thickness” para
OLD PISTON SEAL. (Be sure seal is not twisted or
rolled). (Fig. 15). graph.
(3) Coat new piston boot with lubricant (as speci INSTALLING CALIPER
fied above) leaving a generous amount of lubricant in-
(1) Examine lining for wear damage, or fluid con
WOODEN OR tamination if its condition is found satisfactory it may
PL/xSriC STICK
\
CALIPER-
SEAL IN GROOVE
CALIPER
PISTON SEAL— — T
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O U T E r.- - •'
BUSHING
PISTON DUST
"'s OUTER
BOOT PISTON IN S s A llI D
’ BUSHING
DUST B O O ' . - ^
- PLUG NU33
CALIPER v ANTI-
.RATTLE^ *
SPRING v
DUST BOOT
.AP?RCX:Ma^Lv i
< DIAL / ^G M sfDG- O r DISC
INDICATOR
•PLUG
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(2) With wheel bearings adjusted to zero end play,
check lateral runout. (Both sides of disc). Runout
should not exceed .0025 inch. If runout is in excess
of specification, install a new disc and hub assembly
or reface disc, being careful not to remove more than
.015 inch from each side of disc. Be sure and readjust
wheel bearings after check.
(3) Thickness variation of disc should be made in
conjunction with runout. Measure thickness of disc at
twelve (12) equal points with a m icrometer at a radius
approximately one (1) inch from edge of disc. If thick
ness measurements vary by more than .0005 inch, disc
should be removed and resurfaced or a new disc and
hub assembly installed. (Fig. 19).
(4) Light scoring an d /o r wear is acceptable if heavy
scoring or warping is evident, the disc must be re
finished or replaced (See Refinishing (Refacing) Brak
ing Disc). If cracks are evident the hub and disc assem
bly must be replaced.
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if ridges are not removed before installation of new
lining (pads). BRAKING DISC .
DAMPER.
Lining deposit on the disc, may cause erratic fric A
tion characteristics if new lining is installed without
resurfacing or cleaning the disc.
Excessive runout or wobble in a disc can increase
pedal travel due to piston knockback and increase
seal bushing wear due to necessity of caliper to follow
the disc wobble.
Thickness variation in a disc can also result in pedal
pulsation, chatter and surge due to variation in brake
output when disc section is uneven.
Dishing or distortion can be caused by extreme heat
CUTTING TOOL
and abuse of the brakes.
BLEEDING DISC BRAKE require more pumping, and frequent checking of the
fluid level in the master cylinder during the bleeding
The disc brake hydraulic system can be bled operation. Never use brake fluid that has been drained
manually or with pressure bleeding equipment. On from the hydraulic system, when bleeding the
disc brake equipped vehicles, the brake pedal will brakes.
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REAR BRAKE LINE*!!*, -OUTLET
INLET
MASTER CYLINDER
(Floating Caliper Disc Brakes)
INDEX
Page Page
Bleeding Master C y lin d er........ ................................ 51 Master Cylinder Rem oval.......................................... 50
Cleaning and In sp e c tio n .................................... . 50 Reassembling Master Cylinder................................. 51
Disassembling Master C ylinder............................... 50 Testing Master Cylinder ........................................... 52
General Information .................................................. 49 Testing Hydraulic System Safety S w itc h .............. 53
Hydraulic System Safety Switch ........................... 52 Pressure Metering V alve......................................... 53
Installing Master C ylinder......................................... 52
GENERAL INFORMATION
The tandem m aster cylinder (Fig. 1) (1 and 1/8 reservoirs cast integrally. The m aster cylinder con-
inch bore) is of the compensating type with the sists of a front and rear piston (in tandem) two out-
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lets, with 1 containing a residual pressure valve and with power brake units is serviced in the same m anner
spring (rear brake line outlet only) (Fig. 3). as the m aster cylinder with power brakes with one
The front outlet tube from the m aster cylinder is exception, the m aster cylinder for power brakes does
connected to the hydraulic system safety switch (Figs. not include the push rod.
8 or 9) and thence to the rear brakes. The rear out The drum brake m aster cylinder is different than
let tube from the m aster cylinder is also connected the disc brake m aster cylinder and is covered in the
to the safety switch and the front brakes. service brake section of this group.
The m aster cylinder used on vehicles not equipped
SERVICE PROCEDURES
MASTER CYLINDER REMOVAL (5) Using Tool T-109-178 (or an easy out) remove
tube seats by threading tool firmly into seat, tapping
(1) Disconnect front and rear brake tubes from tool gently with a hammer (Fig. 2). Discard seats.
m aster cylinder and install a plug in rear outlet. (The (6) Remove residual pressure valve and spring
residual pressure valve in front outlet will keep cylin from front outlet (Fig. 3).
der from draining). (7) Remove rubber cups from pistons after noting
(2) Disconnect pedal push rod (standard brakes) position of cup lips. Do not remove center cup of
from brake pedal. rear piston. If cup is damaged or worn, install a new
(3) Remove nuts that attach m aster cylinder to rear piston assembly.
cowl panel an d /o r power brake unit (if so equipped).
(4) Slide m aster cylinder straight out from cowl CLEANING AND INSPECTION
panel arld/or power brake unit (if so equipped).
Clean m aster cylinder thoroughly, using a suitable
DISASSEMBLING MASTER CYLINDER solvent and dry with compressed air. Wash the cylin
der bore with clean b rake fluid and inspect for scor-
To disassemble the m aster cylinder, (Figs. 1 and 4),
clean the outside of the m aster cylinder thoroughly.
(1) Press bail to one side and remove cover and
gasket. Empty brake fluid from reservoirs. CONNECTION TO
REAR BRAKE TUBE
(2) Remove piston retaining screw and gasket (Fig.
4), then slide rear piston assembly out of cylinder
bore.
(3) Upend m aster cylinder and tamp (open end
down) on bench to remove front piston and spring. If
front piston sticks in bore of cylinder, use air pres
sure to force piston out of cylinder. New cups must CONNECTION TO
be installed at reassembly if air pressure is used. FRONT BRAKE TUBE
(4) Remove front piston compression spring from
SPECIAL TOOL NP36
bore.
BAIL COVER
Fig. 2 —Removing Tube Seats
GASKET TAB
T? MASTER CYLINDER
TUBE SEAT j g ; ' - V > ; BODY
OUTLET TO
REAR BRAKES OUTLET TO
REAR PISTON t . NP37
FRONT BRAKES NP35 (REAR BRAKE CONNECTION ONLY)'
ASSEMBLY
Fig. 3 —Removing or Installing Residual Pressure
Valve and Spring
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ing or pitting. Master cylinder bore walls that have front of piston.) (Fig. 4).
light scratches or show signs of corrosion, can usually (3) Carefully work secondary piston cup over piston
be cleaned with crocus cloth. However, cylinder bores and into rear land. The lip m ust be facing toward
that have deep scratches or scoring may be honed, rear (Fig. 4).
providing the diam eter of the bore is not increased (4) Position small end of pressure spring into re
more than .002 inch. If m aster cylinder bore does not tainer, then slide assembly into bore of cylinder (Fig.
clean up at .002 inch when honed, the m aster cylinder 5). Be sure cups enter bore evenly in order not to
should be discarded and a new m aster cylinder in damage sealing quality of cups. (Keep well lubricated
stalled. with brake fluid.)
If m aster cylinder pistons are badly scored or
corroded, replace them with new ones. The piston Rear Piston
cups and seals should be replaced when recondition (1) Carefully work secondary cup over rear end of
ing a m aster cylinder. rear piston with lip of cup toward front (Fig. 4).
When overhauling a m aster cylinder, use all parts (2) Center spring retainer of rear piston assembly
furnished in repair kit. Discard all used rubber parts. over shoulder of front piston. Push piston assemblies
into bore. Carefully work lips of cups into bore, then
REASSEMBLING MASTER CYLINDER seat piston assemblies (Fig. 6).
(3) Holding pistons in seated position, install pis
Front Piston ton retaining screw and gasket. Tighten securely (Fig.
Before assembling m aster cylinder, dip all com 6).
ponent parts in clean brake fluid and place on a clean (4) Install residual pressure valve and spring (Fig.
shop towel or paper (assembling seals dry, can ruin 3) in front brake outlet, then install tube seats firmly.
them). (When the bleeding tubes are attached, the tube seats
(1) Slide thin washer over stem of front piston, will be positioned correctly.)
followed by prim ary cup. (Be sure lip is away from
piston.) (Fig. 4). BLEEDING MASTER CYLINDER
(2) Carefully work seal cup over rear end of piston Before installing m aster cylinder on vehicle, it
and into second land. (Be sure lip of cup is facing must be bled on bench as follows:
COVER
RESIDUAL PRESSURE
VALVE
MASTER CYLINDER
BODY
FRONT PISTON
SPRING
SEAT
PRIMARY CUP
REAR PISTON'
ASSEMBLY
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BUBBLES
\ f ir I ts a r T P
%. mf § F&r ■
"* ~ BLEEDING TUBES ^ N P33A
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FROM MASTER CYLINDER ignition key “ON”, and apply the parking brake. If
PORT STAMPED "F" the light fails to light, inspect for a burned out bulb,
SPRING SWITCH BODY
disconnected socket, a broken or disconnected wire
OUTLET TO LEFT
OUTLET TO FRONT BRAKE TUBE at the switch.
RIGHT
FRONT To test the service brake warning system, raise the
RING
BRAKE TUBE car on a hoist and open a wheel cylinder bleeder
SWITCH SEAL “ O ” RING while a helper depresses the brake pedal and observes
the warning light. If the light fails to light, inspect
for a burned out bulb, disconnected socket, a broken
or disconnected wire at the switch. If the bulb is not
burned out and the wire continuity is proven, re
place the brake warning switch in the brake line
Tee fitting mounted on the fram e rail in the engine
com partm ent below the m aster cylinder.
MOUNTING
BRACKET
DUST SEAL
VALVE STEM
MOUNTING
BRACKET'
NP1051A
Fig. 9 —H ydraulic System S a fety Switch
(Exploded View )
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TO MASTER CYLINDER BRAKE the front brakes. However, the valve (Fig. 2) can be
TUBE ASSEMBLY-FRONT METERING held open manually by using Tool C-412T, to pull the
TO MASTER CYLINDER BRAKE TUBE VALVE
ASSEMBLY-REAR
valve stem down.
MASTER CYLINDER TEE___ / CAUTION: Under no condition should a rigid clamp,
AND SAFETY SWITCH” 1 *7 wedge or block be used to depress the valve stem, as
FRONT BRAKE this can cause an internal failure in the valve, result
TUBE (RIG HTJX^ ing in complete loss of front brakes.
TO PROPORTIONING
It should be noted that the pressure release valve
VALVE stem is in its uppermost position when there is no
pressure present. No attem pt should be made to fur
ther depress the valve stem.
SPECIFICATIONS
BRAKES—SERVICE AND PARKING
Dart 6 Cyl. V-8 & H.D.
Type ............................................................................... . Duo-Servo Single Anchor Duo-Servo Single Anchor
DRUM DIAMETER ............................................................ 10" Front 9" Rear 10"
NUMBER OF BRAKE SHOES ......................................... 8 8
F r o n t................................................................... ............. 2-1/4" Wide 2-9/16" widp.
Rear ................................................................................. 2-1/16" Wide 1-13/16" wide
BRAKE LINING .................................................................. Extruded Asbestos-Bonded Extruded Asbestos-Bonded
Front P rim a ry ................. ........... .................................... 2-1/4 x 8-1/2" 2-1/2" wide 8-1/2" long
Front Secondary ............................................................ 2-1/4 x 11" 2-1/2" wide 11" long
Rear P rim ary ............... ................................................... 2 x 7-5/8" 1-3/4" wide
Rear S e c o n d a ry ............................................................. 2 x 9-5/8" 1-3/4" wide
Thickness Primary ............................................................ 3/16" 3/16" 3/16"
S econdary........................................................ 1/4" 1/4" 1/4"
WHEEL CYLINDER ............................................................ 4 per car 4 per car
Front Wheel Cylinder B o r e ........................................... 1" 1-3/16"
Rear Wheel Cylinder Bore ........................................... 13/16" 15/16"
MASTER CYLINDER BORE ............................................. 1" 1"
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Rear S e c o n d a ry ................. 11" 11"
BRAKE LINING (11 INCH)
Front P rim a ry ..................... 9-1/4" 9-1/4"
Front Secondary ............... 12- 1/ 8" 12- 1 / 8"
Rear Primary ..................... 9-1/2" 9- 1/4"
Rear Secondary ................. 12- 1/ 8" 12- 1/ 8"
Thickness Primary ............... 3/16" 3/16"
Secondary .......... 1/4" 1/4"
WHEEL CYLINDER
Front Wheel Cylinder Bore 1-3/16" 1-3/16"
Rear Wheel Cylinder Bore 15/16" 15/16"
MASTER CYLINDER BORE .. 1" 1"
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TIGHTENING REFERENCE
Foot-PoundsI nch-Pounds
Ca l iper Mounting B o lts ...................................................................... 50-80
Caliper Assembly Bridge B o lts .......................................................... 70-80
Disc Splash Shield B o lts ...................................... .......................... ............................ 17
Caliper Bleeder Screw ............ .................................................... .................................. 100
Shoe Clips (Retainers) ...................................................................... 7-9
Brake Tube Fitting Nuts to Proportioning V alve......................................................90-100
Wheel Assembly to Front Wheel Hub and Disc Assembly Nuts . . . 55
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TIGHTENING REFERENCE
POWER BRAKE TIGHTENING
REFERENCE
Pedal Link to Pedal B o l t ............................................................................. . 30 Foot Pounds
Master Cylinder Mounting N u t s ........................................................................ 100 Inch Pounds
Power Brake Unit to Dash N u t s ....................................................................... 150 Inch Pounds
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CLUTCH
CONTENTS
Page Page
CLUTCH— SE R V IC IN G .................................... 4 GENERAL INFORMATION ........................... 1
CLUTCH HOUSING A L IG N M E N T ............... 9 SERVICE DIAGNOSIS .................................... 2
CLUTCH PEDAL FREE P L A Y ....................... 3 SERVICE PR O CEDURES................................ 3
CLUTCH RELEASE BEARING ..................... 7 SPECIFICATIONS............................................ 10
CLUTCH RELEASE F O R K ............................. 7 STEAM CLEANING PRECAUTIONS ........... 10
PILOT BUSHING— CRANKSHAFT TO TIGHTENING REFERENCE ......................... 11
TRANSMISSION DRIVE P I N I O N ..................... 7 TORQUE SHAFT AND B E A R IN G S ............... 8
GENERAL INFORMATION
The clutches used on all models are a single, dry Some models have centrifugal rollers assembled
disc type (Figs. 1 and 2), with no adjustm ent for wear between the pressure plate and cover. These rollers
being provided in the clutch itself. The clutch pedal are provided to increase the norm al load on the disc
linkage, however, is provided with an adjustable rod assembly at higher engine speeds. As the engine speed
to maintain specified pedal free play. increases, the centrifugal force of the rollers causes
The three pressure plate release levers are preset them to act as wedges between the cover and pressure
during m anufacture and no attem pt should be made plate and exert greater force against the disc.
to adjust them in service.
The clutch sizes for the various car models are de Clutch Pedal and Bracket (Fig. 3 a n d 4)
scribed in specification charts at end of this section. The clutch pedal is connected to the torque shaft
The Semi-Centrifugal type clutch (Fig. 2), combines through a vertically positioned rod. A non-adjustable
the feature of low pedal effort with that of a clutch over-center spring is provided between the pedal and
capable of transm itting the full torque of the engine. the pedal bracket to allow easy clutch pedal operation.
DISC -
SPRING
SPRING
V & v i* ;
PLATE
PIVOT
*:#J5V"
FORK
m i7 9
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PLATE
COVER
7 ^ ^ t PRESSURE SPRING
. * v \
\ ROLLER
RELEASE BEARING , ^
SLEEVE
PIN
EYEBOLT
RELEASE LEVER
STRUT
EYEBOLT NUTS RELEASE LEVER SPRING
NY70A
SERVICE DIAGNOSIS
Condition Possible Cause Correction
CLUTCH CHATTER (a) Worn or damaged disc assembly. (a) Replace disc assembly.
(b) Grease or oil on disc facings. (b) Replace disc assembly.
(c) Improperly adjusted cover assembly. (c) Replace clutch assemb
CLUTCH SLIPPINi (a) Burned, worn, or oil soaked facings. (a) Replace disc assembly.
CLUTCH AND BRAKE PEDAL BRACKET PEDAL STOP LOCK RING
HERi
PLAIN WASHER I
OVER-CENTER SPRING
HOOK
1 RELEASE FORK
gg% _. fo rk rod
TORQUE SHAFT
ASSEMBLY
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(b) Insufficient pedal free play. (b) Adjust release fork rod.
(c) Weak or broken pressure springs. (c) Replace clutch assembly.
DIFFICULT GEAR (a) Excessive pedal free play. (a) Adjust release fork rod.
SHIFTING (b) Worn or damaged disc assembly. (b) Replace disc assembly.
(c) Improperly adjusted cover assembly. (c) Replace clutch assembly.
(d) Clutch disc splines sticking. (d) Remove disc assembly and free up
splines or replace disc.
CLUTCH NOISY (a) Dry clutch linkage. (a) Lubricate where necessary.
(b) Worn release bearing. (b) Replace release bearing.
(c) Worn disc assembly. (c) Replace disc assembly.
(d) Worn release levers. (d) Replace clutch assembly.
(e) Worn or dry pilot bushing. (e) Lubricate or replace bushing.
(f) Dry contact pressure plate lugs in (f) Lubricate very lightly.
cover.
SERVICE PROCEDURES
CLUTCH PEDAL FREE PLAY (4) Adjust interlock rod as described below.
The only adjustm ent required for the clutch is the
G earshift Interlock (Fig. 5) (6 Cyl. only)
pedal linkage adjustm ent to provide the prescribed (1) Disconnect clutch rod swivel from interlock
clutch pedal free play. The adjustm ent is necessary pawl.
to restore pedal free play reduced by norm al clutch (2) Adjust clutch pedal free play as specified.
wear. (3) When first-reverse lever on transmission is in
Adjusting Clutch Pedal Free P la y neutral (middle detent) position, the interlock pawl
(1) Inspect condition of clutch pedal rubber stop will enter the slot in first-reverse lever.
(Figs. 3 or 4). If stop is damaged, install a new one. (4) Loosen swivel clamp bolt and slide swivel on
(2) On 6 cyl. models with A-903 transmission discon rod to enter pawl. Install washers and clip. Hold inter
nect gearshift interlock rod by loosening rod swivel lock pawl forward and tighten swivel clamp bolt to
clamp screw (Fig. 5). 100 inch-pounds. Clutch pedal has to be in full re
(3) Adjust fork rod by turning self-locking adjust turned position during this adjustm ent.
ing nut (Figs. 6 or 7) to provide 5/32 inch free move CAUTION: Do not pull clutch rod rearward to en
m ent at end of fork. This movement will provide pre gage swivel in the pawl.
scribed one-inch free play at pedal. (5) Shift transmission in normal m anner from neu-
WASHER*. NUT
-"i J
SPRING
WASHER
PEDAL
PEDAL ROD
NR181
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Removal
(1) Remove transmission. See “Manual Transmis
sion,” Group 21, for detailed procedure.
(2) Remove clutch housing pan.
(3) Remove one end of return sprnig from clutch
release fork and the other end from torque shaft lever
or clutch housing (Fig. 6 or 7).
(4) Remove spring washer securing fork rod to
torque shaft lever pin and remove rod from pin and
release fork (Figs. 6 or 7).
(5) On all models with the A-903 transmission, re
move clip and plain washer securing interlock rod to
torque shaft lever and remove spring washer, plain
washer and rod from torque shaft.
(6) Remove clutch release bearing and sleeve as
sembly from clutch release fork (Fig. 8) then remove
release fork and boot from clutch housing.
(7) Mark clutch cover and flywheel (Fig. 9) to
m aintain their same relative positions when reinstall
Fig. 5 —Gearshift Interlock (6 cyl. & A903 Trans. Only) ing clutch assembly.
(8) Loosen and back off clutch cover attaching
tral to first, and from neutral to reverse (disengage
bolts, one or two turns at a time, in succession, to
clutch while shifting and engage clutch when in gear).
avoid bending cover flange.
Clutch action should be normal.
(6) Disengage clutch and shift halfway to first or (9) Remove clutch assembly and disc from clutch
reverse. Clutch should now be held down by interlock housing.
to within 1 or 2 inches of floor. CAUTION: Handle clutch and disc carefully to avoid
contaminating the friction surfaces.
CLUTCH— SERVICING
Cleaning and Inspection
Im proper operation or excessive wear may impair (1) Use compressed air to clean dust out of clutch
the clutch function to a point where it may be nec housing. Inspect for oil leakage through engine rear
essary to remove and replace the disc, an d /o r clutch main bearing oil seal and transmission drive pinion
assembly. Should this become necessary, proceed as seal. If leakage is noted, it should be corrected at
follows: this time.
DASH PANEL
SPRING WASHER
FORK
RETURN
SPRING
(6 -CYL.
ENGINE)
(8-CYL.
ENGINE)
NUT,
CONE WASHER * ^
FRAME SIDE RAIL
TORQUE SHAFT BRACKET INTERLOCK ROD
(6 CYL. A903 TRANS. ONLY) RELEASE FORK- NR183B
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DASH
PANEL
FORK RETURN
SPRING
SPRING WASHER (6-CYL MODELS
ONLY)
SCREW
RELEASE FORK
(6-CYL. MODELS ONLY)
P!N / 1 \ "^ IN S U L A T O R
m / \ WASHER
^LEVER FORK ROD ADJUSTING NUT
BEARING^ (6-CYL MODELS ONLY)
SPRING
BRACKET
(6-CYL. [TORQUE SHAFT RETURN SPRINGt CLIP '
MODELS (6-CYL MODELS ONLY) PLAIN
ONLY) WASHER
TORQUE SHAFT BRACKET
SPRING
NUT WASHER
FRAME SIDE RAIL FORK RETURN
CONE WASHER TORQUE SHAFT LEVER
SPRING
INTERLOCK ROD** PLAIN WASHER 318 CU. IN. ENGINE
(6 CYL A9Q3 TRANS, ONLY) FORK RETURN SPRING ONLY
8-CYL. EXCEPT 318 CU. IN. RELEASE FORK
NR185B
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a snug fit without signs of excessive wear. Metallic of grease. Place lubricant in radius back of bushing.
portions of disc assembly should be dry and clean (2) Clean the surfaces of flywheel and pressure
and show no evidence of having been hot. Each of plate thoroughly with fine sandpaper or crocus cloth,
the arched springs between facings should be un and make certain that all oil or grease has been re
broken and all rivets should be tight. moved.
(7) Wipe friction surface of pressure plate with (3) Hold clutch disc, pressure plate and cover in
kerosene, m ineral spirits or other suitable solvent. mounting position, with springs on disc dam per fac
(8) Using a straightedge, check pressure plate for ing away from the flywheel. Do not touch disc facing,
flatness. The pressure plate friction area should be as contamination may result in clutch chatter. Insert
flat within .015 inch and free from discoloration, a Clutch Disc Aligning Arbor through hub of disc
burned areas, cracks, grooves or ridges. and into bushing (Fig. 10). If an Arbor is not available,
(9) Inner ends of release levers should have a uni use a spare transmission drive pinion.
form wear pattern. (4) Install clutch cover attaching bolts (after align
(10) Using a surface plate, test cover for flatness. ing balance punch marks, (Fig. 9), but do not tighten
All sections around attaching bolt holes should be in them. The special 12 point bolts used on 11 inch
contact with surface plate within .015 inch. clutches for 383 cu. in. and larger engines, require no
(11) The cover should be a snug fit on pressure lock washers. The use of lock washers would create
plate lugs. interference problems.
If clutch assembly does not meet these require (5) To avoid distortion of the clutch cover, bolts
ments, it should be replaced. should be tightened a few turns at a time (alternately)
until they are all snug. Tighten 5/16 inch bolts to
(12) Examine condition of clutch release bearing.
200 inch-pounds, 3/8 inch bolts to 30 foot-pounds. Re
CAUTION: The clutch release bearing is a prelubri
move Arbor (or drive pinion if used).
cated, sealed thrust bearing and should not be im
(6) Fill cavity of bearing sleeve with Lubricant.
mersed in solvent.
Also apply a film of lubricant to release fork pads of
The bearing should turn freely, when held in the sleeve (Fig. 11).
hands under light thrust load, with no evidence of
(7) Position release bearing and sleeve assembly in
roughness.
clutch housing as far forward as possible.
(13) If bearing is noisy, rough or dry, install a new
(8) Lubricate fork fingers and retaining spring, at
one on sleeve as detailed under “Clutch Release Bear pivot contact area (Fig. 11) with a film of grease.
ing.”
(9) Engage fork fingers under clutch sleeve retain
ing springs. Be sure retaining springs on sleeve have
Installation lateral freedom (Fig. 8).
The grease recommended for use during reassem
(10) Be sure groove in seal is engaged in seal open
bly procedures is Automotive Multi-Purpose Grease
ing flange in clutch housing (Fig. 8).
NLGI Grade 2 E.P. or Multi-Mileage Lubricant, Part
Number 2525035. (11) Insert threaded end of fork rod assembly in
(1) Lubricate transmission drive pinion pilot bush hole in end of release rod fork (Figs. 6 or 7). Install
ing in end of crankshaft with about one-half teaspoon eye end of fork rod on torque shaft lever pin and
secure with spring washer.
(12) Install one end of return spring to clutch re
lease fork and the other end to torque shaft lever or
clutch housing (Fig. 6 or 7).
(13) On 6 cyl. with A-903 transmission, install
spring washer, plain washer and interlock rod in
FORK CONTACT SLEEVE CAVITY
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torque shaft lever and secure with plain washer and sides of fork contact areas, pivot contact area, edge of
clip. pivot, also the cavity inside clutch sleeve and the fork
CAUTI ON: Do not lubricate splines or pilot end of pads (Fig. 11).
transmission drive pinion when installing transmis (3) Install clutch release fork in housing, being
sion. These areas must be kept dry. careful to engage flat retaining spring in hole in pivot
(14) Install transmission as detailed in “Transmis and under retaining springs of bearing sleeve.
sion Installation,” Group 21. (4) Install dust seal over release fork and engage
(15) Adjust clutch linkage as detailed under “Ad groove of seal in clutch housing (Fig. 8).
justing Clutch Pedal Free Play.” (5) Insert fork rod assembly in hole in release
fork. Install eye end of fork rod on torque shaft lever
PILOT BUSHING— CRANKSHAFT TO pin and secure with spring w asher (Fig. 6 or 7).
TRANSMISSION DRIVE PINION (6) Install one end of retu rn spring to clutch release
fork and the other end to torque shaft lever or clutch
Tools called out are part of Bushing Service Tool housing (Fig. 6 or 7).
Kit C-3887-A. (7) Adjust clutch linkage as described under “Ad
justing Clutch Pedal Free Play”.
Rem oval
(1) Thread bushing puller SP-3631 into bushing CLUTCH RELEASE BEARING (Removed from
firmly and squarely, about 3 or 4 turns. Clutch)
(2) Place receiving cup SP-3633 over threaded shaft
of puller and install nut SP-1191 down against cup. Rem oval
(3) Hold puller and turn nut to draw bushing out of (1) Examine condition of bearing. If bearing is
crankshaft. noisy, rough or dry when rotated by hand, under light
thrust load, remove bearing from sleeve.
Installation (2) Support bearing in a vise or press and press
(1) Soak new bushing in oil before installing. out sleeve.
(2) Place handle SP-3549 on head SP-3551 and use (3) Clean sleeve in solvent and remove all old lubri
this tool to drive new bushing into crankshaft flush cant.
to end.
(3) Place one-half teaspoon of grease in crankshaft Assembly
cavity behind bushing. CAUTION: Exercise care when installing a new clutch
release bearing to avoid damaging bearing race. Never
CLUTCH RELEASE FORK drive bearing on sleeve with a hammer. Use either
of following two methods.
Removal
(1) Remove one end of return spring from clutch Vise M eth od
release fork and the other end from torque shaft lever (1) Position new bearing on sleeve and place old
or clutch housing (Fig. 6 or 7). bearing against face of new bearing.
(2) Remove spring washer securing fork rod to (2) Support parts in a vise and carefully press new
torque shaft lever and remove rod from torque shaft. bearing on sleeve (Fig. 12). Make certain bearing is
(3) Pry dust seal out of clutch housing and remove seated on shoulder of bearing sleeve. Rotate bearings
from release fork (Fig. 8). as they are pressed together.
(4) Grasp outer end of clutch fork and pull fork out
and free of retaining springs and pivot (Fig. 8). The Press M eth od
clutch fork has a riveted flat retaining spring that is (1) Support sleeve on press bed.
engaged in a hole in the pivot. The clutch release OLD SEARING■v. / RELEASE
fork pivot is an 'L' shaped bracket bolted inside the I D i i M i L BEARING
SLEEVE
clutch housing.
(5) Remove fork from clutch housing.
Installation
(1) The grease recommended for use during reas
sembly procedures is Automotive Multi-Purpose
Grease NLGI Grade 2 E.P. or Multi-Mileage Lubri _ _ m a m n
NEW BEAR' '-G ^134 <
cant, Part Number 2525035.
(2) Before installing release fork, lubricate both
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(2) Position new bearing on sleeve and place old (9) Slide or lift fram e end of torque shaft from
bearing on new one. torque shaft bracket, depending on type of bracket,
(3) Bring press ram into contact with old bearing and remove torque shaft assembly from vehicle.
and apply sufficient pressure to seat new bearing (10) Disassemble torque shaft assembly by remov
against shoulder of sleeve. Rotate bearings as they ing snap ring, ball studs, seals and bearings.
are pressed together.
Cleaning and Inspection
Lubrication (1) Clean all parts in kerosene, mineral spirits or
Before installing bearing and sleeve assembly, lub other suitable solvent. Remove all grease from inside
ricate parts as follows: torque shaft.
(1) Fill cavity of bearing sleeve with the previously (2) The two ball studs should be bright and free
recommended Automotive Multi-Purpose Grease. from scratches, ridges or other surface imperfections.
NLGI grade 2 EP, (Fig. 11). (3) The inner surfaces of bearings should also be
(2) Also, apply a film of this same lubricant to re smooth and free from surface scratches or embedded
lease fork pads of sleeve. foreign material. The wear pattern should be uniform
(3) A film of the same type lubricant should be ap over entire surface.
plied to the pivot contact area of fork retaining spring (4) Replace worn or cracked rubber seals.
and contact areas of fork fingers.
Installation Installation
(1) Install bearing and sleeve assembly in clutch (1) Install new seals on ball studs (Figs. 6 or 7).
housing, engaging fork under sleeve springs (Fig. 8). (2) Coat counterbored ends of torque shaft, torque
shaft bearings and ball studs with Multi-Mileage
Be sure springs have lateral freedom.
CAUTION: Do not lubricate splines or pilot end of Lubricant, P art Number 2525035, or Automotive
transmission drive pinion when installing transmis Multi-Purpose Grease, NLGI grade 2 EP.
sion. These areas must be kept dry. (3) Install bearings on ball studs and push studs
(2) Install transmission as detailed in “Transmission and bearings into torque shaft. Install snap ring on
Installation,” Group 21. fram e end of shaft.
(3) Adjust clutch linkage as detailed under “Ad (4) On Dart models, insert ball stud through fram e
justing Clutch Pedal Free Play.” side rail bracket and position inner stud and bracket
against clutch housing. Install two bracket bolts and
TORQUE SHAFT AND BEARINGS washers and tighten to 200 inch-pounds. Install washer
and nut on end of outer stud and tighten to 40 foot
Rem oval pounds (Fig. 6 or 7).
(1) On all models, remove spring clip securing (5) On Challenger place torque shaft assembly
pedal rod to torque shaft lever pin (Figs. 6 or 7) and in approximate position and thread inner ball stud
remove pedal rod from pin.
into clutch housing. Tighten stud to 40 foot-pounds.
(2) On 6 cylinder models equipped with A-903 trans
Position fram e end of torque shaft in slotted fram e
mission, remove clip and plain washer securing gear
bracket. Install lockwasher and nut on stud and
shift interlock rod to torque shaft lever and remove
tighten to 40 foot-pounds (Fig. 7).
spring washer, plain washer and rod from torque
(6) Install pedal rod on torque shaft lever pin and
shaft.
secure with spring washer (Fig. 6 or 7).
(3) Remove one end of retu rn spring from clutch
(7) Insert threaded end of fork rod assembly in hole
release fork and the other end from torque shaft lever
in end of release fork. Install eye end of fork rod on
or clutch housing (Fig. 6 or 7).
torque shaft lever pin (Fig. 6 or 7) and secure with
(4) If so equipped, detach outer torque shaft return
spring washer.
spring from hook attached to torque shaft lever and
(8) Install one end of return spring to clutch release
spring bracket.
fork and the other end to torque shaft lever or clutch
(5) Remove spring washer securing fork rod assem
bly to torque shaft lever pin and remove rod from pin housing (Fig. 6 or 7).
(Fig. 6 or 7). (9) On models so equipped, connect outer torque
(6) Remove nut and cone washer from fram e end shaft retu rn spring between hook on torque shaft
ball stud. lever and spring bracket.
(7) On Dart models, remove two screws and wash (10) On 6 cyl. models, install plain washer and gear
ers securing ball stud bracket to clutch housing shift interlock rod in torque shaft lever (Fig. 6) and
(Fig. 6). secure with spring washer, plain washer and clip.
(8) On Challenger, unscrew ball stud from clutch (11) Adjust clutch linkage.
housing (Fig. 7). (12) Adjust interlock rod.
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CLUTCH HOUSING ALIGNMENT
Bore Runout
(1) Replace one flywheel to crankshaft bolt with a
bolt about 3 inches long. Mount Dial Indicator C-3339
on this bolt with a “C” clamp (Fig. 13).
(2) With C-771 Flywheel Turning Tool, tu rn fly
wheel while noting dial indicator needle deflection.
Bore out-of-round must not exceed .008 inch maxi
mum total indicator reading, or .004 inch, one-half
total indicator reading. Fig. J4 —Offset D o w el D iagram (6 cyl.)
(3) Excess bore runout can be corrected by install
(No. 1736353).
ing correct size offset dowels (Fig. 14 or 15). These
(8) To install dowels, remove clutch housing and
dowels are available in three offset sizes and they
old dowels from rear face of engine block.
must be installed in pairs of the same size: .007 inch,
(9) Install both dowels with slots parallel and
Part Number 1736347; .014 inch, P art Num ber
aligned in direction to correct bore runout. (Slot indi
1736348 and .021 inch, P art Number 1736353.
cates direction of maximum dowel eccentricity). Both
(4) To illustrate recommended correction proce
dowels must be inserted into engine block, up to off
dure, assume total indicator reading is .020 inch, in
set shoulder.
a direction which approximates 2 o’clock on engine
(10) Install clutch housing to engine block bolts.
block (Figure 14 or 15, depending on model).
Tighten 7/16 inch bolts to 50 foot-pounds and 3 /8
(5) In this case, housing is off crankshaft centerline
inch bolts to 30 foot-pounds.
.010 inch (one-half total indicator reading) which is
(11) Remount dial indicator and rem easure bore
.006 inch greater than allowable lim it of .004 inch
runout. Small corrections can be made by removing
(one-half total indicator reading).
clutch housing (if necessary) and turning dowels with
(6) In the case under consideration, installation of
a screwdriver to shift housing and bring bore within
two .007 inch dowels will bring runout within the
limits.
allowable limits of .004 inch or .010 inch minus .007
inch (dowels) which equals .003 inch runout. Face Squareness
(7) The amount of eccentricity of the dowel will (1) Relocate Dial Indicator (Fig. 16) and rotate fly
produce a total indicator reading change of double wheel, using Tool C-771. If total indicator reading is
the dowel eccentricity, therefore, select a pair of greater than .006 inch, note amount of total indicator
dowels with the nearest to one-half of total indicator reading and location of lowest indicator reading (i.e.,
runout of bore. For runout (total indicator reading) point where indicator arm or follower is extended
of .009" through .020", use a .007" dowel (No.
1736347); .022" through .034", use .014" dowel (No.
1736348) and .036" through .050", use .021" dowel
DIAL INDICATOR
NR135
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bolts to 50 foot-pounds and 3/8 inch bolts to 30 foot
pounds.
(3) Install clutch release bearing, fork, linkage and
transmission. Adjust clutch linkage.
SPECIFICATIONS
DART— CHALLENGER
APPLICATION CHART
IDENTIFICATION CHART
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CLUTCH DISC ASSY.
IDENTIFICATION CHART
TIGHTENING REFERENCE
POUNDS POUN DS
FOOT I NCH FOOT INCH
Clutch Cover to Flywheel Bolts (5/16") 200 Flywheel Bolts (All except 426 Hemi) . 55
Clutch Cover to Flywheel Bolts (3/8"). 30 Flywheel Bolts (426 H e m i)................... 70
Clutch Fork Pivot B o lts ....................... 200 Torque Shaft Ball S t u d ....................... 40
Clutch Housing to Engine Bolts (3/8") 30 Torque Shaft Ball Stud Nut................. 40
Clutch Housing to Engine Bolts (7/16") 50 Torque Shaft Ball Stud Bracket Bolts
Clutch Housing Pan Bolts ................. 200 Transmission to Clutch Housing Bolts
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COOLING
CONTENTS
Page Page
ACCESSORY BELT DRIVES ....................... . 9 RADIATOR PRESSURE CAP ....................... 7
CONVERSION TABLE .................................... 12 REVERSE FLUSHING COOLING SYSTEM . 6
ENGINE WATER TEMPERATURE GAUGE 9 SERVICE DIAGNOSIS .................................... 1
FAN 3 SPECIFICATIONS............................................ 10
FLUID FAN D R IV E 3 TIGHTENING REFERENCE........................... 12
PRESSURE TESTING COOLING SYSTEM 8 THERMOSTAT ........ ....................................... 6
PRESSURE TESTING RADIATOR CAP . . 7 TRANSMISSION OIL COOLER ..................... 5
RADIATO R 4 WATER PUMP ................................................ 4
RADIATOR H O S E S 7
GENERAL INFORMATION
In order to provide satisfactory protection for the The maximum cooling system consisting of a larger
wide variety of corporation models the cooling system radiator and on some models radiator shrouds a n d /o r
of each must be tailored to specific needs. To do this hood-to-yoke and bum per to yoke seals are used to
effectively the Corporation offers five basic systems: provide protection against overheating for unusually
(1) Standard severe operation requirem ents.
(2) Air Conditioning The trailer towing package is a combination of the
(3) High Capacity Fan maximum cooling package and the high capacity fan,
(4) Maximum Cooling as necessary to provide protection against overheat
(5) Trailer Towing ing when towing trailers.
The standard system consists of a tube and spacer For internal cooling system protection each cooling
type radiator, 16 psi radiator pressure cap, centrifugal system is factory equipped with sufficient perm anent
water pump, 190°F. therm ostat*, and a four or seven type anti-freeze for —20 °F. protection. It is recom
blade fan. See specifications for application. mended that the coolant be changed annually to in
The cooling system for air conditioned equipped sure adequate anti-freeze and corrosion protection.
vehicles generally requires a greater capacity radiator Air conditioned cars require year round protection
along with a fan shroud, special centrifugal water with perm anent type anti-freeze with a minimum of
pump and drive ratio, larger fan, and therm ostatically + 15°F. protection for summer operation and addi
controlled fan drive (in some installations). See speci tional anti-freeze in the winter according to the pre
fications for applications. vailing tem peratures.
An optional capacity fan to protect against over
heating for unusual operating conditions is available. *318-383-2BBL. have a 195° thermostat.
SERVICE DIAGNOSIS
__________ Condition________________________ Possib le Cause____________________________ Correction_______________
EXTERNAL LEAKAGE (a) Loose hose clamp. (a) Replace the hose clamp.
(b) Hose leaking. (b) Replace the hose.
(c) Leaking radiator. (c) Repair or replace the radiator as
necessary.
(d) Water pump leaking through vent (d) Replace the water pump,
hole.
(e) Loose core hole plug. (e) Install new core hole plug.
(f) Damaged gasket, or dry gasket, if (f) Replace gaskets as necessary,
engine has been stored.
(g) Cylinder head bolts loose, or tightened (g) Replace the cylinder head gasket and
unevenly. torque head in correct sequence.
(h) Leak at heater connection. (h) Clean the heater connections and
replace the hoses and clamps if
necessary.
(i) Leak at water temperature sending (i) Tighten the water temperature send-
unit. ing unit.
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(j) Leak at water pump attaching bolt. (j) Tighten the water pump attaching
bolts to 30 foot-pounds.
(k) Leak at exhaust manifold stud. (k) Seal and re-drive the stud.
(I) Cracked thermostat housing. (I) Replace the thermostat housing.
(m) Dented radiator inlet or outlet tube. (m) Straighten the radiator inlet or outlet
tube as necessary.
(n) Leaking heater core. (n) Repair or replace the heater core.
(o) Cracked or porous water pump hdus- (o) Replace the water pump assembly,
ing.
(p) Warped or cracked cylinder head. (p) Replace the cylinder head.
(q) Cracked cylinder block. (q) Replace the cylinder block.
(r) Sand holes or porous condition in (r) Replace the cylinder block or cylinder
block or head. head as necessary.
(s) Faulty pressure cap. (s) Replace pressure cap.
(t) Loose or stripped oil cooler fittings. (t) Tighten or replace as necessary.
INTERNAL LEAKAGE (a) Faulty head gasket. (a) Install a new head gasket.
(b) Refer to causes (f), (g), (p), (q), (r) and (b) Refer to corrections (f), (g), (p), (q),
(t) listed under External Leakage. (r) and (t) listed under External Leak
age.
(c) Crack in head into valve compart (c) Pressure test cooling system, replace
m ent the cylinder head.
(d) Cracked valve port. (d) Pressure test cooling system, replace
the cylinder head.
(e) Crack in block into push rod compart (e) Pressure test cooling system, replace
ment. the cylinder block.
(f) Cracked cylinder wall. (f) Pressure test cooling system, replace
the cylinder block.
(g) Leaking oil cooler. (g) Repair or replace the oil cooler.
POOR CIRCULATION (a) Low coolant level. (a) Fill radiator to correct level.
(b) Collapsed radiator hose. (A bottom (b) Replace the hose and spring.
hose with faulty spring may collapse
only at medium or high engine
speeds.)
(c) Fan belt lose, glazed, or oil soaked. (c) Tighten or replace the fan belt as
necessary.
(d) Air leak through bottom hose. (d) Reposition hose clamps or replace
the hose. Check radiator outlets for
dents or out-of-rounds.
(e) Faulty thermostat. (e) Replace the thermostat.
(f) Water pump impeller broken or loose (f) Replace the water pump.
on shaft.
(g) Restricted radiator core water pas (g) Flush the radiator thoroughly or rod
sages. out if necessary.
(h) Restricted engine water jacket. (h) Flush the engine cooling system thor
oughly.
OVERHEATING (a) Blocked radiator air passages. (a) Clean out the radiator air passages.
(refer to Causes and (b) Incorrect ignition timing. (b) Time the engine ignition system.
Corrections listed (c) Low engine oil level. (c) Add engine oil to the correct level.
under “Poor Circulation”) (d) Incorrect valve timing. (d) Correct the engine valve timing.
(e) Inaccurate temperature gauge. (e) Replace the temperature gauge.
(f) Restricted overflow tube. (f) Remove restriction from overflow
tube.
(g) Faulty radiator pressure cap or seat. (g) Replace the radiator cap. Clean or re
place seat.
(h) Frozen heat control valve. (h) Free up manifold heat control valve.
(i) Dragging brakes. (i) Adjust the brakes.
(j) Excessive engine idling. (j) Increase idle R.P.M. or stop engine.
(k) Frozen coolant. (k) Thaw out cooling system, add anti
freeze as required.
(I) Faulty fan drive unit. (I) Replace the fan drive unit.
(m) Faulty temperature sending unit. (m) Replace the sending unit.
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Correction ______
OVERFLOW LOSS (a) Overfill ing. (a) Adjust coolant to the correct level.
(Also refer to Causes and (b) Coolant foaming due to insufficient (b) Flush the radiator and add antifreeze
Corrections listed under corrosion inhibitor. as required.
“Poor Circulation and (c) Blown head gasket. (c) Replace the head gasket.
Overheating”) (d) Broken or shifted lower hose spring. (d) Replace lower hose.
CORROSION (a) Use of water containing large concen (a) Use only clean soft water with anti
tration of lime and minerals. freeze.
(b) Insufficient corrosion inhibitor. (b) Use antifreeze as required.
(c) Use of antifreeze for extended length (c) Drain cooling system and replace with
of time. new antifreeze.
TEMPERATURE TOO (a) Faulty thermostat. (a) Replace the thermostat.
LOW—SLOW ENGINE (b) Inaccurate temperature gauge. (b) Replace the temperature gauge.
WARM-UP (c) Faulty temperature sending unit. (c) Replace the sending unit.
WATER PUMP NOISY (a) Seal noisy. (a) Add Water Pump Lube.
(b) Bearing corroded. (b) Replace water pump.
ACCESSORY DRIVE BELTS
INSUFFICIENT (a) Belt too loose. (a) Adjust belt tension.
ACCESSORY OUTPUT (b) Belt excessively glazed or worn. (b) Replace and tighten as specified.
DUE TO BELT SLIPPAGE
BELT SQUEAL WHEN (a) Belts too loose. (a) Adjust belt tension.
ACCELERATING (b) Belts glazed. (b) Replace belts.
ENGINE
BELT SQUEAK AT IDLE (a) Belt to loose. (a)
Adjust belt tension.
(b) Dirt and paint imbedded in belt. (b)
Replace belt.
(c) Non-uniform belt. (c)
Replace belt.
(d) Misaligned pulleys. (d)
Align accessories (file brackets or use
spacers as required).
(e) Non-uniform groove or eccentric pul (e) Replace pulley.
ley.
BELT ROLLED OVER IN (a) Broken cord in belt. (a) Replace belt.
GROOVE (b) Belts not matched (A/C). (b) Install matched belts.
BELT JUMPS OFF (a) Belt too loose. (a) Adjust belt tension.
(b) Belts not matched (A/C). (b) Install matched belts.
(c) Misaligned pulleys. (c) Align accessories.
SERVICE PROCEDURES
FAN FLUID FAN DRIVE
There are no repairs to be made to the fan. If the CAUTION : To prevent silicone fluid from draining
fan is bent or damaged it should be replaced. into fan drive bearing and ruining the grease, do not
place drive unit with shaft pointing downward.
Rem oval
(1) Remove shroud attaching screws, separate
Torque Control D rive
shroud from radiator, position shroud rearw ard on The Torque Control Drive (Fig. 1) is a silicone fluid
engine. Fan attaching screws can now be removed. filled coupling connecting the fan to the fan pulley.
(2) On models equipped with fluid fan drive, re The unit allows fan to be driven in normal m anner at
move fan drive attaching screws. The fan and fluid low engine speeds while limiting the top speed of the
fan drive are removed as a unit. fan to a pre-determ ined level at higher engine speeds.
Installatio n
Use correct fan spacer, if required, so clearance Therm al Control D rive
between fan blades and radiator is 3 /4 to 1-1/4 inches. Air conditioned vehicles only, the Thermal Control
No fan spacer perm itted with fluid fan drive regard Drive (Figs. 2 and 3) is essentially the same as the
less of fan blades to radiator clearance. Install one Torque unit except for a thermostatic spring on the
piece shroud on vehicles so equipped. Tighten fan drive face. This therm ostat senses tem perature from
belt as outlined in “Belt Tension Specifications”. the radiator and engages the drive for higher fan
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3
NK480A NK479A
Fig. 1—Torque Control Fan Drive Fig. 3 —Therm al Control Fan D rive (3 1 8 -3 8 3 -4 4 0 Cubic
Inch Engine w ith 2.93:1 or H igher A xle Ratio)
speed if tem perature from the radiator rises above a
certain point. (2) Loosen power steering pump, idler pulley and
In case of engine overheating during slow car speed alternator. Remove all belts.
or idle operation, increase engine speed to approxi (3) Remove fan, spacer (or fluid drive) and pulley.
mately 1000 rpm in neutral gear. If condition is not CAUTION: To prevent silicone fluid from draining
corrected by increasing engine speed, replace fan into fan drive bearing and ruining the grease, do not
drive unit with a unit known to be operating properly place drive unit with shaft pointing downward.
and test by operating vehicle under same conditions. (4) Remove the bolts attaching the w ater pump
Replace original drive unit assembly if trouble was body to the housing. Remove the w ater pump and dis
corrected with test unit. card gasket.
RADIATOR
R em oval
(1) Drain cooling system.
-A (2) On vehicles with automatic transmission, dis
connect oil cooler lines at radiator bottom tank.
(3) Remove upper and lower radiator hoses (using
pliers C-3250).
(4) Remove shroud attaching screws, separate
shroud from radiator, position shroud rearw ard on
engine for maximum clearance.
(5) Remove radiator attaching screws.
(6) Radiator can now be lifted free from engine
N P 541
compartment. Care should be taken not to damage
Fig. 2 —Therm al Control Fan D rive (31 8
radiator cooling fins or water tubes during removal.
Cubic Inch Engine W ith 2.76:1 A x le Ratio) Fan damage should always be avoided.
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Installatio n erated air passes through the heater core. Anti-freeze
(1) Slide radiator down into position behind is necessary to prevent th e heater core from freezing
radiator support and install attaching screws. in hot w eather when the air conditioner is being used.
(2) Install fan shroud (if so equipped), connect
hoses, and connect transmission oil cooler lines, if TRANSMISSION OIL COOLER
so equipped.
(3) Fill cooling system to 1-1 /4" below filler neck The transm ission oil cooler is located in the bottom
seat with w ater and anti-freeze, as required. A fter radiator tank (water cooled), which is an integral p a rt
warm-up, re-check coolant level. of the radiator.
(4) On vehicles with automatic transmission, meas Some models are equipped with an auxiliary oil
ure transmission oil level after warm-up and add oil cooler (air cooled) m ounted ahead of the radiator and
as required. is connected in series w ith the standard transmission
oil cooler (Fig. 4).
Cleaning In case of a leak, engine coolant may become mixed
(1) Drain cooling system and refill with clean soft with transm ission fluid, also, transmission fluid may
w ater and a reliable cooling system cleaner. enter cooling system. Both cooling system and trans
(2) Operate engine according to directions on mission should be inspected in event cooler is leaking.
Cleaner label.
(3) A fter cleaning operation, flush entire cooling Testing O il Cooler fo r Leaks
system until w ater runs clean. (1) Disconnect both oil cooler lines at radiator.
(4) Regardless of climate, the cooling system should (2) Connect a pressure gauge to one cooler con
be refilled with sufficient perm anent type anti-freeze nection and a shut off valve to the other. Close the
for —20°F protection. To insure adequate corrosion valve.
protection. (3) Connect a source of air pressure to the valve.
(5) If vehicle is equipped with air conditioning the (4) Coat all fittings with oil.
cooling system must contain anti-freeze all year (5) Open the test valve and apply (up to 100 psi) air
round. This is necessary because in the reheat-cycle pressure. Oil bubbles will identify any fitting joint
system used on all vehicles, except Dart, cold refrig leaks. Repair all joint leaks.
NR255A
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(6) Close the valve. Gauge reading will then drop neck, using soft w ater and anti-freeze, depending on
if cooler is leaking. season or if equipped with air conditioning.
(9) Engine should be operated until tem perature
R epairing O il Cooler gauge indicates normal operating tem perature, then,
The transmission auxiliary oil cooler being all alu continue an additional five minutes to release any air
minum can be repaired by a local reliable radiator trapped in system.
service having the equipment for alumibrazing or (10) Check for leaks and coolant level; correct as
heliarc. necessary.
(1) Remove radiator from vehicle.
(2) Remove radiator bottom tank. Reverse Flushing R adiator
(3) Melt the soft solder holding the cooler to the (1) Drain cooling system and remove hoses from
tank. engine.
(4) Remove the stam ped retainer nuts holding the (2) Install Tool C-3514, or other suitable flushing
cooler fittings to the bottom tank and remove the gun in radiator lower outlet.
cooler. (3) Fill radiator and turn on air in short blasts.
(5) Install a new cooler or repair the old cooler CAUTION: I nternal radiator pressure must not ex
w ith silver solder and reinstall as follows: ceed 20 psi, as damage to radiator may result.
(6) Position oil cooler in bottom tank and install (4) Continue this procedure until w ater runs clean.
the stam ped retainer nuts on oil cooler fittings. It is a good policy to reverse flush heater core any
(7) Use soft solder to secure the cooler in the tank. time the radiator is reverse flushed.
(8) Attach bottom tank to radiator using soft (5) Fill cooling system to 1-1/4 inches below filler
solder. neck, using soft water and anti-freeze, depending on
(9) Install radiator as described in Paragraph season or if equipped with air conditioning.
“Radiator”. (6) Engine should be operated until tem perature
(10) Fill cooling system and test for leaks. gauge indicates normal operating tem perature, then,
If the transm ission operates properly after repair continue an additional five minutes to release any air
ing the leak, drain the transmission and torque con trapped in system.
verter while hot, remove the transmission oil pan (7) Check for leaks and coolant level; correct as
and inspect for sludge, rust, dirty or plugged inlet necessary.
filter. If none of these conditions are found, recon THERMOSTAT
ditioning may not be necessary. Reassemble, using
Transmission Fluid AQ-ATF-2848A. The therm ostat is actuated by a pellet containing a
copper-impregnated wax, as shown in (Fig. 5). As
REVERSE FLUSHING THE COOLING SYSTEM the tem perature of the pellet increases, the wax ex
pands and opens the valve. A 190° therm ostat is
Reverse flushing of the cooling system is the forc standard equipment.* The use of 160° thermostat or
ing of w ater through the cooling system, using air alcohol type anti-freeze is not recommended.
pressure in a direction opposite to th at of the norm al If the therm ostat does not close completely when
flow of water. cold, the engine will warm up slowly or not at all,
and heater performance will also be impaired. Poor
Flushing C ylinder Block heater perform ance may also be due to valve open
(1) Drain radiator and remove hoses at radiator. ing at too low a tem perature. Too high a valve open
(2) Remove therm ostat and reinstall therm ostat ing tem perature or a valve that will not open can
housing. cause overheating.
(3) Install Tool C-3514, or other suitable flushing *318-383-2BBL. have a 195° thermostat.
gun to inlet hose.
(4) Connect w ater hose of gun to a pressure w ater
source and air hose of gun to a pressure air source.
(5) T urn on w ater, and when cylinder block is
filled, turn on air (up to 20 psi) in short blasts.
(6) Allow cylinder block to fill between blasts of
air.
(7) Continue this procedure until w ater runs clean.
Test therm ostat and if satisfactory, reinstall: other
EIGHT CYLINDER SIX CYLINDER NU348
wise, replace using a new housing gasket.
(8) Fill cooling system to 1-1/4 inches below filler
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Rem oval
(1) Drain cooling system down to therm ostat level
or below.
(2) Remove upper radiator hose from therm ostat
housing.
(3) Remove therm ostat housing bolts and remove
therm ostat and housing.
'%
lr' ,o o i
Testing Thermostat V
(1) Visually inspect therm ostat to make sure valve KP146
closes tightly. If valve does not close completely due
to dirt, sand or other foreign m aterial, carefully clean
Fig. 7 —Testing Pressure Cap
the sealing edge making sure the sealing edge is
not damaged. If valve does not close tightly when suction at medium or high engine speeds. If this
clean, install a new therm ostat. spring is misplaced in hose, it should be repositioned.
(2) Immerse therm ostat in a container of warm If this spring is deformed hose m ust be replaced.
w ater so that pellet of therm ostat is completely cov
RADIATOR PRESSURE CAP
ered. The pellet must not touch bottom or sides of
container. Radiators are equipped with a 16 psi cap, as stand
(3) Heat the w ater and stir it continuously (to in ard equipm ent (Fig. 6).
sure uniform tem perature) and check w ater tem pera WARNING: When removing pressure cap, turn coun
ture with a therm om eter at the point when a .001" terclockwise to stop, without downward pressure on
feeler gauge can be inserted into valve opening. The cap, permitting built-up pressure to escape through
feeler gauge should pass freely into the valve open over-flow tube. This wi l l prevent hot water from spray
ing at a water tem perature of 187° to 194°F. for a ing out of radiator filler opening. To complete removal
190° therm ostat and a water tem perature of 192° to apply downward pressure and turn counterclockwise.
199° for a 195° therm ostat. If outside of this range,
PRESSURE TESTING RADIATOR CAP
replace therm ostat.
(4) Continue heating water to approximately 210°F Select the short neoprene seal and metal adapter
for a 190° therm ostat and 215° tem perature for a from the kit, Tool C-4080. Slip the seal on the tube at
195° therm ostat. The therm ostat valve should be the bottom of the instrum ent. Then attach either end
fully open at this tem perature. If it is not, replace of the short adapter to the instrum ent. Dip the pres
therm ostat. sure cap in w ater and apply cap to end of adapter.
W orking the plunger, as shown in (Fig. 7) bring the
Installation pressure to 16 pounds on the gauge. If the pressure
(1) Using a new gasket, position therm ostat so cap fails to hold the pressure within a range of 14-17
pellet end is toward engine and attach with bolts pounds, replace the cap with a new tested1cap.
through therm ostat housing. The brass vent valve at the bottom of the cap
(2) If removed, reinstall or replace the upper hose. should hang freely. If the rubber gasket has swollen
(3) Fill cooling system to 1-1/4 inches below filler
neck with water and anti-freeze.
RADIATOR HOSES
The hoses are removed and installed using hose
clamp pliers C-3250.
A hardened, cracked, swollen or restricted hose
should be replaced.
The reinforcem ent spring inside the lower hose is
necessary to prevent collapsing of the hose due to
-GASKET
V IN T VALVE- N H 18 6A
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be 1/2 inch below neck of radiator.
(2) Attach the Tester Tool C-4080 to the radiator,
as shown in (Fig. 8) and apply 15 pounds pressure. If
the pressure drops inspect all points for external
leaks.
(3) If there are no external leaks, after the gauge
dial shows a drop in pressure, detach the tester, start
engine and run the engine to operating tem perature
in order to open the therm ostat and allow the coolant
to expand. Reattach the tester and pump to 7 lbs.
pressure while the engine is running. Race the en
gine, and if the needle on the dial fluctuates it indi
and prevents the valve from hanging loosely, replace cates a combustion leak, usually a head gasket.
the cap. Do not use a replacement cap without this WARNING: Pressure builds up fast. Any excessive
vent valve. amount of pressure built up by continuous engine
operation must be released to a safe pressure point.
PRESSURE TESTING COOLING SYSTEM NEVER PERMIT PRESSURE TO EXCEED 20 lbs.
(1) W ith engine not running, wipe the radiator (4) Remove the wires from the spark plugs on one
filler neck sealing seat clean. The w ater level should bank and operate the engine on the opposite bank.
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If the needle continues to fluctuate, it indicates a however, there may be internal leaks which can be
leak on the bank still in operation. If the needle determ ined by removing the oil dip-stick and if w ater
ceases to fluctuate, the leak is in the bank, from globules appear interm ixed with the oil it will indi
which combustion has been released. cate a serious internal leak in the engine. If there is
(5) If the needle on the dial does not fluctuate, race an internal leak, the engine must be disassembled,
the engine a few times and if an abnormal amount the leak located and necessary new parts installed.
of water emits from the exhaust system at the tail
pipe, it may indicate a leak th at can be a faulty head ENGINE WATER TEMPERATURE GAUGE
gasket, cracked engine block, or the cylinder head
near the exhaust ports. For Removal, Installation and Testing procedures
(6) If the above pressure test of the cooling sys of the w ater tem perature sending and receiving
tem holds without fluctuation, then there is no leak, units, refer to “Electrical” Group 8 “Gauges” .
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SPECIFICATIONS
DART
RADIATOR—Identification Number—Width
Transmission Manual 903 ............................... 2998932—19" 2998932—19" 2998943—19"*
230 ............................... 2998978—22"*
833 ................. ............ 2998978—22"
Automatic 904 ............................... 2998933—19" 2998933—19" 2998943—19"*
727 ............................... 2998945—22"
Air Conditioning........................................... N/A 2998934—22" 2998944—22" 2998945—22"
Maximum Cooling ......................................... 2998935—22" 2998935—22" 2998945—22" 2998978—22"*
Oil Cooler Size Standard ................ ................ 6" 6" 10" 10"
Air Conditioning ................... N/A 6" 10" 12"
Maximum Cooling................. 6" 6" 12" 12"
Shroud Transmission Manual ....................... None None None Yes
Automatic ................. None None None Yes
Air Conditioning........ N/A Yes Yes Yes
Maximum Cooling . . . None Yes Yes Yes
Seal
Hood to Y o k e ................... ....... .................... None Yes** Yes Yes
FAN
Diameter- -Number Blades—Width
1—
l»
IsS
M
* 2998945 Radiator and 18-1/2—7—2-1/2 Fan and Torque Drive Used with Performance Axles 3.55, 3.91, 4.10.
** Air Conditioning and Maximum Cooling only.
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CHALLENGER 9
4404# &
EWGIWE ______________________ 225________________318 __________ 340 383*2 i l l 3S3«4 i l l 3-2 BBL 426 HEMI
CAPACITY (W ith H e a te r) Q u a r t s -
R a d ia to r W id th . . . . . . . . . . . . . . . . . . . . . . . . . 13 -19" * 16 -19" 15.5-26" 14.5-22" 14.5-22" 17-26" 17-26"
14-22" 17.5-26"* 15-26"* 15-26"*
FAN
D ia m e te r— N u m b e r B la d e s —W idth
S ta n d a r d . . . . . . . . . . . . . . . . . . . . . . . ........ 1 7 - 4 - 1 4 /2 18-4-2 B.T. 1 8 4 /2 -7 -2 4 /2 1 8 -7 -2 1 8 4 /2 -7 -2 4 /2 1 8 4 /2 -7 -2 4 /2
A u to m a tic . . . . . . . . . . . . . . . . . . . . . . ........ 1 7 -4 -1 -1 /2 1 8 -4 -2 B.T. 1 8 4 /2 -7 -2 4 /2 1 8 -7 -2 1 8 -7 -2 1 8 -7 -2 1 8 4 /2 -7 -2 4 /2
A ir C o n d itio n in g . . . . . . . . . . . . . . . . ........ 1 8 -4 -2 P.T. 1 8 4 /2 -7 -2 4 /2 1 8 4 /2 - 7 -2 4 /2 1 8 4 / 2 - 7 - 2 4 /2 1 8 4 /2 -7 -2 4 /2 • 1 8 4 /2 - 7 - 2 4 /2 * * N /A
H igh C a p a c ity . . . . . . . . . . . . . . . . . . . ........ 1 8 - 7 - 1 4 /2 1 8 - 7 - 2 4 /4 N /A 1 8 - 7 - 2 4 /8 1 8 -7 -2 -1 /8 1 8 - 7 - 2 4 /8 N /A
Spacer
S ta n d a r d . . . . . . . . . . . . . . . . . . . . . . . ____ . . . 172" 2.20" T o rq u e 1.60" 1.60" T o rq u e -M a n u a l T o rq u e
1 .6 0 "-A u to m atic
A ir C o n d it io n in g . . . . . . . . ___ . . . . . . . . . . . . 1.72" T h e rm a l T h erm al T h erm al T h erm al T h erm al* * N /A
H igh C a p a c ity . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72" 2.20" T o rq u e 1.60" 1.60" L 60" N /A
R a tio {Fan to C ra n k s h a ft)
S ta n d a r d ................................. .......... .95:1 .95:1 • .95:1 .95:1 .95:1 1.20"1
SPECIFICATIONS
A ir C o n d itio n in g . . . . . . . . ___ . . . . . . . . . . . . 1.07:1 1.3:1 1.3:1 1.4:1 1.4:1 1.4:1 N /A
H igh C a p a c ity . . . . . . . . . . ___ _____ .95:1 .95:1 .95:1 .95:1 .95:1 N /A
miER P U M P IM PELLER
D ia m e te r— N u m b e r B la d e s
S ta n d a r d . . . . . . . . . . . . . . . . . . . ___ 4 .38"-8 4.3 8"-8 4.3 8"-8 4.38"-8 4.38"~8 4.38 "-8
A ir C o n d itio n in g _____ . . . . . . . . . . . . . . . . . . . 3.5 0"-6 3.70"-6 3.70"-6 3.50 "-6 3.50"~6 3.50"-6** N /A
* A dd o n e q u a r t w ith M axim um C o o lin g.
** A ir C o n d itio n in g n o t a v a ila b le o n 440 C u b ic In c h w ith 3-2 B B L.
*** A u xiliary 7" x 26" O il C o o ler {air c o o le d ) in s e r ie s w ith s ta n d a r d oil c o o le r.
** ** A ir C o n d itio n in g a n d M axim um C o o lin g only,
7-11
A 383-4BBL w ith H igh P e rfo rm a n c e C a m s h a ft only.
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BELT TENSION SPECIFICATIONS
TORQUE METHOD
DEFLECTION METHOD
t Any belt that has operated for a minimum of a half-hour is considered to be used.
CONVERSION TABLE
U. S. Q u a rt................................. 12 13 14 15 16 17 18 19
Imperial Quart ....................... . 10 10-3/4 11-3/4 12-1/2 13-1/4 14-1/4 15 15-3/4
TIGHTENING REFERENCE
Inch Foot Thread
Pounds Pounds Size
Water Pump B o lts ......................... ____ 30 ____
Lines to Fittings . . . . . . 85 — —
Lines to Auxiliary C o o le r........ 85 — —
Lines to Connector . 50 — —
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ELECTRICAL
CONTENTS
Page Page
ALTERNATOR AND VOLTAGE REGULATOR 15 INSTRUMENT PANELS ............................. 56
BATTERY ..................................................... 1 SPECIFICATIONS........................................ 77
EXTERIOR LIGHTING ................................ 41 STARTING MOTOR .................................... 5
HEADLIGHTS .......................................... 47 TURN SIGNALS .......................................... 72
TAIL AND STOP LIGHTS........................ 52 WINDSHIELD WIPER SYSTEM................. 64
HORNS ....................................................... 74 WINDSHIELD WASHERS ........................... 70
IGNITION SYSTEM .................................... 28 WIRING DIAGRAMS .................................. 85
BATTERY
INDEX
Page Page
Adjustment of Acid Gravity ..................................... 3 High Rate Discharge Test of Battery Capacity . 4
Battery Visual Inspection ........................................ 1 Specifications...................................................... . 77
Charging the Battery ................................................ 4 Specific Gravity Test ......................................... . 1
SERVICE PROCEDURES
BATTERY VISUAL INSPECTION indication of how much unused sulphuric acid re
mains in the solution.
(1) Protect paint finish with fender covers. A hydrom eter should be graduated to read from
(2) Disconnect battery cables at battery. 1.160 to 1.320, in graduations of .005 specific gravity.
(3) Remove battery hold-down clamp and remove Graduated markings should be not less than 1/16 inch
battery from vehicle. apart and accurate to within .002 specific gravity.
(4) Inspect battery carrier and fender side panel Graduated portion of stem should be about two inches
for damage caused by loss of acid from battery. long. Clearance between float and glass barrel, at
(5) Clean top of battery with a solution of clean smallest diameter, should be a minimum of 1/ 8"
warm w ater and baking soda. Scrub areas with a stiff around all sides and barrel must be clean.
bristle brush being careful not to scatter corrosion Liquid level of battery cell should be at normal
residue. Finally wipe off with a cloth moistened with height and electrolyte should be thoroughly mixed
ammonia or baking soda in water. with any battery water which may have just been
CAUTION: Keep cleaning solution out of battery cells added by charging battery before taking hydrometer
to eliminate weakening the electrolyte. readings. See “Adjustment of Acid Gravity.”
(6) Replace damaged or frayed cables. In reading a hydrometer, the gauge barrel must be
(7) Clean battery terminals and inside surfaces of held vertically and just right amount of fluid be
clamp terminals with Cleaning Tool MX-75. drawn up into gauge barrel with pressure bulb fully
(8) Examine battery case and cover for cracks. expanded to lift float freely so it does not touch the
(9) Install battery. sides, top or bottom of the barrel. Take a reading with
(10) Tighten battery hold-down screw nuts to 3 eye on level with liquid level in the gauge barrel. DO
foot-pounds. Observe polarity of battery terminals to NOT TILT hydrometer.
be sure the battery is not reversed. Hydrometer floats are calibrated to indicate cor
(11) Connect cable clamps to battery posts and rectly only at one fixed temperature.
tighten securely. Coat all connections with light min Specific gravity of battery electrolyte strength or
eral grease or petrolatum after tightening. density varies not only with the quantity of the acid
(12) If electrolyte level is low, fill to recommended in solution but also with tem perature. As tem perature
level with mineral-free water. increases, the density of the electrolyte decreases, and
specific gravity is reduced. As tem perature drops,
SPECIFIC GRAVITY TEST the density of the electrolyte increases and the spe
A hydrom eter Tool 40-B is used to m easure specfic cific gravity increases.
gravity of electrolyte in battery cells. This gives an Specific gravity variations caused by tem peratures
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must be considered and corrected to 80 °F. in the A fully charged relatively new battery has a specif
analysis of the battery, otherwise specific gravity ic gravity reading of 1.260 plus .015 minus .005.
readings will not give a tru e indication of state of
charge. Test Conclusions
Use a battery immersion type therm om eter of the (a) Battery specfic gravity is less than 1.220 bat
mercury-in-glass type, having a scale reading as high tery should be recharged. Make a high rate discharge
as 125° F. and designed for not over a 1-inch bulb test for capacity. If battery cells test O.K., recharge
immersion. A suitable dairy type therm om eter may and adjust gravity of all cells uniformly. Test voltage
prove satisfactory for the purpose. regulator setting. Thoroughly test the electrical sys
Draw electrolyte in and out of the hydrom eter bar tem for short circuits, loose connections and corroded
rel several times to bring the tem perature of the hy term inals.
drom eter float to that of the acid in the cell and then (b) Cells show more than 25 points (.025 Specific
m easure the electrolyte tem perature in the cell. Gravity) Variation—Short circuit low cell. Loss of
The tem perature correction in specific gravity read electrolyte by leakage or excessive overcharge; try to
ing at 80° Fahrenheit is zero. Add .004 specific gravity recharge battery. See “Charging the Battery.” See
points for every 10° degrees over 80° F. and subtract “Adjustm ent of Acid Gravity”.
.004 specific gravity points for every 10 degrees (c) Battery specific gravity is above 1.220 and all
under 80° F. All readings m ust be corrected at 80 cells are even. Battery state of charge may be satis
degrees Fahrenheit. Refer to Figure 1 and examples factory. Test by making “High Rate Discharge Test of
one and two as follows: Battery Capacity”. Test voltage regulator setting and
Example 1— all electrical connections are clean and tight.
Hydrom eter Reading 1.260
Acid Tem perature 20 degrees Fahrenheit TEST BATTERY CONDITION AND STATE OF
Subtract Specific Gravity .024 CHARGE WITH CAD-TIP ANALYZER— Part
Correct Specific Gravity is 1.236 Number 1-369 (Fig. 2)
Example 2—
Hydrom eter Reading 1.255 (1) Check electrolyte level in all cells and add
Acid Tem perature 100 degrees Fahrenheit mineral-free w ater to proper level. When a car is
Add Specific Gravity .008 running, the battery is receiving a charge from the
Corrected Specific Gravity is 1.263 alternator. This charge builds up a "surface charge"
T tm ptrofurt in the battery that must be removed before an ac
° F. Gravity Point* curate test can be made.
to Add or
Subtract (2) Remove the surface charge by turning the head
160 lights “on” for one m inute before testing battery. If
the battery has not been operating in a car for at
14® least 8 hours prior to testing, Step 2 is not necessary.
130 IMPORTANT: Be sure that headlights, ignition and
120 all accessories are "off" during test.
110
(3) Remove battery filler plugs and place the RED
probe in the POSITIVE (+ ) CELL and the BLACK
probe in the SECOND CELL. NOTE READING.
(There will be no m eter reading if the probes are
80
70
60
40
NP165
HK525
% 2—Testing B attery Ceils w ith Cad-Tip B attery
Cell A n alyzer
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reversed.) A manual set index pointer is provided to balance of the readings are within the first four scale
assist in making cell comparisons. Set the manual divisions—the battery is too low to make an accurate
index pointer for reference. condition test—Recharge battery and retest.
(4) Move RED probe to SECOND CELL and BLACK CAUTION: Be certain to remove "surface charge"
probe to THIRD CELL; then move RED probe to after recharge and before retesting. See "Step 2."
THIRD CELL and BLACK probe to FOURTH CELL,
etc., until all cells have been tested. Note each cell ADJUSTMENT OF ACID GRAVITY
reading so that CELL COMPARISONS CAN BE
MADE. Always store probe assembly in the space pro H ydrom eter floats usually are not calibrated below
vided in the meter case. 1.160 specific gravity and cannot indicate the condi
tion of a battery in a very low state of charge. There
TEST READING INTERPRETATIONS (Fig. 3) fore, it may be necessary to give the battery several
hours charge before a hydrom eter reading will indi
A—If the readings of any two cells vary FIVE cate that the battery is taking a charge.
scale divisions or more on the TOP scale—regardless If the specific gravity of all cells are not within .015
of the colored sections in which they may fall on points of specified value, corrected to 80 °F, at the end
the bottom scale—The battery is at or near the point of a full charge, remove some of the electrolyte with
of failure and should be replaced. a hydrom eter and add a like amount of distilled water
B—If all cells vary LESS than five scale divisions to reduce the gravity if too high, or add 1.400 Specific
on the TOP scale and all are in the GREEN section Gravity acid to raise specific gravity, if too low. Con
of the Bottom Scale—The battery is in good condition tinue the charge so as to give the electrolyte a chance
and a safe state of charge. to mix and then read the gravity after another hour
C—If all cells vary LESS than five scale divisions of charge to note the effect of the additions. Continue
on the TOP scale but if any of the cells test in the this adjusting procedure until gravity is brought to
RED section of the BOTTOM scale—the battery is in the desired value by charging for one hour after each
good condition but is in a low state of charge— Re adjustm ent.
charge at once to avoid a starting failure. Never adjust the specific gravity of any battery cell
D—If ANY cell readings are in the “RECHARGE which does not gas freely on charge. Unless electro
AND RETEST” section of the TOP SCALE and the lyte has been lost through spilling or leaking, it
n * rv E RY c o n d i T(0a/
J!——rn m iiiiiu m ,—
tT E ry c o n d i t i o n
RED BAND
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should not be necessary to add acid to a battery dur Tester control knob to the OFF position.
ing its life. Acid should never be added unless one is If the voltage in the “High Rate Discharge Test”
certain that the cell will not come up to normal gravi was under 9.5 volt, the battery should be test charged
ty by continued charging. Always make the tem pera to determ ine whether the battery can be satisfactorily
ture correction for hydrom eter readings, as warm charged.
electrolyte will read low and this m ight be m istaken
for failure of the battery to rise normally in gravity. It Charging the B attery
could also be falsely concluded that the battery would Three M inu te Charge Test (Fig. 5)
not take a full charge. This test should not be used if battery temperature
is below 60 degree F.
HIGH RATE DISCHARGE TEST OF (1) Connect Battery Charger positive (+ ) lead to
BATTERY CAPACITY battery positive term inal and negative (— ) lead to
battery negative terminal.
Satisfactory capacity tests can be made only when IMPORTANT: Be sure of correct polarity when charg
battery equals or exceeds 1.220 specific gravity at 80 ing batteries.
degrees Fahrenheit. If the reading is below 1.220 the (2) Trip Battery Charger Power Switch to ON posi
battery should be slow charged until fully charged in tion. Turn tim er switch past three minute m ark then
order to secure proper test results. back to the three minute mark.
(3) Adjust Battery Charger Switch to highest pos
Test Procedure sible rate not exceeding 40 amperes.
(1) Turn control knob of Battery-Starter-Tester to (4) When tim er switch cuts off at the end of 3
OFF position. minutes, tu rn tim er switch back to fast charge.
(2) Turn Voltm eter Selector Switch to the 16 volt (5) Use the 16 volt scale of the Battery Starter
position on test units so equipped. Tester and measure total voltage of battery posts
(3) Connect test am m eter and voltm eter positive while battery is being fast charged. If total voltage
leads to battery positive term inal. Connect am m eter during charge exceeds 15.5 volts, battery is sulphated
and voltm eter negative leads to battery negative te r and should by cycled and slow-charged until specific
minal (Fig. 4). Voltmeter clips must contact battery gravity reaches 1.260 (See “Slow Charging”). A slow
posts or cable clamps and not ammeter lead clips. charge is preferable to bring the battery up to a full
(4) T urn control knob clockwise until am m eter charge.
reading is equal to three times am pere hour rating If specific gravity rem ains constant after testing
of battery. battery at one hour intervals for three hours, battery
(5) Maintain this load for 15 seconds; voltm eter is at its highest state of charge.
should read 9.5 volts or more, which will indicate that (6) Make another capacity test. If capacity test does
the battery has good output capacity. not m eet specifications, replace battery.
(6) A fter the 15 second test, tu rn Battery-Starter-
Fast Charging the B attery (Fig. 6)
If adequate time for a slow charge is not available,
a high rate (FAST) charge is permissible and will give
a sufficient charge in one hour enabling the battery
and alternator to continue to carry the electrical load.
Connect Battery Charger positive (+ ) lead to bat
tery positive term inal and negative (—) lead to bat
tery negative terminal. If battery is not removed from
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vehicle, BE SURE ignition switch is turned off and all
electrical accessories are turned off during charging.
CAUTION: The battery can be damaged beyond re
pair unless the following precautions are taken:
(1) Battery electrolyte tem perature m ust NEVER
exceed 125 degrees Fahrenheit.
If this tem perature is reached, battery should be
cooled by reducing charging rate or remove battery
from the circuit.
(2) As batteries approach full charge electrolyte in
each cell will begin to gas or bubble. Excessive gas
sing must not be allowed.
(3) Do not fast charge longer than one hour.
If battery does not show a significant change in NY839A
specific gravity after one hour of “FAST” charge, the Fig. 6—Fast Charging the Battery
slow charge method should be used.
Remember to use tem perature correction when hour battery; and 6 amperes for a 70 am pere hour
checking specific gravity. The manufacturers of high battery.
rate charging equipment generally outline the neces The average length of tim e necessary to charge a
sary precautions and some models have thermostatic battery by the slow charge method at norm al rates is
temperature limiting and time limiting controls. from 12 to 16 hours, however, when a battery contin
WARNING: When batteries are being charged an ex ues to show an increase in specific gravity, battery
plosive gas mixture forms beneath the cover of each charge should be continued even if it takes 24 hours
cell. Do not smoke near batteries on charge or which or more. Watch the temperature of batteries carefully
have recently been charged. Do not break live circuits and if the temperature of any one of them reaches
at the terminals of the batteries on charge. A spark 110°F., lower the charging rate.
will occur where the live circuit is broken. Keep all Battery will be fully charged when it is gassing
open flames away from the battery. freely and when there is no fu rth er rise in specific
gravity after three successive readings taken at hour
Slow Charging Batteries ly intervals. Make sure hydrom eter readings are cor
Many discharged batteries can be brought back to
rected for tem perature.
good condition by slow charging; especially batteries
The rate of charge for a sulphated battery should
that are sulphated.
be no more than 1/2 the normal slow charge rate.
Battery should be tested with a hydrom eter and a
Many sulphated batteries can be brought back to a
record kept of the readings taken at regular intervals
throughout the charge. When a cell has a specific useful condition by slow charging at half the normal
gravity reading that is 25 points (.025) or more below charging rate from 60 to 100 hours. This long charg
other cells, that cell is faulty and battery should be ing cycle is necessary to reconvert crystalline lead
replaced. sulphate into active m aterials. When a battery takes
Safe slow charging rates are determ ined by allow a full charge, but is returned several times in need of
ing one am pere per positive plate per cell. Proper a recharge, check for a cracked cell partition with a
slow charging rate would be 4 amperes for a 46 syringe to provide air pressure; bubbles will appear
ampere hour battery; 5 amperes for a 59 ampere in an adjacent cell if a crack is present.
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The starter has a 3.5 to 1 reduction gear set built noid shift device, the housing of the solenoid is in
into the S tarter assembly, which is housed in an alu tegral with the starter drive end housing.
minum die casting, Fig. 1. The starter utilizes a sole
SERVICE DIAGNOSIS
Condition Possible Cause Correction
STARTER FAILS TO (a) Weak battery or dead cell in battery. (a) Test specific gravity. Recharge or re
OPERATE place battery as required.
(b) Ignition switch faulty. (b) Test and replace switch if necessary.
(c) Loose or corroded battery cable ter - (c) Clean terminals and clamps, replace
minals. if necessary. Apply a light film of pet
rolatum to terminals after tightening.
(d) Open circuit, wire between the igni (d) Inspect and test all the wiring.
tion—starter switch and ignition ter
minal on starter relay.
(e) Starter relay defective. (e) Test relay and replace if necessary.
(f) Faulty starter. (f) Test and repair as necessary.
(g) Armature shaft sheared. (g) Test and repair.
(h) Open solenoid pull-in wire. (h) Test and replace solenoid if neces
sary.
STARTER FAILS AND (a) Weak battery or dead cell in battery. (a) Test for specified gravity. Recharge
LIGHTS DIM or replace battery as required.
(b) Loose or corroded battery cable ter- (b) Clean terminals and clamps, replace
minals. if necessary. Apply a light film of pet
rolatum to terminals after tightening.
(c) Internal ground in windings. (c) Test and repair starter.
(d) Grounded starter fields. (d) Test and repair starter.
(e) Armature rubbing on pole shoes. (e) Test and repair starter.
STARTER TURNS, BUT (a) Starter clutch slipping. (a) Replace clutch unit.
ENGINE DOES NOT (b) Broken clutch housing. (b) Test and repair starter.
ENGAGE (c) Pinion shaft rusted, dirty or dry, due (c) Clean, test and lubricate.
to lack of lubrication.
(d) Engine basic timing wrong. (d) Check engine basic timing and condi
tion of distributor rotor and cap.
(e) Broken teeth on engine ring gear. (e) Replace ring gear. Inspect teeth on
starter clutch pinion.
STARTER RELAY DOES (a) Batttery discharged. (a) Recharge or replace battery.
NOT CLOSE (b) Faulty wiring. (b) Test for open circuit, wire between
starter relay ground terminal post and
neutral starter switch (automatic
transmission only). Also test for open
circuit; wire between ignition-starter
switch and ignition terminal and start
er relay.
(c) Neutral starter switch on automatic (c) Test and replace the switch if neces
transmission faulty. sary.
(d) Starter relay faulty. (d) Test and replace if necessary.
RELAY OPERATES BUT (a) Faulty wiring. (a) Test for open circuit wire between
SOLENOID DOES NOT starter-relay solenoid terminal and
solenoid terminal post.
(b) Faulty solenoid switch or connections. (b) Test for loose terminal connections
between solenoid and starter field.
(c) Solenoid switch contacts corroded. (c) Test and replace solenoid if neces
sary.
(d) Broken lead or a loose connection in (d) Test and replace solenoid if neces
side solenoid switch (brush holder sary.
plate).
SOLENOID PLUNGER (a) Battery low. (a) Test for specific gravity of battery.
VIBRATES BACK AND Replace or recharge battery.
FORTH WHEN SWITCH (b) Faulty wiring. (b) Test for loose connections at relay,
IS ENGAGED ignition-starter switch and solenoid.
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PLUNGER ASSEMBLY
NU429A
SERVICE PROCEDURES
AMPERAGE DRAW TEST (with Starter Tester) “OFF” position.
Turn voltm eter Selector Switch to 16 Volt position.
Check battery electrolyte gravity with a reliable Connect heavy Positive am m eter lead (Red) to Positive
hydrom eter. Gravity should be not less than 1.220 battery term inal. Connect heavy Negative am m eter
(tem perature corrected). Or see that battery passes lead (Black) to Negative battery term inal.
the High Rate Discharge Test shown in the “Battery” Connect Positive voltm eter lead (Red) to Positive
section of this manual. battery term inal. Connect Negative voltm eter lead
Turn B attery—Starter Tester CONTROL KNOB to (Black) to Negative battery term inal.
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DISCONNECT ignition prim ary lead from ignition RESISTANCE TEST
ballast resistor, or prim ary wire from either side of
coil, to prevent engine from starting. (1) Test battery electrolyte specific gravity. Spe
Crank engine with a remote control starter switch cific gravity should be 1.220 or above.
and observe Exact reading on Voltmeter. Stop crank (2) Disconnect positive battery lead from battery
ing engine. W ithout cranking engine, turn tester term inal post. Connect an 0 to 300 scale am m eter be
CONTROL KNOB clockwise until voltm eter reads tween disconnected lead and battery term inal post.
Exactly the same as when engine was being cranked (3) Connect a test voltm eter with 10 volt scale divi
with the rem ote control starter switch. Am m eter now sion between battery positive post and starter switch
indicates starter amperage draw. Check specifica term inal at starter solenoid.
tions. Engine should be up to operating temperature. (4) Crank engine and observe reading on voltm eter
Extremely heavy oil or a tight engine will increase and ammeter. Voltage should not exceed .3 volt. A
starter amperage draw. voltage reading that exceeds .3 volt indicates there is
high resistance caused from loose circuit connections,
INSULATED CIRCUIT TEST a faulty cable, burned starter relay or burned sole
noid switch contacts. A current that is high and is
(1) Test battery electrolyte specific gravity. Spe combined with slow cranking speed, indicates starter
cific gravity should be 1.220 or above. If battery spe should be removed and repaired.
cific gravity is below 1.220, recharge battery to full
charge before proceeding with test. GROUND CIRCUIT TEST
(2) Turn voltm eter selector switch to 4 volt posi
tion. (1) Connect test voltm eter positive lead to starter
(3) Disconnect ignition coil secondary cable. housing and voltm eter negative lead to battery nega
(4) Connect voltm eter positive lead to battery posi tive post.
tive post and voltm eter negative lead to solenoid con (2) Crank engine with a rem ote control starter
nector which connects to the starter field coils. switch and observe voltm eter reading. Voltmeter
The voltm eter will read off scale to the right until reading should not exceed .2 volt. A reading of .2 volt
starter is actuated. or less indicates the resistance of the ground cable
(5) Connect rem ote control switch to battery and and connections is normal. If voltm eter reading is
solenoid term inal of starter relay. more than .2 volt, it indicates excessive voltage loss in
(6) Crank engine with a rem ote starter control starter ground circuit. Make the following tests to Iso
starter switch and observe voltm eter reading. Volt late point of excessive voltage loss. Repeating test at
m eter reading should not exceed .3 volt. A voltm eter each connection.
reading .3 volt or less indicates voltage drop is normal (a) Starter drive housing.
in cables, starter relay switch solenoid switch and (b) Cable term inal at engine.
connections between battery and starter motor. See (c) Cable clamp at battery.
A small change will occur each time a normal por
“S tarter Ground Circuit Test.”
tion of circuit is removed from the test. A definite
If voltm eter reading is more than .3 volt, it indi
change in voltm eter reading indicates that last part
cates high resistance in starter insulated circuit.
eliminated in the test is at fault.
Make following tests to isolate point of excessive
Maximum allowable voltage loss is as follows:
voltage loss:
Battery ground cable .2 volt
(a) Remove voltm eter lead from solenoid connector
Engine ground circuit .1 volt
and connect to the following points, repeating test at
Each connection .0 volt
each connection. Starter term inal of solenoid, battery
term inal of solenoid, battery cable term inal at sole
noid, starter relay and cable clamp at the battery.
REMOVING THE STARTER
(b) A small change will occur each time a norm al (1) Disconnect ground cable at battery.
portion of the circuit is removed from test. A def (2) Remove cable at starter.
inite change in the voltm eter reading indicates th at (3) Disconnect solenoid lead wires at solenoid te r
the last part elim inated in test is at fault. minals.
Maximum allowable voltage loss is as follows: (4) Remove one stud nut and one bolt attaching
Battery insulated cable .2 volt starter to flywheel housing, slide automatic transm is
Solenoid switch .1 volt
Each connection .0 volt sion oil cooler tube bracket off the stud (if so
Replace faulty cables. Clean and tighten all con equipped) and remove the starter. Do not damage
nections. cylinder block seal.
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TESTING THE STARTER (Bench Test)
5CL2NOID LEAD WIRE
Free Running Test
(1) Place starter in a vise and connect a fully
charged, 12 volt battery to starter as follows:
(a) Connect a test am m eter (100 amperes scale) and
a carbon pile rheostat in series with battery positive
post and starter term inal.
(b) Connect a voltm eter (15 volt scale) across
starter.
(c) Rotate carbon pile to full-resistance position.
(d) Connect battery cable from battery negative
post to starter frame. NU431A
(e) Adjust the rheostat until battery voltage shown Fig. 3 —Unw inding or W in din g Solenoid Lead W ire
on voltm eter reads 11 volts. Amperage draw should
be as shown in specifications. of terminal screw, Fig. 2.
(4) Support brush term inal by placing a finger be
Locked-Resistance Test hind the term inal and remove term inal screw.
(1) Install sta rte r in a test bench. (5) Unwrap shunt field coil lead from starter brush
(2) Follow instructions of test equipm ent manufac terminal. Starter brush holder plate with starter brush
turers and test starter against following specifications. terminal, contact and brushes is serviced as an as
W ith applied battery voltage adjusted to 4 volts. sembly.
Amperage draw should be as shown in specifications. (6) Unwrap solenoid lead wire and unwind wire
from starter brush term inal (Fig. 3).
DISASSEMBLING THE STARTER (7) Remove nut (11/32 wrench), steel washer and
insulating washer from solenoid term inal.
(1) Place the starter gear housing in a vise equipped (8) Straighten solenoid wire and remove brush
with soft jaws. Use the vise as support fixture only. holder plate with brushes and solenoid as an assem
DO NOT clamp. bly.
(2) Remove two through bolts and starter end head (9) Remove solenoid assembly from gear housing
assembly.
well (Fig. 4).
(3) Carefully pull arm ature up and out of gear
(10) Remove nut from starter battery terminal.
housing and starter fram e and field assembly. Re
(11) Remove starter battery term inal from holder
move steel and fiber thrust washer. The wire of shunt
field coil is wrapped on the brush terminal. One set plate.
of brushes are connected to this terminal. The other (12) Remove solenoid contact and plunger from
pair of brushes is attached to the series field coils by solenoid.
means of a terminal screw. Carefully pull frame and (13) Remove solenoid return spring from well of
field assembly up just enough to expose terminal solenoid housing moving core.
screw and wire wrap connection of shunt field at (14) Remove dust cover from gear housing (Fig. 5).
brush terminal. Place two wood blocks between starter (15) Release retainer clip that positions driven gear
frame and starter gear housing to facilitate removal on pinion shaft (Fig. 6).
CONTACT
WASHER .SOLENOID RELAY SCREW
-fc;
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PJNiON SHAFT
STAR^R g 5V=R m m m
H O US! N G
■: ^ h k
>IP ; CLUTCH ASSEMBLY - #
M ir — PINION SHAFT
DP.iVEN GEAR
NO 209 ND211
V'AShEaS
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SHIFTING FORK
PIN
— '
M O VIN G COirz
\ ■
\.
r i
'• fl, i.«r-
.-
SP 3563—
Testing A rm atu re fo r Short Circuit SP 3f>63
Place arm ature in growler and hold a thin steel
blade parallel to the core and just above it, while 1USHING
slowly rotating arm ature in growler. A shorted arm a .j-BUSHING
ture will cause blade to vibrate and be attracted to SP*3566
the core. Replace arm ature if shorted. ^SP-3579
Testing A rm atu re fo r Ground
Contact arm ature shaft and each of the commuta
tor riser bars with a pair of test lamp test probes. If
lamp lights, it indicates a grounded arm ature. Replace
grounded arm ature.
NK74
Testing C om m utator Run-Out, a n d Refacing REMOVING INSTALLING
Place arm ature in pair of “V” blocks and m easure
runout with dial indicator. Measure both shaft and
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If lamp lights, it indicates that field coils are ground
ed and require replacem ent. SP-3562
^ SP-88
A pole shoe impact screwdriver Tool C-3475 should SP-88
5P-3563
be used to remove and install field coils to prevent
SP-3565-A
damage to pole shoe screws and for proper tightening.
Pole shoes that are loose and not properly seated may
cause arm ature core to rub on pole shoes. Make sure
area between the leads and starter frame is clean.
Peen new rivet securely to insure a good electrical I! j it
U RUSHING j- . - k
contact. (
SP 3 6 6 /— ^
SERVICING THE STARTER BUSHINGS SP 3VQ NK75
REMOVING INSTALLI NG
Inspect arm ature shaft bearing, pinion shaft sur Fig . 13 —Removing and Installing Pinion Housing
faces and bushings for wear. Try the bushings for Drive Shaft Bushing
wear by inserting the shafts and test for side play.
Pre-sized starting motor bushings are available as and a solvent will wash lubricant from the clutch.
service bushings. Use Tool C-3944 to remove old bush The starter clutch outer housing and pinion gear
ings and install the new. No burnishing or reaming may be cleaned with a cloth moistened with a clean
is required to fit pre-sized bushings. ing solvent and wiped dry with a clean dry cloth.
The C-3944 Tool and its adaptors are designed to Rotate the pinion. Pinion gear should rotate smooth
service all of the gear reduction m otor bushings with ly in one direction (not necessarily easily), but should
the exception of the end head bushing. End head bush not rotate in opposite direction. If starter clutch unit
ing and end head are serviced as an assembly. does not function properly, or pinion is worn, chipped
Remove and install bushings, (Figs. 12, 13 and 14). or burred, replace starter clutch unit.
SERVICING THE STARTER CLUTCH UNIT ASSEMBLING THE STARTER (Fig. 15)
Do not immerse starter clutch unit in a cleaning The shifter fork consists of two spring steel plates
solvent. Starter clutch is pre-lubricated at the factory assembled with two rivets. There should be approxi<
-SP-3562
SP-88*. b-;.:. .SP-3565-A
T 9 f~
;g
T ilth ■
M ir I
f i :
a :
*| | j -BUSHING
: f r § -
SP-3579'
INSTALLING ilM O V I N G um
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^N U T (2) ^HOUSING
■ SCREW NUT ASSEMBLY
Pi N § ? RE SOLENOID \
CONTACT
'*99#
n\ r r r
r
WASHER
RING CLUTCH FORK
*,55|!5SpSCREW
^ {2) '
FRAME
THRUST WASHER
WASHER (STEEL)
4W \
-V WASHER WASHER
FIELD COILS
INSULATOR
SCREW (4)
WASHER (FIBER)
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SHIFTING FORK
PIN CLUTCH ASSEMBLY
MOVING CORE
w m m m
v - * -rsv-r *»s'
/ - > / ■ .I-:",-**.
<fv 7
rj ’ NU435A
ND 215 SHIFTING FORK
Fig. 19—Soldering Solenoid W inding Lead to
Brush Term inal
Fig. 17—Shifter Fork a n d Clutch A rrangem ent
(14) Install brush holder to solenoid attaching
ing, disassemble contact switch plunger assembly and screws.
reverse the washer. (15) Carefully enter solenoid coil and brush plate
(9) Install solenoid contact plunger assembly into assembly into bore of gear housing and position brush
solenoid and reform double wires to allow for proper plate assembly into starter gear housing (Fig. 20) and
entry of term inal stud into brush holder with the install housing attaching nuts. Tighten securely.
double wires curved around the contactor. (16) Position brushes with arm ature th ru st washer
CAUTION: The contactor must not touch the double as shown in Figure 19. This will hold brushes out and
wires when solenoid is energized after assembly is facilitate proper installation of arm ature.
completed (Fig. 4). (17) Solder shunt coil lead wire to starter brush
Make sure contact spring is positioned on the shaft term inal (Fig. 21).
of the solenoid contact plunger assembly. (18) Install brush term inal screw (Fig. 2).
(10) Assemble battery term inal stud in brush hold (19) Position field fram e to the exact position on
er. gear housing and enter arm ature into field fram e and
Inspect condition of the contacts in brush holder sta rte r gear housing (Fig. 22); carefully engaging
plate. If contacts are badly burned, replace brush splines of shaft with reduction gear by rotating arm a
holder with brushes and contacts as an assembly. tu re slightly to engage the splines.
(11) Position seal on brush holder plate. (20) Install thrust washer (fiber) and washer (steel)
(12) Enter solenoid lead wire through hole in brush on arm ature shaft.
holder (Fig. 18) and install solenoid stud, insulating (21) Position starter end head assembly and install
washer, flat washer and nut.
(13) W rap solenoid lead wire tightly around brush
term inal post as shown in Figure 19 and solder se
curely with a high tem perature resin core solder and
resin flux.
STARTER BATTERY TERMINAL SOLENOID
LEAD RUBBER
WIRE WASHER-
GASKET
N U 436
BRUSH HOLDER NU434A
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SOLDER
SOLDERING GUN
BRUSH
TERMINAL POST
i NK81B
GENERAL INFORMATION
The alternator (Figs. 1 and 2) is fundam entally an minal.
A.C. current generator, with six (6) built-in silicon The main components of the alternator are the
rectifiers, that convert A.C. current into D.C. current. rotor, stator, rectifiers, the end shields and the drive
D.C. current is available at the “output” “BAT” ter- pulley.
SERVICE DIAGNOSIS
_________ Condition_________ ____ _______ Possible Cause____________________Correction____________________
ALTERNATOR FAILS TO (a) Alternator drive belt loose. (a) Adjust drive belt to Specifications.
CHARGE (No Output or (b) Worn brushes and/or slip rings. (b) Install new brushes and/or slip rings.
Low Output) (c) Sticking brushes. (c) Clean slip rings and brush holders.
Install new brushes if necessary.
(d) Open field circuit. (d) Test all the field circuit connections,
and correct as required.
(e) Open charging circuit. (e) Inspect all connections in charging
circuit, and correct as required.
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______ Condition Possible Cause
(f) Open circuit in stator windings. (f) Remove alternator and disassemble.
Test stator windings. Install new
stator if necessary.
(g) Open rectifiers. (g) Remove alternator and disassemble.
Test the rectifiers. Install new recti
fiers if necessary.
LOW, UNSTEADY (a) High resistance in body to engine (a) Tighten ground lead connections. In
CHARGING RATE ground lead. stall new ground lead if necessary.
(b) Alternator drive belt loose. (b) Adjust alternator drive belt.
(c) High resistance at battery terminals. (c) Clean and tighten battery terminals.
(d) High resistance in charging circuit. (d) Test charging circuit resistance. Cor
rect as required.
(e) Open stator winding. (e) Remove and disassemble alternator.
Test stator windings. Install new sta
tor if necessary.
LOW OUTPUT AND (a) High resistance in charging circuit. (a) Test charging circuit resistance and
A LOW BATTERY correct as required.
(b) Shorted rectifier. Open rectifier. (b) Perform current output test. Test the
rectifiers and install new rectifiers as
required. Remove and disassemble
the alternator.
(c) Grounded stator windings. (c) Remove and disassemble alternator.
Test stator windings. Install new
stator if necessary.
EXCESSIVE CHARGING (a) Faulty ignition switch. (a) Install new ignition switch.
RATE TO A FULLY (b) Regulator base improperly grounded. (b) Connect regulator base to a good
CHARGED BATTERY ground.
(c) Faulty voltage regulator. (c) Test voltage regulator. Replace as
necessary.
NOISY ALTERNATOR (a) Alternator mounting loose. (a) Properly install and tighten alternator
mounting.
(b) Worn or frayed drive belt. (b) Install a new drive belt and adjust
to specifications.
(c) Worn bearings. (c) Remove and disassemble alternator.
Install new bearing as required.
(d) Interference between rotor fan and (d) Remove and disassemble alternator.
stator leads or rectifiers. Correct interference as required.
(e) Rotor or rotor fan damaged. (e) Remove and disassemble alternator.
Install new rotor.
(f) Open or shorted rectifier. (f) Remove and disassemble alternator.
Test rectifiers. Install new rectifiers
as required.
(g) Open or shorted winding in stator. (g) Remove and disassemble alternator.
Test stator windings. Install new
stator if necessary.
EXCESSIVE AMMETER (a) High resistance in the alternator and (a) Clean and tighten all connections as
FLUCTUATION voltage regulator circuit. necessary.
SERVICE PROCEDURES
DESCRIPTION OF ELECTRONIC VOLTAGE lator and the feedback from the ignition system is the
REGULATOR OPERATION highest level ripple on the car electrical system. Once
the frequency of operation is established by the igni
The silicon transistor voltage regulator is a switch tion system, the voltage regulator controls the voltage
ing voltage regulator which regulates voltage by vary by varying the on and off time between the ignition
ing the duty cycle of a series of voltage pulses to the firings. While the voltage across the field and the
alternator field. The frequency of the voltage pulses current through the output transistor is switching
is controlled by the ignition frequency of the engine, completely on and off, the field current of the alter
because the voltage regulator is a peak sensing regu nator is only cycling through increm ental changes.
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SPACER
S H IE L D - INSULATOR
HEATSINK
SHIELD
CAPACITOR:
NUT
I SCREW
WASHER
STATOR
WASHER
R J JS W IK JQ
1 r SUP RINGS
V i-* *
1 I
*
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RECTIFIER I
RETAINER ROTOR W ASHER
R E T A IN E R -
\ BRUSH P A C K A G E THRU BOLT (3)
\ IN SE R T B E A R IN G
HBRUSH
\ ASSEMBLY
N Y L O N W ASHER
SC R E W ASSEM BLY
B E A R IN G
ND240E
Fig. I —Isolated Field A ltern ato r (Disassembled V iew )
Since the inductance of the alternator field has a ly after starting, reduce engine speed to idle.
relatively long time constant with respect to the oper (10) A djust the engine speed and carbon pile to
ating frequency of the voltage regulator, there is only obtain 20 amperes flowing in the circuit. Observe the
enough time allowed for a increm ental decrease in voltm eter reading. The voltm eter reading should not
field current through the suppression diode during exceed .7 volts. If a higher voltage drop is indicated,
the off tim e of the transistor. inspect, clean and tighten all connections in the charg
ing circuit. A voltage drop test may be perform ed at
ISOLATED FIELD ALTERNATOR each connection to locate the connection with exces
sive resistance. If the charging circuit resistance
CHARGING CIRCUIT RESISTANCE TEST tested satisfactorily, reduce engine speed, turn off
AND CURRENT OUTPUT TEST carbon pile and tu rn off ignition switch.
(1) Disconnect the battery ground cable. FIELD BRUSH (H O R IZ O N T A L K j* HEAT SINK
(2) Disconnect the “Batt” lead at the alternator NEGATIVE * | ' \ . » . • OUTPUT TERMINAL
output term inal. ( DIODES) RECTIFIERS f SCREW
(3) Connect a 0-75 ampere scale D.C. am m eter in * . #; \> . - x
series between the alternator “B att” term inal and the
disconnected “B att” lead (Fig. 3). FIELD B R U S H - fL .. \
(4) Connect the positive lead of a test voltm eter to (VERTICAL) A
the disconnected “Batt” lead. Connect the negative
\
lead of the test voltm eter to battery positive term inal. POSITIVE
(5) Disconnect the field lead from the alternator. (DIODES)
- ~CT;rlER$
(6) Connect a “jum per” lead from the alternator
field term inal to ground.
(7) Connect an engine tachometer. Connect the bat
4, BEARING
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NU834A
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(11) Then, to make the current output test, move and carbon pile.
the negative lead of the voltm eter to a good ground. (18) Remove jum per between alternator field and
Move the positive lead of the voltm eter to “B att” ground. Connect the field wire to th e alternator field
term inal of the alternator (Fig. 4). term inal.
(12) Start and operate the engine at idle. Imme (19) Connect the battery ground cable.
diately after starting, reduce engine speed to idle.
(13) Adjust the carbon pile and engine speed in ELECTRONIC VOLTAGE REGULATOR
increments until a speed of 1250 rpm and a voltm eter
reading of 15 volts is obtained. VOLTAGE REGULATOR TEST (When Tester
(14) CAUTION: Incremental increases in engine C-4133 is Not Available)
speed should not be large enough to allow voltage to
go above 16 volts. (1) Clean the battery term inals and check the spe
(15) Observe the reading on the test amm eter. The cific gravity. It should be above 1.200 to allow a
output current should be within the limits shown in prom pt regulated voltage check.
the “Specifications”. If the output is slightly less (5 If the specific gravity is below 1.200, charge or use
to 7 amperes) than specified, it may be an indication another battery and do not leave the uncharged bat
of possible “open” rectifier or other alternator in tery in the circuit.
ternal problems. If the output is considerably lower (2) Connect the positive lead from a voltm eter to
than that specified, it may be an indication of a pos the ignition Num ber one (1) term inal of the ballast
sible “shorted” rectifier or other internal problems. resistor. (The Ignition Num ber one (1) term inal of the
In either case, the alternator should be rem oved and ballast resistor is the end which has one or two blue
tested on the bench before disassembly. If the alter wires connected to it). The other end, Ignition Num
nator current output tested satisfactorily, reduce en ber two (2), will have a brown and blue wire or just a
gine speed, turn off carbon pile, and tu rn off ignition brown wire connected to it (Fig. 5).
switch. (3) Connect the negative lead from the voltm eter
(16) Disconnect battery ground cable. to a good vehicle body ground.
(17) Remove test ammeter, voltm eter, tachom eter, (4) Start and operate engine at 1250 rpm with all
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lights and accessories turned off. Check voltmeter,
the regulator is working properly if the voltage read
^ ^ ^-.VOLTAGE REGULATOR p
ings are in accordance with the following chart.
AMBIENT TEMPERATURE \ . TtSTE3 CONNECTOR ..''l-'-. -y •>
NEAR VOLTAGE REGULATOR VOLTAGE RANGE
—20° F 14.3 15.3 ‘Vs-V-»
'*L"s 1 : -;1: : 1
80° F 13.8 14.4
140° F 13.3 14.0
Above 140°F Less than 13.8
It is normal for the car am m eter to show an imme
diate charge and then gradually return to normal
position. The duration the am m eter hand rem ains to
the right will be dependent on the length of cranking ‘ •C'.T,v -Vi;- rOSiT.ON'S
time.
(5) If the voltage is below limits, proceed as follows:
(a) Check for a good voltage regulator ground.
Check for voltage drop between cover of voltage regu TES'fR BUT (O n
lator and body on low voltage scale of voltmeter.
PY938,
(b) Turn off ignition switch and disconnect voltage
regulator connector. Fig. 6—V o ltage Regulator Test (Depressing Test
(c) Turn on the ignition switch, but do not start Button and Black Button " A " )
car, check for battery voltage at the wiring harness (4) Plug connector of voltage regulator tester on
term inal connected to the blue and green leads. Dis voltage regulator on vehicle.
connect wiring harness from voltage regulator when (5) Place knob on the tester to the regulator test
checking the leads.
position.
Turn off ignition switch. If voltage is not present at (6) Press the test button on the voltage regulator
either lead, the problem is in the vehicle wiring or tester. The voltage reading should be in accordance
alternator field circuit. DO NOT DISTORT TERMI with the following:
NALS WITH VOLTMETER PROBE.
(a) If the voltage regulator tem perature is at room
(d) If the previous steps, 5(a) through 5(c) tested tem perature (80°F.) or above, the m eter reading
satisfactorily, change the voltage regulator and repeat
should be in the green or yellow range.
step 4.
(b) If the voltage regulator is at room tem perature
(6) If the voltage is slightly above the limits shown
(80 °F.) or below, the m eter reading should be in the
in chart or is fluctuating, proceed as follows:
green or blue range.
(a) Check ground between voltage regulator and
vehicle body.
VOLTAGE REGULATOR
(b) Check ground between vehicle body and engine.
(c) Check ignition switch circuit between battery ,GROUND
. WIRE
..
TESTER CONNECTOR
term inal of ignition switch and voltage regulator.
(7) If the voltage is more than one-half (1/2) a volt
!
above limits shown in chart, change the voltage regu y'-i-fX' ' If*
t ' ■' xyi'siiy-’w &*..J 4a. *
lator and repeat step 4.
(8) Remove the test voltmeter. LINE
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(7) While holding the test button in, depress Black a slip ring and rem aining test probe to the end shield.
Button (A) (Fig. 6), the m eter reading should rem ain If lamp lights, rotor assembly is grounded and re
within the limits of step 6. quires replacem ent. If lamp does not light after re
(8) While holding the test button in, depress Red moving the field brush and separating the end shields,
Button (B) (Fig. 7), the m eter should read above the the cause of the ground at the first ground test was a
red line. grounded brush.
(9) If all tests rem ain within limits the voltage regu (4) Examine plastic insulator and screw. Screw is a
lator is good. special size and m ust not be substituted.
The tester may be used as a D.C. Voltmeter by (5) Install brush holders, terminals, insulated wash
placing tester knob in either the 18 volt or 1.8 volt ers, shake proof washers and screws. If the parts were
position. Use the red probe and black clip leads for not assembled in this order this could be the cause
testing. of the ground condition.
If alternator perform ance does not m eet current To prevent possible damage to brush assemblies,
output specifications limits, it will have to be removed they should be removed before proceeding with dis
and disassembled for further test and servicing. assembly of the alternator. The field brushes are
m ounted in plastic holders that position the brushes
(1) Disconnect battery ground cable at battery
against the slip rings of the rotor.
negative term inal.
(1) Remove retaining screw lockwasher, insulated
(2) Disconnect alternator output “BATT” and field
washer, and field term inal, and carefully lift plastic
“FLD” leads and disconnect ground wire. holder containing spring and brush assembly from
(3) Remove alternator m ounting bolts and remove end housing (Fig. 8).
alternator. (2) Remove the brush screws, insulating nylon
washers and lift brush assemblies from end shield.
BENCH TESTS CAUTION: Stator is laminated, do not burr stator or
end shield.
Field Coil D r a w (3) Remove through bolts and pry between the sta
If alternator field coil draw has not been tested on tor and drive end shield with blade of a screw driver
vehicle it may be tested on test bench as follows: (Fig. 9). Carefully separate drive end shield, pulley
(1) Connect a wire between one field term inal of and rotor assembly away from stator and rectifier
the alternator and the positive term inal of a fully shield assembly.
charged battery. Connect test am m eter positive lead
to the other field term inal of the alternator and the Testing the Rectifiers w ith Tool C-3829
negative lead to the battery negative terminal. The Rectifier T ester Tool C-3829 provides a quick,
(2) Slowly rotate alternator rotor by hand. Observe simple and accurate test of the alternator rectifiers
amm eter reading. Field coil draw should be 2.3 am without the necessity of disconnecting soldered rec-
peres to 2.7 am peres at 12 volts. A low rotor coil
; BRUSH ASSEMBLY (VERTICAL)
draw is an indication of high resistance in field coil
circuit, (brushes, slip rings, or rotor coil). A higher ■M P H 1 (
rotor coil draw indicates possible shorted rotor coil /
or grounded rotor.
fo r Ground
(1) To test internal field circuit for ground, touch
one test probe from a 110 volt test lamp to one of the
alternator field brush term inals and rem aining test
probe to the end shield. If rotor assembly or field m m
brush is not grounded, lamp will not light.
(2) If lamp lights, remove field brush assem
blies (noting how the parts are assembled) and sepa
rate the end shields by removing the three through
NU350A
bolts.
(3) Again test by placing one of the test probes to Fig. 8 —R e m o v in g m in s ta llin g Field Brushes
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ALTFRNATOP PART NUMBER
TOOL is- '
TEST PROD
DRIVE END NEGATIVE CASE \
SHIELD m RECTIFIERS
,:r V / \ n
f /I h : S«Sr
l|f !jW
SK
* 'V l'T sg*l
J ^
1f
- W
- ! ' RcCTIFiER END
STATOR — SHIELD GROUND LEAD
ND108A TO END HOUSING
NU353A
Fig. 9 —Separating Drive End Shield From Stator Fig. 11—Testing N e g a tiv e Rectifiers
tifier leads. With alternator rectifier end shield sepa When one rectifier is open it will read approxim ate
rated from drive end housing proceed with rectifier ly one ampere, and two good rectifiers will read with
test as follows: in satisfactory range.
Positive Case Rectifier Test (Fig. 10) N e g a tiv e Case R ectifier Test (Fig. 11)
(a) Place alternator on an insulated surface. Con (a) Connect test lead clip to rectifier end housing.
nect test lead clip to the alternator (BAT) output te r (b) Touch exposed connection of each of the nega
minal. tive case rectifiers with test probe.
(b) Plug in Tool C-3829 power source lead into a CAUTION: Do not break the sealing around rectifier
110 volt A.C. power supply. Touch exposed bare metal lead wire. The sealing material is for protection
connections of each of the positive case rectifiers, with against corrosion. Always touch test probe to exposed
test prod. metal connection nearest rectifier.
The reading for satisfactory rectifiers will be 1-3/4 Test specifications are the same, and test results
am peres or more. Reading should be approximately will be approximately the same as for positive case
the same for three rectifiers. rectifiers, except m eter will read on opposite side of
When two rectifiers are good and one is shorted, scale.
reading taken at the good rectifiers will be low, and
reading at shorted rectifier will be zero. Disconnect TESTING RECTIFIERS AND STATOR (When
lead to the rectifier reading zero and retest. The read Tool C-3829 is not available)
ing of the good rectifiers will now be within satisfac
tory range. (a) Separate the three (3) stator leads at “Y” con
nection (Fig. 12). Cut stator connection as close to
connector as possible. If they are cut too short it may
TEST PROD be difficult to get them together again for soldering.
POSITIVE CASE
RECTIFIERS
(b) Test rectifiers with a 12 volt battery and a test
TESTER
lamp equipped with a num ber 67 bulb (4 candle
power) by connecting one side of test lamp to positive
battery post; other side of test lamp to a test probe
with other test probe connected to the negative bat
tery post.
45 * - J»l (c) Contact outer case of rectifier with one probe
and other probe to wire in center of rectifier (Fig. 13).
(d) Reverse the probes, moving probe from recti
fier outer case to rectifier wire, and the probe from
W
/
TO ALTERNATOR
rectifier wire to rectifier outer case.
"B A T " TERMINAL If test lamp “lights” in one direction but does “not
light” in other direction, rectifier is satisfactory. If
lamp lights in “both directions,” rectifier is “short-
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TO 110 VOLT
••>\ WOOD
POWER SOURCE
TO TEST P'?OD •/
_.
■ M--'
CAPACITOR ;
\
■ LAMP
"Y"" CONNECTION ~ ;* S jT "
V /
(OPENED) . ■" NU354A V NU356A
Fig. 12 —Separating the Three Stator Leads Fig. 14—Testing Stator fo r Ground
ed.” If test lamp does “not light” in either direction, ed” or “open” . If stator tested satisfactorily, tin the
rectifier is “open.” Possible cause of an open or blown three stator wires and resolder. Tape connector and
rectifier is a faulty capacitor or a battery that has cement down to stator to make sure the “Y” connector
been installed in reverse polarity. If battery is in does not short out to end shield. If the rectifiers must
stalled properly and the rectifiers are open, test capa be replaced, unsolder the rectifier wire from the stator
citor capacity—.50 microfarad (plus or minus 20%). lead wire at the soldered joint. When removing recti
(e) Unsolder rectifier leads from stator leads. Do fiers, it is necessary to support end shield and/or heat
not blow solder off with air—fine particles of solder sink to prevent damage to these castings.
can short other rectifiers. (4) Place Rectifier Removing and Installing Press in
(f) Test stator for grounds using a 110 volt test a vise and support end shield on clamp anvil under
lamp (Fig. 14). Use wood slats to insulate the stator rectifier to be removed (Fig. 16). Make sure bore of
from rectifier shield. Contact one prod of test lamp to tool completely surrounds rectifier during removal
stator pole fram e, and contact the other prod to each process.
of the three stator leads. Test lamp should “not light.” (5) Carefully apply pressure with tool pressure
If test lamp lights, stator windings are “grounded.” screw until support tool, rectifier end shield, and re
(g) Test stator windings for continuity, by contact mover pin, and remover adapter are in alignment then
ing one prod of test lamp to all three stator leads press the rectifier out of end shield or heat sink.
at “Y” connection. Contact each of the three stator (6) The pulley is an interference fit on rotor shaft,
leads (disconnected from rectifiers). Test lamp should remove pulley with Puller Tool C-4068 (Fig. 17).
“light” when prod contacts each of th e three leads. If (7) Pry drive end bearing spring retainer from end
lamp does not light stator winding is “open” (Fig. 15). shield with a screwdriver (Fig. 18).
(h) Install a new stator if stator tested is “ground- (8) Support end shield and tap rotor shaft with a
TEST LAMP
TEST LAMP
NO . 67 BULB
NU357A
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FIXTURE BEARING RETAiNER
ND111
NR579
INSULATOR
— HEAT SINK
PULLEY*
■# /* » 1-r.,.
% NR578
ND113B
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-C -3770
BEARING
-SP-3925
CUT V -
CHiSEL
NF65A ND526A
Fig. 2 1—Removing Rectifier End Shield Bearing Fig. 2 3 —Cutting Old Slip Rings
end fram e needle bearing, protect end shield by sup (c) Use a chisel to cut through the copper of both
porting shield with Tool C-3925 when pressing bear slip rings at opposite points (180° apart) (Fig. 23).
ing out with Tool C-3770A (Fig. 21). Make sure notches (d) Break the plastic insulator and remove the old
in tool clear raised section of heat sink. The new slip ring.
bearing is prelubricated and no additional lubricant (e) Clean away dirt and particles of old slip ring
should be added, as an excessive amount of lubricant from rotor.
wifi contaminate the slip rings and cause premature (f) Scrape ends of field coil wires clean for good
brush and rotor failures. electrical contact.
(g) Position field coil wires so as to clear path for
REPLACING SLIP RINGS new slip ring.
(h) Position new slip ring carefully on rotor shaft
Slip rings that are damaged can be replaced as fol to insure that slip ring lugs will be in proper position
lows: for connecting field coil wires (Fig. 24).
(a) Remove rotor plastic grease retainer. (i) Place installing Tool C-3900 over rotor shaft
(b) Unwind field coil leads from slip ring lugs (Fig. and position rotor, slip ring and tool assembly in
22) being careful not to break the wire leads. arbor press (Fig. 25). Press slip ring on shaft. When
slip ring is bottomed on rotor fan, the field lead wire
SUP RING SUP RING
SQ ih f p i l i a SOLDER LUG (insulated brush ring) should clear the access hole, the
fan and pole piece.
(j) Tin field coil lead wires.
(k) Coil each field lead wire around the slip ring lug,
starting first wrap against shoulder of lug and wind
ing outward. Solder with resin core solder (Fig. 26).
LEAD W IX t,
SLIP
SLIP RINGS- ------- RING
LUG
KOTOR' NP366A
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PRESS- TOOL TOOL
PRESS
LEAD W iR i
LEAD WIRE-
GREASE RETAINER SLIP RINGS
SUP R 1 N G $ ~ *^;
PRESS'
PRESS
§ ■a H i
BHHHI
i
NP369
FIXTURE
L INST A l LING
■ p 'X ADAPTER
1 INSTALLING
SUPPORT
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H PRESSING. TOOLs
SEARING
r>;" STA IN E R
/, - ^ : 1 W
' / ; c ;:
Y ' •■ lix L»^ ■?,■.& j- S
.*•'■•';
\ ■ \ * * ............
■ \
DRIVE END SHIELD
STA T O i LEAD.
ROTOR
RECTIFIER. LEAD ’NU359A. ND116
■PRESS
DRIVE .:KO — r.LLE Y
‘" ■ — TOOL SHIELD
CAPACITOR-
•BEARING
STATOR >TO O L
3OTOR
ROTOR
PRESS SHAFT ~~ • -
NU360 ND117
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(10) The alternators have the capacitor mounted bolts evenly to 20-30 inch-pounds.
internally. Make sure heat sink insulator is in place (17) Install field brushes in holder. Place one verti
(Fig. 20). cal and one horizontal holder in rectifier end shield.
(11) Install output term inal screw and capacitor (18) Place nylon washer on each term inal and in
through heat sink and end shield. stall lockwashers and attaching screws.
(12) Install insulating washers, lockwashers and (19) Rotate pulley slowly by hand to be sure rotor
lock nuts. fans do not hit rectifiers, capacitor lead, and stator
(13) Make sure heat sink and insulator are in posi connections.
tion then tighten lock nut. (20) Install alternator and adjust drive belt to
(14) Position stator on rectifier end shield. specifications.
(15) Position rotor and end shield assembly on (21) Connect (output) “BAT” and (field) “FLD”
stator and rectifier end shield assembly. Align leads and connect ground wire.
through bolt holes in the stator, rectifier end shield (22) Connect battery ground cable.
and drive end shield. (23) Start and operate engine, and observe alter
(16) Compress stator and both end shields by hand nator operation.
and install through bolts, washers and nuts. Tighten (24) Test current output and regulator setting.
IGNITION SYSTEM-6-CYLINDER
INDEX
Page Page
Assembling the Distributor .........................................32 Idle R.P.M. T e s t .......................................................... 30
Ballast R e s isto r.............................................................36 Ignition Coil ............................................................... 36
Distributor Advance T e s tin g .........................................35 Ignition Tim ing............................................................ 31
Distributor Contact Dwell ........................................ ....30 Installing and Aligning C o n ta c ts ................. ....... .. 35
Distributor Contacts .................................................. ... 34 Lubrication - D istributor.......................................... 35
Distributor Disassembly ...............................................32 Secondary Circuit Inspection ................................. 29
Distributor Installation............................. .....................35 Service Diagnosis ...................................................... 28
Distributor Lubrication ............................................ ....35 Shaft and Bushing Wear T e s t ................................. 31
Distributor Removal .................................................. ....31 Spark Plugs ................................................................ 47
Distributor Resistance T e s t ........................................ 30 Specifications.............................................................. 78
Dwell V ariation.............................................................. 30 Testing Contact Arm Spring T e n s io n ..................... 33
General Information .................................................. ... 28 Timing - Ignition ........................................................ 31
GENERAL INFORMATION
The ignition system consists of two separate cir mary wiring make up the low voltage prim ary circuit.
cuits. The battery, amm eter, ignition switch, ballast The secondary high voltage circuit includes the coil
resistor, prim ary winding of the ignition coil, distribu secondary winding, distributor cap and rotor, spark
to r contacts and condenser, vehicle fram e, and pri plug cables, spark plugs and vehicle frame.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
BURNED OR PITTED (a) Dirt or oil on contacts. (a) If oil is on contact face, determine
DISTRIBUTOR cause and correct condition. Clean
CONTACTS distributor cam of dirt and grease, ap
ply a light film of distributor cam lu
bricant to cam lobes; wipe off excess.
See “Distributor Lubrication.” Re
place contact set and adjust as nec
essary.
(b) Alternator voltage regulator setting (b) Test alternator voltage regulator set
too high. ting, adjust as necessary. Replace
contact set and adjust as necessary.
(c) Contacts misaligned or gap too small (c) Align and adjust contacts.
(d) Faulty coil. (d) Test and replace coil if necessary. Re
place and adjust contacts.
(e) Ballast resistor not in circuit. (e) Inspect conditions, and correctly con
nect the coil.
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(f) Wrong condenser or faulty condenser, (f) Test condenser and replace if neces
sary. Replace and adjust contacts.
(g) Faulty ignition switch. (g) Replace ignition switch.
(h) Bushings worn. (h) Replace housing.
(i) Touching contacts with the hands dur- (i) Replace and adjust contacts,
ing installation.
IGNITION COIL (a) Coil damaged by excessive heat from (a) Replace coil. Inspect condition of the
FAILURE engine. distributor contacts.
(b) Coil tower carbon-tracked. (b) Replace the coil.
(c) Oilleak at tower. (c) Replace the coil.
SERVICE PROCEDURES
SECONDARY CIRCUIT INSPECTION entire length of wire. If punctures or cracks are
Check the high tension cable connections for good present there will be a noticeable spark jum p from
contact at the coil and distributor cap towers and at the faulty area to the probe. Secondary coil wire may
the spark plugs. Terminals should be fully seated. The be checked in th e same m anner, be sure one spark
nipples and spark plug covers should be in good con plug cable is disconnected from spark plug while
dition. Nipples should fit tightly on the coil cap towers running probe along coil wire secondary cable.
and spark plug cover should fit tight around spark Cracked, leaking or faulty cables should be replaced.
plug insulators. Cable connections that are loose will When installing new cable assemblies, install new
corrode and increase the resistance and perm it w ater high tension cable and nipple assembly over cap or
to enter the towers causing ignition malfunction. To coil tower, entering the terminal into the tower, push
maintain proper sealing between the towers and lightly, then pinch the large diameter of nipple (Fig.
nipples, cable and nipple assemblies should not be 1) to release trapped air between the nipple and tower.
removed from the distributor or coil towers unless Continue pushing on the cable and nipple until cables
nipples are damaged or cable testing indicates high are properly seated in the cap towers. Use the same
resistance or broken insulation. procedure to install cable in coil tower (Fig. 2). Wipe
Clean high tension cables with a cloth moistened the spark plug insulator clean before reinstalling
with a non-flammable solvent and wipe dry. Bend cable and cover.
cable to check for brittle or cracked insulation. Resistance type cable is identified by the words
When testing secondary cables for punctures and “Electronic Suppression” printed on cable jacket.
cracks with an oscilloscope follow the instructions of No additional resistors are necessary.
the equipm ent m anufacturers. An ohm meter can be used to check resistance
If an oscilloscope is not available, secondary cables type cables for open circuits, loose term inals or high
can be tested as follows: resistance as follows:
(a) Engine not running, connect one end of a test (a) Remove cable from spark plug and install the
probe to a good ground, other end free for probing. proper adapater between cable and the spark plug.
(b) Disconnect cable at spark plug end. Insulate (b) Lift distributor cap from distributor with cables
cable end from grounding. intact. Do not remove cables from the cap.
(c) With engine running, move test probe along (c) Connect the ohm meter between spark plug
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adapter and the corresponding electrode inside the replace as necessary and repeat test (3).
cap, making sure ohm m eter probes are in good con If faulty contacts are indicated, remove distributor
tact. If resistance is more than 30,000 ohms, remove for complete inspection, service, testing and calibra
cable at cap tower and check cable resistance. If re tion.
sistance is more than 30,000 ohms on cables under
twenty-five inches, or 50,000 ohms on cables over IDLE RPM TEST
twenty-five inches long, replace cable assembly. Test Engine idle rpm setting should be tested and re
all spark plug cables in same manner. corded as it is when the vehicle is first brought into
To test coil to distributor cap high tension cable, the shop for testing. This will assist in diagnosing
remove distributor cap with the cable intact. Do not complaints of engine stalling or complaints of creep
remove cable from the coil or cap. Connect the ohm ing and hard shifting on vehicles equipped with
m eter between center contact in the cap and either automatic transmissions.
prim ary term inal at coil. If the combined resistance of Test procedures are as follows:
coil and cable is more than 25,000 ohms, remove the (1) Turn Selector Switch to CALIBRATE position
cable at coil tower and check cable resistance. If and adjust Dwell Calibrator until Dwell Meter reads
resistance is more than 15,000 ohms, replace cable. If on SET line (test leads separated).
resistance is less, check for a loose connection at the (2) Connect red lead of the test unit to the distribu
tower or for a faulty coil. tor prim ary term inal at the coil and the black lead to
Inspect coil tower for cracks, carbon tracking or oil a good ground.
leaks. (3) Turn Selector Switch to the 6 LOBE position.
(4) Turn Tach-Dwell RPM Switch to the 1000 RPM
DISTRIBUTOR RESISTANCE TEST position.
(5) With engine at normal operating tem perature
This test indicates the resistance of the ignition
(off fast idle), momentarily open the throttle and re
prim ary circuit from the distributor side of th e coil,
lease to make sure there is no bind in the linkage and
through the contacts and distributor ground. Ex
that idle speed screw is against its stop.
cessive resistance in this portion of the ignition sys
(6) Note engine RPM on 1000 RPM scale and adjust
tem will prevent the coil from producing sufficient
carburetor idle speed to specifications shown in Fuel
output for good overall ignition. To perform test, pro
System “Specifications.”
ceed as follows:
(1) Turn Selector Switch of a Tach-Dwell unit to DISTRIBUTOR CONTACT DWELL
CALIBRATE position and adjust Dwell Calibrator
until Dwell Meter reads on the set line (test leads sepa The degrees of distributor dwell are the degrees of
rated). rotation through which the breaker contacts rem ain
(2) Leave Selector Switch in CALIBRATE position, closed. This is also commonly referred to as “dwell
connect Tach-Dwell red lead to distributor term inal of angle” or “cam angle.”
coil and black lead to a good ground. Correct distributor contact dwell is essential for
(3) Turn ignition switch “ON.” Observe dwell m eter good ignition perform ance and contact life.
reading. Meter pointer should be within b ar m arked Test procedures are as follows:
“DISTRIBUTOR RESISTANCE.” If reading is zero or (1) Disconnect vacuum line.
outside of bar, crank engine with the starter until (2) Connect Tach-Dwell red lead to distributor
m eter pointer moves as far to the right as possible. term inal of coil and black lead to a good ground.
(This will indicate that contacts are closed.) A reading (3) Turn Selector Switch to 6 LOBE position.
now within the bar indicates a normal distributor (4) Start engine and operate at idle speed.
prim ary circuit. (5) Observe Dwell-Meter reading. If dwell reading
If reading is outside the bar, high resistance is is within “Specifications,” contact gap, cam rubbing
present in distributor prim ary circuit. block and contact arm are all in satisfactory condition.
(4) Remove test lead from distributor term inal of If dwell reading is not within specifications, incor
coil and connect to the following points: rect contact gap, worn cam, worn rubbing block or
(a) D istributor prim ary term inal (outside) distorted movable contact arm may be indicated.
(b) D istributor prim ary term inal (inside)
(c) Contact term inal bracket (insulated bracket) DWELL VARIATION
(d) Ground side of contacts. This test indicates the mechanical condition of the
(e) D istributor housing. distributor. Excessive wear in distributor mechanical
(5) Repeat test at each connection until a notice parts cause dwell variations which will affect ignition
able change occurs in m eter reading. If a poor con timing.
nection or faulty lead is indicated, clean, tighten or Test procedures are as follows:
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(1) With engine at idle speed, vacuum hose discon tion tim ing and clockwise retards timing.)
nected, and with test leads connected as in Contact (6) Tighten distributor hold-down arm screw after
Dwell Test, turn the Tach-Dwell RPM Switch to 5000 timing has been set and recheck timing adjustm ent
RPM position. with a Power Timing Light.
(2) Slowly increase engine speed to 1500 RPM then (7) When ignition tim ing is correct, reconnect
slowly reduce to idle speed while observing Dwell vacuum hose to distributor.
Meter reading.
If dwell reading varies more than 2 degrees from Ignition Tim ing (w ith C-744 Test Lamp)
initial reading between idle speed and 1500 RPM, (1) Connect C-744 test lamp between distributor
probable wear in the distributor shaft, bushings or prim ary term inal and battery positive post.
breaker plate is indicated. Remove distributor for (2) Turn engine until num ber 6 exhaust valve is
complete inspection and testing on a distributor just closing; continue turning the engine slowly until
tester. Dwell variation at speeds above 1500 RPM m ark on the crankshaft pulley is at specified degree
does not necessarily indicate distributor wear. m ark at case cover.
I MPORTANT: Dwel l and gap of the contacts must (3) Loosen distributor clamp bolt so distributor
both be within their specified limits at the same time. housing can be rotated with a slight drag, then turn
If this cannot be accomplished, it is probable that distributor in the normal rotation until test lamp
wrong contacts are installed, the rubbing block or lights.
cam lobes are badly worn or the movable contact arm (4) Turn distributor against normal distributor ro
is distorted. tation until test lamp goes out. If test lamp lights im
mediately when connected, turn distributor against
IGNITION TIMING normal distributor rotation until light goes out.
(5) Tighten distributor clamp bolt securely and re
To obtain maximum engine performance, the dis move test lamp. If operation is perform ed properly
tributor m ust be correctly positioned on the engine to the engine is tim ed to specifications. If engine is
give proper ignition timing. turned beyond the timing mark, continue turning
The ignition timing test will indicate timing of the engine for two full revolutions of the crankshaft;
spark at No. 1 cylinder at idle (only). this will place the distributor rotor in approximately
Test procedures are as follows: the initial position.
(1) Disconnect vacuum hose at distributor. CAUTION: DO NOT reverse rotation of crankshaft if
(2) Connect secondary lead of Power Timing Light you have passed the timing mark as this would affect
to No. 1 spark plug, red prim ary lead to positive valve timing and distributor timing.
term inal of battery and black prim ary lead to nega
tive battery terminal. Do not puncture cables, boots DISTRIBUTOR REMOVAL
or nipples with test probes. Always use proper
(1) Disconnect vacuum hose at distributor.
adapters. Puncturing spark plug cables with a probe
(2) Disconnect prim ary lead wire at coil.
will damage the cables. The probe can separate the
(3) Unfasten distributor cap retaining clips and lift
conductor and cause high resistance. In addition,
off distributor cap.
breaking the rubber insulation may permit secondary
(4) Rotate engine crankshaft until the distributor
current to arc to ground.
rotor is pointing toward the cylinder block, scribe a
(3) Start engine and set idle to “Specifications”
mark on block at this point to indicate position of the
(Transmission in Neutral).
rotor as reference when reinstalling distributor.
(4) Loosen distributor hold-down arm screw just
(5) Remove distributor hold-down arm screw.
enough so the distributor housing can be rotated in its
(6) Carefully lift the distributor from the engine,
mounting.
shaft will rotate slightly as the distributor gear is dis
(5) Aim Power Timing Light at tim ing plate on
engaged from the camshaft gear.
chain case cover. If light flash occurs when timing
m ark on the vibration dam per is located ahead of the SHAFT AND BUSHING WEAR TEST
specified degree m ark on timing plate in the direction
of engine rotation, tim ing is advanced. To adjust, tu rn (1) Remove distributor rotor.
distributor housing in direction of rotor rotation. (2) Disconnect prim ary lead wire at distributor
If flash occurs when the vibration dam per tim ing terminal. Do not loosen removable contact arm spring
m ark is located past the specified degree m ark in the retaining nut.
direction of engine rotation, timing is retarded. To (3) Clamp distributor hold-down arm in a vise
adjust, turn distributor housing against direction of equipped with soft jaws and apply only enough pres
rotor rotation. Refer to “Specifications.” (Moving the sure to restrict any movement of the distributor dur
distributor housing counterclockwise advances igni ing this test.
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CENTER LINE— I
OF ROTOR ELECTRODt: j
CAP
ROTOR
INSULATOR
SCREW
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PIN-
, - ALIGNMENT MARK
LEAD WIRE ■J '• O N SHAFT
5
NP895A
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CENTER LINE O F ROTOR ELECTRODE in color, or is badly pitted, the contacts will soon be
come unsatisfactory for further operation. Not only
m ust they be replaced, but the ignition system and
engine m ust be checked to determ ine the cause of the
trouble so it can be eliminated. Unless the condition
causing contact burning or excessive pitting is cor
IV rected, new contacts will provide no better service
n1 ' A *P
ftVV*' than the old contacts.
ff/ / Burning o f Contacts
Contact burning will result from high prim ary
voltage, presence of oil or other foreign material, de
fective condenser and im proper contacts adjustment.
High voltage causes an excessively high current flow
through the contacts which burns them rapidly. High
GEAR / (/
* HOLE IN
voltage can result from an improperly adjusted or
ROTATED APPROX. 1 ;V
90 DEGREES SERVICE GEAR ’ inoperative voltage regulator.
% I 5 ^ M A R K ON SHAFT Oil or crankcase vapors which work up into the
CENTER LINE OF GEAR TOOTH
distributor and deposit on the contact surfaces will
N P 896A
cause them to burn rapidly. This is easy to detect
since the oil produces a smudgy line under the con
Fig. 6 —Aligning G e ar Teeth with Centerline tacts. Clogged engine breather pipes perm it crankcase
o f Rotor Electrode pressure to force oil or vapors up into the distributor.
the end of contact arm spring, and slide end of spring Over-oiling of the distributor will also cause burning.
in or out, as necessary. If contact opening is too small (cam angle too large),
(2) Tighten screw and m easure spring tension. Just arcing will occur between the contacts resulting in
the right amount of contact spring tension is very low secondary voltage and engine miss.
important for effective ignition and efficient engine High series-resistance in the condenser circuit will
performance. Spring tension that is too great, will prevent norm al condenser action so the contacts will
cause excessive wear on distributor cam and on the burn rapidly. This resistance may be caused by a
nylon block of the movable contact arm. Spring ten loose condenser mounting or lead connection, or by
sion that is too weak, is unable to keep the contacts poor connections inside the condenser.
in contact with each other when they close. This is
particularly true as engine speed is increased, causing Pitting o f Contacts
high-speed misfiring. Contact pitting results from the transfer of m aterial
from one contact to the other so that a tip builds up
on one contact while a pit forms in the other.
DISTRIBUTOR CONTACTS
A small amount of pitting in several thousand miles
Contact W e a r is normal and does not affect the distributor opera
Contacts which have undergone several thousand tion. However, excessive pitting such as long sharp
miles of operation will have a rough surface, but this
should not be interpreted as m eaning that contacts MOVABLE CONTACT ARM
TOOL- / /
are worn out. If the contact area has a gray color and 'r -
roughness between the contacts matches so that a
large contact area is m aintained, the contacts will
continue to provide satisfactory service.
However, if th e contact area is oily, m ottled or dark M ^
118
^ C O N T A C T ARM AND SPRING A fr. j
PULL'SCALE \ ^
-W / "Jf
*fr-
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N Y 703B NY1122B
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spikes is harm ful and causes arcing and voltage loss. so that gear is not damaged and proceed with tests as
Contacts with this condition should be replaced. follows:
Excessive pitting can be due to too small a contact (1) T urn the Tach-Dwell switch to the 6 LOBE posi
opening, high prim ary voltage or wrong condenser tion and Motor Switch to correct direction of rotation.
capacity. Inspect to be certain the condenser capacity, R efer to “D istributor Advance Specifications” in this
contact spring tension, and contact gap are within the manual.
specified range. See “Specifications”. (2) T urn battery switch “ON.”
(3) Regulate tester speed control to operate distrib
INSTALLING AND ALIGNING CONTACTS utor at 200 distributor rpm .
(4) Align the “O” of distributor tester degree ring
(1) Loosen the term inal screw nut, and remove pri with any of the arrow flashes.
m ary lead and condenser lead. (5) Adjust tester speed control to operate distribu
(2) Remove the stationary contact lock screw and tor at speeds called for under “Specifications” and
remove the old contact set. observe arrow flashes opposite tester degree ring to
(3) Install a new contact set; the sleeve at one end determ ine degrees of advance.
of the adjustable bracket fits over and pivots on the (6) If advance is not according to specifications,
upper contact plate mounting pin. replace with correct distributor shaft assembly (shaft,
(4) Connect the condenser and prim ary leads. cam, yoke, governor weights as complete assembly)
(5) Align the contacts, if necessary, by bending the or distributor assembly, less cap and rotor.
stationary contact bracket only. Never bend the
movable contact arm to obtain alignment. Vacuum D iap h ra g m Leak Test
(6) A fter aligning the contacts, adjust contact W ith distributor m ounted in D istributor Tester and
clearance to “Specifications,” using dial indicator with vacuum unit attached to distributor, proceed as
(Fig. 8). Recheck the contact arm spring tension. follows:
(7) Test the dwell angle to show proper degree of (1) Place thum b over end of vacuum pump hose
closure. See Paragraph, “D istributor Contact Dwell.” and adjust the regulator control knob to give a read
The lock screw should be loosened ju st enough so that ing of 20 inches of vacuum with hose closed off to be
the stationary contact bracket can be moved with a sure tester hose does not leak.
slight drag; otherwise, it will be difficult to set the (2) Attach tester vacuum pump hose to the tube on
contacts accurately. A fter setting the contacts to the vacuum unit. Vacuum gauge should hold on maxi
correct gap, tighten the stationary bracket lock screw. mum vacuum obtainable if no leaks exist.
(3) Observe breaker plate while perform ing leak
DISTRIBUTOR LUBRICATION test to test response of the breaker plate. There
should be instant response to pull of the diaphragm,
(1) Lubricate the felt wick under the rotor in top of
moving plate without a drag, bind or jerk in either
distributor cam with 1 drop of SAE 10W oil.
direction.
(2) Wipe the distributor cam free of dirt and old
(4) If leakage is indicated, replace vacuum unit as
grease with a clean lintless cloth. Apply a light film of
sembly.
new distributor cam lubricant Num ber 1473595 or
equivalent over the entire cam surface. Lubricant Vacuum Advance Curve
m ust be able to adhere to the cam surface thereby If only the vacuum advance curve is to be checked,
resisting being thrown from the cam by centrifugal connect tester vacuum pump hose to distributor vac
force, m ust not m elt at operating tem peratures and uum advance unit and perform operations 1 through
m ust not harden or dry out with age, m ust not chemi 4 under “Centrifugal Advance Curve,” then proceed
cally react or be affected by ozone or cause corrosion as follows:
or pitting of the metal, m ust possess m oisture control (1) Turn tester vacuum pump “ON.” Adjust vacu
properties to prevent rust formation on the cam. um pump regulator to vacuum test specifications. See
CAUTION: A thin film is all that is required. Do not “Specifications” and observe arrow flashes on tester
over-lubricate. Excess grease will be thrown from the degree ring to determ ine degrees of advance.
distributor cam when engine is running. If this grease (2) If vacuum advance is below or above specifica
strikes the contacts, arcing and burning of contacts tions, replace the vacuum advance unit. Retest vacu
will result. um advance curve.
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(2) Carefully engage distributor drive gear with (10) When timing is correct, connect vacuum hose
camshaft drive gear so that when distributor is in to the distributor.
stalled properly, rotor will be in line with previously (11) Remove Power Timing Light from engine.
scribed line on cylinder block. If engine has been
cranked while distributor is removed, it will be neces
sary to establish proper relationship between the dis IGNITION COIL
tributor shaft and N umber 1 piston position as fol
The ignition coil is designed to operate with an
lows:
external ballast resistor. When testing the coil for
(a) Rotate the crankshaft until num ber one piston
output, include resistor in tests. Inspect the coil for
is at top of compression stroke. Mark on inner edge of
external leaks and arcing.
crankshaft pulley should be in line with the “Q”
Test coil according to coil tester M anufacturer’s in
(TDC) m ark on timing chain case cover.
structions. Test coil prim ary resistance. Test ballast
(b) Rotate rotor to a position just ahead of the
resistor resistance. Test coil secondary resistance. Re
num ber one distributor cap term inal.
place any coil or ballast resistor that does not m eet
(c) Lower the distributor into the opening, engag
specifications.
ing distributor gear with drive gear on camshaft.
Every time an ignition coil is replaced because of a
W ith distributor fully seated on engine, rotor should
burned tower, carbon tracking, or any evidence of
be under the cap num ber 1 tower with distributor
arcing at the tower, the nipple or boot on the coil end
contacts just separating.
of the secondary cable, replace cable. Any arcing at
(3) Install the distributor cap (make sure all high
the tower will carbonize the nipple so that placing it
tension wires “snap” firmly in the cap towers).
(4) Install hold-down arm screw and tighten finger on a new coil will invariably cause another coil fail
tight. ure.
(5) Attach prim ary lead wire to the coil. Do not If secondary cable shows any signs of damage,
connect distributor vacuum hose at this time. cable should be replaced with a new cable with a neo
(6) Connect secondary lead of Power Timing Light prene nipple since the old cable can cause arcing,
to the Num ber 1 spark plug (using proper adaptor) and therefore, ruin a new coil.
and red prim ary lead to the positive term inal of bat
tery with black prim ary lead to negative battery BALLAST RESISTOR
term inal. Do not puncture the cable cap nipples or
The ballast resistor is a compensating resistance in
spark plug covers to make a contact. Use proper
the ignition prim ary circuit. During low speed opera
adapters.
tion, when prim ary circuit current flow is high, bal
(7) Start engine and run engine at idle speed.
(8) Rotate distributor housing so that tim ing m ark last resistor tem perature rises, increasing resistance.
on crankshaft dam per is aligned with specified degree This reduces current flow, thereby prolonging igni
m ark on chain case cover. Refer to “Specifications” tion contact life. At high speed operation, when pri
(Moving distributor housing counter-clockwise ad m ary current flow is low, the ballast resistance cools
vances tim ing and clockwise retards timing). off allowing more current flow, which is required for
(9) Tighten distributor hold down arm screw after high speed operation. During starter operation, the
tim ing has been set and recheck tim ing adjustm ent ballast resistor is bypassed, allowing full battery volt
with a Power Timing Light. age to ignition prim ary circuit.
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GENERAL INFORMATION
The ignition system consists of two separate cir m ary wiring make up the low voltage prim ary circuit.
cuits. The battery, ammeter, ignition switch, ballast The secondary high voltage circuit includes the coil
resistor, prim ary winding of the ignition coil, distribu secondary winding, distributor cap and rotor, spark
tor contacts and condenser, vehicle frame, and pri plug cables, spark plugs and vehicle frame.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
BURNED OR PITTED (a) Dirt or oil on contacts. (a) If oil is on contact face, determine
DISTRIBUTOR cause and correct condition. Clean
CONTACTS distributor cam of dirt and grease, ap
ply a light film of distributor cam lu
bricant to cam lobes; wipe off excess.
See “Distributor Lubrication.” Re
place contact set and adjust as nec
essary.
(b) Alternator voltage regulator setting (b) Test alternator voltage regulator set
too high. ting, adjust as necessary. Replace
contact set and adjust as necessary.
(c) Contacts misaligned or gap too small. (c) Align and adjust contacts.
(d) Faulty coil. (d) Test and replace coil if necessary. Re
place and adjust contacts.
(e) Ballast resistor not in circuit. (e) Inspect conditions, and correctly con
nect the coil.
(f) Wrong condenser or faulty condenser. (f) Test condenser and replace if neces
sary. Replace and adjust contacts.
(g) Faulty ignition switch. (g) Replace ignition switch.
(h) Bushings worn. (h) Replace housing*.
(i) Touching contacts with the hands dur (i) Replace and adjust contacts.
ing installation.
IGNITION COIL (a) Coil damaged by excessive heat from (a) Replace coil. Inspect condition of the
FAILURE engine. distributor contacts.
(b) Coil tower carbon-tracked. (b) Replace the coil.
(c) Oil leak at tower. (c) Replace the coil.
Prestolite—Recondition distributor.
SERVICE PROCEDURES
SECONDARY CIRCUIT INSPECTION the equipm ent m anufacturers.
If an oscilloscope is not available, secondary cables
Check high tension cable connections for good con
can be tested as follows:
tact at the coil and distributor cap towers and at the
(a) Engine not running, connect one end of a test
spark plugs. Terminals should be fully seated. The
probe to a good ground, other end free for probing.
nipples and spark plug covers should be in good con
(b) Disconnect cable at spark plug end. Insulate
dition. Nipples should fit tightly on the coil cap tow
cable end from grounding.
ers and spark plug covers should fit tight around (c) With engine running, move test probe along
spark plug insulators. Cable connections that are loose entire length of wire. If punctures or cracks are
will corrode and increase the resistance and perm it present there will be a noticeable spark jum p from
water to enter the towers causing ignition malfunc
the faulty area to the probe. Secondary coil wire
tion. To maintain proper sealing between the towers
may be checked in the same m anner, be sure one
and nipples, cable and nipple assemblies should not be
removed from the distributor or coil towers unless spark plug cable is disconnected from spark plug
nipples are damaged or cable testing indicates high while running probe along coil wire secondary cable.
resistance or broken insulation. Cracked, leaking or faulty cables should be replaced.
Clean high tension cables with a cloth moistened When installing new cable assemblies, install new
with a non-flammable solvent and wipe dry. Bend high tension cable and nipple assembly over cap or
cables to check for brittle or cracked insulation. coil tower, entering the terminal into the tower, push
W hen testing secondary cables for punctures and lightly, then pinch the large diameter of the nipple
cracks with an oscilloscope follow the instructions of (Fig. 1) to release trapped air between nipple and
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I
W*i-
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r *j»r
Fig. 3 —Removing Secondary Cable and Cover
from Spark Plug (Typical)
intact. Do not remove cables from cap.
(c) Connect the ohm meter between spark plug
i!N26-: adapter and the corresponding electrode inside the
cap, making sure ohm meter probes are in good con
Fig. 1—Installing Secondary Cable and N ip p le a t tact. If resistance is more than 30,000 ohms, remove
Distributor Cap Tower
cable at cap tower and check the cable resistance. If
tower. Continue pushing on the cable and nipple resistance is more than 30,000 ohms on cables under
until cables are properly seated in the cap towers. Use twenty-five inches long or 50,000 ohms on cables over
the same procedure to install cable in coil tower (Fig. twenty-five inches long, replace cable assembly. Test
2). all spark plug cables in same manner.
Use the following procedure when removing the To test coil to distributor cap high tension cable, re
high tension cable from the spark plug. First, remove move distributor cap with the cable intact. Do not
the cable from the retaining bracket. Then grasp the remove cable from the coil or cap. Connect the ohm
insulator as close as possible to the spark plug and m eter between center contact in the cap and either
use a straight and steady pull (Fig. 3). Do not use prim ary term inal at coil. If the combined resistance
pliers and do not pull the cable at an angle. Doing so of coil and cable is more than 25,000 ohms, remove
will damage the insulation, cable term inal or the the cable at coil tower and check cable resistance. If
spark plug insulator. Wipe spark plug insulator clean resistance is more than 15,000 ohms, replace the
before reinstalling cable and cover. cable. If resistance is less, check for a loose connec
Resistance type cable is identified by the words tion at the tower or for a faulty coil.
“Electronic Suppression” printed on the cable jacket. Inspect coil tower for cracks, carbon tracking or
No additional resistors are necessary. oil leaks.
Use an ohm m eter to check resistance type cable for
open circuits, loose term inals or high resistance as DISTRIBUTOR RESISTANCE TEST
follows: This test indicates the resistance of the ignition
(a) Remove cable from spark plug and install the prim ary circuit from the distributor side of the coil,
proper adapter between cable and spark plug. through the points and the distributor ground. Exces
(b) Lift distributor cap from distributor with cables sive resistance in this portion of the ignition system
will prevent the coil from producing sufficient output
for good over-all ignition. To perform test, proceed as
follows:
(1) Turn Selector Switch of a Tach-Dwell unit to
CALIBRATE position and adjust Dwell Calibrator un
til Dwell Meter reads on the set line (test leads sepa
rated).
(2) Leave Selector Switch in CALIBRATE position,
connect Tach-Dwell red lead to distributor term inal
of coil and black lead to a good ground.
(3) Turn ignition switch “ON.” Observe dwell
m eter reading. Meter pointer should be well within
MN266
bar m arked “DISTRIBUTOR RESISTANCE.” If read
Fig. 2 —Installing Secondary Cable and N ip p le
ing is zero or outside of bar, crank engine with the
a t Coil Tower starter until m eter pointer moves as far to right as
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possible. (This will indicate that contacts are closed.) (2) Connect Tach-Dwell red lead to distributor
A reading now within th e b ar indicates a norm al dis term inal of coil and black lead to a good ground.
tributor prim ary circuit. (3) Turn Selector Switch to 8 LOBE position.
If reading is outside the bar, high resistance is (4) Start engine and operate engine at idle speed.
present in distributor prim ary circuit. (5) Observe dwell m eter reading. If the dwell read
(4) Remove test lead from distributor term inal of ing is within “Specifications” the contact gap, cam
coil and connect to the following points: rubbing block and contact arm are all in satisfactory
(a) Distributor prim ary term inal (outside). condition.
(b) Distributor prim ary term inal (inside). If dwell reading is not within specifications, incor
(c) Contact term inal bracket (insulated bracket). rect contact gap, worn cam, worn rubbing block or
(d) Ground side of the contacts. distorted contact arm may be indicated.
(e) Distributor housing.
(5) Repeat test at each connection until a notice DUAL CONTACTS
able change occurs in the m eter reading. If a poor
connection or faulty lead is indicated, clean, tighten Block one set of contacts with a clean insulator and
or replace as necessary and repeat test (3). adjust the opposite set of contacts to specifications
If faulty contacts are indicated remove distrib using the dwell meter. Loosen stationary contact lock
utor for complete inspection, service, testing and cali screw just enough, so stationary contact can be moved
bration. with a slight drag; otherwise it will be difficult to set
contacts accurately.
IDLE RPM TEST When one set of contacts has been adjusted for
correct clearance tighten stationary contact lock
Engine idle rpm setting should be tested and re screw.
corded as it is when the vehicle is first brought into Block adjusted set of contacts with an insulator and
the shop for testing. This will assist in diagnosing adjust rem aining set of contacts in the same m anner
complaints of engine stalling, creeping and hard shift as the first set. Remove insulator and recheck tight
ing on vehicles equipped with automatic transm is ness of stationary contact lock screw.
sions. If contacts have been properly adjusted the dwell
Test procedures are as follows: should be as specified for two contact sets.
(1) Turn Selector Switch to CALIBRATE position
and adjust Dwell Calibrator until Dwell Meter reads DWELL VARIATION
on SET line (test leads separated).
(2) Connect red lead of the test unit to distributor This test indicates the mechanical condition of the
prim ary term inal at coil and black lead to a good distributor. Excessive wear in distributor mechanical
ground. parts cause dwell variations which will affect ignition
(3) Turn Selector Switch to 8 LOBE position. timing.
(4) Turn the Tach-Dwell RPM Switch to the 1000 Test procedures are as follows:
rpm position. (1) With engine at idle speed, vacuum hose discon
(5) With engine at normal operating tem perature nected, and test leads connected as in “Contact Dwell
(off fast idle), m om entarily open the throttle and re Test,” tu rn Tach-Dwell RPM Switch to the 5,000 RPM
lease to make sure there is no bind in the linkage and position.
that idle speed screw is against its stop. (2) Slowly increase engine speed to 1500 RPM then
(6) Note engine RPM on 1000 RPM scale and adjust slowly reduce to idle speed while observing dwell
carburetor idle speed to specifications. See “Fuel Sus- m eter reading.
tem ” specifications. If dwell reading varies more than 2 degrees from
initial reading between idle speed and 1500 RPM,
DISTRIBUTOR CONTACT DWELL probable wear in the distributor shaft, bushings or
contact plate bearing and pivot pin is indicated. Re
The degrees of distributor dwell are the degrees of move distributor for complete inspection and testing
rotation through which the contacts rem ain closed. on a distributor tester. Dwell variation at speeds
This is also commonly referred to as “dwell angle” or above 1500 does not necessarily indicate distributor
“cam angle.” wear. Dwell and gap of the contacts must both be
The correct distributor point dwell is essential for within their specified limits at the same time. If this
good ignition perform ance and contact point life. cannot be accomplished, it is probable that wrong
Test procedures are as follows: contacts are installed or the rubbing block or cam
(1) Disconnect vacuum line. lobes are badly worn or movable contact is distorted.
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IGNITION TIMING (383 Cu. ln.440Cu. In) on the vibration dam per is located past the specified
degree m ark on the timing plate. The timing is re
(Solenoid Distributor—Fig. 4) tarded. To adjust turn distributor housing clockwise.
To obtain maximum engine performance, the dis Timing may vary from the specified specifications a
tributor must be correctly positioned on the engine to plus or minus 2-1/ 2 ° and still fall within range, but
give proper ignition timing. The ignition tim ing test if the timing is checked it should be adjusted to the
will indicate the tim ing of the spark at No. 1 cylinder specification shown on the distributor charts.
at curb idle (Hot only). (6) To check the distributor solenoid for proper
Test procedures are as follows: operation, disconnect the wire at the carburetor. Aim
(1) Disconnect vacuum hose at distributor, and the power timing light at the timing m arks on the
plug hose. chain case. The tim ing should advance at least 5-1/2°
(2) Connect the secondary lead of a power timing and the engine speed should increase.
light to No. 1 spark plug, red prim ary lead to positive (7) Stop the engine and tighten the distributor hold-
term inal of the battery and the black prim ary lead to down screw.
the negative battery term inal. Do not puncture cables, (8) Reconnect the wire at the carburetor throttle
stop.
boots or nipples with test probles. Always use proper
(9) Reconnect the vacuum hose to the distributor.
adapters. Puncturing the spark plug cables with a
(10) Remove the timing light.
probe will damage the cables. The probe can separate
the conductor and cause high resistance. In addition
IGNITION TIMING (318 Cu. In. and 340 Cu. In.)
breaking the rubber insulation may permit secondary
current to arc to ground. To obtain maximum engine performance, the dis
(3) Loosen the distributor hold-down mounting tributor m ust be correctly positioned on the engine to
screw just enough so distributor housing can be ro give proper ignition timing.
tated in its mounting. The ignition timing test will indicate the tim ing of
(4) Start the engine and set the curb idle as shown the spark at No. 1 cylinder at idle (only).
in “Specifications”. (Transmission in N eutral and En Test procedures are as follows:
gine Hot). (1) Disconnect vacuum hose at distributor.
(5) Aim the power tim ing light at the timing marks (2) Connect secondary lead of Power Timing Light
on the chain case cover. If the tim ing light flash occurs to No. 1 spark plug, red prim ary lead to positive te r
when the timing m ark on the vibration dam per is lo minal of battery and black prim ary lead to negative
cated ahead of specified degree m ark on the timing battery terminal. Do not puncture cables, boots or
plate. The timing is advanced. To adjust turn distrib nipples with test probes. Always use proper adapters.
utor housing (Not Vacuum Chamber) Counter clock Puncturing the spark plug cables with a probe will
damage the cables. The probe can separate the con
wise. Do not use vacuum chamber as a turning handle.
ductor and cause high resistance. In addition break
If the timing light flash occurs when the timing mark
ing the rubber insulation may permit secondary cur
rent to arc to ground.
(3) Start engine and set idle to “Specifications”
(Transmission in Neutral).
(4) Loosen distributor hold-down arm screw just
enough so distributor housing can be rotated in its
mounting.
(5) Aim Power Timing Light at timing plate on
chain case cover. If light flash occurs when tim ing
m ark on vibration dam per is located ahead of speci
fied degree m ark on timing plate in the direction of
engine rotation, timing is advanced. To adjust, tu rn
distributor housing in direction of rotor rotation.
If flash occurs when the vibration timing m ark is
located past the specified degree m ark in the direc
tion of engine rotation, timing is retarded. To adjust,
turn distributor housing against direction of rotor ro
tation. Refer to “Specification.” (Moving the distribu
tor housing against shaft rotation advances tim ing
and with shaft rotation retards timing.
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(6) Tighten distributor hold-down arm screw after (3) Unfasten distributor cap retaining clips and lift
timing has been set and recheck tim ing adjustm ent off distributor cap.
with a Power Timing Light. (4) Scribe a m ark on the edge of distributor hous
(7) When ignition tim ing is correct, reconnect vac ing to indicate position of the rotor as reference when
uum hose to distributor. reinstalling distributor.
Ignition Timing ( w i t h C-744 Test Lamp) (5) Remove distributor hold-down clamp screw and
(1) Connect C-744 test lamp between distributor clamp.
prim ary term inal and battery positive post. (6) Carefully lift distributor from engine.
(2) Turn engine until num ber 6 exhaust valve is
just closing; continue turning engine slowly until SHAFT AND BUSHING WEAR TEST
specified degree m ark on the crankshaft pulley is a t
specified degree m ark at timing case cover. (1) Remove distributor rotor.
(3) Loosen distributor clamp bolt so distributor (2) Disconnect prim ary lead wire at distributor
housing can be rotated with a slight drag, then turn term inal. DO NOT LOOSEN inner n u t that holds
distributor in the normal rotation until test lamp movable contact arm tension spring to term inal post.
lights. (3) Clamp the ribbed section of distributor housing
(4) Turn distributor against normal distributor ro lightly in a vise equipped with soft jaws and attach
tation until test lamp goes out. If test lamp lights dial indicator to body of distributor with the indicator
immediately when connected, turn distributor against plunger arm resting against movable contact arm at
normal distributor rotation until light goes out. the rubbing block and with the rubbing block of con
(5) Tighten distributor clamp bolt securely and re tact arm on the highest point of cam lobe (Fig. 5).
move test lamp. If the operation is perform ed proper (4) Place one end of a wire loop around the top of
ly the engine is timed to specifications. If engine is distributor shaft. Hook a spring scale in the other end
turned beyond the timing mark, continue turning of wire loop and pull on a line with the plunger of
engine for two full revolutions of the crankshaft; this indicator gauge. Be sure wire loop on shaft end is
will place the distributor rotor in approximately the down on the shaft to insure a straight pull and also
initial position.
that wire loop does not interfere with indicator or
CAUTION: DO NOT reverse rotation of the crank
shaft, if you have passed the timing mark as this holding bracket. Apply a five pound pull and read the
would affect valve timing and distributor timing. movement of plunger on indicator dial. (Be sure rub
bing block of contact arm is on highest point of the
DISTRIBUTOR REMOVAL cam lobe during this test.) If plunger movement ex
(1) Disconnect vacuum hose at distributor. ceeds .006 inch, replace bushings an d /o r distributor
(2) Disconnect prim ary lead wire at coil. shaft, see “Distributor Disassembly.”
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DISTRIBUTOR DISASSEMBLY (Figs. 4,6 and 7)
(1) Remove distributor rotor. The distributor cap
clamp springs on Chrysler built distributors are held
in place by peened metal around the openings and
should not be removed. CAP
(2) Remove the retainer attaching vacuum advance
unit to the contact plate advance arm (Prestolite).
(3) Remove the two screws and lockwashers attach
ing vacuum advance unit to distributor housing and
remove the advance unit. ROTOR
(4) Remove prim ary lead wire and rubber grommet
as an assembly. Push grommet towards inside of dis
tributor to remove. Do not pull on the wire.
(5) Remove two screws, and lockwashers attaching
the contact plate to housing and lift out the contact LEAD
plate, contacts and condenser as an assembly.
CONDENSER
(6) Remove oil wick from the distributor cam well.
Remove spring clip from oil well in cam and re
move cam and yoke assembly and spacer (Prestolite).
(7) If side play exceeded .006 inch in “Shaft and
Bushing W ear Test,” (Chrysler Built distributors) re CONTACT PLATE
place housing and bushings or shaft and cam assem FELT
bly as necessary. Prestolite distributors replace bush
ing an d /o r distributor shaft as follows: a*" -SNAP RING
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CAP DRIVER TO O L
SPRING
CONTACT
LEAD
ROTOR
CONDENSER
X'
SCREW
WASHER — CONTACT SST KD281
WASHER
DitVER TOO!
C tA M r
BEA9.1HG -
LOC KW AS H E R
SCREW
HOUSING ^
tOCKRING
CLAMP - i *
WASHER
WASHER ~
SCREW
SCR£W '
VACUUM
one - CHAMili
wL mm
BOSHING
w asher
COLLAR
ND310B
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CONTACT ARM
DRIVER TOOL AND SPRING
ADAPTOR-4^.
BUSHING' """
PULL SCALE
NB154C
Burning of Contacts
Contact burning will result from high prim ary volt
age, presence of oil or other foreign material, defec
tive condenser and im proper contacts adjustm ent.
KD 285
High voltage causes an excessively high current flow
through the contacts which burns them rapidly. High
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voltage can result from an im properly adjusted or
inoperative voltage regulator.
Oil or crankcase vapors which work up into the
distributor and deposit on the contact surfaces will
cause them to burn rapidly. This is easy to detect
since the oil produces a smudgy line under the con
tacts. Clogged engine breather pipes perm it crankcase
pressure to force oil or vapors up into the distributor.
Over-oiling of the distributor will also cause burning
of th e contacts.
If the contact opening is too small (cam angle too
large), arcing will occur between the contacts result
ing in low secondary voltage and engine miss.
High series-resistance in the condenser circuit will
prevent normal condenser action so the contacts will
burn rapidly. This resistance may be caused by a
loose condenser mounting or lead connection, or by Fig. 13 —Adjusting Contact Clearance
poor connections inside the condenser.
DISTRIBUTOR LUBRICATION
Pitting o f Contacts (1) Add 3 drops of SAE 10W oil to the oiler on
Contact pitting results from the transfer of m aterial outside of distributor base, (Prestolite only).
from one contact to the other so that a tip builds up (2) Lubricate felt wick under the rotor in top of
on one contact while a pit forms in the other. distributor cam with 1 drop of SAE 10W oil.
A small amount of pitting in several thousand miles (3) Wipe the distributor cam free of dirt and old
is normal and does not affect the distributor opera grease with a clean lintless cloth. Apply a light film of
tion. However, excessive pitting such as long sharp new distributor cam lubricant Number 1473595 or
spikes is harm ful and causes arcing and voltage loss. equivalent over the entire cam surface. Lubricant
Contacts with this condition should be replaced. must be able to adhere to the cam surface thereby
Excessive pitting can be due to too small a contact resisting being thrown from the cam by centrifugal
opening, high prim ary voltage or wrong condenser force, must not melt at operating tem peratures and
capacity. Inspect to be certain the condenser capacity, must not harden or dry out with age, m ust not chem
contact spring tension, and contact gap are within the ically react or be affected by ozone or cause corrosion
specified ranges. See “Specifications”. or pitting of the metal, m ust possess m oisture control
properties to prevent rust formation on the cam.
INSTALLING AND ALIGNING CONTACTS CAUTION: A thin film is all that is required. Do not
(1) Loosen term inal screw nut, and remove prim ary over-lubricate. Excess grease will be thrown from the
lead and condenser lead. distributor cam when engine is running. If this grease
(2) Remove stationary contact lock screw and re strikes the contacts, arcing and burning of contacts
move old contact set. will result.
(3) Install a new contact set; the sleeve at one end TESTING DISTRIBUTOR ADVANCE
of adjustable bracket fits over and pivots on upper
contact plate mounting pin. Centrifugal Advance Curve
(4) Connect condenser and prim ary leads. Mount distributor assembly (less cap and rotor) in a
(5) Align contacts, if necessary, by bending station reliable stroboscope-type distributor tester and pro
ary contact bracket only. Never bend movable contact ceed with tests as follows: Clamp around ribbed sec
arm to obtain alignment. tion of distributor housing. The bottom section of
(6) After aligning contacts, adjust contact clear distributor housing is not a machined surface and
ance to “Specifications,” using dial indicator (Fig. 13). concentricity would be affected, causing a wobble.
Recheck contact arm spring tension. (1) Turn Tach-Dwell switch to 8 “LOBE” position
(7) Test dwell angle to show proper degree of clo and Motor Switch to correct direction of rotation. Re
sure. See Paragraph, “D istributor Contact Dwell.” fer to “Distributor Specifications” in this manual.
The lock screw should be loosened just enough so (2) Turn battery switch “ ON.”
stationary contact bracket can be moved with a (3) Regulate tester speed control to operate distrib
slight drag; otherwise, it will be difficult to set con utor at 200 distributor rpm.
tacts accurately. A fter setting contacts to the correct (4) Align the “0 ” of the distributor tester degree
gap, tighten stationary bracket lock screw. ring with any one of the arrow flashes.
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(5) Adjust tester speed control to operate distribu distributor shaft and NO. 1 piston position as follows:
tor at speeds called for under “Specifications” and (a) Rotate crankshaft until num ber one piston is at
observe arrow flashes opposite tester degree ring to top of compression stroke.
determine degrees of advance. (b) Rotate rotor to the position of num ber one dis
(6) If advance is not according to specifications, re tributor cap terminal.
place with a new distributor shaft with correct cali (c) Lower distributor into the opening, connect
bration (shaft, cam, yoke, governor weights and prim ary lead and install distributor cap. Make sure all
springs as an assembly) or with a new distributor as high tension wires “snap” firm in cap towers. Install
sembly, less cap and rotor. distributor hold-down clamp screw. Tighten screw
For Prestolite distributors corrections can be at finger tight.
tem pted by bending the prim ary and secondary spring (d) Connect secondary lead of a Power Timing
tabs on the cam yoke to increase or decrease spring Light to NO. 1 spark plug (using proper adapter).
tension. Connect red prim ary lead to positive term inal of bat
DO NOT attempt calibration of Chrysler built dis tery and black prim ary lead to negative battery
tributors. term inal.
(e) Start and operate engine at idle speed. Rotate
Vacuum D iaph ragm Leak Test distributor housing so that specified timing m ark and
With distributor mounted in distributor tester and pointer are in alignment (Moving the distributor hous
with vacuum unit attached to distributor, proceed as ing against shaft rotation advances timing and with
follows: shaft rotation retards timing).
(1) Place thumb over end of vacuum pump and (f) Tighten distributor clamp screw after timing
hose and adjust regulator control knob to give a read has been set and recheck timing adjustm ent with a
ing of 20 inches with hose closed off to be sure tester Power Timing Light.
hose does not leak. (g) If timing is correct, connect vacuum hose to
(2) Attach tester vacuum pump hose to the tube on distributor and remove timing light from engine.
the distributor vacuum unit. The vacuum gauge
should hold on maximum vacuum obtainable if no IGNITION COIL
leak exists.
(3) Observe contact plate while perform ing leak The ignition coil is designed to operate with an
test to test response of contact plate. There should be external ballast resistor. When testing the coil for
instant response to the pull of the diaphragm, moving output, include resistor in tests.
the plate without a drag or bind. Inspect coil for external leaks and arcing. Always
(4) If leakage is indicated, replace vacuum unit as m ake two tests when testing the coil. One when the
sembly. coil is cold, the other after the coil has been warmed
up.
Vacuum Advance Curve Test coil according to coil tester M anufacturer’s in
Connect tester vacuum pump hose to the distribu structions. Test coil prim ary resistance. Test ballast
tor vacuum advance unit and perform operations 1 resistor resistance. Test coil secondary resistance. Re
through 4 under “Centrifugal Advance Curve.” Then place any coil and ballast resistor that does not m eet
proceed as follows: specifications.
(1) Turn tester vacuum pump “ON.” A djust Every time an ignition coil is replaced because of a
vacuum pump regulator to vacuum test specifications. burned tower, carbon tracking or any evidence of arc
See “Specifications” and observe arrow flashes on ing at the tower, the nipple or boot on the coil end of
tester degree ring to determ ine degrees of advance. the secondary cable, replace cable. Any arcing at the
(2) If vacuum advance is above or below specifica tower will carbonize the nipple so that placing it on a
tions, replace vacuum advance unit. Retest vacuum new coil will invariably cause another coil failure.
advance curve. If the secondary cable shows any signs of damage,
the cable should be replaced with a new cable with
DISTRIBUTOR INSTALLATION a neoprene nipple since the old cable can cause arc
(1) Position distributor on engine. Align rotor with ing, and therefore, ruin a new coil.
marks previously scribed on distributor housing. Clean
top of cylinder block to insure a good seal between BALLAST RESISTOR
distributor base and block. The ballast resistor is a compensating resistance in
(2) Engage tongue of distributor shaft with slot in the ignition prim ary circuit. During low speed opera
distributor and oil pump drive gear. If engine has tion, when the prim ary circuit current flow is high,
been cranked while distributor is removed, it will be ballast resistor tem perature rises, increasing resist
necessary to establish the proper relationship between ance. This reduces current flow, thereby prolonging
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Fig. 14—N o rm al Conditions Fig. 15—Cold Fouling Fig. 16—W e t Fouling Fig. 17—O v erh eatin g
ignition contact life. At high speed operation, when at idle and low speeds, improved plug service will be
prim ary current flow is low, the ballast resistance obtained by using the next step hotter spark plugs.
cools off allowing more current flow, which is re
quired for high speed operation. During starter oper W e t Fouling
ation, the ballast resistor is bypassed, allowing full Wet fouling (Fig. 16) tells you that the plug has
battery voltage to the ignition prim ary circuit. drowned in excess oil. In an old engine, suspect worn
rings or excessive cylinder wear. Use of a h o tter plug
SPARK PLUGS may relieve such fouling, but plugs can’t take the
place of needed engine overhaul. Remember that
Spark plug appearance or conditions can reflect a "break-in" fouling of new engines may occur before
wide variety of engine conditions as follows: normal oil control is achieved. In new or recently
overhauled jobs, such fouling plugs can be cleaned
N o rm a l Conditions and reinstalled.
Normal conditions (Fig. 14). This plug has been run
ning at the correct tem perature in a “healthy” en O verh eatin g
gine. The few deposits present will probably be light Overheating (Fig. 17) is indicated by a white or light
tan or gray in color with most regular grades of com gray insulator which appears “blistered.” Electrode
mercial gasoline. Electrode burning will not be in evi gap wear rate will be considerable in excess of
dence; gap growth will average not more than about .001"/1000 miles. This suggests that a cooler heat
.001"/1000 miles. Chances are the plug, as pictured, range should be used . . . however, over-advanced
could be cleaned, the gap electrodes filed, regapped ignition timing, detonation and cooling system stop
and reinstalled with good results. pages can also overheat the correct spark plug heat
ranges.
Cold Fouling
Cold fouling or carbon deposits (Fig. 15). This dry Cleaning an d Regapping
black appearance is fuel carbon and can be due to Carefully clean the spark plugs in an abrasive type
over rich fuel-air m ixture, possibly resulting from a cleaner. Use a pin type feeler gauge to check spark
faulty choke, clogged air cleaner, im proper carbu plug gap. Reset gaps to .035 inch. Before setting spark
retor idle adjustm ent, or dirty carburetor. However, if plug gap, file center electrode flat, make adjustment
only one or two plugs in a set are fouled like this it is by bending ground (side) electrode, never bend the
a good idea to check for sticking valves or faulty igni center electrode.
tion cables. This condition also results from prolonged When installing spark plugs, tighten to 30 foot
operation at idle. If the vehicle is operated extensively pounds.
EXTERIOR LIGHTING
HEADLIGHTS
INDEX
Page Page
Compensating the A im ers......................................... 49 Service D iagnosis.......................................... 48
General Information .................................................. 48 Switch .................................... See “Instrument Panel”
Headlight Sealed-Beam R eplacem ent.................... 50 Testing Aimer Calibration — ............................. ... 49
Measuring Headlight A im ..................... ................... 50 Visual Headlight Adjustment
Mounting and Adjusting the A im e rs ................. 49 (Without A im ers)................. ............................... . 50
Pre-Aiming Instructions............... ............................ 48
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GENERAL INFORMATION
SERVICE DIAGNOSIS
Condition Possible Cause Correction
HEADLIGHTS DIM (a) High resistance in lighting circuit. (a) Test lighting circuit including ground
(engine running connection. Make necessary repairs.
above idle) (b) Faulty sealed beam units. (b) Replace sealed beam units!
(c) Faulty voltage regulator. (c) Test voltage regulator and alternator.
Make necessary repairs.
LIGHTS FLICKER (a) Loose connections or damaged wires (a) Tighten connections and check for
in lighting circuit. damaged wiring.
(b) Light wiring insulation damaged pro- (b) Test wiring and replace or tape dam-
ducing momentary short. aged wires.
LIGHTS BURN OUT (a) High voltage regulator setting. (a) Adjust voltage regulator.
FREQUENTLY (b) Loose connections in light circuit. (b) Tighten connections.
LIGHTS WILL NOT (a) Discharged battery. (a) Recharge battery and correct cause.
LIGHT (b) Loose connections in lighting circuit. (b) Tighten connections.
(c) Burned out lamps. (c) Replace bulbs or sealed beam unit.
(d) Open or corroded contacts in head (d) Replace headlight switch.
light switch.
(e) Open or corroded contact in dimmer (e) Replace dimmer switch.
switch.
HEADLIGHTS DIM (a) Partly discharged battery. (a) Charge battery.
(engine idling or (b) Faulty battery. (b) Test battery. Replace if necessary.
shut off) (c) High resistance in light circuit. (c) Test headlight circuit including
ground connection. Make necessary
repairs.
(d) Faulty sealed beam units. (d) Replace sealed beam units.
(e) Corroded battery terminals. (e) Clean terminals.
SERVICE PROCEDURES
PRE-AIMING INSTRUCTIONS satisfactory adjustm ent can be made.
(4) Place vehicle on a level floor.
(1) Test dimm er switch operation. (5) Adjust front suspension height as necessary.
(2) Observe operation of high beam indicator (6) Inspect tire inflation.
light m ounted in instrum ent cluster. (7) Rock vehicle sideways to allow vehicle to
(3) Inspect for badly rusted or faulty headlight as assume its normal position.
semblies. These conditions m ust be corrected before a (8) If gasoline tank is not full, place a weight in
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trunk of vehicle to simulate weight of a full tank (6-
1/4 pounds p e r gallon).
(9) There should be no other load in vehicle other
than driver or substituted weight of approximately
150 pounds placed in driver’s position.
(10) Remove each headlight trim panel. Do not re
move sealed beam retainer rims.
(11) Thoroughly clean headlight lenses.
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VERTICAL A D JU STM EN T SCREWS
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(2) Horizontal line at level of headlight centers.
(3) Vertical line in line with center of left head
light.
(4) Vertical line in line with center of hood.
(5) Vertical line in line with center of right head
light.
H ig h B e a m
A djust high beam of headlights to m atch the pat
terns in Figure 7 and the corresponding num bers
listed below:
(1) High beam pattern of both headlights.
SOCKET
A N D CABLE
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In s ta lla tio n In s ta lla tio n
(1) Enter lamp into fender opening, index with (1) Position lens gasket on grille and install lens
lamp housing and install cap nuts. and attaching screws.
(2) Connect lamp socket connectors to harness con
nector. RADIATOR AIR SHIELD PARK AND TURN
SIGNAL LAMP— Challenger (Fig. 12)
FENDER SIDE MARKER LAMP AND
R em oval
REFLECTOR— Challenger (Fig. 10) (1) From underneath radiator grille air shield, dis
R em o val connect lamp socket connector at harness connector.
(1) Working under front fender, remove two cap- (2) Remove the three screws attaching lamp to
nuts attaching lamp bracket to lamp. shield and remove lamp and socket as an assembly.
(2) Pull lamp away from fender and disconnect Lamp bulb can be replaced by removing the lens at
harness connector and remove lamp. taching screws.
To replace lens or bulb, remove lamp assembly and
In s ta lla tio n
remove screws from rear of lamp housing. (1) Determine that the “U” nut is in position on
In s ta lla tio n air shield, then install the lamp and attaching screws.
(1) Position lamp on fender and install lamp brack (2) Connect lamp connector to harness connector.
et and two capnuts.
(2) Connect lamp connector to harness connector. REAR BUMPER, TAIL, STOP, TURN SIGNAL
AND BACK-UP LAMP Dart (Fig. 13)
GRILLE, PARK AND TURN SIGNAL LAMP—
Dart (Fig. 11) R em o val
(1) Working under rear bumper, disconnect lamp
R em o val connector from harness connector.
(1) Remove four screws attaching lens to grille and (2) Remove two screws attaching lamp to bum per
remove lens and gasket. Lamp bulb can be replaced and pull lamp towards front of vehicle and out from
after lens is removed. under bumper.
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FEN D ER SIDE PANEL
(REFERENCE)
C A PN U T (2),
GASKET
LENS
PY356
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PY361
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To replace lens or lamp bulbs, remove four screws
attaching lens lamp housing.
In s ta lla tio n
(1) Position lamp on bum per and install lamp at
taching screws.
(2) Connect lamp connector to harness connectors.
N U T (2)
H O U S IN G GASKET
PANEL DECK O P E N IN G
LOWER
H O U S IN G
C O N N EC TO R (PART
\ BODY W IR IN G ) !
LENS GASKET
LETTERS (5)
BEZEL
BACK-UP LAMP
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LAMP ASSEMBLY
PY357
INSTRUMENT PANELS
INDEX
Page Page.
Brake System Warning L ig h t....................... ............. ... 58 Printed Circuit Board Replacement ..................... 61
Circuit Breakers.......................................................... ... 63 Service Diagnosis ..................... ................................ 57
Fuse Block .................................................. ............... ... 62 Specifications............................................................. 77
General Information .................................................. ... 56 Speedometer Replacement .................................... 61
Heater or Air Conditioning C ontrols....................... ... 63 Switch Replacement ........................................ ....... 63
Instrum ents.................................................................. ... 61 Tests in Vehicle ....................................................... . 57
Instrument Clusters ..................... ................................59 Tests Out of V e h ic le .................................................. 62
Light Bulb R eplacem ent...... ......... ............. ............. ... 59
GENERAL INFORMATION
The fuel and tem perature gauges operate on the vides a change of resistance in the fuel gauge circuit
constant voltage principle through a voltage lim iter with any up or down movement of the float. This
m ounted externally on the printed circuit board. resistance registers on the instrum ent panel gauge,
m etered to the capacity of the tank.
Fuel L e v e l I n d i c a t i n g S y s t e m W hen the fuel level in the tank is low, the resist
A hinged float arm on the fuel tank raises or lowers ance of the circuit is increased restricting current
dependent on the fuel level. The float arm contacts flow and consequently positions the instrum ent panel
a variable resistor in the gauge sending unit th at pro- gauge pointer to low.
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Resistance in the circuit is at a minimum when the O il P re s s u re W a r n in g lig h t
tank is full and the float arm is raised. W ith resist The oil pressure warning switch, mounted on the
ance at a minimum, current flow is high, registering engine, is controlled by the engine oil pressure.
full on the instrum ent panel gauge. W hen the engine oil pressure is high (normal oper
ating condition of the engine) th e switch is held in the
T e m p e r a tu r e In d ic a tin g S y s te m
The operation of the tem perature indicating system "OFF" or "OPEN" position allowing no current to
is identical in operation with the fuel system with the flow to the oil pressure w arning lamp on the instru
exception of the method of varying the resistance of m ent panel.
the sending unit. In this system the sending unit re W hen the engine oil pressure is low the switch is in
sistance varies in direct relation to the tem perature the "ON" or "CLOSED" position allowing current to
of the coolant. flow to the oil pressure w arning lamp on the instru
When the engine is cold, the resistance of the disc m ent panel causing the w arning light to be illumin
in the tem perature sending unit is high and a low ated.
tem perature will be indicated on the gauge.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
ALL GAUGES READ (a) Faulty voltage limiter. (a) Test the voltage limiter. Replace as
HIGH (“against the necessary.
peg”) AFTER IGNITION (b) Cluster not properly grounded to (b) Tighten cluster mounting screws,
SWITCH IS TURNED panel.
“ON”
GAUGE POINTERS DO (a) Faulty voltage limiter or an open (a) Test voltage limiter. Test wiring, re
NOT MOVE WHEN circuit on battery side (input of pair or replace as necessary,
IGNITION SWITCH limiter).
IS TURNED “ON”
TEMPERATURE GAUGE (a) Fuel tank sending unit or instrument (a) Test sending unit and gauge,
INDICATES NORMAL panel fuel gauge is faulty.
OPERATION, BUT THE (b) Fuel tank is improperly grounded. (b) Test fuel tank for a good ground.
FUEL GAUGE INDICATES Testing the system with the tank send
A HIGHER OR LOWER ing unit positioned for both “empty”
FUEL LEVEL THAN and “full” is usually sufficient to
ACTUALLY EXISTS determine the calibration in the range
between these positions.
FUEL GAUGE INDI (a) Faulty instrument panel temperature (a) Test wiring, repair or replace as nec-
CATES CORRECTLY BUT gauge, wiring or faulty temperature essary. Test gauge and sending unit,
TEMPERATURE GAUGE sending unit in engine.
INDICATES HIGHER
OR LOWER TEMPERA
TURE THAN ACTUAL
ENGINE TEMPERATURE
ERRATIC TEMPERATURE (a) Loose or dirty electrical connections, (a) Clean and tighten all electrical con
GAUGE OPERATION nections and test the gauge operation.
ERRATIC OPERATION (a) Loose or dirty electrical connections (a) Test fuel tank sending unit, and pro-
OF FUEL GAUGE or faulty fuel tank sending unit. ceed as follows:
(1) Clean and tighten all electrical
connections.
(2) Inspect fuel tank ground strap
and make sure tank is grounded to
the frame.
SERVICE PROCEDURES
TESTS IN VEHICLE the voltage lim iter in the vehicle, connect one lead of
a voltm eter or test light to the tem perature sending
V o lta g e L im ite r unit and the other lead to a good ground. Leave the
The voltage lim iter can be tested in the vehicle or sending unit lead wire attached to the sending unit.
with the instrum ent cluster removed. To quickly test Turn the ignition switch to the "ON" position. A
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fluctuating voltm eter or a flashing light indicates the O il P re s s u re W a r n in g L ig h t
voltage lim iter is operating. To test the oil pressure warning light, remove the
term inal from the oil pressure sending unit. Connect
Fuel G au g e one lead of the gauge tester to the term inal and the
(1) Disconnect term inal at fuel tank sending unit. other test lead to a good ground.
Connect one lead of Tester C-3826 to disconnected W ith the ignition switch in the “on” position and
wire and the other to a good ground. T urn ignition the gauge tester in the "L" position, the warning
key on. lamp should not light. With the gauge tester in the
(2) T urn knob on dial of tester to “H” and observe "M" position, the warning lamp should show a dull
gauge on panel. It should read “Full,” plus 3 /3 2 " or glow. With the gauge tester in the "H" position, the
minus 1/32". lamp should show full brilliance.
With dial knob on “M,” panel gauge should Should the oil pressure warning light fail to re
read 1/ 2. spond to the above tests, indications are of possible
With dial knob on “L,” panel gauge should read loose connections, broken wire, or a burned out bulb.
“Empty,” plus 1/32" or minus 3/32".
On vehicles equipped with Low Fuel W arning Relay,
BRAKE SYSTEM WARNING LIGHT
lamp should light when panel gauge goes from 1/2
to “E” position. The brake warning light flashes only when the
If lamp does not light when gauge pointer is be parking brake is applied with the ignition key turned
tween 1/2 capacity and empty, use a jum per wire “ON”. The same light will also illuminate should one
between cavities 2 and 3 of low fuel w arning con of the two service brake systems fail when the brake
nector, bulb should illuminate. If no light, check bulb pedal is applied. To test the system turn the ignition
and wiring, if bulb and wiring are O.K. and lamp key “ON”, and apply the parking brake. If the light
lights, relay is faulty and should be replaced. fails to light, inspect for a burned out bulb, discon
(3) If panel gauge does not perform as described, nected socket, a broken or disconnected wire at the
continuity of circuit from tank sending unit to panel switch.
unit should be tested with special attention to printed To test the service brake warning system, raise the
circuit board before replacing panel gauge. car on a hoist and open a wheel cylinder bleeder
(4) Should panel unit perform properly, fuel tank while a helper depresses the brake pedal and ob
sending unit ground strap should be inspected for serves the warning light. If the light fails to light,
proper installation on fuel line. If ground continuity inspect for a burned out bulb, disconnected socket,
is satisfactory, remove tank unit for testing. See a broken o r disconnected wire at the switch. If the
“Fuel System.” Group 14. bulb is not burned out and the wire continuity is
proven, replace the brake warning switch in the brake
T e m p e ra tu re G a u g e line “Tee” fitting mounted on the fram e rail in the en
Disconnect the term inal from the tem perature
gine compartm ent below the m aster cylinder.
sending unit on the engine. Connect one test lead of
Tester C-3826 to the term inal and the other test lead
to a good ground. Place the pointer of the gauge L ig h t B u lb R e p la c e m e n t— D a r t M o d e ls
Instrum ent cluster light bulbs can be replaced from
tester on the “L” position and tu rn the ignition switch
under the instrum ent panel by perform ing certain
to “on.” The tem perature gauge should show “C” plus
other steps enum erated below to afford access to the
or m inus 1/8 inch. Thermal gauges are slow in opera
bulbs.
tion. Allow time for gauge to heat up.
(1) Remove emergency flasher and bracket.
Place the pointer on the tester on the “M” position
and the tem perature gauge should advance to the (2) Remove steering column opening cover.
driving range left of 1/2 position of the dial. Place the (3) Remove cluster mounting screws and rock out
pointer of the tester in the “H” position and the cluster.
gauge should advance to the “H” position of the dial. (4) Remove air conditioner spot cooler duct (so
Should the gauge respond to the above tests, but equipped).
not operate when the term inal is attached to the send (5) Remove wire harness out of attaching clip to
ing unit, indications are of a defective sending unit clear bulbs.
and it should be replaced. Should the gauge fail to (6) Disconnect speedom eter cable.
respond to the above tests, indications are of possible (7) Disconnect printed circuit board connector.
loose connections, broken wire, open printed circuit, (8) Remove fuse block from bracket.
or faulty gauge. The instrum ent cluster should be re (a) Brake system warning light.
moved for fu rth er inspection. See “Instrum ent Cluster (b) Fuel and tem perature gauge illumination.
Removal.” Perform step (1).
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(c) Left turn signal indicator. Perform step (1). HIGH BEAM I NDICATOR
(d) Left speedom eter illumination or high BRAKE WARNING
beam indicator. Perform steps (1), (2), (3), (5), (6), (8). OIL PRESSURE
(e) Right speedom eter illumination. Perform
The following bulbs are replaced from under the
steps (2), (3), (4), (5), (7).
(f) Right turn signal indicator. Perform step panel.
(4). RIGHT TURN SIGNAL
(g) Am m eter gauge illumination. Perform step LEFT TURN SIGNAL
(4). ASH RECEIVER
(h) Low oil pressure warning. Perform step HEATER CONTROL FLOOD LAMP
(4). GLOVE BOX LAMP
To remove light socket, turn counter clockwise and REVERSE INDICATOR LAMP
pull out. For replacem ent bulb number, see “Bulb COURTESY LAMP
Chart” in Specifications. To replace the radio lamp, remove the two mount
ing screws and the single support bracket n u t and
LAMP PANEL BULB REPLACEMENT— lower radio until lamp is accessible. Do not discon
Challenger nect wiring. Replace bulb, install radio.
For Rallye panels remove mounting screws then INSTRUMENT CLUSTERS— Dart (Fig. 1)
lower lamp panel so socket is accessible. Replace
bulb, install lamp panel. On Standard panel, bulbs R em oval
can be replaced without lowering lamp panel. (1) Disconnect battery ground cable.
(2) Apply tape on top of steering column and
CLUSTER BULB REPLACEMENT— Challenger switches to prevent damage to painted surfaces.
(3) Remove column opening cover (four screws).
To replace the following bulbs the radio m ust be (4) Remove lower column plate (three bolts).
removed. See Accessory Group of this manual for (5) Remove upper column clamp (two nuts and one
radio “Removal” and “Installation”. bolt).
BRAKE SYSTEM ALTERNATOR IN D IC A TO R
W A R N IN G LIGHT W IN D SH IELD
WIPER HEATER OR
CONTROL A IR C O N D ITIO N E R
CONTROLS
HEADLIGHTS,
M A P LIGHT
DOME A N D
PANEL LIGHTS M A P LIGHT
SWITCH
ASH TRAY
(O P TIO N A L)
A N D LIGHTER
REAR SPEAKER
REAR DEFOGGER
CONTROL
(O P T IO N A L) (O P TIO N A L)
R A D IO CONTROLS
(O PTIO N A L)
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(6) Remove six cluster mounting screws.
(7) Disconnect speedom eter cable at speedometer.
(8) Remove fuse block (one mounting screw).
(9) Rock cluster out and release wiring harness
from spring clip at back of cluster; continue to rock
the cluster out while using a screw driver to hold
harness clear of speedometer.
(10) Disconnect left printed circuit board connector
and the brake system warning light.
(11) From front of panel disconnect the right
printed circuit board connector and ammeter leads,
then complete cluster roll-out.
in s ta lla tio n — D a r t
(1) Position cluster in front of panel opening, con
nect right printed circuit m ultiple connector and am
m eter leads.
(2) Reaching up under instrum ent panel, hold main Fig. 2—Instrument Cluster Bezel—Removal and
harness towards front of vehicle while rolling cluster Installation—Challenger
into panel opening. Holding cluster into place, install
wire harness in retainer clip above speedom eter drive. angle bezel out in such a m anner as to clear the clock
(3) Install four screws in underside of upper lip of reset button. Reach between bezel and panel and dis
cluster and two screws in lower lip of cluster. connect stereo control wiring harness (if so equipped).
(4) Reaching up under panel, connect left printed On Rallye cluster, clock reset knob and odometer
circuit board m ultiple connector and speedom eter reset knob m ust be removed from cluster bezel to
cable. remove clock.
(5) Raise steering column into position and install (7) Remove the four cluster to panel mounting
upper column clamp and retaining nuts finger tight. screws.
Install steering column lower support plate with three (8) Disconnect all wiring harnesses and remove
retaining bolts. Tighten column upper clamp nuts cluster.
securely, remove protective tape from column and
switches and reposition floor covering. In s ta lla tio n
(1) Rest cluster in opening and connect wiring har
(6) Connect battery ground cable and test opera
nesses. Replace the cluster to panel mounting screws.
tion of all instrum ents.
(2) Position cluster bezel and connect stereo con
trol wiring harness (if so equipped).
INSTRUMENT CLUSTER— Challenger (Figs. 2
and 3)
R em o val
Before performing this operation it is advisable to
put a protective cover over the top of the instrument
panel and steering column to prevent damage.
(1) Disconnect battery ground cable.
(2) Remove the six lamp panel mounting screws.
Carefully slide lamp panel out and lay on top of in
strum ent panel. It is not necessary to disconnect wir
ing harness.
(3) Remove the four switch bezel mounting screws,
let bezel hang loose. It is not necessary to disconnect
switches.
(4) Remove the three steering column “Duffy” plate
mounting screws and the two column support clamp
retainer nuts. Allow column to rest on seat.
(5) From under instrum ent panel disconnect speed
om eter cable.
(6) Remove six cluster bezel mounting screws,
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CAUTION: When installing cluster bezel be sure stall eight retaining screws.
stereo control harness is tucked into panel to avoid (4) Install instrum ent cluster. See “Instrum ent
being trapped by bezel. Cluster Installation”.
Install bezel mounting screws.
(3) Connect speedom eter cable and install clock INSTRUMENTS
reset knob and odometer reset knob.
R e p la c e m e n t
(4) Raise steering column into position and install
(1) Remove instrum ent cluster. See “Instrum ent
column support clamp retainer nuts and “Duffy” plate.
Cluster Removal.”
(5) Position switch panel and install mounting (2) W ith cluster face down on padded work bench,
screws.
remove eight screws retaining cluster bezel to cluster
(6) Install lamp panel.
housing.
(7) Remove protective covering. Connect battery (3) Carefully separate cluster housing from bezel.
ground cable and check cluster operation. (4) Remove the m ounting stud nuts of the gauge to
be removed and remove gauge from front of housing.
SPEEDOMETER— Challenger (5) Position new gauge studs through back of hous
ing and install attaching nuts. Do not overtighten.
R em oval (6) Carefully position cluster housing on bezel and
To replace the speedometer, it is necessary to re install eight retaining screws.
move the instrum ent cluster. See “Instrum ent Cluster (7) Install instrum ent cluster. See “Instrum ent Clus
Removal and Installation.” ter Installation.”
(1) Place cluster face down on a padded work
bench. VOLTAGE LIMITER
(2) Remove the seven cluster lens snap pin retain
ers and lift lens from housing. R em o val
(3) Remove two speedom eter mounting screws with (1) Disconnect battery ground cable.
attached insulators. Remove speedom eter from cluster (2) Remove radio, see “Accessory Group” of this
housing. manual.
(3) Disconnect wire plugs from limiter.
In s ta lla tio n (4) Remove mounting screw and limiter.
(1) Position speedom eter on cluster housing and
install mounting screws and insulators. In s ta lla tio n
(2) Assemble cluster lens to cluster housing and (1) Install lim iter and mounting screw.
secure with snap pins. (2) Connect wire plugs to limiter.
(3) Install radio, see “Accessory Group” of this
SPEEDOMETER— Dart manual.
(4) Connect battery ground cable and check lim iter
R em o val operation.
(1) Remove instrum ent cluster. See “Instrum ent
Cluster Removal” . PRINTED CIRCUIT BOARDS
(2) With cluster face down on padded work bench, R e p la c e m e n t— A ll M o d e ls
remove eight screws retaining cluster bezel to cluster (1) W ith the cluster face down on a padded work
housing. bench, remove all light bulb sockets and voltage
(3) Carefully separate housing from bezel. Loosen limiter.
two fuel gauge m ounting nuts. (2) Remove eight screws retaining cluster bezel to
(4) Remove two speedom eter mounting screws and cluster housing and carefully separate.
rubber washers from back of cluster housing. (3) Remove fuel and tem perature gauge stud nuts
(5) Carefully lift speedom eter head out of housing. and remove gauges from housing.
(4) Remove printed circuit board retaining screws
In s ta lla tio n and lift board off from housing.
(1) Position new or repaired speedom eter head (5) Place new printed circuit board on housing and
in housing, aligning screw holes with holes in speed secure with retaining screws.
om eter head. (6) Position tem perature and fuel gauge studs
(2) Install two rubber washers and retaining screws through printed circuit board from housing side and
in back of housing and tighten. Tighten two fuel install retaining nuts. Do not overtighten.
gauge m ounting nuts. (7) T ransfer light bulb sockets and voltage lim iter
(3) Carefully position housing on bezel and in to new printed circuit board.
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(8) Carefully position housing on bezel and install forms properly make sure the fuel tank ground strap
eight retaining screws. on the fuel line at the tank is making a good ground.
Should the gauge perform properly and the ground
TACHOMETER strap be properly installed, remove the fuel tank
sending unit as outlined in “Fuel System”, Group 14
R e p la c e m e n t and test as follows:
(1) Remove instrum ent cluster. See “Instrum ent (1) Using an ohm meter with a 0 to 100 ohm scale,
Cluster Removal” . connect one lead to body of sending unit and the
(2) With cluster face down on a padded work bench, other lead to term inal in center of unit.
remove eight screws retaining cluster bezel to cluster (2) Hold unit so float arm contacts “Empty Stop.”
housing. The reading on ohm meter scale should be 73 ohms,
(3) Carefully separate housing from bezel. plus or minus 12.0 ohms.
(4) Remove four tachom eter housing screws and (3) Raise arm to “Full Stop.” The reading should
remove through front of cluster housing. now be 9.6 ohms, plus or minus 1 ohm.
(5) Install new or repaired tachom eter through If the unit does not perform to these specifications,
front of cluster housing. inspect the stops or arm for possible distortion. If the
(6) Install four mounting screws. stops or arm cannot be repaired or are not damaged,
(7) Position bezel on housing and install eight the unit should be replaced.
retaining screws.
(8) Install instrum ent cluster. See “Instrum ent FUSE BLOCK— Dart (Fig. 4)
Cluster Installation”.
The fuse block is located at the lower edge of the
TESTS OUT OF VEHICLE instrum ent panel and is retained to the instrum ent
panel lower reinforcem ent by a self tapping screw.
P r in t e d C irc u it B o a r d In the fuse block are mounted radio, cigar lighter,
A visual inspection of the conductors should be air-conditioner or heater, tail-stop-dome light, and ac
made for cracks or damaged circuits. If no visual cessory fuses. The fuse capacity is printed on the fuse
damage is evident, each circuit should be tested for block as an aid to replacem ent requirem ents.
continuity with an ohm meter or a test light. Should
an open circuit be detected, the printed circuit board FUSE BLOCK— Challenger (Fig. 5)
should be replaced.
The fuse block is located in the passenger com part
In s tru m e n ts ment under the instrum ent panel to the left of the
(1) Connect a jum per wire to voltage lim iter input brake pedal and is retained to the bulkhead discon
term inal. Connect other end of the jum per wire to nect by two locking tabs.
positive post (+ ) of a 12 volt test battery. To release the fuse block from the bulkhead dis-
(2) Connect a jum per wire from negative (— ) post
of battery to instrum ent cluster base (ground).
(3) Connect one lead from Tester C-3826 to gauge
sending term inal being tested.
(4) Connect rem aining tester lead to instrum ent
cluster base (ground).
When the gauge tester is in “L” position, the gauge
being tested should read on the low side of dial.
With gauge tester on “M”, the gauge should read in
the center of the dial scale and on the high end of
the dial when pointer of tester is placed on “H” .
If gauges do not perform as stated, inspect for an
open printed circuit before replacing gauge.
Caution: A direct connection from a 12 volt battery
will damage the gauges or printed circuit boards.
F u e l T a n k S e n d in g U n it
Before removing any unit of the fuel level indicat
ing system, the panel fuel gauge should be tested
first. See “Tests in Vehicle” . If the panel gauge per
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Carefully slide lamp panel out and lay on top of in
strum ent panel. It is not necessary to disconnect wir
ing harness.
(3) Remove the four switch bezel mounting screws.
Carefully slide assembly out and to the right overlap
ping cluster, then lower it until free then disconnect
wiring harness.
(A) Wiper Switch—Pull control knob from shaft.
Remove mounting nut and remove switch from bezel
assembly.
(B) Headlamp Switch—Remove the two switch
mounting screws and remove switch from bezel as
sembly.
(C) Rear Defogger or Top Lift Switch—Remove the
two switch m ounting screws and remove switch from
bezel assembly.
(D) Dimmer Switch— Remove the seven screws
Fig. 5—Fuse Block and Bulk H ead Disconnect— holding mounting plate to bezel. Remove wiper and
Challenger dimmer switch knobs and separate plate from bezel.
Remove dimmer switch mounting n u t and separate
connect, unlock locking tabs and pull fuse block away
switch from mounting plate.
from bulkhead disconnect.
In s ta lla tio n
CIRCUIT BREAKERS (1) Connect wiring harness to switch bezel. Slide
bezel into position and install mounting screws.
Use only identical type and value circuit breakers
(2) Install lamp panel and mounting screws.
as replacem ents during service. See “Specifications”
(3) Remove protective covering. Connect battery
for the location of circuit breakers.
ground cable and check switch operation.
SWITCH REPLACEMENT HEATER OR AIR CONDITIONING CONTROLS
H e a d lig h t S w itc h — D a r t
R e m o v a l— D a r t
The headlight switch is serviced from under the (1) Disconnect battery ground cable.
instrum ent panel after removing the fuse block
(2) Remove radio. See “Radio Removal”, Acces
m ounting screw. Move the fuse block out of the way.
sories Group 1.
If air conditioning equipped, remove the left spot (3) Loosen set screw(s) in bottom of control lever
cooler hose from the outlet.
knob(s) and remove.
Remove the knob by depressing the release button (4) From behind instrum ent panel, remove 2 con
on the switch and pull the knob out. A fter removing
trol assembly retaining nuts.
the bezel with Tool C-3824, lower the switch and dis (5) Lower assembly below instrum ent panel and
connect the multiple connector. disconnect blower switch wires, control cables or vac
W in d s h ie ld W ip e r S w itc h — D a r t uum connector if air conditioning equipped.
(1) Remove air conditioning duct (so equipped). The blower switch is attached to the control as
(2) Loosen set screw and remove switch knob. sembly with two metal screws.
(3) Remove spanner nut with Tool C-3824.
In s ta lla tio n
(4) Remove wiring harness from harness clip for (1) From a position below instrum ent panel, con
access. nect and adjust control cables, blower switch wires
(5) Disconnect wiring connector at switch and re or the vacuum connector if air conditioning equipped.
move switch. See “Control Cable Adjustm ents” , Accessories,
Group 1.
SWITCH REPLACEMENT— Challenger (2) Position control assembly on mounting studs
R em o val and install two retaining nuts.
Before performing this operation it is advisable to (3) Install control lever knob(s).
put a protective cover over the top of the instrument (4) Install radio. See “Radio Installation” , Acces
panel and steering column to prevent damage. sories, Group 1.
(1) Disconnect battery ground cable. (5) Connect battery ground cable and test operation
(2) Remove the six lamp panel m ounting screws. of controls.
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HEATER CONTROLS— Challenger (9) Remove the four remaining control mounting
screws and slide unit out of panel.
R em o val
In s ta lla tio n
Before performing this operation it is advisable to
(1) Position control in instrum ent panel and install
put a protective cover over the top of the instrument
four mounting screws.
panel and steering column to prevent damage.
(2) Connect wiring harness to blower switch.
(1) Disconnect battery ground cable.
(3) Install the two control bracket screws the one
(2) Remove the six lamp panel mounting screws.
in the tem perature control linkage and the top screw
Carefully slide lamp panel out and place on top of
of the heater-defroster linkage.
instrum ent panel. It is not necessary to disconnect
(4) Position cluster bezel in instrum ent panel and
wiring harness.
install the six mounting screws. Connect wiring h ar
(3) Remove the four switch bezel mounting screws. ness.
Carefully slide assembly out and to the right, over (5) Install left trim bezel.
lapping cluster, then lower it until free from instru (6) Connect wiring harness to switch bezel. Slide
m ent panel. Disconnect wiring harness and remove bezel into position and install mounting screws.
switch bezel. (7) Install lamp panel and mounting screws.
(4) Remove left trim bezel by removing the four (8) Remove protective covering. Connect battery
exterior screws and one from under instrum ent panel. ground cable and check control operation.
(5) Remove the six cluster bezel mounting screws.
Slide bezel forward allowing it to rest on steering HEATER BLOWER SWITCH— Challenger
column. R em o val
(6) Using the access area provided through the (1) Disconnect battery ground cable.
switch bezel removal, remove top screw of heater- (2) From under instrum ent panel disconnect wiring
defroster linkage. harness from switch.
(7) From under instrum ent panel remove screw (3) Remove the two mounting screws and switch.
from tem perature control linkage, then remove the In s ta lla tio n
two screws from heater control bracket, (one is lo (1) Position switch in instrum ent panel and install
cated on bottom of panel and the other is behind the m ounting screws.
heater unit). (2) Connect wiring harness to switch.
(8) Remove wiring harness from blower motor (3) Connect battery ground cable and check switch
switch. operation.
Page Page
End Play A djustm ent................................................ 66 Motor Rem oval..................... ...................................... 67
General Information .................................................. 64 Panel Switch T e s ts .................................................... 66
Links ........................................................................... 68 Pivot Replacem ent.............................................. . 70
Lubrication ................................................................. 70 Service Diagnosis................................................ . 65
Motor Installation ......... . .......................................... 67 Wiper Arm Adjustment ............................................ 65
GENERAL INFORMATION
The windshield wipers can be operated with the Two speed wiper motors have perm anent m agnet
windshield wiper switch only when the ignition switch fields and are controlled by feeding power to two
is in the Accessory or Ignition position. A circuit different brushes for low and high speed. For low
breaker, integral with the wiper switch protects the speed operation the current first flows through the
circuitry of the wiper system and the vehicle. All torque limiting resistor and then to the low speed
models are equipped with a two speed wiper system brush (terminal “L” Fig. 3). For high speed, the brush
as standard equipment. A variable speed wiper system (terminal “H ”) is fed directly.
is offered as optional equipment. The two speed wiper system, on the Dart will com
Variable speed wiper motors are controlled by re plete the wipe cycle and retu rn to the park position
sistors in the field circuit. Variable speed motors have when the switch is turned “Off”. These two speed sys
a rheostat built into the wiper switch. tems park in the lowest portion of the wipe pattern.
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A depressed parking feature in the variable speed The two speed wiper system used on the Challenger
wiper system is accomplished by reversing the rota models accomplishes its depressed parking action by
tion of the motor and the use of an eccentric motor reversing the rotation of the motor and the use of a
shaft. When the wiper switch is turned “Off” the parking cam on the motor crank pin. When the wiper
motor rotation is reversed, the m otor inner shaft stops switch is turned “ Off”, the m otor direction is reversed
and the outer shaft rotates 180 degrees. This in effect, and at the same time, the parking cam rotates 180°
lengthens the drive link slightly to park the blades degrees, lengthening the drive link slightly to park
in the depressor position. The linkage shortens again the blades in a depressed position. Motor operation
when the motor is turned “On” and reverses the in the wipe direction returns the cam to “ru n ” posi
action. tion to restore the normal link and wipe pattern.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
WIPER FAILS TO (a) Binding Linkage. (a) Relieve binding condition.
OPERATE (b) Faulty instrument panel switch. (b) Test Switch. See “Panel Switch
Tests.”
(c) Linkage disconnected. (c) Repair as necessary.
(d) Faulty motor. (d) Test motor. See “Motor Testing.".
(e) Open or grounded wiring. (e) Test wiring for continuity. Repair as
necessary.
WIPER BLADES NOT (a) Arm set at incorrect position. (a) Adjust arm. See “Wiper Arm Adjust
PARKING PROPERLY ment."
BLADES SLAP AGAINST (a) Improperly adjusted wiper arm. (a) See “Wiper Arm Adjustment."
WINDSHIELD (b) Looseness of the motor crank or (b) Tighten on replace the part,
MOULDINGS other drive parts.
ON DRY GLASS
BLADES CHATTER (a) Twisted arm holds blade at wrong (a) Replace wiper arm. Do not attempt to
angle to glass. straighten bent or twisted arm.
(b) Bent or damaged blades. (b) Replace blades.
(c) Foreign substances such as body pol- (c) Clean the glass or blades,
ish on glass or blades.
MOTOR WILL NOT (a) Motor park switch failure in the (a) Replace motor assembly.
STOP WHEN INSTRU "closed” position.
MENT PANEL SWITCH
IS TURNED “OFF”
MOTOR STOPS IN ANY (a) Motor park switch failure in the (a) Replace motor assembly,
POSITION WHEN IN open position.
STRUMENT PANEL (b) Open parking circuit or open field cir- (b) Test continuity of blue, red and green
SWITCH IS TURNED cuit. wiring circuit and correct as neces
“OFF" sary.
NO SPEED CONTROL (a) Open circuit in red or green wiring (a) Test continuity and correct as neces-
(Variable) (red or brown wire—2- sary.
speed).
(b) Defective control switch. (b) Replace switch.
SERVICE PROCEDURES
WIPER ARM ADJUSTMENT— Variable on Dart blade. With the force applied, the clearance between
and Variable or Two Speed System on Challenger the tip of the wiper blade and the windshield lower
moulding (Dart) or the side of the wiper blade and
To determ ine if an adjustm ent is required, apply a
constant upward force of 50 ounces parallel to the the blade stop (Challenger) should be as follows:
windshield glass at the end of the wiper arm (where
Models Clearance in Inches
the blade is attached to the arm). W ith the force ap
Right Left
plied, pull the wiper blade away from the windshield Dart .5 to 2.25 .25 to 2.00
glass once or twice to prevent glass friction from Concealed Wipers
affecting upward movement of the wiper arm and Challenger
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If the clearance is not in the specified range, use
Tool C-3983 and reposition the wiper arm and blade
assembly (Fig. 1).
T w o S p e e d (D a rt)
To determ ine if an adjustm ent is required apply a
constant downward force of 25 ounces, parallel to the
windshield glass, at the end of the wiper arm (where
the wiper blade is attached to the arm). With the 25
ounce force applied pull the wiper blade away from
the windshield glass once or twice to prevent glass
friction from affecting downward movement of the
wiper arm and blade. W ith this force applied the
clearance between the tip of the wiper blade and the
windshield moulding should be as follows: Fig. 2 —End Play Adjustment (V ariab le Speed)
Models Clearance in Inches Between Tip of
Blade and Windshield Moulding move from the instrum ent panel. For removal and
Right Left installation of the wiper switch see “Instrum ent
Dart .5 to 2.25 .25 to 2.00 Panels”.
If the clearance is not in the specified range refer Using a continuity tester or an ohmmeter, test for
to Figure 1 and reposition the wiper arm and blade continuity (no resistance) between the contact te r
assembly. minals of the switch as shown in the following chart.
CAUTION: The use of a screwdriver or other prying For test purposes, the first position is the “Off”
tool to remove an arm may distort it in a manner that position. The “Low” position is the first detent past
will allow it to come off the pivot shaft in the future, the “Off” position. The “High” position is the second
regardless of how carefully it is reinstalled. NEVER detent of the switch. The bench test of the switch
under any circumstances push or bend the spring does not require the use of a twelve volt battery.
clip in the base of the arm in an attempt to release “Ground” is the case of the switch.
the arm. This clip is self-releasing.
SWITCH CONTINUITY CHART
END PLAY ADJUSTMENT (Variable Speed)
C h ry s le r M a n u fa c tu r e d T w o S p e e d -
To adjust the arm ature shaft end play, tu rn the (D a rt)
adjustm ent screw in until it bottoms and back-off 1/8
Off Low High
tu rn (Fig. 2). This adjustm ent can be made without B to B/U. B to B/U.
B to B/U.
removing the wiper m otor from the vehicle. B to PI. B to PI. B to PI.
A to P2. B to A. B to H.
PANEL SWITCH TESTS
P2-open P2-open
T w o -S p e e d H-open H-open A-open
To test the switch, disconnect the wiring and re-
V a ria b le S p e e d
The two speed switches contain a resistor while the
variable speed uses a rheostat to provide a means of
controlling the current flow to the motor. The switch
is designed to provide a circuit to the motor to reverse
the current to the field winding which reverses the
direction of the arm ature. A circuit breaker, built into
the switch, protects the circuitry.
To test the switch, disconnect the wiring to the
switch and remove the switch from the instrum ent
panel. For removal and installation of the wiper
switch, see “Instrum ents and Indicators.”
Using a continuity tester or an ohmmeter, test for
continuity (no resistance) between the contact te r
minals of the switch as shown in the above chart. For
test purposes the “P ark” position is the switch “Off”
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position. The “Low” speed is the position immediately
past the “Off” detent and the High position is at the
extrem e position of the switch travel. In the test
chart, the reference "Ground" means to attach one
lead of the continuity tester or ohmmeter to the switch
case.
MOTOR TESTING
Tw o Speed ( D a r t ) ( f i g . 3 )
(1) Disconnect motor leads at motor. Connect
jum per from battery positive term inal to motor ter
Fig. 3 —W ip e r M oto r—Two Speed
minal “H ”.
(1) Connect a jum per wire from the green lead to
SWITCH CONTINUITY CHART ground. Connect a second jum per from battery posi
tive term inal to brown and red leads in bulkhead dis
C h ry s le r M a n u fa c tu r e d T w o S p e e d connect. (The ground circuit is completed through
Challenger the car body.) The motor should run continuously.
Disconnect leads.
Off Low High (2) Connect jum per wire from green lead to brown
B to B/U B to B/U B to B/U lead. Connect red lead to ground. Connect third
B to P B to A B to FI jum per wire from battery positive term inal to blue
A to Ground F2 to Ground F2 to Ground lead. The wiper should run to the park position.
F2-Open Fl-Open P-Open CAUTION: Motor can be damaged if not wired cor
Fl-Open H-Open A-Open
rectly.
SWITCH CONTINUITY CHART MOTOR REMOVAL
(V e n d o r M a n u fa c tu re d V a ria b le S p e e d ) (D a rt)
(1) Disconnect battery ground cable.
O ff Low High
(2) Disconnect wiper motor wiring harness.
B to B/U. B to B/U. B to B/U. (3) Remove three wiper m otor mounting nuts. (On
B/U to P. B/U to A. B/U to A. vehicles without air conditioning it is easier to remove
A to F2. A to FI. FI to R2 crank arm nut and crank arm from under instrum ent
*A through the panel first and omit steps (4 )and (5).
rheostat or
resistor to FI.
(4) Work motor off mounting studs far enough to
FI to Ground. F2 to Ground. F2 to ground. gain access to crank arm mounting nuts. CAUTION:
P-open. P- open. Do not force or pry motor from mounting studs as
*As the switch knob of the variable speed switch is ro drive link can easily be distorted.
tated the resistance shown on the ohmmeter should (5) Using a 1/2 inch open end wrench, remove mo
vary from a high reading to a low reading in a smooth tor crank arm nut. Carefully pry arm off shaft.
rate of change. (6) Remove wiper motor.
Connect second jum per from term inal “P2” to
ground. Motor should run at high speed. Remove
MOTOR INSTALLATION
jum pers.
(2) Connect jum per from battery positive term inal
(D a rt)
to resistor term inal. Connect second jum per from te r Before installing wiper motor, be sure all three
minal “L” to second resistor terminal. Connect a third spacers are inserted in holes of motor grommets.
jum per from term inal “P2” to ground. The motor
(1) Balance wiper motor on upper right motor
should run forward at low speed. Remove jum pers.
grommet.
(3) Connect jum per from battery positive term inal
(2) Index the flats on motor shaft to mate with flats
to motor term inal “P I ” . Connect a second jum per
from motor term inal “L” to ground. The motor should on crank arm. Start and tighten crank arm nut on
run in reverse rotation for at least a half revolution shaft, being careful that crank arm remains indexed
and park. Remove jumpers. and fully seated on shaft. (On vehicles without air
conditioning, it is easier to do step (3) before step (2)
V a ria b le S p e e d from under instrum ent panel.)
Disconnect m otor leads at bulkhead disconnect. (3) Position wiper motor, then install and tighten
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the three mounting nuts, being sure that ground strap
is attached securely.
(4) Connect wiper m otor harness.
(5) Connect battery ground cable and test opera
-P IV O T ASSEMBLY
tion of windshield wiper system.
MOTOR REMOVAL
(C h a lle n g e r )
(1) Disconnect battery ground cable. ■ PIVOT CRANK ARM
(2) Using Tool C-3982 (Fig. 1) carefully remove
wiper arm and blade assemblies. PIVOT PIN
(3) Remove left cowl screen. PIVOT PIN
(4) Remove drive crank arm retaining nut and drive BUSH IN G
crank. Disconnect wiring to motor.
(5) Remove three wiper motor m ounting nuts and
remove motor.
NR485
MOTOR INSTALLATION
Fig. 4 —Removing Link and Bushing
(C h a lle n g e r) drive link after removal of assembly from vehicle
(1) Position motor on the three studs on dash panel. (Fig. 6).
Make certain rubber gasket and spacers between mo (3) To remove connecting link from pivots, remove
tor and dash panel, are properly positioned. glove box. Reaching through glove box opening,
(2) Install the three nuts that m ount m otor to dash gently pry the bushing and link from the right pivot
panel and connect wiring to motor. Make sure ground pin. (Fig. 5). Lift the link from the pivot crank
strap is installed under one nut. arm pin and repeat operation at left pivot (Fig. 5).
(3) Position drive crank on motor and install nut. W ithdraw from under left side of panel.
Tighten to 140 inch-pounds.
(4) Connect battery ground cable and test opera L u b ric a tio n
tion of wiper motor. The crank arm pin and the pivot pins for all sys
(5) Install left cowl screen. tems should be lubricated with Automotive Multi
(6) Using Tool C-3982 (Fig. 1) carefully replace purpose Lubricant NLGI2.
arm and blade assemblies. (See Wiper Arm A djust
In s ta lla tio n
ment). (1) Install bushing on motor crank arm pin, posi
tion drive link on bushing so large side of pivot bush-
LINKS
R e m o v a l (D a rt)
(1) Disconnect battery ground cable.
(2) If air conditioning equipped, remove the duct
supply left spot cooler to provide easier access to
the left wiper pivot.
Insert a wide blade screwdriver between plastic
link bushing and the pivot crank arm. Gently twist
the screwdriver to force the bushing and link from
the pivot pin (Fig. 4). Remove three m otor m ount
ing nuts, pull motor away from bulkhead and remove
motor crank arm retaining nut. After crank arm is
removed from motor shaft, remove drive link assem
bly from under left side of panel.
In heater equipped models, remove m otor drive
crank arm retaining nut and pry crank arm off of
m otor shaft. Gently pry drive link and bushing from
left pivot crank arm pin and withdraw assembly from
under panel. Remove m otor drive crank arm from
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f t*— -RIGHT PIVOT ASSEMBLY FRONT OF
CAR
MOTOR
DRIVE LINK
CON NECTION
CONNECTING LINK BULKHEAD
L/Kl\ LINK
DRIVE RETAINER
FRONT OF CAR
t SPRING WASHER
jL 'z B U SH IN G
M O TO R
TO LEFT PIVOT
C O N N E C T IO N
\
“ ^ r a - D R . V E CRANK
NR484B A N D PIN
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(4) Remove links and pivots through cowl top open (3) Position crank arm on motor shaft and tighten
ing. The linkage and pivots can be serviced on bench mounting nut to 140 inch-pounds.
after removal from the vehicle. (4) Connect battery ground cable.
(5) Test W iper System Operation.
LUBRICATION (6) Install left cowl screen.
(7) Using Tool C-3982 (Fig. 1) carefully replace
Should it be necessary to service the wiper system arm and blade assemblies. (See W iper Arm Adjust
for any reason, the parking spring in the two speed ments).
parking mechanism should be lubricated with Mopar
Lubricant provided with service package. Apply the PIVOT REPLACEMENT
lubricant to inside coils of spring first and to the out (D a rt)
side of the spring coils after installation of the spring. (1) Remove battery ground cable.
The three speed crank arm pin and the pivot pins (2) Using Tool C-3982, remove wiper arm assembly
for all systems should be lubricated with Automotive (Fig. 1).
Multi-Purpose Lubricant NLGI 2. (3) From under instrum ent panel, remove two re
taining nuts from pivot mounting studs and lower
LINKAGE AND PIVOT INSTALLATION pivot far enough to remove connecting link (and drive
link on left pivot) from pivot crank arm pin (Fig.
(C h a lle n g e r ) 5). If air conditioning equipped, it is necessary to re
If servicing of the mechanism on the 2-Speed Motor move glove box for access to right connecting link
Crank is required, be certain that during reassembly, and pivot retaining nuts. Remove pivot assemblies.
the link is positioned between the ears of the cover (4) Install replacem ent pivot assembly, with new
retainer. Seat the rubber cover fully in the groove gasket, loosely on the mounting studs.
provided for it on the cover retainer. (5) Lubricate pivot pins and snap link bushings
Any retainer clips distorted during removal should fully into position on pivot pins.
be replaced. Place foam rubber washer and flat metal (6) Tighten pivot mounting nuts.
washer on pins. Lubricate pin and install links and (7) Reconnect battery ground cable and test wiper
retainer clips. system for operation and parking action.
(1) Insert the linkage and pivots, assembled as a (8) Replace glove box if required and using Tool
unit, through the cowl panel opening. C-3982, install and adjust the wiper arm and blade as
(2) Bolt pivots in position. semblies. (See Wiper Arm Adjustment).
WINDSHIELD WASHERS
GENERAL INFORMATION
Dart and Challenger models are equipped with a pump assembly mounted directly to the reservoir. A
foot operated pump as standard equipm ent or electric perm anently lubricated sealed motor is coupled to a
washers as part of an option. rotor type pump. Fluid, gravity fed from the reser
Foot pump equipped models have a unique reser voir, is forced by the pump through rubber hoses to
voir mounted in the engine compartm ent. Check the nozzles which direct the stream s to the wind
valves are built into the re a r of the foot pump to con shields.
trol the direction of fluid flow from the reservoir to The pump and reservoir in either system are serv
the pump and from the pump to the nozzles. iced as separate assemblies.
Electric pump equipped models have the electric
SERVICE DIAGNOSIS
FOOT PUMP
Condition Possible Cause Correction
HIGH OPERATING EFFORT (a) Low aimed nozzles. (a) Adjust nozzles.
(b) Pinched hoses. (b) Correct as necessary.
LOW OUTPUT (a) Low aimed nozzles. (a) Adjust nozzles.
(b) Leaky hoses. (b) Correct as necessary.
(c) Defective pump. (c) Replace pump.
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SERVICE DIAGNOSIS
ELECTRIC PUMP
As an aid to determ ine if the pump assembly is de switch. If pump does not operate, it may be defective
fective, connect a jum per wire from the blade ter or frozen. Replace the pump and m otor assembly if
minal of the pump (Fig. 3), to the positive term inal of defective.
the battery. If pump operates, check wiring and
Condition Possible Cause Correction
INTERMITTENT (a) Loose wiring connections. (a) Repair as necessary.
OPERATION OF (b) Faulty switch. (b) Replace switch.
SYSTEM (c) Faulty motor. (c) Replace motor and pump assembly.
MOTOR RUNS DOES (a) Nozzle jets plugged. (a) Clean nozzle jets.
NOT PUMP FLUID (b) Broken or loose hose. (b) Replace hose.
(c) Faulty pump. (c) Replace motor and pump assembly.
(d) Nozzle jet under air intake grille. (d) Adjust nozzles.
PUMP ASSEMBLY (a) Poor ground. (a) Clean ground wire terminal and tight
INOPERATIVE en mounting screw.
(b) Loose wiring terminals. (b) Tighten terminals.
(c) Corroded terminals. (c) Clean and tighten terminals.
(d) Broken wires. (d) Repair or replace the wires.
(e) Faulty switch. (e) Replace switch assembly.
(f) Faulty motor. (f) Replace motor and pump assembly.
LOW OUTPUT (a) Low aimed nozzles. (a) Adjust nozzles.
(b) Poor electrical connections. (b) Clean and tighten terminals.
(c) Pinched or leaky hoses. (c) Correct as necessary.
(d) Defective motor. (d) Replace motor arid pump assembly.
SERVICE PROCEDURES
N o z z le A d ju s tm e n t (3) Using a suitable extension and a 7 /8 inch deep-
To compensate for lateral adjustm ent, loosen the well socket through filler neck, remove pump mount
m ounting screws and move the nozzle and bracket ing nut inside reservoir. Remove ground wire.
assembly until the nozzle is centered between the It may be necessary in some older pumps to use a
grille louvers. Vertical nozzle adjustm ent is made 15/16 in. deep-well socket due to the expansion of
by bending the tab of the nozzle mounting bracket the nylon nut through absorption of windshield
up or down. washer fluid.
Adjust nozzles so that the centers of the stream s (4) Remove pump from bottom of reservoir and
contact the windshield glass as shown in Figures 1 discard rubber gasket.
and 2. The oval pattern formed by the stream strik
ing the windshield glass is not “centered” on the
CENTER LINE OF
center of the stream. The stream is toward the bottom
of the oval pattern.
Foot pump models may be aimed higher for im
proved water distribution.
M o to r a n d P u m p A s s e m b l y
R em oval
(1) Remove reservoir mounting screws, remove
reservoir and pump assembly. Empty fluid from
reservoir. (On Challenger models equipped with air
conditioning it will be necessary to loosen the upper
horn at mounting bracket and allow horn to rotate OF LOWER W INDSHIELD
M O U L D IN G
down out of the way to remove reservoir).
(2) Disconnect m otor feed wire connector and
rubber hose from bottom of pump.
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BOTTOMi O
u Fr RESERVOIR
i ^ INTAKE SCREEN A N D
FO OT PUMP UPPER TARGET ^ M O U N T IN G NUT ASSEMBLY
:T O HIT UPPER M O U L D IN G
ELECTRIC PUMP
/ -PLASTIC
WASHER
UPPER TARGET
CENTER LINE OF
W IN DSHIELD ELECTRIC PUMP
LOWER TARGET PY862
OUTLET
Fig. 2—Washer Aiming D iagram (Challenger)
In s ta lla tio n
Any time the pump is removed from the reservoir,
Fig. 3—Reservoir and Pump Assembly
always replace the rubber gasket.
(1) Install new rubber gasket on reservoir (Fig. 3). FOOT PUMP
(2) Install pump assembly through gasket. Place
plastic washer under screen and nut assembly, and R em o val
CAUTION: Before removing foot pump, clamp the
tighten securely (approximately 25 inch-pounds). Do
hose at the reservoir to prevent the siphoning of
not overtighten.
washer fluid into the passenger compartment.
(3) Reconnect ground wire. Ground wire may be
(1) Remove the two screws which m ount the pump
spliced, soldered or recrimped.
to the floor pan.
Crimping may be facilitated by making small cuts
(2) Disconnect hoses.
along the brass barrel, using diagonal cutters and then
peening using a center punch and hammer. In s ta lla tio n
(4) Install pump and reservoir in vehicle with (1) Attach the hoses first.
m ounting screws making sure motor ground wire is (2) Mount pump assembly and install mounting
installed under one of the mounting screws. (On Chal screws.
lenger models equipped with air conditioning reposi (3) Tighten the mounting screws securely.
tion horn and tighten mounting screw). (4) Remove the clamp from the hose at the reser
(5) Connect motor feed wire connector and rubber voir.
hose to pump. Fill reservoir, inspect for leaks and (5) Check the system for leaks and test opera
test operation of washer system, making sure the tion of the system making sure the nozzles are prop
nozzles are adjusted properly. erly aimed.
Page Page
Emergency F las h er.................................................... 74 Service Diagnosis ..................... ............................... 73
General Information .................................................. 72 Switch ......................................................................... 73
GENERAL INFORMATION
The tu rn signals are activated with a lever mounted straight ahead position, a lobe m ounted to the under
on the left side of the steering column just below the side of the steering wheel contacts one of two cancel
steering wheel. When the driver wishes to signal his ing cams in the turn signal switch m ounted in the
intentions to change direction of travel, moving the steering column upper housing. Contact of the lobe
lever up causes the right tu rn signals to flash. Moving with the canceling cam returns the switch to the off
the lever down causes the left tu rn signals to flash. position.
A fter completion of a tu rn the system is deactivated When the system is activated, one of two indicator
automatically. As the steering wheel returns to the lights mounted in the instrum ent cluster or on the
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front fender flashes in unison with the tu rn signal the right of the steering column, under the instru-
lights indicating to the driver th at the system is m ent panel in a bracket m ounted on the ash receiver
operating. side for Challenger and D art Models.
The tu rn signal flasher is a plug in type m ounted to
SERVICE DIAGNOSIS
Condition Possible Cause Correction______________
EXTERNAL LAMPS (a) Faulty pilot bulb in instrument clus- (a) Replace bulb.
OPERATE NORMALLY, ter.
NO INDICATIONS ON
INSTRUMENT CLUSTER
SYSTEM DOES NOT (a) Faulty flasher unit. (a) Replace flasher.
FLASH (b) Faulty external bulb. (b) Replace faulty bulb.
(c) Faulty contact in switch. (c) Replace switch.
SYSTEM DOES NOT (a) Broken or loose cancelling finger. (a) Replace cancelling finger.
CANCEL AFTER (b) Improperly aligned cancelling finger. (b) Align cancelling finger properly.
COMPLETION OF (c) Broken or faulty switch. (c) Replace switch.
TURN
ENTIRE SYSTEM DOES (a) Open circuit in feed wire to switch. (a) Check wiring circuits. Refer to "Wir
NOT OPERATE ing Diagrams."
(b) Faulty fuse. (b) Replace fuse.
(c) Faulty flasher unit. (c) Replace flasher.
PILOT LAMP ILLUMI (a) Loose or corroded external lamp (a) Clean and tighten ground connection.
NATES BRIGHTLY, ground connection.
EXTERNAL LAMPS
GLOWS DIMLY WITH
NO FLASH
SERVICE PROCEDURES
TURN SIGNAL SWITCH upper bearing retainer screws and remove retainer
and tu rn signal switch and flasher switch.
R em o val
(1) Disconnect negative battery term inal at battery. In s ta lla tio n
(2) Remove steering column cover and remove two (1) Attach string or wire left in steering column
screws attaching wiring trough (cover) from steering jacket tube during removal, to turn signal switch wir
column. ing and carefully pull string on wire down through
(3) Disconnect wiring connectors at steering col column jacket tube until directional switch wires can
umn. be connected. Position turn signal switch in steering
(4) Remove horn ring ornam ent, horn ring or rim column jacket tube and install switch retainer and at
blow switch pad and ornam ent (if so equipped). taching screws.
(5) Disconnect horn wires at steering wheel hub. (2) Install tu rn signal switch actuating lever.
(6) Remove horn ring. (3) Install steering wheel on steering shaft with
(7) Loosen steering wheel nut several turns and
m aster splines aligned.
install steering wheel puller Tool C-3428B. Loosen
(4) Install washer and nut. Tighten nut to 27 foot
steering wheel first, then remove steering wheel nut
and steering wheel. pounds.
(8) Remove screw attaching tu rn signal operating (5) Install horn switch parts previously removed
lever and remove lever. from steering wheel.
Attach a piece of string or fine wire to turn signal (6) Connect horn switch wires.
switch wiring before removing switch from steering (7) Connect wiring connectors at steering column.
column. When switch is removed leave string or wire (8) Install wiring trough (cover) and steering col
in steering column jacket tubes as an aid to replace umn cover.
ment of wiring. (9) Connect battery ground cable, test operation of
(9) Remove screws attaching tu rn signal switch and tu rn signals and horns.
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EMERGENCY FLASHER
The emergency flasher system is energized by a When the flasher is operating, application of the
switch on the right side of the steering column just brake pedal will override the system and interrupt
above the ignition switch and is part of the tu rn sig the flasher. All lights will rem ain on bright until the
nal switch, when the driver wishes to draw attention brake pedal is released.
to the vehicle. W hen the switch is activated all turn The system consists of a separate switch and flasher
signal lights and the turn signal indicators flash simul unit. The flasher is m ounted on the brake support
taneously. bracket for Challenger and on the lower edge of the
Before the switch is activated, the turn signal instrum ent panel just below the left side of the glove
switch should be in the neutral position to prevent box on Dart models.
a characteristic feed back through the accessory The flasher is a plug-in type and is not to be con
circuit causing intermittent operation of the acces fused with the turn signal flasher.
sories.
HORNS
GENERAL INFORMATION
The horn circuit consists of a horn switch located completes a ground circuit to the horn relay closing a
in the steering wheel hub and a horn relay m ounted set of points in the relay and allowing battery current
in the passenger compartm ent under the instrum ent to flow from the relay to the horns which are grounded
panel at left kick pad. Battery current from the “B” to the sheet m etal of the vehicle.
term inal of the starter relay flows to the “B” term inal The steering wheel-rim horn switch (Fig. 1) is a
of the horn relay. When the steering wheel horn ring full circle horn switch, operated by squeezing a soft
or rim horn switch (optional) is depressed, the switch strip on the inside of the steering wheel rim.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
HORNS WILL NOT (a) Improper adjustment. (a) See “Adjusting.”
SOUND (b) Broken or faulty wiring. (b) See “Testing."
(c) Faulty horn. (c) See “Testing." Replace horn if neces
sary.
(d) Faulty relay. (d) See “Testing." Replace relay if neces
sary.
SERVICE PROCEDURES
T e s tin g other test light lead to a good body ground. If the
A. Horns will not sound light fails to illuminate, inspect for corroded battery
Should the horns fail to sound, disconnect wire con term inals, dead battery or an open circuit in the
nector at horn and connect one lead of a test light wire from the starter relay to the “B” term inal of
to the connector term inal and the other lead of test the horn relay.
light to a good body ground. Depress the horn ring. Should the test light illuminate, touch a jum per
Should the test light illuminate, the horns are faulty. wire from relay “S” term inal to good body ground.
Replace or adjust horns. Sounding of the horns will indicate a poor ground
If the test light fails to light, reconnect the con circuit in the horn switch, an open wire from the “S”
nector to the horn term inal and connect one lead of term inal of the horn relay or a poorly grounded steer
test light to the horn relay “B” term inal and the ing column.
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To determ ine if the horn relay is defective, connect A djustm ent will only clear up sound and cannot
a jum per wire from “B” to “H” term inals. If horns change horn tone frequency.
operate, the horn relay is faulty and should be re (5) Connect a test am m eter between positive post
placed. of a 12 volt battery and horn term inal post. Connect
B. Horn sound continuously a jum per lead from negative battery post to horn
Should the horns sound continuously, disconnect base. Clean paint from horn bracket where connection
wires from horns and the positive wire from “B” ter is made. Turn adjusting screw to obtain a reading of
minal of horn relay. Remove wire from “S” term inal six amperes minimum to eight am peres maximum for
of horn relay and place one lead of a test light (with Sparton horns, four am peres minimum to six amperes
its own battery) to the wire connector and the other maximum for Prestolite horns.
lead to a good ground. If the light illuminates; either Amperage must not exceed eight amperes maxi
the wire is shorted to ground or the horn button is mum for Sparton horns, six amperes maximum for
sticking. Remove steering wheel and disconnect wire Prestolite horns.
from horn switch. Repeat above test and if light still
illuminates; wire is shorted to ground. Repair or re IGNITION AND STEERING LOCK
place wire.
If light does not illuminate; horn switch is sticking. The ignition lock is located on the right side of the
Repair or replace horn switch. steering column.
If the light does not illuminate on the first test; con The ignition switch has five positions. Starting from
nect one lead of a test light (without integral battery) the fuel counterclockwise position they are:
to the horn wire connector (green wire) and the other Accessory, Lock, Off, On and Start. In “Lock” or
lead to a good body ground. If test light illuminates, “Accessory” positions, the steering and ignition sys
there is a short in the horn wiring. Repair or replace tems are locked to provide anti-theft protection for
wire. If the test light does not illuminate; connect the the car.
positive lead back on the “B” term inal of the horn The ignition key cannot be turned to the lock posi
relay and repeat above test. If the light now illumi tion until the gear selector is placed in the Park (P)
nates, then the relay contacts are sticking. Replace position for automatic transmissions or reverse gear
horn relay. position for m anual transmissions.
The Accessory position perm its the operation of
A d ju s tin g
the electrical accessories when the engine is not run
(1) Disconnect connections at each horn to deter ning.
mine which horn is not operating. The “Off” position allows the engine to be turned
(2) Remove horn and bracket assembly. off without locking the steering.
(3) W ith a suitable tool (Fig. 1), turn tone adjuster The key can be inserted or withdrawn only on the
counterclockwise until there is no vibration (sound). “Lock” position. Do not attem pt to pull the shift lever
(4) Turn tone adjuster clockwise, approximately out of Reverse or Park after the key has been turned
1/4 turn at a time until tone has a clear mellow to the lock position.
sound. Do not turn tone adjuster while horn is sound
ing. R em o val
(1) Disconnect negative battery term inal at battery.
(2) Remove steering column cover and remove two
screws attaching wiring trough (cover) from steering
column.
(3) Disconnect wiring connectors at steering col
umn.
(4) Remove horn ring ornament, horn ring or rim
blow switch pad and ornam ent (if so equipped).
(5) Disconnect horn wires at steering wheel hub.
(6) Remove horn ring.
(7) Loosen steering wheel nut several turns and
install steering wheel puller Tool C-3428B. Loosen
steering wheel first, then remove steering wheel nut
and steering wheel.
(8) Remove screw attaching tu rn signal operating
lever and remove lever. On Tilt Columns, lever screws
out.
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(14) Remove the lower snap ring from the steering
shaft.
(15) Remove the lock plate pin retaining ring from
the lock plate hub. Some resistance may be encoun
tered due to the friction of the ring retaining tangs.
(16) Use Tool C-4113 pin removing and installing
tool and press the steering shaft lock plate retaining
pin out of the shaft and plate and remove the lock
plate. DO NOT attempt removal of the plate by ham
mering as damage to the collapsible column may re
sult.
(17) Remove the lock lever guide plate screws and
plate.
(18) With a small probe tool inserted in the access
hole provided in the housing boss, depress the key
cylinder retainer toward the cylinder to disengage it
from the slot in the housing bore, then withdraw the
key cylinder from the lock housing.
In s ta lla tio n
Before installing ignition switch and key cylinder
make sure the shift housing is in a lockable position
(park with automatic, or reverse with manual tran s
mission). When installing the key cylinder it m ust be
turned to “lock” position, key removed. Also make
sure ignition switch is turned to the “lock” position
to index its cam with the lock cylinder position.
(1) Install ignition switch and screws.
(2) Install ignition switch lock cylinder.
Fig. 2 —Horn Adjustments (3) Install lock lever guide plate and two screws.
Attach a piece of string or fine wire to turn signal (4) Install warning buzzer switch if removed.
switch wiring before removing switch from steering (5) Install the steering shaft bearing lower snap
column. When switch is removed leave string or wire ring and place the bearing and housing assembly on
in steering column jacket tubes as an aid to replace the steering shaft.
ment of wiring. (6) Use Tool C-3879 and a steering wheel nut and
(9) Remove screws attaching turn signal switch and flat washer to draw the steering shaft up into the
upper bearing retainer screws and remove retainer bearing and housing assembly until the lower snap
and tu rn signal switch and flasher switch. ring contacts the bearing, then install the upper snap
(10) Remove two retaining screws and lift out the ring.
ignition key lamp assembly. DO NOT scuff light tube (7) Install the three bearing housing to lock housing
coating as this will result in some loss of light. attaching screws.
(11) Remove snap ring from upper end of steering (8) Install lock plate and retaining pin.
shaft. (9) Install bearing housing on steering shaft.
(12) Remove three bearing housing attaching (10) Install bearing housing attaching screws.
screws. (11) Install bearing upper snap ring.
(13) With Tool C-3044 attached to the three thread (12) Install key lamp assembly, retainer and two
ed holes for the tu rn signal switch retaining screws, screws.
pull bearing and housing from steering shaft.
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SPECIFICATIONS
ELECTRICAL
BATTERY
Standard Special
Equipment Equipment
Engine-Cubic I nch Battery Battery
Displacement Part Number Part Number
198 2875951 2875320
2444564
225 2875951 2875320
2444564
318 2875951 2875320
2444564
340 2875951 2444564
383 2875320 2642967
426 2642969
440 2642969 2642967
ALTERNATOR
Rotation .......................................... .......................................................................... Clockwise at Drive End
Voltage .................................................. .................................................................... 12 Volt System
Current Output ...................................................................................................... .... Design Controlled
Voltage O u tp u t.......................................................................................................... Limited by Voltage Regulator
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Brushes (F ie ld )................. .................................................................................... .... 2
Condenser Capacity ...................................................................................................50 Microfarad ± 20%
Field Current Draw
Rotating Rotor by Hand @ 12 V o lts ................................................................ ....2.38 to 2.75 Maximum amperes
Current Output—
Std. with 198 & 225 Cu. In. E n g ..........................................................................26 ± 3 amperes*
Std. (All Other Models) ................................................................................... ....34.5 ± 3 amperes*
Special Equipment,
Heavy Duty and/or Air Conditioning........................................................ .... 44.5 ± 3 amperes*
Special Equipment (F le e ts )........................................................................... .... 51 ± 3 amperes*
*Plus or minus three ampere tolerance is provided to allow for temperature variation. Current output is meas
ured at 1250 engine RPM and 15 volts at the alternator. If measured at the battery, current output will be ap
proximately 5 amperes lower than above values.
Voltage is controlled by variable load (carbon pile) across the battery.
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
Single Barrel Carburetor Single Barrel Carburetor
Engine Application Manual Trans. Automatic Trans.
Engine Displacement ......................... 198 Cu. In. 198 Cu. In.
Distributor Part No.— (Chrysler Built) 3438237 3438237
Advance— Centrifugal (Distributor
Degrees at Distributor R P M ).......... 0° to 7.5° @ 525 0° to 7.5° @ 525
9.3° to 11.3° @ 750 9.3° to 11.3° @ 750
12° to 14° @ 1600 12° to 14° @ 1600
Advance—Vacuum (Distributor.............. 0.5° to 3.5° @ 7" 0.5° to 3.5° @ 7"
Degrees at Inches of M ercury).......... 5.25° to 7.75° @ 10" 5.25° to 7.75° @ 10"
Contact G a p .............................................. .017" to .023" .017" to .023"
Dwell Angle ...... .................................... 41° to 46° 41° to 46°
Contact 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 R eb u ilt).......... .000" to .003" * .000" to .003" *
Shaft End Play (After Assem bly).......... .003" to .017" .003" to .017"
Rotation .................................................... Clockwise Clockwise
T im in g .............................................. ......... 2-1/2° BTC** TDC**
Spark Plug T y p e ......................... ............. N14Y-Champion or *** N14Y-Champion or ***
P-6-6P Mopar * * * P-6-6P Mopar * * *
Size ............................... ......................... 14MM-3/4" Reach 14MM-3/4" Reach
Gap ...................................... ............. .035" .035"
Firing O rd e r.............................................. 1-5-3-6-2-4 1-5-3-6-2-4
Coil ........................................................ . Chrysler-Essex —or— Chrysler-Prestolite
Identification N u m b er......................... 2444241 2444242
Primary Resistance @ 70°-80°F — 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F . . . 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 7 0°-80°F ................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine Stopped................. 3.0 amperes
Engine Id lin g ..................... 1.9 amperes
* Service wear tolerance should not exceed .006 inch. “No gaskets required.
**Plus or minus 2-1/2°. Set at curb idle speed; See “Fuel System”
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IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
225 225
Single Barrel Carburetor Single Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Engine Displacement ............................. 225 Cu. In. 225 Cu. In.
Distributor Part No.— (Chrysler Built) .. 2875822 2875826
Advance— Centrifugal (Distributor
Degrees at Distributor R P M ).......... 1° to 5° @ 550 RPM 1° to 5° @ 550 RPM
9.2° to 11.2° @ 900 RPM 9.2° to 11.2° @ 900 RPM
12° to 14° @ 2000 RPM 12° to 14° @ 2000 RPM
Advance—Vacuum (Distributor
Degrees at Inches of M ercury).......... 0.5° to 3.5° @ 10" 0.5° to 3.5° @ 7"
5.25° to 7.75° @ 15" 5.25° to 7.75° @ 10"
Contact G a p ............................................. .017" to .023" .017" to .023"
Dwell A n g le .............................................. 41° to 46° 41° to 46°
Contact Arm Spring T ension................. 17 to 20 oz. 17 to 20 oz.
Condenser C apacity................................. .25 to .285 mfd. .25 to .285 mfd.
Shaft Side Play (New or Rebuilt) _____ .000" to .003" * .000" to .003" *
Shaft End Play (After Assem bly).......... .003" to .017" .003" to .017"
Rotation .................................................... Clockwise Clockwise
T im in g ................... . . . . . .......................... TDC** TDC**
Spark Plug T y p e ....................................... N14Y-Champion or * * * N14Y-Champion or ** *
P-6-6P Mopar *** P- 6-6P Mopar ***
Size . , .................................................... 14MM-3/4" Reach 14MM-3/4" Reach
Gap ........................................................ .035" .035"
Firing O rd er.............................................. 1-5-3-6-2-4 1-5-3-6-2-4
Coil ............................................................ Chrysler-Essex —or- Chrysler-Prestolite
Identification Number ......................... 2444241 2444242
Primary Resistance @ 7 0 °-8 0 °F ___ 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F . . . 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 7 0 °-80 °F ....................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine Stopped................. 3.0 amperes
Engine Id lin g ..................... 1.9 amperes
* Service wear tolerance should not exceed .006 inch. "No gaskets required.
** Plus or minus 2-1/2°. Set at curb idle; See "Fuel System”.
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
LA-318 LA-318
2-Barrel Carburetor 2-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
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Spark Plug T y p e ...................................... N- 14Y Champion or
P-6-6P Mopar
Size ........................................................ 14MM-3/4" Reach
Gap .............................. ........................ .035"
Firing O rd e r.......................................... 1- 8-4-3-6-5-7-2
Coil ................. .......................................... Chrysler-Essex —or— Chrysler-Prestolite
Identification N um ber......................... 2444241 2444242
Primary Resistance @ 7 0 °-8 0 °F ___ 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F . . . 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 70°-80 °F ....................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine Stopped................. 3.0 amperes
Engine Id lin g ..................... 1.9 amperes
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
340 340
Engine Application 4-Barrel Carburetor 4-Barrel Carburetor
____________ _________ _______________________ Manual Transmission__________ Automatic Transmission
Engine Displacement ..................................... 340 Cu. I n. 340 Cu. In.
Distributor Part No.— (Chrysler Built) . . . . . 3438317 3438325
(Prestolite Built) . . . . IBS-4015B
Advance— Centrifugal (Distributor
Degrees at Distributor RPM) ................. 1.5° to 6.5° @ 700 RPM 1.5° to 5.5° @ 650 RPM
8° to 10° @ 900 RPM 8° to 10° @ 850 RPM
Advance—Vacuum (Distributor
Degrees at Inches of M ercu ry)................. 1° to 4.6° @ 7.7" 1° to 4.6° @ 7.7"
7° to 10° @ 10.5" 7° to 10° @ 10.5"
Contact G a p ...................................................... .014" to .019" .014" to .019"
Dwell Angle ...................................................... one set points 27° to 32° 30° to 34°
both sets points 37° to 42°
Contact Arm Spring T en sio n ___; ................. 17 to 21.5 oz. 17 to 20 oz.
Condenser C apacity....................................... .25 to .285 mfd. .25 to .285 mfd.
Shaft Side Play (New or R e b u ilt)......................... 000" to .003"* .000" to .003"*
Shaft End Play (After Assembly)........................... 003" to .017" .003" to .017"
R otation............................................................. Clockwise Clockwise
Timing ............................................................. 5°BTC** 5° BTC**
Spark Plug Type .............................................. N9Y-Champion N9Y-Champion
Size ................................................................ 14MM-3/4" Reach 14MM-3/4" Reach
G a p ................................................................. .035" .035"
Firing O rd e r...................................................... 1-8-4-3-6-5-7-2 1- 8-4-3-6-5-7-2
Coil .................................................................... Chrysler-Essex—or— Chrysler-Prestolite
Identification N u m b e r................................. 2444241 2444242
Primary Resistance @ 7 0 °-8 0 °F ............... 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F............ 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 7 0 °-8 0 °F ............................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine S topped....................... 3.0 amperes
Engine Idling ........................... ................................................ 1.9 amperes______________________
* Service wear tolerance should not exceed .006 inch.
** Plus or minus 2-1/2°. Set at curb idle. See “Idle Speed Adjustment, Fuel System.”
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IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
383 383
2-Barrel Carburetor 2-Barrel Carburetor
Engine Appl ication________________ ________________ Manual Trans._____ Automatic Trans.
Engine Displacement ..................................... 383 Cu. In. 383 Cu. In.
Distributor Part No.— (Chrysler B u ilt).......... 3438231 3438231
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
383 383
4-Barrel Carburetor 4-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Engine Displacem ent....................... ............... 383 Cu. In. 383 Cu. In.
Distributor Part No.— (Chrysler B u ilt).......... 3438233 3438233
Advance—Centrifugal (Distributor
Degrees at Distributor R P M )..................... 0. to 4.6° @ 600 RPM 0° to 4.6° @ 600 RPM
5.6° to 7.6° @ 800 RPM 5.6° to 7.6° @ 800 RPM
10° to 12° @ 2300 RPM 10° to 12° @ 2300 RPM
Advance—Vacuum (Distributor
Degrees at Inches of M ercu ry)................. 0.5° to 4.3° @ 10.5" 0.5° to 4.3° @ 10.5"
9.7° to 12.0° @ 15.5" 9.7° to 12° @ 15.5"
Contact G a p .............................................................. 016" to .021" .016" to .021"
Dwell Angle ...................................................... 28.5° to 32.5° 28.5° to 32.5°
Contact Arm Spring Tension ......................... 17 to 20 oz. 17 to 20 oz.
Condenser C ap acity.................................................25 to .285 mfd. .25 to .285 mfd.
Shaft Side Play (New or R e b u ilt)..........................000" to .003"* .000" to .003"*
Shaft End Play (After Assembly)............... .003" to .017" .003" to .017"
R otation.............................................................. Counterclockwise Counterclockwise
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383 383
4-Barrel Carburetor 4-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Timing .......................................................... TDC** 2-1/2° BTC
Spark Plug T y p e .......................................... J-11Y Champion or J-11Y Champion or
P-3-4P Mopar*** P-3-4P Mopar***
Size ............................................................ 14MM-3/8" Reach 14MM-3/8" Reach
G a p .............................................................. .035" .035"
Firing O rd e r................................................. 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2
Coil ................................................................. Chrysler-Essex —or— Chrysler-Prestolite
Identification N u m b er............................. 2444241 2444242
Primary Resistance @ 7 0 °-8 0 °F ............ 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F........ 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 7 0 °-8 0 °F ............................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine Stopped....................... 3.0 amperes
___________ Engine Id lin g ........................... ................................................ 1.9 amperes________________ _____
* Service wear tolerance should not exceed .006 inch.
** Plus or minus 2-1/2°. Set at curb idle. See “Fuel System”.
* * * J-11Y Champion. If J-11Y are not available, use Mopar P-3-4P or Champion J-1Q-Y.
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
440 Special Cam 440 Special Cam
4-Barrel Carburetor 4-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Engine Displacement ................................... . 440 Cu. In. 440 Cu. In.
Distributor Part No.— (Chrysler B u ilt)----- . 3438222 3438222
Advance— Centrifugal (Distributor
Degrees at Distributor R P M )................... . 0° to 4.6° @ 600 RPM 0° to 4.6° @ 600 RPM
5.6° to 7.6° @ 800 RPM 5.6° to 7.6° @ 800 RPM
10° to 12° @ 2300 RPM 10° to 12° @ 2300 RPM
Advance—Vacuum (Distributor
Degrees at Inches of M ercu ry)............... . 0.5° to 4.3° 10.5" 0.5° to 4.3° @ 10.5"
9.7° to 12° @ 15.5" 9.7° to 12° @ 15.5"
Contact G a p .................................................... . .016" to .021" .016" to .021"
Dwell A n g le .................................................... • 28.5° to 32.5° 28.5° to 32.5°
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IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
440 440
6-Barrel Carburetor 6-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Engine Displacement — .............................. 440 Cu. In. 440 Cu. In.
Distributor Part No.— (Chrysler B u ilt).......... 3438314 2875982
(Prestolite B u ilt ) ___ IBS 4014 IBS 4014D
Advance-Centrifugal (Distributor
Degrees at Distributor RPM) ............— . 0° to 4.5° @ 650 RPM 0° to 5.3° @ 600 RPM
9° to 11° @ 950 RPM 9° to 11° @ 850 RPM
12° to 14° @ 2400 RPM 12° to 14° @ 2400 RPM
Advance-Vacuum (Distributor
Degrees at Inches Mercury) ..................... 0.5° to 3.5° @ 11" 0.5° to 3.5° @ 11"
9.5° to 12.5° © 15.5" 9.5° to 12.5° @ 15.5"
Contact Gap . . . ....................................................... 014" to .019" .014" to .019"
Dwell Angle ...................................................... One set points 27° to 32° One set points 27° to 32°
both set points 37° to 42° both set points 37° to 42°
Contact Arm Spring Tension......................... 17 to 21.5 oz. 17 to 21.5 oz.
Condenser C apacity..................................................25 to .285 mfd. .25 to .285 mfd.
Shaft Side Play (New or R e b u lt).......................... 000" to .003" * .000" to .003"*
Shaft End Play (After Assem bly).......................... 003" to .017" .003" to .017"
Rotation ............................................................ Counter-Clockwise Counterclockwise
T im in g ................................................................ 5° BTC** 5° BTC**
Spark Plug T y p e .............................................. J11Y Champion or J11Y Champion or
P-3-4P Mopar*** P-3-4P Mopar * * *
Size ................................................................ 14MM-3/8" Reach 14MM-3/8" Reach
Gap .........................................................................035" .035"
Firing O rd e r...................................................... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2
Coil .................................................................... Chrysler-Essex —or— Chrysler-Prestolite
Identification N u m b er................................. 2444241 2444242
Primary Resistance @ 70°-80°F ................ 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F ............ 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistor @ 70°-80°F ..................................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor
in circuit) Engine Stopped ....................... 3.0 amperes
Engine Id lin g ............................. 1.9 amperes
IGNITION SYSTEM
WITH CLEANER AIR SYSTEM
Hemi-426 Engine - A102
Two Four Barrel Carburetors
Two 4-Barrel Carburetor Two 4-Barrel Carburetor
Engine Application Manual Transmission Automatic Transmission
Engine Displacem ent..................................... 426 Cu. In. 426 Cu. In.
Distributor Part No.— (Chrysler B u ilt)........ 2875987 2875989
(Prestolite Built) . . . . IBS-4014E IBS-4014F
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Hemi-426 Engine - A102
Two Four Barrel Carburetors
Engine Application Two 4-Barrel Carburetor Two 4- Barrel Carburetor
Manual Transmission Automatic Transmission
Contact Gap ............................................... .014" to .019"
Dwell Angle .............................................. Individual Contacts 27° to 32°
Total Dwell 37° to 42°
Contact Arm Spring Ten sio n................. 17 to 21.5 oz.
Condenser C apacity................................ .25 to .285 mfd.
Shaft Side Play (New or R eb u ilt).......... .000" to .003" *
Shaft End Play (After Assembly)............ .003" to .017"
R otation...................................................... Counterclockwise
Timing ................................... ................. TDC * * 5° BTC**
Spark Plug T y p e ....................................... N10Y Champion***
Size ......................... ............................. 14MM-3/4" Reach
G a p .......................................................... .035"
Firing O rd e r.............................................. 1-8-4-3-6-5-7-2
Coil ....................... ..................................... Chrysler-Essex —or— Chrysler-Prestolite
Identification N u m b e r......................... 2444241 2444242
Primary Resistance @ 7 0 °-8 0 °F ........ 1.41 to 1.55 Ohms 1.65 to 1.79 Ohms
Secondary Resistance @ 70°-80°F . . . 9200 to 10700 Ohms 9400 to 11700 Ohms
Ballast Resistor 2095501
Resistance @ 7 0 °-8 0 °F ....................... 0.5 to 0.6 Ohms
Current Draw (Coil and ballast resistor in
circuit) Engine Stopped ..................... 3.0 amperes
Engine Id lin g ......................................... 1.9 amperes
LIGHT BULBS
Challenger (Rallye) Challenger Dart
Air Conditioner Control ................................................ ** 1815 * * 1815 **1445
Ash Receiver.................................................................... **1445 ** 1445 **1445
Back-up L ig h ts................................................................ 1156 (2) 1156 (2) 1156 (2)
C lo ck................................................ ............................... * * *
Cornering Lights.............................................................. 1445 1445
Dome Lamp .................................................................... 550 or 1004 550 or 1004 1004
Door Adjar Ind icato r...................................................... 1892 1892
Pocket Panel L a m p ........................................................ 90 90
Fender Mounted Turn Signal Indicator..................... 330 (2) 330(2) 330 (2)
Gear Selector Indicator (Column) ............................. ** 161 ** 161 ** 161
Gear Selector with Console.......................................... **57 ** 57 ** 57
Glove Compartment........................................................ 1891 1891 1891
Headlamp Switch Rheostat V a lv e ............................... 15.5 Ohms 15.5 Ohms 28 Ohms
High Beam Indicator...................................................... 57 57 158
Instrument Cluster and Speedometer Illumination .. ** 1893 ** 1816 (3) * * 158(4)
Ignition L a m p .................................................................. 1445 1445 1445
License L ig h t................................................................ 67 67 67
Low Fuel Indicator ........................................................ 1892 1892
Map and Courtesy L a m p .............................................. 89 89 89
Oil In d icato r................................................................... 57 57 158
Park and Turn Signal .................................................... 1157 (2) 1157 (2) 1157 (2)
Radio— AM and T a p e .................................................... **1816 **1816 **1816
Radio—AM-FM Stereo .................................................. ** 1815 **1815
Reverse 4-Speed Transmission Indicator ................. 53 53 53
Sealed Beam Hi-Beam (No. 1 ) ................................... 4001 4001
Sealed Beam Hi-Lo Beam (No. 2 ) ............................. 4002 4002
Sealed Beam— Single “7” ............................................ 6012
Seat Belts In d ica to r...................................................... 1892 53 53
Stereo Indicator ............................................................ 1445 1445
Switch L ig h tin g .............................................................. * *
E-Bodies.org
Challenger (Rallye)____ Chal lenger___________Dart______
Tachom eter................. ...................................
Tail, Stop and Turn S ig n a l................... 1157 (4) 1157 (4) 1157 (2)
Trunk and/or Under Hood L a m p ................. 1004 1004
Turn Signal Indicator (Panel) ..................... 57 (2) 1004
* - Included in Instrument Cluster Lighting.
** - Headlamp Rheostat Dimming.
FUSES
Car Model and Ampere Rating
Challenger Dart
Accessory ............... ..................................... 20 20
Emergency Flasher...................................... 20 —
Heater and Air Conditioner (Blower Motor) 20 20
Instrument L am p s........................................ 3 3
Radio and Back-up Lam ps........................... 20 20
Stop and Dome L am p s.............................. 20 20
Tail Lamps and Cigar Lighter .................... 20 20
CIRCUIT BREAKERS
Car Model and Ampere Rating
Challenger Dart
Convertible___ On fuse b lo c k ............................. 30
Headlamps.......... Integral with headlamp switch. 20 15
Windshield Wipers Integral with wiper sw itc h ........
2-speed m oto r............... 6.0 6.0
3-speed m oto r............... 7.5* 7.5*
Variable speed motor .. 7.5* 7.5*
optional
W IRING DIAGRAMS
INDEX
Page Page
Body Wiring Diagram— Dart ..................... ............. 86 Instrument Panel Accessory
Body Wiring Diagram— Challenger........................ 87 Wiring Diagram— Challenger............................. 92-93
Clutch Start Switch Cable (Manual Instrument Panel Accessory
Transmission Only) D a r t ............. ........................ 101 Wiring Diagram— D a r t............................................ 100
Electric Window Lift Wiring Diagram— Challenger. 88 Instrument Panel Wiring Diagram
Engine Compartment Wiring (Rallye Cluster)— Challenger............................. 94-95
Diagram— Except Hemi-Engines .......................... 89 Instrument Panel Wiring Diagram—
Engine Compartment Wiring Standard Cluster—C hallenger............................. 97
Diagram— Hemi-Engines— Challenger ................ 90 Instrument Panel Wiring Diagram— D a r t............ 98-99
Front End Lighting— Challenger ..................... . 91 Overhead Console Wiring Diagram— Challenger .. 100
Front End Lighting— D a r t ......................................... 91 Rear Window Defogger Wiring Diagram — .......... 101
WIRING ADAPTATIONS
INDEX
Page Page
Air Conditioner, Heater and Windshield Instrument Panel Harness to Body Harness
Washer Wiring— D a rt............................................. 102 Hook-up—Challenger ............................................ 105
Air Conditioner, Heater, Rear Window Defogger, Instrument Panel Main Harness Hook-up— Dart .. 106
Speed Control and Console Gear Selector Instrument Panel to Body Wiring Hook-up— D a rt.. 107
Wiring— Challenger................................................ 103 Overhead Console Wiring—Challenger................... 109
Cluster Wiring—Challenger...................................... 104 Stereo, Clock, Courtesy Lamp and Headlamp
Console Wiring— C hallenger..................................... 101 Delay Relay Wiring— C hallenger......................... 108
Instrument Panel Main Harness Wiring— Steering Column Cross Section—Challenger . . . . 110
Challenger................................................................ 104 Top Lift, Window Lift and Cluster Lamp
Wiring— Challenger ................................................ 109
E-Bodies.org
CTRICAL— WIRING
GROUND TO RIGHT SIDE
o
( XZD- X2-18BK-
E2-18 O- b REAR WINDOW
0-C14-14BK-CHO) GROUND
L7-18BK
^ MARKER
J LAMP
TO CONSOLE WIRING CONSOLE WIRING TO GEAR SHIFT DEFOGGER MOTOR
ON INSTRUMENT PANEL SELECTOR LAMP ^ O RIGHT TAIL,
L7-18BK— L ) STOP AND
------C11-18BK —
“ >_C 13— E C =K ^C13-14BK TURN SIGNAL
-------C12-20W —
18BK LAMP
TO REAR WINDOW DEFOGGER OPTIONAL B2-18V/W
DIAGRAMS
RESISTANCE CABLE TO RIGHT
SWITCH WIRING ON
OPTIONAL BACK-UP LAMP
INSTRUMENT PANEL
~ \T O DOME L1-18BK/W*
n-M2-18BK-r
CTJ-M1-18BK1- J
LAMP >L7-18BK-£Z3___ih TO LICENSE
LAMP
OPTIONAL L7-18BK/LBL*
TO LEFT
TO INSTRUMENT M1M8BK- TO TRUNK
~ \ BACK-UP
PANEL M12-18BK- LAMP0 B2-18V-
JLAMP
TO TRUNK LAMP 'dr VJ
WIRING TO LEFT TAIL,
SWITCH
{ TO FUEL GAUGE L|_7-18BK- p \ STOP AND
D8-18DGN-1 J t u r n SIGNAL
L7-18BK- LAMP
B2-18V-
~ )T O LEFT SIDE
MARKER LAMP
D7-18BR- OPTIONAL L7-18BK/Y* COLOR CODE
TO LEFT BK BLACK
LEGEND
FRONT DOOR BR BROWN
JAMB SWITCH SPLICE DBL DARK BLUE
DGN DARK GREEN
LBL LIGHT BLUE
F24-18BR- MALE FEMALE O ORANGE
TO FADER SWITCH! TO REAR V VIOLET
SPEAKER W WHITE
WIRING ON
INSTRUMENT PANEL -F25-18BR- MALE FEMALE Y YELLOW
INSULATORS VIEWED
* WITH TRACER
FROM TERMINAL SIDE
REAR SPEAKER WIRING (SERVICE) PY828
Fig. I —Body W iring Diagram —D art
E-Bodies.org
OPTIONAL L7-18BK/GY* K TO RIGHT SIDE
— L7-18BK ) MARKER LAMP
OPTIONAL
GROUND D7-18BR/W*
8
( ) ------ D7-18BR
TO CONSOLE ----- L7-18BK— ~^r
-X2-18BK- TO GEAR SHIFT O P T IO N A L / TO RIGHT TAIL,
WIRING O N
INSTRUMENT 3- -E2-18 O - SELECTOR LAMP L7-18BK/W* ■ STOP AND TURN
PANEL SIGNAL
----------- D7-18BR------
------------ L7-18BK------ 1____( J - - L y
D7-
18BR
-M2-18Y-1 -M2-18Y-
I -M 1-18P ----------- CPD TO DOME LAMP
M l-
18P __ MB DOME LAMP WIRING
M2-18Y -M 1-18P-
- B2-18V-
r> TO BACK-UP LAMP
------- *IGHT
— — M11-18BK-------- -- COURTESY LAMP WIRING
-M I-1 8 P -J L7-18BK
(CONVERTIBLE)
-M 1 -1 8 P - --------- M1-18P-
LEFT L7-18BK TO LICENSE LAMP
-M2-18Y- I D
-M 2-18Y-
L7-18BK
OPTIONAL
-M11-18BK- TRUNK LAMP
L7-18BK/LGN*
-M 1 -1 8 P -
L L7-18BK-
- B2-18V -
D 8-18 D G N 4 to
• M2-18Y- OPTIONAL TO LEFT TAIL,
TO INSTRUMENT
PANEL WIRING
-G4-18DBL- TO FUEL GAUGE
— L7-18BK—
■ D8-18DGN -
D8-18DGN/W*
— L7-18BK- z OPTIONAL
L7-18BK/LBL*
■STOP A ND TURN
SIGNAL LAMP
WIRING
• D8-18DGN-
— D7-18BR —
DIAGRAMS— ELECTRICAL
PANEL
STEREO r COLOR CODE
COM PONENT TO LEFT REAR SPEAKER
WIRING "B" CHANNEL BK BLACK
Bt BROWN
DBL DARK BLUE
DGN DARK GREEN
C13-18BK GY GREY
TO SWITCH W IR IN G , -C 11-18B K .
O N INSTRUMENT 1 LBL LIGHT BLUE
-C 12-20W - — G=CD-----C13-14BK— ( o j ) ------- C14-14BK-------(Z@>GROUND
I LGN LIGHT GREEN
PANEL LEGEND
RESISTANCE CABLE
REAR WINDOW REAR WINDOW SPLICE —+ O ORANGE
-
DEFOGGER WIRING DEFOGGER P PINK
V VIOLET
TO SWITCH W IR IN G .
-T2-12BR- MALE FEMALE w WHITE
O N INSTRUMENT | T 3 -1 2 Y - G 3 ------- T4-12BK— e© ground
INSULATORS VIEWED Y YELLOW
PANEL FROM TERMINAL SIDE * WITH TRACER
FOLDING TOP FOLDING TOP
MOTOR WIRING MOTOR PY115
8-87
E-Bodies.org
8-88
ELECTRICAL— WIRING
TO LEFT FRONT DOOR
MASTER SWITCH
DIAGRAMS
PY113
E-Bodies.org
TO INSTRUMENT HORNS (STANDARD)
PANEL
TWO-SPEED J J d F - -V3-18BR- -£ V3A-
cfc 18BR*
WINDSHIELD F.
__ 1 '
WIPER MOTOR B G . V5-18DGN-
A H -V6-18DBL-
— V4-18R-
DASH
BACK-UP
LAMP
SWITCH
B2-18BK*
B1-18BK 1—
------- 1
WINDSHIELD
WIPER MOTOR-
THREE SPEED
NEUTRAL START AND
BACK-UP LAMP SWITCH
AUTOMATIC
TRANSMISSION
/GROMMET
WIRING
■4 TO
INSTRUMENT
PANEL
(MANUAL
TRANSMISSION
DIAGRAMS— ELECTRICAL
CLUTCH
START SWITCH)
LEGEND
SPLICE----- $-----------
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUr
DGN DARK GREEN
GY GRAY
R RED
BODY ® V VIOLET
GROUND J Y YELLOW
* WITH TRACER
A2A-10BK
L MANUAL TRANSMISSION PY335
8-89
E-Bodies.org
8-90
BACK-UP LAMP SWITCH
k - B1-18BK--------------------1
(MANUAL TRANSMISSION,
ONLY) (FOUR SPEED) ' ---------- B2-18BK*-------- “ I INSTRUMENT PANEL
ELECTRICAL— WIRING
V
DASH LINE
V5-18DGN
DIAGRAMS
V6-
18DBL
LEGEND
HORNS SPLICE -4 -
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
GY GRAY
R RED
V VIOLET
TO INSTRUMENT PANEL * Y YELLOW
* WITH TRACER
(MANUAL TRANSMISSION
CLUTCH START SAFETY SWlTCHpH- PY336
E-Bodies.org
RIGHT PARK A N D RIGHT FENDER
TURN SIG NAL TURN SIGNAL
D 5A -18B K /T*
Q 3 L _ i|
1 5
9 13 17 21 25 29
-L6C-18BK/Y* o > t p 2 6
L3C-16R- 10 14 18 22 26 30
-L4A-16V* -L9E-18BK R1GHT MARKER
L9C-16BK— LAMP n 15 19 23 27 31
3 7
RIGHT DUAL L9E-18BK-
HEADLAMPS 12 16 20 24 28 32
L3C-16R— 4 8
-L3B-16R — -L6B-18BK/Y*-
(D -L9B-16BK-
BULKHEAD DISCONNECT
L9C-16BK-
- D5-18BK/T*
-L3B-16R-
-L3A -16R - j-— G RO U N D
16 12
a -L9-16BK------
15 n BULKHEAD
LEFT DUAL — L 9 A -16 B K -
CONNECTOR
14 10
HEADLAMPS I—L3A-16R-
-L3-16R- -L3-16R J 13
/1JU>L4 A-16V* --- -
Of-------------- L 4 -1 6V *- -L4-16V*
^ K 9 A -1 6 B K - D6-18BK/LGN*-
-L6-18BK/Y*- COLOR CODE
L6B-18BK/Y*—1 BK BLACK
D6A-18BK/LGN LGN LIGHT GREEN
C pc
-L6A-18BK/Y* R RED
LEFT PARK A ND T TAN
TURN SIGNAL V VIOLET
Y YELLOW
LEFT FENDER * WITH TRACER
TURN SIGNAL LEFT MARKER LAMP
PY225
( g S £™-L9A-18BK™1
HEADLAMP
GROUND
LEFT PARK
A N D TURN
SIGNAL LAMP
C:OLOR CODE
BK BLACK
LGN LIGHT GREEN
R RED
T TAN
V VIOLET
Y YELLOW.
LEFT -L9A-18BKJ LEFT FRONT *
HEADLAMP FENDER TURN LEFT SIDE WITH TRACER
INDICATOR MARKER LAMP
E-Bodies.org
RIGHT SPEAKER
GLOVE BOX LAMP ... 11,^1, I
C10-181GN —
TO ROAD LAMP
X30-20DBL—
(ENGINE COMPARTMENT)
X33-20BK*—
E-Bodies.org
LEFT SPEAKER
TO M AIN HARNESS
(SEE INSTRUMENT PANEL
W IRING DIAGRAM)
MAP LAMP GROUND
— X50B-18BK
__M5A-18P
— X57-18LGN
— G4A-18DBI
TO M AIN HARNESS
— C6A-16LGN (SEE INSTRUMENT PANEL WIRING DIAGRAM)
C5A-14DGN
— X32-20BK
r^,2-uvp
-iB!_W2',4Y— i
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
GY GRAY
LBL LIGHT BLUE
LGN LIGHT GREEN
O ORANGE
P PINK
R RED
T TAN
V VIOLET
W WHITE
Y YELLOW
— X31-20Y * WITH TRACER
— C1G-18LGN
— X30-20DBL TO REAR W INDO W
— X33-20BK* DEFOGGER WIRING (SIDE COWL) PY279
E-Bodies.org
E-Bodies.org
HEADLIGHT
— L3-16R
— L4-16V*
FY278
E-Bodies.org
CIGAR LIGHTER
H2-16DGN R /* - H2-16DGN/R*
E-Bodies.org
-E2G-18 O HEADLAMP DELAY RELAY _ L2A. 16LGN
P=*Cl2-,
LEGEND
SPLICE----- +-----------
10
MALE FEMALE
MALE
E Q
FEMALE
INSULATORS VIEWED
FROM TERMINAL SIDE
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
GY GRAY
LBL LIGHT BLUE
LGN LIGHT GREEN
O ORANGE
P PINK
R RED
T TAN !
V VIOLET
W WHITE
Y YELLOW
* WITH TRACER
PY126
-H2-16DGN/R' H2-16DGN/R*
E-Bodies.org
RIGHT TURN
SIGNAL LAMP
[
— B1-18W — -- -
INSTRUMENT LAMP CP- INSTRUMENT LAMP
-E2D -18 0 H I
OIL WARNING
HIGH CIGAR LIGHTER INDICATOR LAMP
-C 5-16D G N —|
O
LOW
C4-16BR
s BATTERY HIGH BEAM"
C1-14BK* INDICATOR LAMP
P5-18BK *
^"| 16LGN AMMETER
X1-16R P4-18DBL*-
[Z r *14BK
l - VARIABLE SPEED ONLY -V10-1SBR — W —
— A1-12R- — R6A-12BK-
14DGN
HIGH LOW
•L7A-18BK -
•X I2-18R*
C1-14BK*
-X12-18R
13 E2D- J2A-16DBL* - J2-16DBL*
18 O
HEATER -P4-18DBL* J2-16DBL*i
- J2B-18DBL*- -G5-18DBL*
BLOWER
-E2D-18 O -
MOTOR - Q13A-18R- -Q13A-18R* J1-12R —■
RESISTOR E2B-18 O
-D 5 -1 8 T -
-R6-12BK - -R6-12BK
J2B-18DBL* -Q13-18R-
M 6A-18Y* -D 9-18T-
D32- [-D10-18LGN-
18P
■ Q2A-14BK- Q2A-14BK—
V I-
-G 1-18B K- -G1-18BK —
16P
- f i H3-+18BK— rol
TURN SIGNAL M6A-18Y* D 6--H8LG N -|o
-L3-18R- — L3-18R-----
-L4-16V* -L 4 -1 6 V *——
E-Bodies.org
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
GY GRAY
LBL LIGHT BLUE
LGN LIGHT GREEN
O ORANGE
P PINK
R RED
T TAN
V VIOLET
W WHITE
Y YELLOW
* WITH TRACER I
-L3-18R
-1 4 -16 V * L4-16V* PY124
E-Bodies.org
FUSE BLOCK
TO BODY
REVERSE GEAR E2-18 O - CONSOLE
DC B A CONNECTOR
E F G H INDICATOR LAMP
CONSOLE LAMP
(FOUR SPEED CABLE
TRANSMISSION ONLY)
-Q2C-18BK-
V U T S PART OF INSTRUMENT
W X Y 7 -18BK* j PANEL WIRING
DELAY
TO HEADLAMP / FUSE
SWITCH 1 RELAY
MAP LAMP L2B-16LGN
' BULKHEAD _£1
DISCONNECT -M12-18BR L2A-16LGN
GLOVE BOX MAP LAMP TO FOOT DIMMER SWITCH
-G3-16R -
LAMP SWITCH HEADLAMP
-M5-18P- DELAY RELAY WIRING
C10-18LGN REAR WINDOW DEFOGGER
-M3A-18P SWITCH WIRING
ASH nnR-— C12-18W —£1
RECEIVER r M3-18P
LAMP -----C11-18BK— n h
CONTROL TO BODY
XIA- WIRING
16P SWITCH
~ lS 18 0 PART OF COLOR CODE
CIGAR BK BLACK
LIGHTER INSTRUMENT
PANEL BR BROWN
WIRING M6B- LGN LIGHT GREEN
PART OF INSTRUMENT
PANEL WIRING 18Y* O ORANGE
o 1 P
R
PINK
RED
-X1-16R TO FUSE TO BODY IGNITION
BLOCK WIRING SWITCH W WHITE
M3-18P-
_ TO FUSE BLOCK LAMP Y YELLOW
ACCESSORY LAMP, * WITH TRACER
MAP LAMP AND TIME • E2-18 O- -0 = “0 (LIGHTING TERMINAL)
DELAY RELAY WIRING PY125
W i n
TO BODY • M2-18Y-
WIRING ■M1-18R-
SEAT
-G10-18Y- BELTS
TO TO OVERHEAD
OVERHEAD LOW
-G7-18DBL- — d D FUEL CONSOLE LAMP
CONSOLE SOCKET BEZEL
BODY WIRING -M3-18BK- DOOR
-M1-18R AJAR
X2-18GY
GROUND
TO HEADER
TO
OVERHEAD -G10-18Y - TO INSTRUMENT
CONSOLE -G7-18DBL- PANEL WIRING LEGEND
WIRING ■ M3-18BK-
■M3-18BK- IQj s
INSULATORS VIEWED
FROM TERMINAL SIDE
TO RIGHT
DOOR AJAR TO LEFT COLOR CODE
SWITCH CABLE DOOR AJAR BK BLACK
TO BODY SWITCH DBL DARK BLUE
AND RIGHT GY GRAY
DOOR AJAR R RED
TO RIGHT DOOR Y YELLOW
SWITCH
WIRING
ZJ -M3-18BK ■ -BE AJAR SWITCH
E-Bodies.org
Fig. 14—Rear W in d o w D efogger W ir in g D ia g ra m
SCHEMATIC DIAGRAM
TO INSTRUMENT PANEL
CONSOLE WIRING
ORANGE
CONSOLE FRONT
FLOOR PAN
GEAR SHIFT
SELECTOR BULB
E-Bodies.org
8-102
ELECTRICAL— WIRING
LGN
VIEW Z
WINDSHIELD WIPER
AND WASHER
ADAPTATIONS
. AIR CONDITIONER
AND HEATER VACUUM
. ■ SWITCH SPOT TAPE
i i i n &
AIR CONDITIONER
1 AIR CONDITIONER
SWITCH LAMP
AND HEATER SWITCH
WINDSHIELD WASHER WIRING
TO INSTRUMENT
TO AIR O LAMP TERMINAL
CONDITIONER
AND HEATER
MOTOR
RESISTOR COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
LGN LIGHT GREEN
O ORANGE
T TAN
TO TEMPERATURE * WITH TRACER
CONTROL SWITCH
E-Bodies.org
HEATER
WIRING
TO AIR CONDITIONER AND
HEATER
CONSOLE GEAR
SELECTOR WIRING
TO AIR CONDITIONER BLOWER
MOTOR RESISTOR
CAVITY NUMBER THREE
foST
WIRING
HEATER VACUUM SWITCH
ADAPTATIONS-ELECTRICAL
REAR
WINDOW COLOR CODE
DEFOGGER
BK BLACK I
SWITCH BR BROWN
DBL DARK BLUE
DGN DARK GREEN
LGN LIGHT GREEN
O ORANGE
T TAN
W WHITE
Y YELLOW
* WITH TRACER
TO REAR
WINDOW
DEFOGGER
WIRING
PY428
8-103
Fig. 3—Air Conditioner, H eater, Rear W in d o w D e fo g g e r Speed C o n tro l a n d Console G e m Selector W irin g —Challenger
E-Bodies.org
BRAKE WARNING LAMP BULB TO FUEL GAUGE
AND CONNECTOR TO OIL GAUGE
TO TACHOMETER
LEFT TURN
SIGNAL LAMP BULB
AND CONNECTOR
FEED WIRE TO
VOLTAGE
LIMITER
FEED WIRE
TO TEMPERATURE
GAUGE
COLOR CODE
BK BLACK HIGH BEAM BULB
DBL DARK BLUE RIGHT TURN AND SOCKET
SIGNAL LAMP
GY GRAY
BULB AND
LGN LIGHT GREEN
R RED CONNECTOR
T TAN
V VIOLET
* WITH TRACER PY432
TO PARKING BRAKE
STARTER AND
LAMP SWITCH
IGNITION SWITCH
WIRING (VIEW X )
EMERGENCY FLASHER TO BODY
TO STOP LAMP SWITCH WIRING
(VIEW Y) (VIEW X ) (VIEW Y)
TO FOOT DIMMER SWITCH'
TO LEFT FRONT DOOR SWITCH4 PY431
E-Bodies.org
PARKING BRAKE WARNING
LAMP SWITCH
DOOR
AUTOMATIC
SWITCH
SPEED
CONTROL BRAKE
SWITCH AND STOP
LAMP SWITCH
WIRING
ADAPTATIONS-ELECTRICAL
LAMP ASSEMBLY
IGNITION
SWITCH LAMP AIR CONDITIONER AND
ASSEMBLY HEATER BLOWER
TIME DELAY ,
MOTOR REGISTOR PY427
8-105
RELAY
E-Bodies.org
COLOR CODE
8-106
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
GY GRAY
ELECTRICAL— WIRING
LGN LIGHT GREEN
O ORANGE
P PINK
R RED
HEATER BLOWER T TAN
BK
MOTOR SWITCH V VIOLET
LGN / DBL
W WHITE
Y YELLOW
* WITH TRACER
ADAPTATIONS
KEY-IN
BUZZER RELAY DUAL MASTER
CYLINDER WARNING
LAMP
DBL
DGN
VIEW Z VIEW U
E-Bodies.org
HEAD LAMP
DELAY RELAY HEAD LAMP
FOOT DIMMER SWITCH
HORN RELAY
GROUND WIRE
WIRING
ADAPTATIONS— ELECTRICAL
GROUND WIRE
ROUTE UNDER
CARPET
PARKING BRAKE
WARNING LAMP SWITCH
OF ARROW V
8-107
PY551.
E-Bodies.org
8-108
ELECTRICAL— WIRING
ADAPTATIONS
COURTESY LAMP
LOCATION WITHOUT
AIR CONDITIONER
COLOR CODE
BK BLACK
BR BROWN
DBL DARK BLUE
DGN DARK GREEN
TO GY GRAY
BATTERY BUSS BAR LBL LIGHT BLUE
(FUSE BLOCK) LGN LIGHT GREEN
O ORANGE
P PINK
R RED
T TAN
V VIOLET
W WHITE
Y YELLOW
. HEADLAMP DELAY RELAY * WITH TRACER PY430
Kg, 9 -S tereo , Clock, Courtesy Lamp and Headlamp Delay Relay W iring-C hailenger
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CLUSTER LAMP BK BLACK LGN LIGHT GREEN
HARNESS BR BROWN O ORANGE
COLOR DBL DARK BLUE P PINK
CODE DGN DARK GREEN R RED
GY GRAY T TAN
LBL LIGHT BLUE V VIOLET
W WHITE
Y YELLOW
* WITH TRACER
TO TOP LIFT
AND WINDOW
LIFT SAFETY RELAY
TOP LIFT
SWITCH
TO INSTRUMENT
PANEL OVERHEAD
CONSOLE WIRING
LOW FUEL
W A R N IN G LAMP'"
BULB
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8-110
.SPEED CONTROL AND
TURN SIGNAL LEVER
ELECTRICAL— WIRING
TO STEERING COLUMN GEAR
SELECTOR INDICATOR LAMP
IGNITION AND
ADAPTATIONS
STARTER SWITCH
TO STARTER
AND IGNITION
SWITCH WIRING
TURN SIGNAL SWITCH
TO TURN SIGNAL-
SWITCH WIRING
GEAR SELECTOR-
INDICATOR LAMP WIRING KEY-IN
BUZZER
TO IGNITION KEY- WIRING
LAMP ASSEMBLY
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ENGINE
CONTENTS
Page Page
CRANKCASE VENTILATION SYSTEM . . . 85 383-440 CUBIC INCH ENGINES ........ .. 45
GENERAL INFORMATION 1 426 CUBIC INCH “ HEMI” ENGINES . . . . 67
SERVICE DIAGNOSIS 1 REPAIR OF DAMAGED OR WORN
198-225 CUBIC INCH 6 CYLINDER THREADS .................. .......... .................. 85
ENGINES 5 SPECIFICATIONS AND TIGHTENING
318-340 CUBIC INCH V8 E N G IN ES 24 REFERENCE .............................. .......... 86-102
ENGINE APPLICATION
Model Engine Type & Compression
Application Displacement Ratio Remarks
Challenger 6 (Std.) 225 Cubic Inch 8.4 to 1 1 BBL. Carb. Single Exhaust
Challenger 8 (Std.) 318 Cubic Inch 8.8 to 1 2 BBL. Carb., Single Exhaust
(Opt.) 340 Cubic Inch 10.5 to 1 4 BBL. Carb., Dual Exhaust
(Opt.) 383 Cubic Inch 8.7 to 1 2 BBL. Carb.,— Std. Cam, Single Exhaust
(Opt.) 383 Cubic Inch 9.5 to 1 4 BBL. Carb., Std. Cam, Dual Exhaust
(Opt.) 383 Cubic Inch 9.5 to 1 4 BBL. Carb., Spec. Cam., Dual Exhaust
R/T (Std.) 383 Cubic Inch 9.5 to 1 4 BBL. Carb., Spec. Cam., Dual Exhaust
(Opt.) 426 Cubic Inch 10.25 to 1 2-4 BBL. Carb. Spec. Cam, Dual Exhaust
(Opt.) 440 Cubic Inch 9.7 to 1 4 BBL. Carb., Spec. Cam., Dual Exhaust
(Opt.) 440 Cubic Inch 10.5 to 1 3-2 BBL. Carb. Spec. Cam, Dual Exhaust
Dart 6 (Std.) 198 Cubic Inch 8.4 to 1 1 BBL. Carb. Single Exhaust
6 (Opt.) 225 Cubic Inch 8.4 to 1 1 BBL. Carb., Single Exhaust
Swinger 8 (Std.) 340 Cubic Inch 10.5 to 1 4 BBL. Carb., Dual Exhaust
(Opt.) 318 Cubic Inch 8.8 to 1 2 BBL. Carb., Single Exhaust
GENERAL INFORMATION
Six C ylinder Engine The water pump housing is integral with the cylinder
The 6 cylinder engine, (Fig. 1) is inclined toward block.
the right at an angle of 30 degrees from the vertical
V8 Engines
in the engine compartment. This design permits a The V8 engines are all the valve-in-head type with
lower hood line and allows space in the engine com hydraulic tappets. Engines vary in compression ratio,
partment for the long intake manifold branches. The piston displacement, camshafts, valve springs, car
engine has in-line overhead valves and wedge shaped buretors, intake manifolds and exhaust systems. The
combustion chambers and a nominal compression three-two barrel and four barrel carburetor equipped
ratio of 8.4:1. engines use premium fuel.
The lubrication system consists of an externally The 426 hemi-head engine (Fig. 2) has twin four-
barrel carburetors, nonsilenced low-restriction air
mounted rotor type pump on the lower right side of
cleaner, low-restriction intake manifold and exhaust
the cylinder block. A full flow replaceable element
headers, hydraulic tappets.
type oil filter is mounted on the rear of the oil pump Engine oiling system consists of a rotor type oil
body. Oil is forced by the oil pump to a series of oil pump and a full flow oil filter. On the 318 and
passages in the engine (Fig. 46). 340 cubic inch engines, the pump is mounted inter
The semi-series flow cooling system contains an nally. On the 383, 426 and 440 cubic inch engines,
aluminum water pump body with a pressed in ball the pump is mounted externally. Oil is forced by the
bearing and seal assembly and stamped steel impeller. oil pump to a series of oil passages in the engine.
SERVICE DIAGNOSIS
_________ Condition_________________________ Possib le Cause______________ ______________Correction_______________ _
ENGINE WILL (a) Weak battery. (a) Test battery specific gravity. Re-
NOT START charge or replace as necessary.
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Fig. 1—Six Cylinder Engine C u taw ay V ie w
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W * v'
\ vj
*: f v
-,w
/ I* '■ r & jr * \ ^
N N 1033
ENGINE LOSS OF (a) Incorrect ignition timing. (a) Refer to “Ignition Timing.”*
POWER (b) Worn or burned distributor rotor. (b) Install new rotor.
(c) Worn distributor shaft or cam. (c) Remove and repair distributor.*
(d) Dirty or incorrectly gapped spark (d) Clean plugs and set gap at .035".
plugs.
(e) Dirt or water in fuel line, carburetor (e) Clean lines, carburetor and replace
or filter. filter.**
(f) Incorrect carburetor float setting. (f) Adjust float level.**
(g) Faulty fuel pump. (g) Install new pump.
(h) Incorrect valve timing. (h) Refer to “Checking Valve Timing.”***
(i) Blown cylinder head gasket. (i) Install new head gasket.***
(j) Low compression. (j) Test compression of each cylinder.***
(k) Burned, warped, or pitted valves. (k) Install new valves.***
(I) Plugged or restricted exhaust system, (I) Install new parts as necessary.
(m) Faulty ignition cables. (m) Replace any cracked or shorted
cables.
(n) Faulty coil or condenser. (n) Test and replace as necessary.*
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ENGINE MISSES ON (a) Dirty, burned, or incorrectly gapped (a) Replace contacts and adjust.*
ACCELERATION distributor contacts.
(b) Dirty, or gap too wide in spark plugs. (b) Clean spark plugs and set gap at
.035".
(c) Incorrect ignition timing. (c) Refer to “Ignition Timing.”*
(d) Dirt in carburetor. (d) Clean carburetor.**
(e) Acceleration pump in carburetor. (e) Install new pump.**
(f) Burned, warped or pitted valves. (f) Install new valves.***
(g) Faulty coil or condenser. (g) Test and replace if necessary.*
ENGINE MISSES AT (a) Dirty or incorrectly gapped distrib (a) Clean or replace as necessary.*
HIGH SPEED utor contacts.
(b) Dirty or gap set too wide in spark plug. (b) Clean spark plugs and set gap at
.035".
(c) Worn distributor shaft or cam. (c) Remove and repair distributor.*
(d) Worn or burned distributor rotor. (d) Install new rotor.
(e) Faulty coil or condenser. (e) Test and replace if necessary.*
(f) Incorrect ignition timing. (f) Refer to “Ignition Timing.”*
(g) Dirty jets in carburetor. (g) Clean jets.**
(h) Dirt or water in fuel line, carburetor (h) Clean lines, carburetor and replace
or filter. filter.**
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 engine oil level.**
(d) Dirt in tappets. (d)
Clean tappets.**
(e) Bent push rods. (e)
Install new push rods.***
(f) Worn rocker arms. (f)
Inspect oil supply to rockers.***
(g) Worn tappets. (g)
Install new tappets.***
(h) Worn valve guides. Ream and install new valves with O/S
(h)
stems.***
(i) Excessive run-out of valve seats or (i) Grind valve seats and valves.***
valve faces.
(j) Incorrect tappet lash. (j) Adjust to specifications.
CONNECTING ROD (a) Insufficient oil supply. (a) Check engine oil level.***
NOISE (b) Low oil pressure. (b) Check engine oil level. Inspect oil
pump relief valve and spring.***
(c) Thin or diluted oil. (c) Change oil to correct viscosity.
(d) Excessive bearing clearance. (d) Measure bearings for correct clear
ance.***
(e) Connecting rod journals out-of-round. (e) Remove crankshaft and regrind
journals.***
(f) Misaligned connecting rods. (f) Replace bent connecting rods.***
MAIN BEARING NOISE (a) Insufficient oil supply. (a) Check engine oil level.***
(b) Low oil pressure. (b) Check engine oil level. Inspect oil
pump relief valve and spring.***
(c) Thin or diluted oil. (c) Change oil to correct viscosity.
(d) Excessive bearing clearance. (d) Measure bearings for correct clear
ances.***
(e) Excessive end play. (e) Check No. 3 main bearing for wear
on flanges.***
(f) Crankshaft journal out-of-round or (f) Replace crankshaft or regrind jour
worn. nals.
(g) Loose flywheel or torque converter. (g) Tighten to correct torque.
OIL PUMPING (a) Worn, scuffed, or broken rings. (a) Hone cylinder bores and install new
AT RINGS rings.***
(b) Carbon in oil ring slots. (b) Install new rings.***
(c) Rings fitted too tight in grooves. (c) Remove the rings. Check grooves. If
groove is not proper width, replace
piston.***
OIL PRESSURE DROP (a) Low oil level. (a) Check engine oil level.
(b) Faulty oil pressure sending unit. (b) Install new sending unit.
(c) Clogged oil filter. (c) Install new oil filter.
(d) Worn parts in oil pump. (d) Replace worn parts or pump.
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Possibl e Cause _____________________ Correction______________
(e) Thin or diluted oil. (e) Change oil to correct viscosity.
(f) Excessive bearing clearance. (f) Measure bearings for correct clear
ance.***
(g) Oil pump relief valve stuck. (g) Remove valve and inspect, clean, and
reinstall.
(h) Oil pump suction tube loose, bent or (h) Remove oil pan and install new tube
cracked. if necessary.
* 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.
SERVICE PROCEDURES
TUNE-UP tem and make necessary adjustments.
(8) Reset ignition timing with vacuum advance line
(1) Test battery specific gravity, add water if nec disconnected. Ignition timing should be set to com
essary, clean and tighten battery connections. pensate for altitudes and/or gasoline grades.
(2) Test cranking voltage. See “Starting Motor (9) Set carburetor idle mixture adjustment. Adjust
Cranking Voltage” Electrical Group 8. throttle stop screw to specifications. Perform a com
(3) Tighten intake and exhaust manifold bolts to 15 bustion analysis.
foot-pounds. (10) Test fuel pump for pressure and vacuum. Re
(4) Perform cylinder compression test. Compres fer to “Fuel System” Group 14, Specifications.
sion should not be less than 100 pounds and not vary (11) Inspect manifold heat control valve in exhaust
more than 25 pounds. The recommended compression manifold for proper operation and apply Manifold
pressures are to be used only as a guide to diagnosing Heat Control Valve Solvent Part Number 2525054 or
engine problems. An engine in good condition may equivalent to bushing and shaft.
exhibit higher pressures. Many conditions which are (12) Every 6 months remove filter element and
difficult to control cause variations in compression blow out dirt gently with an air hose. Direct air from
readings. An engine should not be disassembled to inside out, and keep nozzle 2 inches away from ele
determine the cause of low compression unless some ment to avoid damaging. Clean metal housing and
other malfunction is present. install element. Every two years, install a new factory
(5) Clean or replace spark plugs as necessary and recommended filter element or equivalent. Service
adjust gap to .035 inch. Tighten to 30 foot-pounds. unit more frequently when driving under severe
(6) Test resistance of spark plug cables. Refer to conditions, such as in dusty areas (Fig. 3).
“Ignition System Secondary Circuit Inspection” Elec (13) Inspect crankcase ventilation system as out
trical Section. lined on page 85.
(7) Inspect the breaker plate contacts, primary wire (14) Inspect and adjust accessory belt drives refer
and vacuum advance operation. Test coil output volt ring to Cooling System, Group 7 for proper adjust
age, primary and secondary resistance. Test Condens ments.
er. Replace parts as necessary. Refer to Ignition Sys (15) Road test vehicle as a final test.
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NY861
TRANSMISSION EXT. V
HOUSING A-
REAR --
(A ) 2 0 0 IN. LBS.
35 FT. LB.
<£>
40 FT. LBS.
50 FT. LB.
VIEW A <S>
& 90 FT. LBS.
RIGHT SIDE 75 FT. LB.
V NR36A
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B STRUT-USED WITH AIR the next normal oil change.
CONDITIONER ONLY (22) Start engine and run until normal temperature
is reached.
(23) Inspect timing (with vacuum advance line re
moved), adjust carburetor and transmission linkage as
necessary. Connect vacuum line and road test vehicle.
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FRONT I
DOWEL HOLE
\ COOLANT PASSAGES
OIL FEED HOLE
INTAKE VALVES
\ CO OLANT PASSAGE
EXHAUST VALVES
BY-PASS TUBE
NY129
Fig. 9 —Cylinder H ea d
(5) Allow engine to idle at 550 rpm at this 190° buretor as an assembly.
F. temperature for five minutes. (10) Remove closed ventilation system, evapora
(6) Adjust tappets, Hof; intake .010 inch, exhaust tive control system (if so equipped) and cylinder
.020 inch. head cover.
(7) Place new cylinder head cover gasket in posi (11) Remove rocker arms and shaft assembly.
tion and install the cylinder head cover. Tighten (12) Remove push rods and identify to insure in
nuts to 40 inch-pounds. stallation in original location.
(8) Install closed ventilation system and evapora (13) Remove 14 head bolts and remove cylinder
tive control system (if so equipped). head.
(14) Place cylinder head in holding fixture Tool C-
CYLINDER HEAD 3626 and remove spark plugs and tubes.
The chrome alloy cast iron cylinder head (Fig. 9)
is held in place by 14 bolts. Spark plugs are located at Installation
the wide edge of the combustion chambers and alum (1) Clean all gasket surfaces of cylinder block and
inum spark plug tubes serve as spark plug gaskets. cylinder head and install spark plugs.
(2) Inspect all surfaces with a straightedge if there
is any reason to suspect leakage. If out of flatness
Removal
(1) Drain cooling system. exceeds .00075 times the span length in any direction;
(2) Remove carburetor air cleaner and fuel line. either replace head or lightly machine the head gasket
(3) Disconnect accelerator linkage. surface. As an example, if a 12 inch span is .004" out
(4) Remove vacuum control tube at carburetor and of flat, allowable is 12 x .00075 = .009". Head is OK.
distributor. The cylinder head surface finish should be 70-180
(5) Disconnect spark plug wires by pulling straight micro-inches.
out in line with the plug. (3) Coat new gasket lightly with Chrysler Sealer,
(6) Disconnect heater hose and clamp holding by Part Number 1057794 or equivalent. Install gasket
pass hose. and cylinder head.
(7) Disconnect heat indicator sending unit wire. (4) Install cylinder head bolts. Starting at top cen
(8) Disconnect exhaust pipe at exhaust manifold ter, tighten all cylinder head bolts to 50 foot-pounds
flange. in sequence (Fig. 10). Repeat the procedure, retight
(9) Remove intake and exhaust manifold and car ening all cylinder head bolts to 65 foot-pounds.
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(19) Install closed ventilation system and evapora
tive control system (if so equipped).
Rem oval
(1) With cylinder head removed, compress valve
springs, using Tool C-3422A (Fig. 11).
(2) Remove valve retaining locks, valve spring re
tainers, valve stem cup seals and valve springs.
Remove any burrs from valve stem lock grooves to
prevent damage to the valve guide when valves are
Fig. 10—Cylinder H ead Tightening Sequence removed. Identify valves to insure installation in
(5) Install rocker arms and shaft assembly with original location.
“FLAT” on end of rocker shaft “ON TOP” and point
ing toward front of engine, as shown in Fig. 8 to V a lv e Inspection
provide proper lubrication to rocker assemblies. In (1) Clean valves thoroughly and discard burned,
stall rocker shaft retainers between rocker arms so warped and cracked valves.
they seat on rocker shaft and not on extended bush (2) Measure valve stems for wear. The intake valve
ing of rocker arm. Be sure to install long retainer in stem diameter (new valve) should measure .372 to
center position only. Install rocker shaft bolts (long .373 inch and exhaust valve stem diameter (new
bolt at rear of engine) and tighten to 25 foot-pounds. valve) should measure .371 to .372 inch. If wear ex
(6) Loosen the 3 bolts holding intake manifold to ceeds .002 inch, replace the valve.
exhaust manifold. This is required to maintain proper (3) Remove carbon and varnish deposits from in
alignment. side of valve guides, with a reliable guide cleaner.
(7) Install intake and exhaust manifold and carbu (4) Measure valve stem guide clearance as follows:
retor assembly to the cylinder head with cup side of (a) Install sleeve Tool C-3973 over valve stem
the conical washers against manifolds. Tighten nuts to and install valve (Fig. 12). The special sleeve places
10 foot-pounds. the valve at the correct height for measuring with a
(8) Tighten 3 bolts holding intake manifold to ex dial indicator.
haust manifold to 15 foot-pounds. (b) Attach dial indicator Tool C-3339 to cylinder
Sequence: Tighten inner bolt first, then the outer
head and set it at right angle to the valve stem being
two bolts.
measured (Fig. 13).
(9) Connect heater hose and by-pass hose clamp.
(c) Move valve to and from the indicator. The total
(10) Connect heat indicator sending unit wire, ac
dial indicator reading should not exceed .017 inch.
celerator linkage and spark plug cables.
(11) Install vacuum control tube at carburetor and Ream guides for valves with oversize stems if dial
distributor.
(12) Connect exhaust pipe to exhaust manifold TOOL
flange.
(13) Install fuel line and carburetor air cleaner. . ,/
(14) Fill cooling system. }' CfHW Jzk HEAD ASSEMBLY
fWmlwmm /
(15) Operate engine until normal operating tem J^sjw M /
perature is reached (approximately 190° F. water
temperature).
(16) Allow engine to idle at 550 rpm at this 190° F.
temperature for five minutes.
(17) Adjust tappets, Hot; intake .010 inch, exhaust
.020 inch.
(18) Place new cylinder head cover gasket in posi
■ ' N u I51A
tion and install the cylinder head cover. Tighten nuts W mmmmmim
to 40 inch-pounds.
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A -S E A T WIDTH (INTAKE 1/16 TO 3/32 INCH
EXHAUST: 3/64 TO 1/16 INCH)
B-FACE ANGLE (INTAKE: 45°— EXHAUST: 43°)
C-SEAT ANGLE (INTAKE: 45°-E XH A U ST: 45°)
D-C O N TAC T SURFACE
1 1 I f W , WM 1 I ■ N H 645B
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RETAINER,
KU51C
Fig. 16 —Testing Va lv e Spring If the spring is more than 1/16 inch out of square,
install a new spring.
Testing V a lve Springs (Fig. 16)
(1) Whenever valves have been removed for inspec
Installation
tion, reconditioning or replacement, valve springs
(1) Coat valve stems with lubrication oil and insert
should be tested. As an example, the compressed
them in cylinder head.
length of the spring to be tested is 1-5/16 inches. Turn
(2) If valves or seats are reground, test valve stem
table of Tool C-647 until the surface is in line with the
height with Tool C-3746. If valve is too long, grind off
1-5/16 inch mark on the threaded stud and the zero
the tip until length is within limits.
mark to the front. Place spring over the stud on table
(3) Install new cup seals on all valve stems (long
and lift the compressing lever to set the tone device.
seal on intake valve and short seal on exhaust valve)
Pull on torque wrench until ping is heard. Take read
and over valve guides (Figs. 18 and 19).—Install valve
ing on torque wrench at this instant. Multiply this
springs and retainers.
reading by two. This will give the spring load at the
(4) Compress valve springs with Tool C-3422A, in
test length. Fractional measurements are indicated on
stall locks and release the tool. If valves and/or seats
the table for finer adjustments. Refer to specifica are reground, measure the installed height of springs.
tions to obtain specified height and allowable tensions.
Make sure measurement is taken from the bottom of
Discard the springs that do not meet specifications. the spring seat in the cylinder head to the bottom
(2) Inspect each valve spring for squareness with a surface of the spring retainer. (If spacers are in
steel square and surface plate, test springs from both stalled, measure from the top of spacer). If height
ends, (Fig. 17). is greater than 1-11/16 inches, install a 1/16 Inch
spacer in the head counterbore to bring the spring
RETAINER
V.V .V r S^R' MG
f.
« - ~ SPRING
\
^ VALVE
% S ,C UP SEA*.
9
\ "--"t
i f f ; -IS ,
x;eu.53
fig * -17—Inspecting Waive Spring Squareness
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height back to normal 1-5/8 inches to 1-11/16 inches. TORQUE WRFNCH
VALVE TIMING
(1) Rotate crankshaft until No. 6 exhaust valve is
closing and No. 6 intake valve is opening. Install a dial
indicator so that indicator pointer contacts valve
spring retainer on No. 1 intake valve parallel to the
axis of the valve stem.
(2) Turn No. 1 intake adjusting screw in one com
plete turn to remove the lash. Adjust dial indicator to
zero. Rotate crankshaft clockwise (normal running
direction) until valve has lifted .023 inch. The timing
of the crankshaft pulley should now read from 12
degrees before top dead center to dead center. Re
adjust lash.
(3) If reading is not within specified limits:
(a) Inspect sprocket index marks.
(b) Inspect timing chain for wear.
(c) Inspect accuracy of “DC” mark on timing indi NU263
cator.
Fig, 2 1—Measuring Chain Stretch
TIMING CHAIN COVER, OIL SEAL any movement of the chain may be measured.
AND CHAIN (2) Place a torque wrench and socket over the cam
shaft sprocket lock bolt and apply torque in the direc
Cover Rem oval tion of crankshaft rotation to take up slack; 30 foot
(1) Drain cooling system. pounds (cylinder head installed) or 15 foot-pounds
(2) Remove radiator and fan. (cylinder head removed). With torque applied to the
(3) Install Tool C-3732A and pull vibration damper camshaft sprocket bolt, crankshaft should not be
assembly off end of crankshaft (Fig. 20). permitted to move. It may be necessary to block the
(4) Loosen oil pans bolts to allow clearance and re crankshaft to prevent rotation.
move chain case cover and gasket. (3) Holding a scale with dimensional reading even
It is normal to find particles of neoprene collected
with the edge of a chain link, apply torque in the
between seal retainer and crankshaft oil slinger after
reverse direction 30 foot-pounds (cylinder head in
seal has been in operation.
(5) Slide crankshaft oil slinger off end of crank stalled) or 15 foot-pounds (cylinder head removed)
shaft. and note the amount of chain movement (Fig. 21).
(4) If chain movement exceeds 3/16 inch, install a
M easuring Timing Chain fo r Stretch new timing chain.
(1) Place a scale next to the timing chain so that (5) If chain is satisfactory, slide the crankshaft oil
slinger over the shaft and up against sprocket (flange
away from sprocket).
J
(6) If chain is not satisfactory, remove camshaft
-DAMPER PULLEY
-TOOL
M lig1 TIMING
MARKS
■ p p t
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sprocket attaching bolt and remove timing chain
REMOVING AND
with camshaft sprocket. INSTALLING PLATE
(7) Turn crankshaft to line up the centerline of (TOOL)
'^.-JgM O V ER SCREW
camshaft and crankshaft with the timing mark on . /^/'fTOOL)
crankshaft sprocket.
(8) Install camshaft sprocket and timing chain. SLEEVE (TOC.;.
(9) Line up timing marks on the sprockets with the
centerline of crankshaft and camshaft (Fig. 22).
(10) Tighten camshaft sprocket lock bolt to 35 foot
pounds. Slide the crankshaft oil slinger over shaft and
up against sprocket (flange away from sprocket).
-C H A IN CASE COVER
- -C H A IN CASE COVER
WASHER
CHAIN "j '
CASE
COVER
LOCK
FUEL PUMP ECCENTRIC 1/ BOLT
(INTEGRAL WITH CAMSHAFT)
J
IV
OIL PUMP AND DISTRIBUTOR DRIVE
GEAR (INTEGRAL WITH CAMSHAFT) NU265
Fig. 2 9 —Camshaft and Sprocket Assembly
N Y 1 6 4 ;/ The helical oil pump distributor drive gear and cam
shaft lobe taper both tend to produce only a rearward
Fig. 27—Inspecting Seal for Proper Seating thrust.
Cover Installation
(1) Be sure mating surfaces of chain case cover and R em oval
cylinder block are clean and free from burrs. (1) Remove tappets, using Tool C-3661; identify to
(2) Using a new gasket, slide chain case cover over insure installation in original location.
locating dowels and tighten bolts to 15 foot-pounds. (2) Remove timing sprockets, distributor and oil
Be sure all oil pan gaskets are in place and tighten oil pump.
pan bolts to 200 inch-pounds. (3) Remove fuel pump.
(3) Place damper pulley assembly hub key in the (4) Install a long bolt into the front of camshaft to
slot in crankshaft, lubricate seal lip with Lubriplate facilitate removal of the camshaft; remove camshaft,
and slide hub on the crankshaft. being careful not to damage cam bearings with the
(4) Place installing tool, part of puller set Tool C- cam lobes.
3732A in position and press damper pulley assembly
on the crankshaft (Fig. 28). Installation
(1) Lubricate camshaft lobes and camshaft bearing
CAMSHAFT journals and insert the camshaft in cylinder block
(Fig. 30).
The camshaft has an integral oil pump and dis Whenever an engine is rebuilt and/or a new cam
tributor drive gear and fuel pump eccentric (Fig. 29). shaft and/or new tappets are installed, one quart of
Rearward camshaft thrust is taken by the rear face engine supplement, Chrysler Part Number 1879406 or
of the aluminum camshaft sprocket hub, bearing di equivalent should be added to the engine oil to aid in
rectly on the front of the cylinder block, eliminating break-in. The oil mixture should be left in the engine
the need for a thrust plate. for a minimum of 500 miles. Drain the oil mixture at
the next normal oil change.
When replacing camshaft, all of the tappet faces
must be inspected for crown with a straight edge, if
*#• any negative crown (dish) is observed, tappet must be
replaced. The tappet must have a definite crown.
>.
CAMSHAFT
7j a r
'f
'■'TOOL
NY 159 A
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Installation of Distributor alignment with drilled oil passage or passages from
Before installing the distributor, time the engine as the main bearing.
follows: (3) Install remaining shells in like manner. Install
The distributor rotates clockwise. NO. 1 camshaft bearing 3/32 inch inward from the
(1) Rotate crankshaft until the mark on inner edge front face of the cylinder block.
of crankshaft pulley is in line with the “0 ” (TDC) (4) Apply sealer to the plug and install a new welch
mark on the timing chain case cover. No. 1 cyl. com plug at the rear of camshaft. Be sure this plug does
pression stroke (both valves closed). not leak.
(2) With distributor “O” rings in position, hold the
distributor over mounting pad. CYLINDER BLOCK
(3) Turn the rotor to point forward, corresponding Piston Rem oval
to 4 o’clock. (1) Remove the top ridge of cylinder bores using
(4) Install distributor so that with distributor fully Tool C-3012 before removing pistons from cylinder
seated on the engine, the gear has spiraled to bring block. Keep tops of the pistons covered during this
the rotor to a 5 o’clock position. operation.
(5) Turn the housing until the ignition contacts are (2) Pistons and connecting rods must be removed
separating and rotor is under No. 1 cap tower. from top of cylinder block. Rotate crankshaft so that
(6) Install hold down bolt and connect the primary each connecting rod is centered in the cylinder bore.
wire. (3) Inspect connecting rods and connecting rod
(7) Adjust timing to specifications, using a timing caps for cylinder identification. Identify them if neces
light, then re-connect the vacuum line. sary.
(4) Remove connecting rod cap. Install connecting
CAMSHAFT BEARINGS (Engine Removed rod bolt guide set on connecting rod bolts. Push each
from Vehicle) piston and rod assembly out of cylinder bore. Be care
ful not to nick crankshaft journals.
Removal (5) Install bearing caps on mating rods.
(1) With camshaft removed, drive out rear cam
bearing welch plug. Cleaning an d Inspection
(2) Install proper size adapters and horse shoe (1) Clean cylinder block thoroughly and check all
washers (part of Tool C-3132A) at the back of each core hole plugs for evidence of leaking.
bearing shell and drive out all bearing shells. (2) If new core plugs are installed, coat edges of
plug and core hole with Number 1057794 Sealer or
Installation equivalent. Drive the core plug in so that the rim lies
(1) Install new camshaft bearings with Tool C- at least 1/64" below the lead-in chamfer.
3132A by sliding the new camshaft bearing shell over (3) Examine block for cracks or fractures.
the proper adapter.
(2) Position bearing in tool. Install horseshoe lock Cylinder Bore Inspection
The cylinder walls should be tested for out-of-round
and drive the bearing shell into place, (Fig. 31). The
camshaft bearing oil hole or holes must be in exact and taper with Tool C-119. If the cylinder bores show
more than .005" out-of-round, or a taper of more than
C A M S H A FT B EA R IN G O IL H O L l
.010" or if the cylinder walls are badly scuffed or
scored, the cylinder block should be rebored and
honed, and new oversize pistons and rings fitted.
Whatever type of boring equipment is used, boring
* • |MH . * 1
ianntiTimrr
and honing operation should be closely coordinated
» with the fitting of pistons and rings in order that
specified clearance may be maintained.
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scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones (C-3501-3810). If the
cylinder bore is straight and round 20-60 strokes
depending on the bore condition will be sufficient to
provide a satisfactory surface. Inspect cylinder walls
after each 20 strokes. Use honing oil C-3501-3880 or a
light honing oil available from a major oil distributor. THE ELLIPTICAL SHAPE OF DIAMETERS AT (C) A N D (D)
Do not use engine or transmission oil, mineral spirits THE PISTON SKIRT SHOULD CAN BE EQUAL OR DIAMETER
BE .0 0 8 TO .010 IN. LESS AT AT (D) CAN BE .0015 IN.
or kerosene. DIAMETER (A) THAN ACROSS GREATER THAN (C)
(3) Honing should be done by moving the hone up THE THRUST FACES AT D IA M
and down fast enough to get a cross-hatch pattern. ETER (B). MEASUREMENT
When hone marks intersect at 60°, the cross hatch IS MADE >/8 IN. BELOW
LOWER RING GROOVE NY221B
angle is most satisfactory for proper seating of the
rings. (See Fig. 32). Fig. 3 3 —Piston Measurements
(4) After honing, it is necessary that the block be Finished Pistons
cleaned again to remove all traces of abrasives. All pistons are machined to the same weight in
CAUTION: Be sure all abrasives are removed from grams, regardless of oversize to maintain piston bal
engine parts after honing. It is recommended that a ance. For cylinder bores which have been honed or
solution of soap and water be used with a brush and rebored, all service pistons include pins and are avail
the parts then thoroughly dried. The bore can be con able in standard and the following oversizes: .005,
sidered clean when it can be wiped clean with a white .020, .040 inch.
cloth and cloth remains clean. Oil bores after cleaning
to prevent rusting. Fitting Pistons
The piston and cylinder wall must be clean and dry.
Specified clearance between the piston and cylinder
PISTONS, PINS AND RINGS
wall is .0005 to .0015 inch.
The pistons are cam ground so that the diameter at (1) Pistons and cylinder bores should be measured
at normal room temperature, 70 degrees F.
the pin boss is less than its diameter across the thrust
(2) Measure piston diameter at the top of skirt 90
face. This allows for expansion under normal oper
degrees to piston pin axis.
ating conditions. The expansion forces the pin bosses
(3) Measure cylinder bores halfway down cylinder
away from each other, and the piston assumes a more bore and transverse to engine crankshaft center line.
round shape. Inspect pistons for taper and elliptical
shape before they are fitted into cylinder bores. (See Fitting Rings
Fig. 33). (1) Measure piston ring gap about two inches from
the bottom of the cylinder bore in which it is to be
fitted. (An inverted piston can be used to push rings
down to insure positioning rings squarely in cylinder
wall).
(2) Insert feeler stock in the gap. Ring gap should
be .010 to .047 inch for compression rings and .015 to
.062 inch for oil ring steel rails in standard size bores.
Maximum gap in .005 inch o /s bores should be .060
inch for compression rings and .070 inch for oil ring
steel rails.
(3) Measure side clearance between piston ring and
ring land, (Fig. 34).
Clearance should be .0015 to .004 inch for top com
pression ring and intermediate ring.
(4) Starting with oil ring expander, place expander
ring in lower ring groove and install oil control ring
using instructions in package. Steel rail service oil
ring should be free in groove, but should not exceed
.005 inch side clearance.
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PRESS-— ___ M AIN SCREW (TOOL)
,s’
^ — PILOT (TOOL)
A N V IL (TOOL)
KR165 A NR808
Fig. 3 4 —M easuring Piston Ring Side Clearance Fig. 3 6 —Removing Piston Pin
(5) Install compression rings in middle and top (2) Lubricate piston pin holes in piston and con
grooves, using ring installer, Tool C-3805. Be sure the necting rod.
mark “TOP” on each compression ring is to the top of (3) Arrange tool parts for installation of piston pin
piston. (Fig. 37).
(4) Install spring inside the pilot and install spring
Piston Pin Rem oval and pilot in the anvil.
(1) Arrange Tool C-3724 parts for removal of (5) Install piston pin over main screw.
piston pin (Fig. 35). (6) Place piston, with “Notch Front” up, over the
(2) Install pilot on main screw. pilot so that pilot extends through piston pin holes.
(3) Install screw through piston pin. (7) Position connecting rod over the pilot which ex
(4) Install anvil over threaded end of main screw tends through piston hole. The oil hole in connecting
with small end of anvil against piston boss. Be sure rod must point toward the direction shown in Figure
spring is removed from anvil. 38.
(5) Install nut loosely on main screw and place as (8) Install main screw and piston pin in piston (Fig.
sembly on the press (Fig. 36). Press piston pin out of 39).
connecting rod. (9) Install nut on main screw to hold assembly to
When the pin falls free from connecting rod, stop gether. Place assembly on a press (Fig. 39).
the press to prevent damage to bottom of the anvil. (10) Press piston pin in the piston until pin bottoms
(6) Remove tool from piston.
on pilot, properly positioning pin in connecting rod.
Installation (11) Remove tool and arrange tool parts and piston
(1) Measure piston pin fit in the piston. It should be assembly in the same manner, as shown in Figure 35
a sliding fit in piston at 70 degrees F. Piston pins are for measuring pin fit.
supplied in standard sizes only. (12) Place assembly in a vise (Fig. 40).
N U T (TO O L ) A N V IL (TO O L)
A N V IL (T O O L) SPRING (TO O L)
PILO T (TO O L)
PISTO N
NUT PISTO N
PILOT (TO O L) (TO O L) ^ P IS T O N PIN
G U ID E -S M A L L
G U ID E -S M A L L
PIS TO N PIN (TO O L)
(TO O L ) C O N N E C T IN G ROD
C O N N E C T IN G RO D
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INDENT-ASSEMBLE TOWARDS FRONT OF NUT J7
ENGINE j (TOOL) ■ *
\ "TORQUE WRENCH
" ■ —“ SOCKET
\
-PILOT (TOOL)
■M A IN SCREW (TOOL)
OIL HOLE-ASSEMBLE
TOW AR DS RIGHT SIDE
OF ENGINE
NR810
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(3) Install bearing cap and tighten to 45 foot into position on crankshaft journal.
pounds. (8) Install rod caps, tighten nuts to 45 foot-pounds.
(4) Turn connecting rod 1/4 turn in each direction.
A slight drag should be felt which indicates clearance CRANKSHAFT MAIN JOURNALS
is satisfactory. Correct clearance is from .0005 to .0015
inch. Crankshaft journals should be inspected for exces
(5) Side play should be from .006 to .012 inch. sive wear, taper and scoring. Limits of taper or out-
of-round on any crankshaft journal should be held to
INSTALLING PISTON AND CONNECTING .001 inch. Journal grinding should not e xceed .012
ROD ASSEMBLY inch under the standard journal diameter. Do not
grind thrust faces of No. 3 main bearing. Do not nick
(1) Compression ring gaps should be located on the connecting rod or main bearing journal fillets. After
left side of the engine and staggered about 60° apart. regrinding, remove rough edges from crankshaft oil
Neither gap should line up with oil ring rail gaps. holes and clean out all oil passages.
(2) Rotate oil ring expander so that ends are at
right side of engine. Rotate steel rails so that gaps are CRANKSHAFT MAIN BEARINGS
approximately opposite and positioned above piston
pin holes. The NOs. 1, 2 and 4 lower main bearings are inter
(3) Immerse piston head and rings in clean engine changeable (Fig. 42). The NOs. 2 and 4 upper main
oil. Slide the ring compressor, Tool C-385, over the bearings are interchangeable.
piston and tighten with special wrench (part of Tool The NO. 1 upper main bearing is not interchange
C-385). Position of rings must not change during this able and is chamfered on the tab side for timing chain
operation. oiling and can be identified by a red marking on the
(4) The notch on top of piston must point toward edge of the bearing. Upper main bearings are grooved
front of engine so that squirt hole in connecting rod is and lower main bearings are plain and are not inter
toward right side of engine. changeable. The NO. 3 upper and lower main bear
(5) Install connecting rod bolt protectors on rod ings are flanged to carry the crankshaft thrust loads
bolts, the long protector should be installed on squirt and are not interchangeable with any other main
hole side of connecting rod. Rotate crankshaft so that bearings in the engine. Bearings that are not badly
connecting rod journal is on the center of cylinder worn, scored or pitted should be reinstalled in the
bore. same bearing bore.
(6) Insert rod and piston into cylinder bore and The bearing caps are not interchangeable and the
guide rod over the crankshaft journal (Fig. 41). Be numbers should be marked at removal to insure cor
careful not to nick connecting rod journals. rect assembly. Bearings are available in standard and
(7) Tap piston down in cylinder bore, using handle the following undersizes, .001, .002, .003, .010 and
of a hammer. At the same time, guide connecting rod .012 inch. Never install an undersize bearing that will
reduce the clearance below specifications.
S I, < KANKSHAFT (CONNECTING ROD) JOURNAL
'-.
LOWER
NY 14 7
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Removal
(1) Remove oil pan and inspect the bearing cap
identifying numbers.
(2) Remove bearing caps one at a time. Remove
BRIDGE
upper bearing by inserting Tool C-3059 (Fig. 43) into (PART OF
oil hole on crankshaft. TOOL)
TOOL
(3) Slowly rotate crankshaft clockwise, forcing out
upper bearings.
\ /7 SEAL
Installation SEAL
O nly one main bearing should be selectively fitted 1 RETAINER
while all other main bearing caps are properly
torqued.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side. SIDE V A :. GROOVES NY 133
(1) Start bearing in place, and insert Tool C-3059
into oil hole of crankshaft (Fig. 43). Fig. 4 4 —Installing Rear M ain Bearing O il Seal
(2) Slowly rotate crankshaft counter-clockwise slid (5) Fit remaining bearings in same manner.
ing the bearing into position. Remove Tool C-3059. It is permissible to use one .001 inch undersize
bearing shell with one standard bearing shell, or one
MEASURING MAIN BEARING CLEARANCE .002 inch undersize bearing shell with one .001 inch
undersize shell. Always use the smaller diameter
Shim Stock M ethod bearing half as the upper. Never use an upper bear
(1) Smooth edges of a 1/2 x 3/4 inch piece of brass
shim stock, .001 inch thickness. ing more than .001 inch smaller than the lower bear
(2) Install bearing in center main bearing cap, ing half and never use a new bearing half with a used
bearing tang in groove in cap, lubricate bearing and bearing half.
position shim stock across the bearing, install cap,
tighten bolts to 85 foot-pounds. REAR MAIN BEARING OIL SEAL
(3) If a slight drag is felt as crankshaft is turned (Crankshaft Removed)
(moved no more than 1/4 turn in either direction),
clearance is .001 inch or less and is considered satis U pper Seal
factory. (1) Install a new oil seal in the cylinder block so
If however, no drag is felt, the bearing is too large that both ends protrude.
or if the crankshaft cannot be rotated, the bearing is (2) Tap seal down into position, using Tool C-3743
too small and should be replaced with the correct size. (with bridge removed) until the tool is seated in the
(4) Measure crankshaft end play .002 to .007 inch. bearing bore.
If end play is less than .002 inch or more than .007 (3) Hold tool in this position and cut off the portion
inch, install a new number 3 main bearing. of the seal that extends above the block on both sides.
TOOL
\
'J:, S M
' 7
■ ■ S i
I f l i
S7AL'
nr Ail'T:*
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Lower Seal (3) Trim off portion of seal that protrudes above
(1) Install a new seal in seal retainer so that ends cap (Fig. 45).
protrude (Fig. 44). (4) Install two side seals in grooves in seal retainer.
(2) Install the bridge on the tool and tap seal down (5) When installing seal retainer, tighten screws to
into position until tool is seated. 30 foot-pounds.
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Inspect oil drain plug and plug hole for stripped or
damaged threads and repair as necessary. Install a BODY ■ GASKET
ft,
v*»
v-'"' <sT
4
... VALVE
'SPRING
rule against flat surface inside the case and meas ■ \ v
ure from edge of rule to edge of oil screen. Measure SCREW AND LOCKWASHER PLUG
ment should be 1-1/8 inches with screen properly 2 V
GASKET V/-
positioned.
Screen must be an interference with bottom of oil SCREW AND LOCKWASHER NY206B
pan.
Fig. 4 8 —O il Pump Disassembled View
Installation (3) Install exhaust pipe to manifold, use a new gas
198 or 225 Cubic Inch Engine (Dart) ket. Tighten to 30 foot-pounds.
(1) Using a new pan gasket set, install oil pan and (4) Lower vehicle, install oil dipstick and fill crank
tighten screws to 200 inch-pounds. case to recommended level with proper grade of
(2) Lower engine to its original position, install motor oil. Connect negative ground cable to battery.
front engine mount bolts. Tighten to specifications.
(3) Connect steering and idler arm ball joints to OIL PUMP
center link. Tighten retainer nuts to 40 foot-pounds
and secure with cotter pins. Removal
(1) Drain radiator, disconnect upper and lower
(4) Install upper and lower radiator hoses. Install
hoses. Remove fan shroud, if so equipped.
fan shroud, if so equipped.
(5) Refill radiator, install battery cables. (2) Raise vehicle on hoist, support front of engine
with a jack stand placed under the right front corner
(6) Lower vehicle install oil dipstick and fill crank
of engine oil pan. (Do not support the engine at the
case to recommended level with proper grade of motor
oil. crankshaft pulley or vibration damper.) Remove front
engine mount bolts.
(3) Raise engine approximately 1-1/2 to 2 inches.
225 Cubic Inch Engine (Challenger) (4) Remove oil filter, oil pump attaching bolts and
(1) Using a new oil pan gasket set, install the oil
remove pump assembly.
pan and tighten bolts to 200 inch-pounds.
(2) Connect steering and idler arm ball joints to Installation
center link. Tighten retaining nuts to 40 foot-pounds (1) Using new “O” rings, install oil pump and
and secure with cotter pins. Install dust shield. tighten to 200 inch-pounds.
STRAIGHT EDGE
COVER
FEELER GAUGE
NY1193
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O U rtR ROTOR
. t'UMs' r v w
I%
OUTER ROTOR
DIAMETER
NY136 NY138
Fig. SO—Measuring O u ter Rotor Thickness Fig. 5 2 —M easuring O u ter Rotor Clearance
(2) Lower engine to its original position, install (4) If inner rotor length measures less than .649
front engine mount bolts. inch (Fig. 51), replace inner rotor.
(3) Connect upper and lower radiator hoses. Install (5) Install outer rotor into pump body, pressing to
fan shroud, if so equipped. one side with fingers and measure clearance between
(4) Install oil filter. outer rotor and pump body (Fig. 52). If measurement
(5) Refill radiator. is more than .014 inch, replace oil pump body.
(6) Install inner rotor into pump body and place a
Disassembly (Fig. 48)
(1) Remove pump cover and seal ring. straightedge across face between bolt holes (Fig. 53).
(2) Press off drive gear. Support gear to keep the If a feeler gauge of more than .004 inch can be in
serted between the rotors and straightedge, replace
load off of aluminum body.
(3) Remove pump rotor and shaft and lift out outer pump body.
(7) If clearance between inner rotor and outer
pump rotor.
rotor (Fig. 54) is more than .010 inch, replace inner
(4) Remove oil pressure relief valve plug and lift
out spring and plunger. and outer rotors.
(8) Inspect oil pump relief valve plunger for scor
Inspection ing and for free operation in its bore. Small scores
(1) Clean all parts thoroughly. Mating face of oil may be removed with 400 grit wet or dry paper.
pump cover should be smooth. Replace cover if it is (9) For 198-225 cubic inch engines the relief valve
scratched or grooved. spring has a free length of 2-9/32 to 2-19-64 inch and
(2) Lay a straightedge across the oil pump cover should test 14.85 to 15.85 lbs. when compressed to
surface (Fig. 49). If a .0015 inch feeler gauge can be 1-19/32 inch. Discard spring that fails to meet speci
inserted between cover and straightedge, cover should fications.
be replaced.
(3) If outer rotor length measures less than .649 FEELER GAUGE
inch (Fig. 50), and the diameter less than 2.469 inches,
replace outer rotor.
/
INNER ROTOR
STRAIGHT EDGE
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(10) If oil pressure is low, inspect for worn bear
ings, or look for other causes of possible loss of oil
pressure.
Assembly
(1) Assemble pump, using new parts as required.
(2) Install new oil seal rings between cover and
body. Tighten cover bolts to 95 inch-pounds.
(3) Install the oil pump on engine. Tighten attach
ing bolts to 200 inch-pounds.
OIL FILTER
Page Page
C am shaft................................................................. , 35 Measuring Connecting Rod Bearing Clearance . .. 39
Camshaft Bearings................................................ 36 Measuring Main Bearing Clearance................... 41
Connecting Rods .................................................... 39 Oil F ilte r.................................................................. 24
Crankcase Ventilation S ystem ............................. 85 43
Crankshaft Identification....................................... 39 Oil Pump ............................................................... 43
Crankshaft Main Bearings .................................... 40 Piston, Pins and R in g s........................................ . . 37
Crankshaft Main Journals...................................... 40 Rear Main Bearing Oil S e a ls ............................... 41
Cylinder B lo c k ............... ........................................ 37 Repair of Damaged or Worn Th read s............... 85
Cylinder Heads ..................................................... . . 27 Rocker Arms and Shaft Assembly..................... 27
Distributor Drive Shaft B ushing......................... 36 Specifications____. . . ' ........................................... 90
Engine Assembly.................................................... 26 Timing Chain Cover, Oil Seal and Chain .......... 33
Engine M o un ts....................................................... 25 24
Hydraulic T ap p ets.................................................. 31 Valves and Valve Springs.................................... .. 28
Installing Piston and Connecting Rod Assembly . . 39 Valve T im in g ............... ........................................... .. 32
SERVICE PROCEDURES
TUNE-UP diagnosing engine problems. An engine in good con
dition may exhibit higher pressures. Many conditions
(1) Test battery specific gravity, add water if neces which are difficult to control cause variations in com
sary, clean and tighten battery connections. pression readings. An engine should not be disassem
(2) Test cranking voltage. See “Starting Motor bled to determine the cause of low compression un
Cranking Voltage” Electrical Section of this manual. less some other malfunction is present.
(3) Tighten the intake manifold bolts to specifica (5) Clean or replace spark plug as necessary and
tions. adjust gap to .035 inch. Tighten to 30 foot-pounds
(4) Perform cylinder compression test. Compres using new gaskets.
sion should not be less than 100 pounds for 318 Cubic (6) Test resistance of spark plug cables. Refer to
Inch Engine or 110 pounds for 340 Cubic Inch Engine “Ignition System Secondary Circuit Inspection” Elec
and not vary more than 40 pounds. The recommended trical Section.
compression pressures are to be only as a guide to (7) Inspect the breaker plate contacts, primary wire
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and vacuum advance operation. Test coil output volt V IE W A V IE W B
RIGHT SIDE LEFT SIDE
age, primary and secondary resistance. Test Conden 340 CUBIC IN C H 340 CUBIC IN C H
ser. Replace parts as necessary. Refer to Ignition Sys (S A M E -A S 318 (S A M E -A S 318
tem and make necessary adjustments. CUBIC IN C H CUBIC IN C H
EXCEPT AS S H O W N ) EXCEPT AS S H O W N )
(8) Reset ignition timing with vacuum advance line
disconnected. Ignition timing should be set to com
pensate for altitudes and/or gasoline grades.
(9) Set carburetor idle mixture adjustment. Adjust
throttle stop screw to specifications. Perform a com
bustion analysis.
(10) Test fuel pump for pressure and vacuum. Re <^ /
fer to “Fuel System” Group 14, Specifications.
(11) Inspect manifold heat control valve in the
right exhaust manifold for proper operation and apply V IE W B
LEFT SIDE
Manifold Heat Control Valve Solvent Part Number
‘2525054 or equivalent to the bushing and shaft.
(12) Every 6 months, remove air cleaner filter ele 55 FT. LB.
ment and blow out dirt gently with air hose. Direct air $ 75 FT. LB.
¥ PY604
from inside out, and keep nozzle 2 inches away from
element to avoid damaging. Clean metal housing and Fig. 2 —Front Engine Mounts—3 18-340
Cubic Inch—Dart
replace element (Fig. 1). Every two years, install a
new factory recommended filter element or equiv (4) Raise engine just enough to remove front en
alent. Service unit more frequently when driving gine mount assembly.
under severe conditions, such as in dusty areas.
(13) Inspect crankcase ventilation system as out Installation
(1) Install insulator to engine bracket and tighten
lined on page 85.
to specified torque.
(14) Inspect and adjust accessory belt drives refer
(2) Lower engine and install washers and prevail
ring to “Cooling System,” Group 7, for proper ad
ing torque nuts to insulator studs; tighten nuts to
justments.
specified torque.
(15) Road test vehicle as a final test. (3) Connect throttle at transmission and carbu
retor.
FRONT ENGINE MOUNTS (Figs. 2,3 and 4)
REAR ENGINE MOUNTS (Figs. 5 and 6)
Removal Removal
(1) Raise hood and position fan to clear radiator (1) Raise vehicle on hoist.
hose and radiator top tank.
(2) Disconnect throttle linkage at transmission and
at carburetor.
(3) Remove torque nuts from insulator studs.
VIEW A
RIGHT SIDE A
T IG H T E N IN G * /^
TORQUE
50 FT. LB.
<B> 55 FT. LB.
75 FT. LB.
NR40A
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TRANSMISS I O N
EXTENS I O N
SPACER (2)
SCREW A N D WASHER
ASSEMBLY (2)<g>
T IG H T E N IN G
TORQUE
Fig. 4—Front Engine Mounts—3 4 0 Cubic Inch—
Challenger <g>|50 FT. LBT
(2) Install transmission jack. CROSS MEMBER
(3) Remove rear engine crossmember from frame PY433
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(6) Connect propeller shaft, wires, linkage, speed OIL FEED INTAKE SPARK DOWEL
ometer cable, oil cooler lines at transmission, connect
exhaust pipes to manifolds. Install transmission filler
tube.
(7) Lower vehicle and remove engine lifting fixture
from engine. Install carburetor and fuel lines.
(8) Install radiator, fan shroud, hoses, oil cooler
lines and connect all wires and linkage.
(9) Install hood using scribe marks for proper
alignment.
(10) Close all drain cocks and fill cooling system,
install battery.
(11) Fill engine crankcase and transmission. Refer
to “Lubrication” Group 0, for quantities and lubri
cants to use. Inspect entire system for leaks and cor Fig. 7—Cylinder Head Assembly
rect as necessary.
Whenever an engine has been rebuilt and/or a new Figure 7 are held in place by 10 bolts. The spark
camshaft and/or tappets are installed, one quart of plugs are located in peak of the wedge between the
engine supplement, Chrysler Part Number 1879406 or valves.
equivalent should be added to the engine oil to aid in
break-in. The oil mixture should be left in the engine Rem oval
for a minimum of 500 miles. Drain the oil mixture at (1) Drain cooling system and disconnect battery
the next normal oil change. ground cable.
(12) Start engine and run until normal operating (2) Remove alternator, carburetor air cleaner and
temperature is reached. fuel line.
(13) Test timing (with vacuum advance line re (3) Disconnect accelerator linkage.
moved) and adjust carburetor and transmission link (4) Remove vacuum control hose between carbu
age as necessary. Connect vacuum lines, install air retor and distributor.
cleaner and road test the vehicle. (5) Remove distributor cap and wires.
(6) Disconnect coil wires, heat indicator sending
ROCKER ARMS AND SHAFT ASSEMBLY unit wire, heater hoses and by-pass hose.
Rem oval (7) Remove closed ventilation system and evapora
(1) Disconnect spark plug wires by pulling on the tive control system (if so equipped) and cylinder
boot straight out in line with plug. head covers.
(2) Disconnect closed ventilation system and evap (8) Remove intake manifold, ignition coil and car
orative control system (if so equipped) from cylin buretor as an assembly.
der head cover. (9) Remove exhaust manifolds.
(3) Remove cylinder head cover and gasket. (10) Remove rocker arm and shaft assemblies. Re
(4) Remove five rocker shaft bolts and retainers. move push rods and identify to insure installation in
(5) Remove rocker arms and shaft assembly. original location.
(11) Remove the 10 head bolts from each cylinder
Installation head and remove cylinder heads.
(1) Install rocker arm and shaft assemblies with (12) Place cylinder heads in holding fixture Tool
“NOTCH” on end of rocker shaft pointing to center-
C-3626. Remove spark plugs.
line of engine and toward front of engine on the left
bank and to the rear on right bank, making sure to
install the long stamped steel retainers in the number Installation
(1) Clean all gasket surfaces of cylinder block and
two and four positions, tighten to 210 inch-pounds.
(2) Inspect cylinder head cover for distortion. cylinder heads.
Straighten if necessary. (2) Inspect all surfaces with a straightedge if there
(3) Install cylinder head cover and tighten to 40 is any reason to suspect leakage. If out of flatness ex
inch-pounds. ceeds .00075 times the span length in any direction;
(4) Install closed crankcase ventilation system and either replace head or lightly machine the head gasket
evaporative control system (if so equipped). surface. As an example, if a 12 inch span is .004" out
of flat, allowable is 12 x .00075 = .009". Head is OK.
CYLINDER HEADS The cylinder head surface finish should be 70-180
The chrome alloy cast iron cylinder heads shown in micro-inches.
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(3) Coat new gaskets lightly with number 1057794
Sealer and install on cylinder block.
(4) Remove cylinder heads from holding fixtures
Tool C-3626 and place heads on engine.
(5) Install cylinder head bolts. Starting at top cen
ter, tighten all cylinder head bolts to 50 foot-pounds
in sequence, as shown in Figure 8. Repeat procedure,
retighten all cylinder head bolts to 85 foot-pounds on
318 Cubic Inch Engine and 95 foot-pounds on 340
Cubic Inch Engine.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install push rods, rocker arm and shaft assem
blies with the “NOTCH” on the end of rocker shaft
pointing to centerline of engine and toward front of Fig. 9 —In tak e M anifold Tightening Sequence
engine on the left bank and to the rear on right bank, 3 1 8 Cubic Inch Shown (Typical)
making sure to install the long stamped steel retain
ers in the number two and four positions, tighten to wire, heater hoses and by-pass hose.
210 inch-pounds. (13) Install vacuum control hose between carbu
(8) Coat intake manifold side gaskets lightly with retor and distributor.
number 1057794 sealer or equivalent and end gaskets (14) Install accelerator linkage and adjust as neces
with 1316241 sealer or equivalent. Install intake mani sary.
fold gaskets with the bead down and end seals locked (15) Install distributor cap and wires.
in the tangs of head gasket. Add a drop of sealer in (16) Install fuel line, alternator and drive belt.
the “V” notches at ends of side seals after installation. Tighten alternator mounting bolt to 30 foot-pounds
(9) Position intake manifold on engine and install and adjusting strap bolt to 200 inch-pounds. See Cool
the twelve attaching cap screws “Finger Tight.” Tight ing Section on adjusting belt tension.
en cap screws one through four to 25 foot-pounds and (17) Place new cylinder head cover gaskets in posi
tighten remaining cap screws to 25 foot-pounds, in the tion and install cylinder head covers. Tighten to 40
tightening sequence shown in Figure 9, then retight inch-pounds.
en cap screws one through four to 35 foot-pounds and (18) Install closed crankcase ventilation system and
follow by retightening the remaining cap screws to evaporative control system (if so equipped).
(19) Fill cooling system and install battery ground
35 foot-pounds in sequence shown.
cable.
(10) Install exhaust manifolds with new gaskets,
the extended shield is used on left side, tighten to 30 VALVES AND VALVE SPRINGS
foot-pounds.
(11) Adjust spark plugs to .035 inch gap and install The valves are arranged in-line in the cylinder
the plugs tightening to 30 foot-pounds. heads and inclined 18 degrees. The rocker shaft sup
(12) Install coil wires, heat indicator sending unit port and the valve guides are cast integral with the
heads.
Rem oval
(1) With cylinder head removed, compress valve
springs using Tool C-3422A, as shown in Fig. 10.
(2) Remove valve retaining locks, valve spring re
tainers, valve stem cup seals and valve springs.
(3) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guide. Identify valves to insure installation in
original location.
V a lv e Inspection
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. New intake valve
stem diameter should measure .3715 to .3725 inch and
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. V A IV !-;
HH
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NK11
REPAIR STANDS NK9
Fig. 12 —Measuring Valve Guide W e a r
Fig. 10—Compressing Va lv e Spring
Reamer Reamer Valve Guide
exhaust valve stem diameter should measure .3705 to Tool Number Oversize Size
.3715 inch. If wear exceeds .002 inch, replace valve. C-3433 .005 in. .379-.380 in.
C-3430 .015 in. .389-.390 in.
(3) Remove carbon and varnish deposits from in .030 in. .404-.405 in.
C-3427
side of valve guides with a reliable guide cleaner.
(4) Measure valve stem guide clearance as follows: (6) Slowly turn reamer by hand and clean guide
(a) Install sleeve Tool C-3973 over valve stem (Fig. thoroughly before installing new valve. Do not at
11) and install valve. The special sleeve places the tempt to ream the valve guides from standard directly
valve at the correct height for checking with a dial to .030 inch. Use step procedure of .005, .015 and .030
indicator. inch so the valve guides may be reamed true in rela
(b) Attach dial indicator Tool C-3339 to cylinder tion to the valve seat.
head and set it at right angle of valve stem being
Re facing Valves an d Va lve Seats
measured (Fig. 12). (1) The intake and exhaust valve seats and intake
(c) Move valve to and from the indicator. The total valve face have a 45 degree angle. The exhaust valve
dial indicator reading should not exceed .017 inch. face has a 43 degree angle. The valve face and valve
Ream the guides for valves with oversize stems if dial seat angles are shown in Figure 13.
indicator reading is excessive or if the stems are (2) Inspect the remaining margin after the valves
scuffed or scored. are refaced (Fig. 14). Valves with less than 3/64 inch
(5) Service valves with oversize stems are available margin should be discarded.
in .005, .015 and .030 inch oversize. Reamers to ac (3) When refacing valve seats, it is important that
commodate the oversize valve stem are as follows: the correct size valve guide pilot be used for reseating
stones. A true and complete surface must be obtained.
/ , ' i .. L
VA'.Vc
TOC)'.
A - S ; : - r H (intake i /:*? t o 3/32 inch
EXHAUST: 3/64 TO 1/16 INCH)
B-FACE ANGLE (INTAKE: 45°—EXHAUST: 43°)
C-SEAT ANGLE (INTAKE: 45°—EXHAUST: 45°)
D-CONTACT SURFACE
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tion, reconditioning or replacement, valve springs
should be tested. As an example the compression
length of the spring to be tested is 1-5/16 inches. Turn
table of Tool C-647 until surface is in line with the
1-5/16 inch mark on the threaded stud and the zero
mark to the front. Place spring over stud on the table
and lift compressing lever to set tone device. Pull on
torque wrench until ping is heard. Take reading on
torque wrench at this instant. Multiply this reading
by two. This will give the spring load at test length.
Fractional measurements are indicated on the table
for finer adjustments. Refer to specifications to ob
tain specified height and allowable tensions. Discard
the springs that do not meet specifications.
(2) Inspect each valve spring for squareness with a
steel square and surface plate, test springs from both
ends (Fig. 16).
Fig. 14 —In tak e and Exhaust Valves
If the spring is more than 1/16 inch out of square,
install a new spring.
(4) Measure the concentricity of valve seat using
dial indicator No. 13725. Total runout should not ex Installation
ceed .002 inch (total indicator reading). (1) Coat valve stems with lubrication oil and insert
(5) Check the valve seat with Prussian blue to de them in cylinder head.
termine where the valve contacts the seat. To do this, (2) If valves or seats are reground, check valve
coat valve seat lightly with Prussian blue then set stem height with Tool C-3968 (Fig. 17). If valve is too
valve in place. Rotate the valve with light pressure. If long, grind off the tip until length is within limits.
the blue is transferred to the center of valve face, (3) Install new cup seals on all valve stems and over
contact is satisfactory. If the blue is transferred to top valve guides (Fig. 18). Install valve springs and retain
edge of valve face, lower valve seat with a 30° stone. ers.
If the blue is transferred to bottom edge of valve face (4) Compress valve springs with Tool C-3422A, in
raise valve seat with a 60° stone. stall locks and release tool. If valves and/or seats are
(6) When seat is properly positioned the width of reground, measure the installed height of springs.
intake seats should be 1/16 to 3/32 inch. The width of Make sure measurement is taken from bottom of
the exhaust seats should be 3/64 to 1/16 inch. spring seat in cylinder head to the bottom surface of
Testing V a lv e Springs (Fig. 15) spring retainer (if spacers are installed, measure from
(1) Whenever valves have been removed for inspec the top of spacer). If height is greater than 1-11/16
inches, install a 1/16 inch spacer in head counterbore
to bring spring height back to normal 1-5/8 inches to
1-11/16 inches.
i a a r fv m m
V A L V F S P R IN G
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KR145B
Fig. 16—Checking Valve Spring Squareness
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which, when fed to the tappets, causes them to lose
length and allows valves to seat noisily. Any leaks on
intake side of pump through which air can be drawn
will create the same tappet action. When tappet noise
is due to aeration, it may be intermittent or constant,
and usually more than one tappet will be noisy. When
oil level and leaks have been corrected, engine should
be operated at fast idle for sufficient time to allow all
of the air inside of the tappets to be bled out.
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on one tappet at a time to avoid mixing of parts.
TOOL
Mixed parts are not compatible. Do not disassemble a
tappet on a dirty work bench. /
CLEAN
KEROSENE • '■*
Disassembly (Fig. 19)
(1) Pry out plunger retainer spring clip.
(2) Clean varnish deposits from inside of tappet I
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, flat check valve, check valve spring, check
valve retainer and plunger spring.
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TIMING CHAIN COVER, OIL SEAL
AND CHAIN y
Cover Rem oval
(1) Drain cooling system and remove radiator, fan
belt and water pump assembly. m
(2) Remove pulley from vibration damper and bolt
and washer securing vibration damper on crankshaft.
(3) Install Tool C-3688 and pull vibration damper
from end of crankshaft (Fig. 21).
(4) Remove fuel lines and fuel pump.
w i m x ,i t o r q u e
(5) L oosen oil pan bolts and remove the front bolt WRENCH
at each side.
(6) Remove chain case cover and gasket using ex .... '% 9 9 f NU268
treme caution to avoid damaging oil pan gasket. Fig. 2 2 —Measuring Timing Chain Stretch
It is normal to find particles of neoprene collected
between the crankshaft seal retainer and crankshaft (6) If chain is not satisfactory, remove camshaft
oil slinger. sprocket attaching cup washer, fuel pump eccentric
(7) Slide crankshaft oil slinger from end of crank and remove timing chain with crankshaft and cam
shaft. shaft sprockets.
When installing timing chain, use Tool C-3509 to
M easuring Timing Chain fo r Stretch prevent camshaft from contacting the welch plug in
(1) Place a scale next to timing chain so that any the rear of engine block. Remove distributor and oil
movement of chain may be measured. pump-distributor drive gear. Locate tool against rear
(2) Place a torque wrench and socket over cam side of cam gear and attach tool with distributor re
shaft sprocket attaching bolt and apply torque in tainer plate bolt (Fig. 23).
direction of crankshaft rotation to take up slack; 30 (7) Place both camshaft sprocket and crankshaft
foot-pounds (with cylinder head installed) or 15 foot sprocket on the bench with timing marks on exact
pounds (cylinder heads removed). With a torque ap imaginary center line through both camshaft and
plied to the camshaft sprocket bolt, crankshaft should crankshaft bores.
not be permitted to move. It may be necessary to (8) Place timing chain around both sprockets.
block crankshaft to prevent rotation. (9) Turn crankshaft and camshaft to line up with
(3) Holding a scale with dimensional reading even keyway location in crankshaft sprocket and in cam
with edge of a chain link, apply torque in the reverse shaft sprocket.
direction 30 foot-pounds (with cylinder heads in (10) Lift sprockets and chain (keep sprockets tight
stalled) or 15 foot-pounds (cylinder heads removed) against the chain in position as described).
and note amount of chain movement (Fig. 22). (11) Slide both sprockets evenly over their respec
(4) Install a new timing chain, if its movement ex tive shafts and use a straight edge to check alignment
ceeds 3/16 inch. of timing marks (Fig. 24).
(12) Install the fuel pump eccentric, cup washer,
(5) If chain is satisfactory, slide the crankshaft oil
and camshaft bolt. Tighten bolt to 35 foot-pounds.
slinger over shaft and up against sprocket (flange
away from sprocket).
n ;o s
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REMOVING AND
/ v - INSTALLING PLATE
# (TOOL)
REMOVER SCREW (TOOL)1
REMOVER
BLOCKS (TOOL
NK18A
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DISTRIBUTOR DRIVE
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PY704
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Whenever an engine has been rebuilt and/or a new DISTRIBUTOR DRIVE SHAFT BUSHING
camshaft and/or tappets are installed, one quart of
engine supplement, Chrysler Part Number 1879406 or Rem oval
equivalent should be added to the engine oil to aid in (1) Insert Tool C-3052 into old bushing and thread
break-in. The oi l mixture should be left in the engine down until a tight fit is obtained, (Fig. 34).
for a minimum of 500 miles. Drain the oil mixture at (2) Hold puller screw and tighten puller nut until
the next normal oil change. bushing is removed.
Whenever the camshaft is replaced, all of the tap
Installation
pet faces must be inspected for crown with a straight (1) Slide new bushing over burnishing end of Tool
edge. I f any negative crown (dish) is observed, tappet C-3053 and insert the tool and bushing into the bore.
must be replaced. (2) Drive bushing and tool into position, using a
hammer, (Fig. 35).
CAMSHAFT BEARINGS (3) As the burnisher is pulled through the bushing
(Engine Removed from Vehicle) by tightening the puller nut, the bushing is expanded
tight in block and burnished to correct size, (Fig. 36).
Rem oval DO NOT REAM THIS BUSHING.
(1) With engine completely disassembled, drive
out rear cam bearing welch plug. Distributor Timing
(2) Install proper size adapters and horse shoe Before installing the distributor and oil pump drive
washers (part of Tool C-3132A) at back of each bear shaft, time engine as follows:
ing shell to be removed and drive out bearing shells, (1) Rotate crankshaft until No. 1 cylinder is at top
(Fig. 33). dead center on the firing stroke.
(2) When in this position, the straight line on vibra
Installation tion damper should be under (“0 ”) on the timing in
(1) Install new camshaft bearings with Tool C- dicator.
3132A by sliding the new camshaft bearing shell over (3) Coat shaft and drive gear with engine oil. Install
proper adapter. the shaft so that after gear spirals into place, it will
(2) Position rear bearing in the tool. Install horse index with the oil pump shaft, so slot in top of drive
shoe lock and by reversing removal procedure, care gear will point to the first intake manifold bolt on left
fully drive bearing shell into place. side of engine as shown in (Fig. 31).
(3) Install remaining bearings in the same manner.
Bearings must be carefully aligned to bring oil Installation of Distributor
holes into full register with oil passages from the (1) Hold the distributor over the mounting pad on
main bearings. Also, Number two bearing must index cylinder block with vacuum chamber pointing toward
with the oil passage to the left cylinder head and right of engine.
Number four bearing must index with the oil passage (2) Turn rotor until it points forward and to ap
to the right cylinder head. If the camshaft bearing proximate location of No. 1 tower terminal in distrib
shell oil holes are not in exact alignment, remove and utor cap.
reinstall them correctly. Install a new core hole plug (3) Place distributor gasket in position.
at the rear of camshaft. Be sure this plug does not (4) Lower the distributor and engage the shaft in
leak. the slot of distributor drive shaft gear.
r . .-. ^
- -
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-
i
•M A IN BEARING OIL HOl.F NK26
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(2) If new core plugs are installed, coat edges of
plug and core hole with Number 1057794 Sealer or
equivalent. Drive the core plug in so that the rim lies
at least 1/64" below the lead-in chamfer.
(3) Examine block for cracks or fractures.
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V-8 ,020 TO .028 IN, LESS
CROSS-MATCH PISTON "THAN DIAMETER AT (C )/
PATTERN JL ... ’Jilif -
-S* * it
. •' 34 - 4 0 ’ c "n J
k a
S M Im lr r i
NP998
skirt 90 degrees to piston pin axis. Cylinder bores
should be measured halfway down the cylinder bore
Fig. 3 7 —Cross Hatch Pattern and transverse to the engine crankshaft center line.
face. This allows for expansion under normal operat Pistons and cylinder bores should be measured at
ing conditions. Under operating temperatures, expan normal room temperature, 70 degrees F.
sion forces the pin bosses away from each other, thus,
causing the piston to assume a more nearly round Piston Pins
shape. It is important that pistons be checked for ta (1) With new piston and new pins at room tempera
per and elliptical shape before they are fitted into the ture, 70°F., pin should be a light thumb push fit in
cylinder bore (Fig. 38 and 39). the piston and connecting rod. Replacement is neces
sary if there is excessive clearance between the pin
Finished Pistons and the piston. Ream piston and connecting rod to
All pistons are machined to the same weight in next oversize. New pistons are supplied with properly
fitted pins.
grams, regardless of oversize to maintain piston bal
Install piston pin lock rings with the beveled edge
ance. For cylinder bores which have been honed or
away from the piston pin, using Tool C-3915 (340
rebored, pistons are available in standard and the cubic inch engine).
following oversizes: .005, .020, .040 inch. (2) Assemble pistons and rods for the left hand cyl
inder bank (1-3-5-7) with piston boss marked “Front”
Fitting Pistons and indent on piston head on the same side as the
Piston and cylinder wall must be clean and dry.
larger chamfer on large end of connecting rod. As
Specified clearance between the piston and the cyl
semble pistons and rods to be used in the right cylin
inder wall is .0005 to .0015 inch.
der bank (2-4-6-8) with “Front” and indent opposite
Piston diameter should be measured at the top of
the large chamfer in the connecting rod.
.017 TO G25 ;N. LESS .
V-8 Fitting Kings
PISTON THAN DIAMETER AT (C)
(1) Measure piston ring gap about two inches
from bottom of cylinder bore in which it is to be fitted
(An inverted piston can be used to push the rings
down to insure positioning rings squarely in the cyl
inder wall before measuring).
(2) Insert feeler stock in the gap. The ring gap
should be between .010 to .020 inch for compression
rings and .015 to .062 inch for oil ring steel rails in
T 318 CUBIC INCH standard size bores (for new service rings). Maximum
gap in .005 inch O/S bores should be .060 inch for
THE ELLIPTICAL SHAPE OF THE DIAMETER (D) SHOULD BE
PISTON SKIRT SHOULD BE .010 .0000 TO ,001 INCH compression rings and .070 inch for oil ring steel
TO .013 IN. LESS AT DIAMETER LARGER THAN (C)
(A) THAN ACROSS THE THRUST rails.
FACES AT DIAMETER (B) NU249 (3) Measure side clearance between piston ring and
ring land (Fig. 40). Clearance should be .0015 to .003
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CONNECTING RODS
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sure the oil ring expander ends are butted and the .jfc ...... — ' CRANKSHAFT JOURNAL
a 9
rail gaps located as shown in Figure 42.
(3) Immerse the piston head and rings in clean en
gine oil, slide the ring compressor, Tool C-385, over
the piston and tighten with the special wrench (part
of Tool C-385). Be sure position of rings does not
change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert TOOL NK32
rod and piston into cylinder bore and guide rod over Fig. 4 3 —Removing or Installing Connecting Rod
the crankshaft journal (Fig. 43).
(6) Tap the piston down in cylinder bore, using a CRANKSHAFT MAIN JOURNALS
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal. The crankshaft journals should be checked for ex
(7) The notch or groove on top of piston must be cessive wear, taper and scoring. Limits of taper or
pointing toward front of engine and the larger cham out-of-round on any crankshaft journals should be
fer of the connecting rod bore must be installed to held to .001 inch. Journal grinding should not exceed
ward crankshaft journal fillet. .012 inch under the standard journal diameter. Do
(8) Install rod caps, tighten nuts to 45 foot-pounds. NOT grind thrust faces of Number 3 main bearing.
Do NOT nick crank pin or main bearing fillets. After
regrinding, remove rough edges from crankshaft oil
a D holes and clean out all oil passages.
a D CRANKSHAFT MAIN BEARINGS
a D Bearing caps are not interchangeable and should be
a D marked at removal to insure correct assembly. Upper
and lower bearing halves are NOT interchangeable.
a D Lower main bearing halves of 1, 2 and 4 are inter
a D changeable. Upper main bearing halves of 1, 2 and 4
are interchangeable.
a D Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
a D NOT interchangeable with any other bearing halves
FRONT in the engine, (Fig. 44). Bearing shells are available in
TOP VIEW OF BLOCK standard and the following undersizes: .001, .002,
A-EXPANDER GAPS B-RAIL GAPS .003, .010 and .012 inch. Never install an undersize
IF YOU HAVE FOLLOWED THE INSTRUCTIONS,
i
THE RING WILL BE IN THIS POSITION O N THE
PISTON.
n
L I
UPPER
LOWER
THRUST BEARING
*
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bearing shell that will reduce clearance below specifi
cations. 4
Rem oval
(1) Remove oil pan and identify bearing caps before
removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Tool C-3059 (Fig.
45) into the oil hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Installation
Only one main bearing should be selectively fitted
while all other main bearing caps are properly NK33A
torqued.
Fig. 4 6 —Installing Rear M ain Upper O il Seal
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side. inch, install a new number 3 main bearing.
(1) Start bearing in place, and insert Tool C-3059 (5) Fit remaining bearings in same manner.
into oil hole of crankshaft (Fig. 45). It is permissable to use one .001 inch undersize
(2) Slowly rotate crankshaft counter-clockwise slid bearing shell with one standard bearing shell or one
ing the bearing into position. Remove Tool C-3059. .002 inch undersize bearing shell with one .001 inch
undersize shell. Always use the smaller diameter
MEASURING MAIN BEARING CLEARANCE bearing half as the upper. Never use an upper bear
ing half more than .001 inch smaller than the lower
Shim Stock M eth od
(1) Smooth edges of a 1/2 x 3 /4 inch piece of brass bearing half and never use a new bearing half with a
shim stock, .001 inch thickness. used bearing half.
(2) Install bearing in center main bearing cap, REAR MAIN BEARING OIL SEAL
bearing tang in groove in cap, lubricate bearing and (Crankshaft Removed)
position shim stock across the bearing, install cap,
tighten bolts to 85 foot-pounds. Upper Seal
(3) If a slight drag is felt as crankshaft is turned (1) Install a new rear bearing oil seal in the cylin
(moved no more than 1/4 turn in either direction), der block so that both ends protrude.
clearance is .001 inch or less and is considered satis (2) Using Tool C-3511 tap seal down into position
factory. until tool is seated in bearing bore, (Fig. 46).
If, however, no drag is felt, the bearing is too large (3) Hold tool in this position and cut off the portion
or crankshaft cannot be rotated, bearing is too small of seal that extends above the block on both sides,
and should be replaced with the correct size. (Fig. 47).
(4) Measure crankshaft end play .002 to .007 inch.
If end play is less than .002 inch or more than .007 Lower Seal
(1) Install a new seal in bearing cap so that ends
TOOL BEARING protrude.
^ r.l<
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\ RELIEF VALVE
v ,,0" RING / SPRING. I
\ RELIEF VALVE RETAINER
r ^ X )U T E R ROTOR ■ . .
------ RETAINER NF931B ^B O LT NF930S
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STRAIGHT
EDGE
:a i
FEELER GAUGE
■ .I- wc
\ OUTER ROTOR
PUMP BODY
NF932 NP935
Fig. 51—M easuring O il Pump Cower Flatness Fig * 54—M easuring O uter Rotor Clearance
(6) Install outer rotor into pump body, pressing to inch can be inserted between the rotors and straight
one side with fingers and m easure clearance between edge, replace pump body.
outer rotor and pump body (Fig. 54). If measurem ent (9) Inspect oil pump relief valve plunger for scor
is more than .014 inch, replace oil pump body. ing and for free operation in its bore. Small scores
(7) Install inner rotor and shaft into pump body. If may be removed with 400 grit wet or dry paper.
clearance between inner rotor and outer rotor (Fig. (10) The relief valve spring has a free length of
55) is more than .010 inch, replace inner and outer 2-1/32 to 2-3/64 inch and should test 16.2 to 17.2 lbs.
rotors. when compressed to 1-11/32 inch. Discard spring that
(8) Place a straightedge across face between bolt fails to meet specifications.
holes (Fig. 56). If a feeler gauge of more than .004 (11) Install the relief valve spring, a new retainer
cap. (Spring seats inside retainer cap). Press retainer
in housing so that top of retainer cap is within the
OUTER
ROTOR”
, r - - 5 L E R GAUGE
INNER
“- ? \ ROTOR
DIAMETER
NF933
9HHHIi
Ml'A.f -HI
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MF934 i iRpr:
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relief valve bore diameter as shown in Figure 57. In
stall cotter pin.
(12) If oil pressure is low, inspect for worn bear
ings, or look for other causes of possible loss of pres
sure.
Assembly
(1) When assembling oil pump, be sure to use a
new oil seal ring between cover and body.
(2) Tighten cover bolts to 95 inch-pounds.
(3) Prime oil pump.
(4) Install oil pump and strainer to rear main bear
ing cap. Tighten bolts to 35 foot-pounds.
Servicing the O il Pressure Relief V a lve
It is necessary to remove the oil pan, and remove
Fig. 57—Proper Retainer Cap Installation
oil pump from rear main bearing cap to service the 383-440 Cubic Inch Engines
pressure relief valve.
To remove the relief valve, proceed as follows: dry paper providing extreme care is used not to round
(1) Remove cotter pin, drill a 1/8 inch hole in the off the sharp edge portion of the valve.
relief valve cap and insert a self-threading sheet (5) The relief valve spring has a free length of
metal screw into cap. 2-1/32 to 2-3/64 inch and should test 16.2 to 17.2
(2) Clamp screw into a vise and while supporting lbs. when compressed to 1-11/32 inch. Discard spring
oil pump, remove cap by tapping pump body using a that do not meet specifications.
soft hammer. Discard cap. (6) Install the relief valve, spring and a new re
(3) Remove spring and plunger. tainer cap. (Spring seats inside retainer cap). Press
(4) Clean parts thoroughly. Inspect oil pump re retainer in housing so that top of retainer cap is
lief valve for scoring and free operation in its bore. within the relief valve bore diameter as shown in
Small scores may be removed with 400 grit wet or Figure 57. Install cotter pin.
Page Page
Cam shaft ......................................................................... 56 Measuring Connecting Rod Bearing Clearance . . . 62
Camshaft Bearings .................................................... ... 57 Measuring Main Bearing C learance ....................... ... 63
Connecting R o d s ........................................................... 61 Oil F ilte r ....................................................................... ... 67
Crankcase Ventilation System ................................. ... 85 Oil P a n ......................................................................... ... 64
Crankshaft Identification .............................................. 61 Oil Pump ........................................ .......................... ... 64
Crankshaft Main Bearings .......................................... 62 Piston, Pins and R in g s ............................................ ... 59
Crankshaft Main Journals ............................................ 62 Repair of Damaged or Worn T h re a d s ................... ... 85
Cylinder B lo c k ............................................................... 58 Rear Main Bearing Oil S e a l ........................................ 64
Cylinder Heads ............................................................. 48 Rocker Arms and Shaft Assem bly ......................... ... 47
Distributor Drive Shaft B ushing ............................. ...57 Specifications ............................................................. ... 94
Engine Assembly ............................. ..............................47 Timing Chain Cover, Oil Seal and C h a in ................. 54
Engine M o un ts .......................................................... ..... 46 T u n e-U p ......................................................................... 45
Engine Oiling System ..................................................64 Valves and Valve Springs ........................................ ... 49
Hydraulic Tappets .................................................... ...52 Valve T im in g ............................................................... ... 53
Installing Piston and Connecting Rod Assembly .. 62
SERVICE PROCEDURES
TUNE-UP pounds.
(4) Perform cylinder compression test. Compres
(1) Test battery specific gravity, add water if nec sion should not be less than 100 pounds for 383 Cubic
essary, clean and tighten battery connections. Inch Engine with two barrel carburetor and not vary
(2) Test cranking voltage. See “Starting Motor more than 40 pounds. 110 pounds for 383, 440 Cubic
Cranking Voltage” Electrical Section of this manual. Inch Engine with four or six barrel carburetor and
(3) Tighten the intake manifold bolts to 50 foot should not vary more than 40 pounds. The recom-
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mended pressures are to be used only as a guide to
diagnosing engine problems. An engine in good con
dition may exhibit higher pressures. Many conditions
which are difficult to control cause variations in com
pression readings. An engine should not be disassem
bled to determine the cause of low compression unless
some other malfunction is present.
(5) Clean or replace spark plugs as necessary and
adjust gap to .035 inch. Tighten to 30 foot-pounds
using new gaskets.
(6) Test resistance of spark plug cables. Refer to
“Ignition System Secondary Circuit Inspection” Elec
trical Section.
(7) Inspect the breaker plate contacts, primary wire
and vacuum advance operation. Test coil output volt NY861
age, primary and secondary resistance. Test Conden
ser. Replace parts as necessary. Refer to Ignition Sys Fig. J—Cleaning Filter Element
tem and make necessary adjustments. Installation
(8) Reset the ignition timing with the vacuum (1) Install insulator to engine bracket and tighten
advance line disconnected. The ignition timing should to specified torque.
be set to compensate for altitudes and/or gasoline (2) Lower the engine and install washers and pre
grades. vailing torque nuts to insulator studs; tighten nuts to
(9) Set carburetor idle mixture adjustment. Adjust specified torque.
throttle stop screw to specifications. Perform a com (3) Connect throttle at transmission and carbu
bustion analysis. retor.
(10) Test the fuel pump for pressure and vacuum.
Refer to “Fuel System” Group 14, Specifications. REAR ENGINE MOUNTS (Fig. 3)
(11) Inspect the manifold heat control valve in the
right exhaust manifold for proper operation and apply Removal
Manifold Heat Control Valve Solvent Number 2525054 (1) Raise vehicle on hoist.
or equivalent to the bushing and shafts. (2) Install transmission jack.
(12) Every 6 months, remove filter element and (3) Remove rear engine crossmember from frame
blow out dirt gently with air hose. Direct air from and remove rear mount.
inside out, and keep nozzle 2 inches away from ele
ment to avoid damaging (Fig. 1). Clean the metal
Installation
housing and replace the element. Every two years (1) Install rear engine mount to crossmember and
install a new factory recommended filter element or
equivalent. Service the unit more frequently when
driving under severe conditions, such as in dusty
areas.
(13) Inspect crankcase ventilation system as out
lined on page 85.
(14) Inspect and adjust the accessory belt drives
referring to “Cooling System” Group 7 for proper
adjustments.
(15) Road test vehicle as a final check.
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flange studs on intake manifold.
(2) Attach chain hoist to fixture eyebolt.
(3) Remove engine from repair stand and lower en
gine carefully until engine is positioned in vehicle.
(4) Install engine support fixture Tool C-3487 and
adjust to support rear of engine.
(5) Remove chain hoist from fixture eyebolt.
(6) Raise vehicle on hoist, install and tighten en
gine front support mounting bolts.
(7) Install transmission and engine rear support
crossmember.
(8) Lower engine into position and install engine
rear support crossmember bolts. Remove engine sup
port fixture Tool C-3487A.
(9) Connect propeller shaft, wires, linkage, cable,
oil cooler lines at the transmission, connect exhaust
pipes to manifold using new gaskets. Install transmis
sion filler tube.
(10) Lower vehicle and install radiator, fan shroud,
hoses, oil cooler lines and connect all wires and link
Fig. 3—Engine Rear Support—Challenger age.
tighten nut to specified torque. (11) Remove engine lifting fixture from intake
(2) Install rear crossmember to frame and tighten manifold and install carburetor and fuel lines. Con
bolts to specified torque. nect throttle linkage.
(12) Install hood, using scribe marks for proper
ENGINE ASSEMBLY alignment.
(13) Close all drain cocks and fill cooling system.
Removal (14) Fill engine crankcase and transmission. Refer
(1) Scribe the outline of hinge brackets on hood to
assure proper adjustments when installing. to “Lubrication” Group 0 for quantities and lubri
(2) Remove hood. cants to use and check entire system for leaks and
(3) Drain cooling system and remove battery. correct as necessary.
(4) Remove all hoses, fan shroud, disconnect oil Whenever an engine has been rebuilt and/or a new
cooler lines and remove radiator. camshaft and/or tappets are installed, one quart of
(5) Disconnect fuel lines and wires attached to en engine supplement, Chrysler Part Number 1879406 or
gine units. Remove air cleaner and carburetor. equivalent should be added to the engine oil to aid in
(6) Attach engine lifting fixture to carburetor break-in. The oil mixture should be left in the engine
flange studs on intake manifold. for a minimum of 500 miles. Drain the oil mixture at
(7) Raise vehicle on a hoist and install engine sup the next normal oil change.
port fixture Tool C-3487A to support rear of engine. (15) Start engine and run engine until normal
(8) Drain transmission and torque converter. operating temperature is reached.
(9) Disconnect exhaust pipes at manifolds, propel (16) Inspect ignition timing and adjust carburetor
ler shaft, wires, linkage, cable, and oil cooler lines at as necessary.
the transmission. (17) Adjust accelerator and transmission linkages.
(10) Remove engine rear support crossmember and Road test vehicle.
remove transmission from vehicle.
(11) Lower vehicle and attach chain hoist to fixture ROCKER ARMS AND SHAFT ASSEMBLY
eyebolt.
(12) Remove engine front mounting bolts. Raise The rocker arms are of stamped steel and are ar
engine with a chain hoist and work engine out of ranged on one rocker arm shaft, per cylinder head.
chassis. The push rod angularity tends to force the pairs of
(13) Place engine in repair stand Tool C-3167 and rocker arms toward each other where oilite spacers
adapter C-3662 for disassembly, using transmission carry the side thrust at each rocker arm. The rocker
mounting bolts.
shaft is held in place by bolts and stamped steel re
Installation tainers attached to the five brackets on the cylinder
(1) Attach engine lifting fixture to carburetor head.
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Removal
(1) Remove cylinder head cover and gasket.
(2) Remove rocker shaft bolts and retainers and
remove rocker arms and shaft assembly.
(3) If rocker arm assemblies have been disassem
bled for cleaning, inspection, or replacement, refer to
Figure 4 for proper reassembly.
Installation
(1) Install rocker arms and shaft assembly making
sure to install the long stamped steel retainers in the
number two and four positions.
(2) Install rocker shafts so that 3/16 inch diameter
rocker arm lubrication holes point downward into the
rocker arm, so that the 15° angle of these holes
point outward towards the valve end of the rocker
arms, (Fig. 5). This is necessary to provide proper
lubrication to the rocker assemblies.
The 15° angle of the rocker arm lubrication 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.
(3) Tighten rocker shaft bolts to 25 foot-pounds. Fig. 5 —Rocker Arm Lubrication Holes
(4) Inspect cylinder head cover for distortion. (3) Disconnect accelerator linkage.
Straighten if necessary. (4) Remove closed ventilation system and evapora
(5) Place new cylinder head cover gaskets in posi tive control system (if so equipped).
tion and install cylinder head covers. Tighten nuts (5) Remove vacuum control hose at carburetor and
to 40 inch-pounds. distributor.
(6) Install closed crankcase ventilation system and (6) Disconnect distributor cap, coil wires and heat
evaporative control system (if so equipped). er hose.
(7) Disconnect heat indicator sending unit wire.
CYLINDER HEADS (8) Remove spark plugs.
(9) Remove intake manifold, ignition coil and car
The chrome alloy cast iron cylinder heads are held
buretor as an assembly.
in place by 17 bolts. The spark plugs enter the cylin
(10) Remove tappet chamber cover.
der head horizontally and are located at the wedge
(11) Remove cylinder head covers and gaskets.
of the combustion chambers.
(12) Remove exhaust manifolds.
(13) Remove rocker arm and shaft assemblies. Re
Rem oval
(1) Drain cooling system. move push rods and identify to insure installation in
(2) Remove alternator, carburetor, air cleaner and original location.
fuel line. (14) Remove the 17 head bolts from each cylinder
head and remove cylinder heads.
(15) Place cylinder head in holding fixture Tool
%ROC!CeR ARMS-RIGHT C-3626.
Installation
■ 9 / - (1) Clean gasket surfaces of the cylinder block and
cylinder head. Remove all burrs from edges of cylin
9 \ . V :-f9 ' der heads.
.1 (2) Inspect all surfaces with a straightedge if there
^ ■ • ■IS’*' ■ ? is any reason to suspect leakage. If out of flatness
exceeds .00075 times the span length in any direction;
ROCKER ASMS—I t FT NH660 either replace head or lightly machine the head gasket
surface. As an example, if a 12 inch span is .004" out
of flat, allowable is 12 x .00075 = .009". Head is OK.
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The cylinder head surface finish should be 70-180 CYLINDER HEAD INTAKE PUSH RODS INSTALLING ROD
micro-inches.
(3) Coat new gaskets lightly with a suitable sealer,
Chrysler Number 1057794 or equivalent. Install gas
ASSEMBLIES . j !
A
kets and cylinder heads.
(4) Install cylinder head bolts. Starting at top cen
ter, tighten all cylinder head bolts to 40 foot-pounds /
in sequence (Fig. 6). Repeat the procedure, tightening in
all head bolts to 70 foot-pounds. •■-w-
(5) Inspect push rods and replace any worn or bent j
rods.
(6) Install push rods in the tappets maintaining
alignment, using rod, (Fig. 7).
(7) Install rocker arm and shaft assembly starting
^ ' ' EXHAUST PUSH RODS KK659
each push rod into its respective rocker arm socket
(Fig. 4) making sure to install the long stamped steel
retainers in the number two and four positions. Fig. 7 —Push Rods Installed
Tighten bolts to 25 foot-pounds. (18) Fill cooling system. Adjust belt tensions as out
(8) Place new cylinder head gasket in position and lined in “Cooling System” Group 7.
install cylinder head covers. Tighten nuts to 40 inch-
pounds. VALVES AND VALVE SPRINGS
(9) Install exhaust manifolds and tighten nuts to 30 Valves are arranged in-line in the cylinder heads
foot-pounds. and inclined 30 degrees outward from vertical. The
(10) Adjust spark plugs to .035 inch gap and install intake and exhaust valves operate in guides that are
plugs, tighten plugs to 30 foot-pounds. cast integral with the heads.
(11) Install a new tappet chamber cover and tighten
end bolts to 9 foot-pounds. Rem oval
(12) Install intake manifold, carburetor and igni (1) With cylinder head removed, -compress valve
tion coil as an assembly and tighten manifold bolts to springs, using Tool C-3422A, (Fig. 8).
40 foot-pounds. (2) Remove valve retaining locks, valve spring re
(13) Install distributor cap. Connect the coil wire, tainers, valve stem cup seals and valve springs.
heat indicator sending unit wire, accelerator linkage, (3) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
spark plug cables and insulators.
valve guide. Identify valves to insure installation in
(14) Install vacuum control hose at carburetor and
original location.
distributor.
(15) Install closed ventilation system and evapora
tive control system (if so equipped).
(16) Install alternator and drive belts. Tighten al
TOOL
ternator adjusting strap bolt to 200 inch-pounds, and
CYLINDER HEAD
alternator mounting bolt to 30 foot-pounds. ASSEMBLY
(17) Install fuel line and carburetor air cleaner.
! |f ti.
si?--1 "
U n f '* . « j -
REPAIR STAND
(TOOL)
KR137A
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V a lve Inspection
(1) Clean valves thoroughly, and discard any
burned, warped or cracked valves.
(2) Measure valve stems for wear. Refer to specifi
cations for proper size. If wear exceeds .002 inch, re
place the valve.
(3) Remove carbon and varnish deposits from in
side of valve guides with a reliable guide cleaner.
(4) Measure valve stem guide clearance as follows:
Install sleeve Tool C-3973 over valve stem (Fig. 9) VALVE
and install valve.
(5) The special sleeve places the valve at the cor KR143
rect height for measuring with a dial indicator. At
tach dial indicator Tool C-3339 to the cylinder head Fig. 10—Measuring Valve Guide W e a r
and set it at a right angle to the valve stem being gin after the valves are refaced (Fig. 11). Valves with
measured (Fig. 10). less than 3/64 inch margin should be discarded.
(6) Move valve to and from the indicator. Total dial (1) The angle of both the valve and seat should be
indicator reading should not exceed .017 inch. If the identical. When refacing valve seats, it is important
dial indicator reading is excessive or if the stems are
that the correct size valve guide pilot be used for
scored or worn excessively, ream the guides for new reseating stones. A true and complete valve seat
valves with oversize stems. surface must be obtained.
(7) Service valves with oversize stems are available (2) Inspect valve seat with Prussian blue to deter
in .005, .015 and .030 inch oversize. Reamers to ac mine where valve contacts seat. To do this, coat valve
commodate the oversize valve stem are as follows: seat lightly with Prussian blue, then set valve in
Reamer Reamer Valve Guide place. Rotate valve with light pressure. If the blue is
Tool Number Oversize Size transferred to the center of the valve face, the contact
C-3433 .005 in. .379-.380 in. is satisfactory. If the blue is transferred to the top
C-3430 .015 in. .389-.390 in. edge of the valve face, lower the valve seat with a 30°
C-3427 .030 in. .404-.405 in.
stone. If the blue is transferred to the bottom edge of
(8) Slowly turn reamer by hand and clean the the valve face raise the valve seat with a 60° stone.
guide thoroughly before installing new valves. Do not (3) When the seat is properly positioned the width
attempt to ream the valve guides from standard di
of the intake seats should be 1/16 to 3/32 inch. The
rectly to .030 inch. Use step procedure of .005, .015
width of the exhaust seats should be 3/64 to 1/16
and .030 inch so the original valve guide centers may
inch.
be maintained.
(4) Measure the concentricity of the valve seat us
Refacing Valves an d V a lv e Seats ing dial indicator No. 13725. The total runout should
The intake and exhaust valve faces have a 45 de not exceed .003 inch (total indicator reading).
gree angle. Always inspect the remaining valve mar-
V
TOOL
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(5) When valves and seats are reground, the posi
tion of the valve in the cylinder head is changed,
shortening the operating length of the hydraulic tap
pet. This means that the plunger is operating closer to
its “bottomed” position, and less clearance is available
for thermal expansion of the valve mechanism during
high speed driving.
(6) The design of the valve mechanism includes a
safety factor to allow for a limited amount of wear,
and the refacing of the valves and seats.
(7) To insure that limits have not been exceeded,
the dimension from valve spring seat in the head to
the valve tip should be measured with gauge, Tool
C-3648 (Fig. 12).
(8) The end of the cylindrical gauge and the bottom
of slotted area represent the maximum and minimum
allowable extension of the valve stem tip beyond the
m ^ KH333A
spring seat.
(9) If the tip exceeds the maximum, grind stem tip Fig. 13—Testing Valve Springs
to within gauge limits. Clean tappets if tip grinding is
required. ends with a steel square and surface plate (Fig. 14).
(3) If the spring is more than 1/16 inch out of
square, install a new spring.
Testing the V a lve Springs ( f i g . 13)
(1) Whenever valves are removed for inspection, Installation
reconditioning or replacement, the valve springs (1) Coat valve stems with lubricating oil and insert
should be tested. As an example, the compressed them in position in cylinder head.
length of the spring to be tested is 1-15/32 inches. (2) Install new cup seals on the intake and exhaust
Turn the table of Tool C-647 until the surface is in line valve stems and over valve guides (Fig. 15 and 16) and
with the 1-15/32 inch mark on the threaded stud and install valve springs and retainers.
the zero mark to the front. Place the spring over the (3) Compress valve springs with Tool C-3422A. In
stud on the table and lift the compressing lever to set stall locks and release tool.
the tone device. Pull on the torque wrench until a ping If valves and/or seats are reground, measure in
is heard. Take the reading on torque wrench at this stalled height of the springs. Make sure measurement
instant. Multiply this reading by two. This will give is taken from the bottom of spring seat in cylinder
the spring load at the test length. Fractional meas head to bottom surface of spring retainer. If the
urements are indicated on the table for finer adjust height is greater than 1-57/64 inches, install a 1/16
ments. Refer to specifications to obtain specified inch spacer in the head counterbore to bring the
height and allowable tension. Discard the springs spring height b a c k to normal 1-53/64 to 1-57/64 inch.
that do not meet specifications.
(2) Inspect each valve spring for squareness at both
VALVE SPRING
VALVE T OOL .
MEASUREMENT
M AXIM UM ”MEASUREMENT KR.144 B
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RETAINER while engine is running and create foam. Foam in oil
pan would be fed to the hydraulic tappets by the oil
SPRING
pump causing them to lose length and allow valves to
seat noisily.
Tappet Removal
(1) The tappet can be removed without removing
intake manifold or cylinder heads by following this
recommended procedure: Remove cylinder head cov
ers.
(2) Remove rocker arms and shaft assembly.
(3) Remove push rods and identify to insure instal
lation in original location.
(4) Slide a magnetic pickup tool through push rod
Li KR147B opening in cylinder head and seat tool firmly in the
head of tappet.
(5) Pull tappet out of bore with a twisting motion.
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If all tappets are to be removed, identify tappets to assemble tappet, clean and test again (Fig. 18).
insure installation in original location. (7) If tappet still does not operate satisfactorily
A diamond shaped marking stamped on the engine after cleaning, install a new tappet assembly.
numbering pad indicates that some tappet bodies are If the tappet or bore in cylinder block is scored,
.008 inch oversize. scuffed, or shows signs of sticking, ream the bore to
CAUTION: The plunger and tappet bodies are not next oversize.
interchangeable. The plunger and valve must always
be fitted to the original body. It is advisable to work Installation
on one tappet at a time to avoid mixing of parts. (1) Lubricate tappets.
Mixed parts are not compatible. Do not disassemble a (2) Install tappets and push rods in their original
tappet on a dirty work bench. positions.
(3) Install rocker arm and shaft assembly.
Disassembly (Fig. 1 7) (4) Start and operate engine. Warm up to normal
(1) Pry out plunger retainer spring clip. operating temperature.
(2) Clean varnish deposits from inside of tappet CAUTIO N: To prevent damage to valve mechanism,
body above plunger cap. engine must not be run above fast idle until all hy
(3) Invert tappet body and remove plunger cap, draulic tappets have filled with oil and have become
plunger, flat check valve, check valve spring, check quiet.
valve retainer and plunger spring.
VALVE TIMING
Cleaning and Assembly
(1) Clean all tappet parts in a solvent that will re (All Models)
move all varnish and carbon. (1) Turn crankshaft until NO. 6 exhaust valve is
(2) Replace tappets that are unfit for further serv closing and NO. 6 intake valve is opening.
ice with new assemblies. (2) Insert a 1/4 inch spacer between rocker arm pad
(3) If plunger shows signs of scoring or wear and and stem tip of NO. 1 intake valve (second valve on
valve is pitted, or if valve seat or end of plunger the left bank).
indicates any condition that would prevent valve from (3) Install a dial indicator so plunger contacts valve
seating, install a new tappet assembly. spring retainer as nearly perpendicular as possible.
(4) Assemble tappets (Fig. 17). (4) Allow spring load to bleed tappet down giving
in effect a solid tappet. Zero the indicator.
Testing (5) Turn the crankshaft clockwise (normal running
(1) Fill a pan with clean kerosene. direction) until intake valve has lifted .025 inch with
(2) Remove cap from plunger and plunger from 256-260° camshaft and .033 inch with 268-284° cam
tappet body. shaft. See specifications for engine application. The
(3) Fill tappet body with kerosene and install timing on the timing indicator, located on the chain
plunger. case cover, should read from 10 degrees BTDC to 2
(4) Unseat check valve with a brass rod to permit degrees ATDC. If the reading is not within specified
complete installation of plunger. Replace cap. limits: Inspect timing sprocket index marks, inspect
(5) Hold tappet in an upright position and insert timing chain for wear, and determine accuracy of
lower jaw of pliers, Tool C-3160, in the groove of the DC mark on timing indicator. Turn crankshaft
tappet body (Fig. 18).
(6) Engage jaw of pliers with top of tappet plunger.
Test leakdown by compressing the pliers. If plunger TOOL
Nv
collapses almost instantly as pressure is applied, dis-
Cl £A>: __
RrTA’.NER CHECK VALVE PLUNGER <~^OS2>-
SPRING RETAINER
SPRING CLIP
\
TAPPET BODY^
PLUNGER SPRING
PLUNGER^
CHECK VALVE'
PLUNGER CAP'' NR65
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counterclockwise until valve is closed and remove the TORQUE WRENCH-
indicator and spacer. ?■
CAUTI ON: Do not turn crankshaft any further clock
wise, as the valve spring might bottom and result in
m
■■m
MR / i-
dfc.
serious damage.
fr 9 -
TIMING CHAIN COVER, OIL SEAL AND •# #9'
TIMING CHAIN
f,? *
Cover Removal ..; *
(1) Drain cooling system and remove radiator and BHMP'-'aj
water pump assembly.
*
(2) Remove crankshaft vibration damper attaching ^ 9; 1W B o i
bolt.
(3) Remove two of the pulley bolts, install Tool C-
3688, and pull damper assembly off end of crankshaft
(Fig. 19). KR151A
(4) Remove chain cover and gasket. It is normal
to find particles of neoprene collected between seal Fig. 2 0 —M easuring Timing Chain Stretch
retainer and crankshaft oil slinger after seal has slinger over shaft and up against sprocket (flange
been in operation. away from sprocket).
(5) Slide crankshaft oil slinger off end of crank (6) If chain is not satisfactory, remove camshaft
shaft. sprocket attaching bolt and remove timing chain
with crankshaft and camshaft sprockets.
M easuring Timing Chain fo r Stretch
(1) Place a scale next to the timing chain so any When installing timing chain, use Tool C-3509 to
movement of the chain may be measured. prevent camshaft from contacting the welch plug in
(2) Place a torque wrench and socket over cam- the rear of engine block. Remove distributor and oil
shaft sprocket attaching bolt and apply torque in the pump-distributor drive gear. Locate tool against rear
direction of crankshaft rotation to take up slack; 30 side of cam gear and attach tool with distributor re
foot-pounds (with cylinder heads installed) or 15 foot tainer plate bolt (Fig. 21).
pounds (cylinder heads removed). With torque ap
(7) Place camshaft sprocket and crankshaft sprock
plied to the camshaft sprocket bolt, crankshaft should
et on the bench with timing marks on exact imaginary
not be permitted to move. It may be necessary to
center line through both camshaft and crankshaft
block crankshaft to prevent rotation.
sprocket bores.
(3) Holding a scale with dimensional reading even
(8) Place timing chain around both sprockets.
with edge of a chain link, apply torque in the reverse
(9) Turn crankshaft and camshaft to line up with
direction 30 foot-pounds (with cylinder heads in
keyway location on crankshaft sprocket and dowel
stalled) or 15 foot-pounds (cylinder heads removed),
hole in camshaft sprocket.
and note amount of chain movement (Fig. 20).
(10) Lift sprockets and chain (keep sprockets tight
(4) Install a new timing chain, if its movement ex
against chain in position as described).
ceeds 3/16 inch.
(5) If chain is satisfactory, slide crankshaft oil
TOOL
CHAIN CASE COVER ARM (TOOL)
TIMING INDICATOR
—CYLINDER BLOCK
TIMING MARK
VIBRATION DAMPER
.TOOL
I
DISTRIBUTOR DRIVE GEAR (CAMSHAFT) KR162
KR149A
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(11) Slide both sprockets evenly over their respec REMOVER BLOCKS (TOO':
\ ■; LIP OF SEAL
tive shafts. CHAIN CASE COVE,? V i-i-rrAior-:?
(12) Use a straight edge to measure alignment of
timing marks (Fig. 22). m /
(13) Install washer and camshaft sprocket bolt,
tighten to 35 foot-pounds. Check to be sure that rear
face of aluminum camshaft sprocket is flush with end m
of camshaft. Slide the crankshaft oil slinger over shaft
and up against sprocket (flange away from sprocket).
KR153B
Fig. 2 4 —Removing O il Semi
INSTALLING^
PLATE
(TOOL)
SEAL
-
ASSEMBLY
'
SC.ciiVV
(TOOL)
* CHAIN CASE COVER
NN358 KR154B
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REMOVER SCREW
(TOOL) CHAIN CASE COVER
/ TIMING INDICATOR
- CYLINDER BLOCK
- TIMING MARK
.y VIBRATION DAMPER
^ ^j,.''!
TOOL
liB l
-
^ “""HN STALLING PLATE KR157A
(TOOL)
SEAL' ***»»'• Fig. 2 8 —Installing Vibration D am per Assembly
CHAIN CASE COVER
RETAINER
need for a thrust plate. The helix of the oil pump and
KR155B distributor drive gear and camshaft lobe taper both
Fig. 2 6 —Installing New Sea/ tend to provide a rearward thrust.
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of engine supplement Chrysler Part Number 1879406
BUSHING
or equivalent should be added to the engine oil to aid /
in break-in- The oil mixture should be left in the en TOOL
gine for a minimum of 500 miles* Drain the oil mix
ture at the next normal oil change.
Whenever camshaft is replaced, all of tappet, faces
must be inspected for crown with a straight edge* If y
any contact surface is dished or worn, tappet must be im k m ^
replaced. :T
CAMSHAFT BEARINGS
(Engine Removed from Vehicle)
Removal $ W KR159
(1) With engine completely disassembled, drive out
camshaft rear bearing welch plug. Fig. 3 1—Removing D is trib u to r D rive Shaft Bushing
(2) Install proper size adapters and horse shoe 4 camshaft bearings. If camshaft bearing oil holes are
washers (part of Tool C-3132A) at the back of each not in exact register, remove and reinstall them cor
bearing to be removed and drive out bearings (Fig. rectly. Install a new welch plug at rear of camshaft.
30). Be sure this plug does not leak,
Installation DISTRIBUTOR DRIVE SHAFT BUSHING
(1) Install new camshaft bearings with Tool C-
3132A. Place new camshaft bearing over proper Rem oval
adapter. (1) Insert Tool C-3052 into the old bushing and
(2) Position bearing in the tool. Install the horse thread down until a tight fit is obtained (Fig. 31).
shoe lock and by reversing removal procedure, care (2) Hold remover screw and tighten nut until bush
fully drive bearing into place. ing is removed.
(3) Install remaining bearings in like manner.
Install the NO. 1 camshaft bearing 1/32 inward Installation
from the front face of cylinder block. (1) Slide a new bushing over burnishing end of
The oil holes in camshaft bearings and the cylinder Tool C-3053 and insert tool bushing into the bore.
block must be in exact register to insure proper lubri (2) Drive bushing and tool into position, using a
cation (Fig. 30). hammer (Fig. 32).
The camshaft bearing index can be inspected after (3) As the burnisher is pulled through the bushing
installation by inserting a pencil flashlight in the by tightening remover nut, the bushing is expanded
bearing. The camshaft bearing oil hole should be per tight in the block and burnished to correct size (Fig.
fectly aligned with the drilled oil passage from the 33). DO NOT REAM THIS BUSHING.
main bearing. Other oil holes in the camshaft bear
Distributor Timing
ings should be visible by looking down on the left Before installing distributor and oil pump drive
bank oil hole above and between NO. 6 and NO. 8 shaft, time the engine as follows:
cylinders to NO. 4 camshaft bearing and on the right
bank above and between NO. 5 and 7 cylinders to N O .
BUSHING
TOOL
KR164 KR160
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tacts are just separating, install and tighten hold
BUSHING down clamp.
TOOL
CYLINDER BLOCK
The cylinder block is of the deep block design
which eliminates the need for a torque converter
housing adapter plate. Its sides extend three inches
below the crankshaft center line.
Piston Removal
(1) Remove top ridge of cylinder bores with a reli
able ridge reamer before removing pistons from cyl
KR161 inder block. Be sure to keep tops of pistons covered
during this operation.
Fig. 3 3 —Burnishing Distributor Drive Shaft Bushing The pistons and connecting rods must be removed
(1) Rotate crankshaft until NO. 1 cylinder is at top from the top of the cylinder block. When removing
dead center on the firing stroke. piston and connecting rod assemblies from the en
(2) When in this position, the straight line on the gine, rotate the crankshaft so each connecting rod is
vibration damper should be under “0 ” on timing indi centered in cylinder bore.
cator. (2) Inspect connecting rods and connecting rod caps
(3) Coat shaft and drive gear with engine oil. Install for cylinder identification. Identify them if necessary.
the shaft so that after gear spirals into place, it will (3) Remove connecting rod cap. Install connecting
index with the oil pump shaft, so slot in top of drive rod bolt guide set on connecting rod bolts. Push each
gear will be parallel with center line of crankshaft piston and rod assembly out of cylinder bore. Be care
(Fig. 34). ful not to nick crankshaft journals.
(4) Install bearing caps on mating rods.
installation of Distributor
(1) Hold distributor over mounting pad on cylinder Cleaning and Inspection
(1) Clean cylinder block thoroughly and inspect all
block with vacuum chamber pointing toward center of
core hole plugs for evidence of leaking.
engine. (2) If new core plugs are installed, coat edges of
(2) Turn rotor until it points forward and to ap plug and core hole with Number 1057794 Sealer or
proximate location of No. 1 tower terminal in the dis equivalent. Drive the core plug in so that the rim lies
tributor cap. at least 1/64" below the lead-in chamfer.
(3) Place distributor gasket in position. (3) Examine block for cracks or fractures.
(4) Lower the distributor and engage the shaft in
the slot of distributor drive shaft gear. Cylinder Bore Inspection
(5) Turn distributor clockwise until breaker con 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
D IS TR IB U TO R A N D O IL
P U M P D R IV E
than .010" or if the cylinder walls are badly scuffed
GEAR S LO T or scored, the cylinder block should be rebored and
honed, and new pistons and rings fitted. 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
clearance may be maintained.
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it will reduce taper and out-of-round as well as re causing the piston to assume a more nearly round
moving light scuffing, scoring or scratches. Usually, a shape. It is important that old or new pistons be meas
few strokes will clean up a bore and maintain the re ured for taper and elliptical shape before they are
quired limits. fitted into the cylinder bore (See Fig. 36).
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501, Finished Pistons
equipped with 280 grit stones (3501-3810) if the cylin All pistons are machined to the same weight in
der bore is straight and round. 20 to 60 strokes de grams, regardless of oversize so piston balance can be
pending on the bore condition will be sufficient to maintained. For cylinder bores which have been
provide a satisfactory surface. Inspect cylinder walls honed or rebored, pistons are available in standard
after each 20 strokes. Use honing oil C-3501-3880 and the following oversizes: .005, .020, and .040 inch.
or a light honing oil available from major oil dis
tributors. Do not use engine or transmission oil, min Fitting Pistons
eral oil or kerosene. Piston and cylinder wall must be clean and dry.
(3) Honing should be done by moving the hone up Specified clearance between the piston and the cyl
and down fast enough to get a cross-hatch pattern. inder wall is .0003 to .0013 inch.
When hone marks intersect at 60°, cross hatch angle Piston diameter should be measured at the top of
is most satisfactory for proper seating of rings (See skirt 90 degrees to piston pin axis. Cylinder bores
Fig. 35). should be measured halfway down the cylinder bore
(4) After honing, it is necessary that the block be and transverse to the engine crankshaft center line.
cleaned again to remove all traces of abrasives. Wash Pistons and cylinder bores should be measured at
cylinder block and crankshaft thoroughly. normal room temperature, 70 degrees F.
CAUTION: Be sure all abrasives are removed from All service pistons include pins, and are available in
the engine parts after honing. It is recommended that standard and the following oversizes: .005, .020 and
a solution of soap and water be used with a brush and .040 inch.
the parts then thoroughly dried. The bore can be con
sidered clean when it can be wiped clean with a white
Fitting Rings
cloth and the cloth remains clean. Oil bores after (1) Measure piston ring gap about two inches
cleaning to prevent rusting.
from bottom of cylinder bore in which it is to be
fitted. (An inverted piston can be used to push rings
PISTONS, PINS AND RINGS down to insure positioning rings squarely in cylinder
wall before measuring.)
Pistons
(2) Insert feeler stock in the gap. Ring gap should
The pistons are cam ground so that the diameter at be between .013 to .052 inch for the compression
the pin boss is less than its diameter across the thrust rings and .015 to .062 inch for the oil ring steel rails
face. This allows for expansion under normal operat in standard size bores. Maximum gap on .005 inch
ing conditions. Under operating temperatures, expan O/S bores should be .060 inch for compression rings
sion forces the pin bosses away from each other, thus and .070 inch for the oil ring steel rails.
CROSS-HATCH (3) Measure side clearance between piston ring and
PATTERN
.020 TO .028 IN. LESS
*-D
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ring groove (Fig. 37). Clearance should be .0015 to N U T (T O O L)
.003 inches for the top compression ring and inter A N V IL (TO O L)
mediate ring. Steel rail service oil ring should be free
PIST O N
in groove, but should not exceed .005 inch side
clearance. PILOT (TO O L)
(4) Install the three piece oil ring in lower ring
groove using instructions in ring package. M A IN
/S C R E W (TO O L)
(5) Install compression rings in middle and top
groove as shown on Instruction sheet. Be sure the -S M A L L
mark “top” on each compression ring faces top of PISTO N PIN (TO O L)
piston.
C O N N E C T IN G RO D
(6) For the two top rings use ring installer Tool
C-3673 for 383 cubic inch engines and Tool C-4001 KR195B G U ID E -L A R G E (TO O L )
for the 440 cubic inch engines.
Fig. 3 8 —Tool A rrangem ent for Removing Piston Pin
Piston Pin Removal
(1) Arrange Tool C-3684 parts for removal of piston and pilot in the anvil. Install piston pin over main
pin, (Fig. 38). screw.
(2) Install pilot on main screw. (5) Place piston, with “front” up, over the pilot so
(3) Install main screw through piston pin. pilot extends through piston pin hole.
(4) Install anvil over threaded end of main screw (6) Position connecting rod over the pilot which ex
with small end of anvil against piston boss. Be sure tends through piston pin hole.
spring is removed from anvil. Assemble rods to pistons of the right cylinder bank
(5) Install nut loosely on main screw and place as (2, 4, 6, and 8) with indent on piston head opposite to
sembly on a press, (Fig. 39). the larger chamfer on the large bore end of connect
(6) Press piston pin out of connecting rod. ing rod. Assemble rods to pistons of the left cylinder
When pin falls free from connecting rod, stop press bank (1, 3, 5, and 7) with indent on piston head on the
to prevent damage to bottom of anvil. same side as the large chamfer on the large bore end
(7) Remove tool from piston. of the connecting rod.
(7) Install main screw and piston pin in piston,
Installation (Fig. 40).
(1) Test piston pin fit in the piston. It should be a (8) Install nut on puller screw to hold assembly
sliding fit in the piston at 70 degrees F. Piston pins together. Place assembly on a press (Fig. 41).
are supplied in standard sizes only. (9) Press piston pin in until piston pin “bottoms”
(2) Lubricate piston pin holes in the piston and on the pilot. This will position pin in connecting rod.
connecting rod. (10) Remove tool and arrange tool parts and piston
(3) Arrange Tool C-3684 parts for installation of assembly in same manner (Fig. 38).
piston pin (Fig. 40). (11) Place assembly in a vise (Fig. 42).
(4) Install spring inside the pilot and install spring (12) Attach torque wrench to nut and tighten up to
^ P i L O T (TOOL)
- ANVIL (TOOL)
NRSG8
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A N V IL (TO O L ) NUT
(TOOL)
SP R IN G (TO O L)
PILOT (TO O L) \ ■TORQUE WRENCH
NUT
(TO O L )
------- PISTO N
PISTO N PIN
\ •■"——SOCKET'
G U ID E -S M A L L
(TO O L)
\ m s*
C O N N E C T IN G R O D
PILOT (TOOL)
G U ID E -L A R G E (TO O L )
KR196B
MAIN SCREW (TOOL)
*PRESS
I
- ‘MAIN SCREW (TOOL)
-PISTON
-ANVIL (TOOL)
KR169
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(3) Immerse piston head and rings in clean engine
oil, slide ring compressor, Tool C-385, over the piston
and tighten with special wrench (part of Tool C-385).
Be sure position of rings does not change during this
operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal (Fig. 45).
(6) Tap piston down in cylinder bore, using handle
of a hammer. At the same time, guide connecting rod
into position on crankpin journal.
Fig. 4 4 —S h o w in g Location o f In t e r n a l M a r k i n g
o f C o u n te rw e ig h t (7) The notch or groove on top of piston must be
pointing toward front of engine and larger chamfer of
Bearings are available in .001, .002, .003, .010 and connecting rod bore must be installed toward crank
.012 inch undersize. pin journal fillet.
Install the bearings in pairs. Do not use a new bear (8) Install rod caps, tighten nuts to 45 foot-pounds.
ing half with an old bearing half. Do not file the rods
or bearing caps. CRANKSHAFT MAIN JOURNALS
MEASURING CONNECTING ROD Crankshaft main bearing journals should be in
BEARING CLEARANCE spected for excessive wear, taper and scoring. Journal
grinding should not exceed .012 inch under the
S h im S to c k M e th o d standard journal diameter. DO NOT grind the thrust
(1) (a) 383 engine with 2-barrel carburetor, place faces of the NO. 3 main bearing. Do not nick crankpin
an oiled .001 inch brass shim stock (1/2 inch wide and or main bearing fillets. After regrinding, remove
3 /4 inch long) between the bearing and connecting rough edges from crankshaft oil holes and clean out
rod journal. all oil passages.
(b) 383 engine with 4-barrel carburetor and 440
with tri-metal bearings, use an oiled .002 inch brass
CRANKSHAFT MAIN BEARINGS
shim stock (1/2 inch wide and 3 /4 inch long) between
the bearing and connecting rod journal. New lower main bearings halves Numbers 1, 2, 4, 5
(2) Install bearing cap and tighten to 45 foot are interchangeable (Fig. 46). New upper main bear
pounds. ing halves Number 2, 4 and 5 are also interchange
(3) Turn crankshaft 1/4 turn in each direction. A able. Upper and lower bearing halves are not inter
slight drag should be felt which indicates clearance changeable because upper bearing is grooved and
is satisfactory. 383 engine with 2-barrel carburetor, lower bearing is not.
correct clearance is from .0005 to .0015 inch; 383 The NO. 1 upper main bearing IS NOT INTER-
with 4-barrel carburetor and 440 with tri-m etal bear
ings correct clearance is from .001 to .002 inch. CRANKSHAFT JOURHAI.
(4) Side play should be from .009 to .017 inch
(two rods).
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TOOL ; i BEARING
SSflflHfll
\
\
W , W sk
•THRUST BEARING
* * 3 p ' ■ * ^
flg ja B M ' I
<51® l® *P, N U 256 IN STAI LING KBS iB
CHANGEABLE AND IS CHAMFERED on the tab side (2) Install bearing in center main bearing cap,
for timing chain oiling and can be identified by a red bearing tang in grove in cap, lubricate bearing and
marking on edge of bearing. position shim stock across the bearing, install cap,
Upper and lower NO. 3 bearings are flanged to tighten bolts to 85 foot-pounds.
carry the crankshaft thrust loads and are not inter (3) If a slight drag is felt as crankshaft is turned
changeable with any other bearings in the engine. (moved no more than 1/4 turn in either direction),
Bearings that are not badly worn or pitted must be clearance is .001 inch or less and is considered satis
reinstall ed in the same position. factory.
Bearing caps are not interchangeable and should be If, however, no drag is felt, the bearing is too large
marked at removal to insure correct assembly. Bear or crankshaft cannot be rotated, bearing is too small
ings are available in standard and the following and should be replaced with the correct size.
undersizes: .001, .002, .003, .010, .011 and .012 inch. (4) Measure crankshaft end play .002 to .007 inch.
Do not install an undersize bearing that will reduce If end play is less than .002 inch or more than .007
clearance below specifications. inch, install a new number 3 main bearing.
(5) Fit remaining bearings in same manner.
R em oval It is permissable to use one .001 inch undersize
(1) Remove oil pan and identify bearing caps before bearing shell with one standard bearing shell or one
removal. .002 inch undersize bearing shell with one .001 inch
(2) Remove bearing caps one at a time. Remove undersize shell. Always use the smaller diameter
upper half of bearing by inserting Tool C-3059 (Fig.
bearing half as the upper. Never use an upper bear
47) into oil hole of crankshaft.
ing half more than .001 inch smaller than the lower
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing.
In s ta lla tio n
Only one main bearing should be selective l y fitted
while all other main bearing caps are properly ■
BRIDGE
torqued. (PART OF TOOL)
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) S tart bearing in place, and insert Tool C-3059
into oil hole of crankshaft (Fig. 47).
(2) Slowly rotate crankshaft counter-clockwise slid SEAL
ing the bearing into position. Remove Tool C-3059.
SEAL
MEASURING MAIN BEARING CLEARANCE RETAINER -
SIDE SEAL „
S h im S to c k M e t h o d GROOVES 0237
(1) Smooth edges of a 1/2 x 3/4 inch piece of brass
shim stock, .001 inch thickness.
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bearing half and never use a new bearing half with a
used bearing half.
U pper Rear M a i n S e a l I n s t a l l a t i o n
(1) Install a new rear main bearing oil seal in cyl
inder block so that both ends protrude.
(2) Tap seal down into position, using Tool C-3625
for 383 Cubic Inch Engines or Tool C-3743 for 440
Cubic Inch Engines, with bridge removed until tool
is seated in bearing bore.
(3) Hold the tool in this position and cut off portion
of seal that extends above the block on both sides.
KR238
L o w e r R e a r M a in S e a l In s ta lla tio n
(1) Install a new seal in seal retainer so ends pro Fig. 4 9 —T rim m in g R ea r M a in B earin g L o w e r O i l S eal
trude (Fig. 48).
sible. These side seals are made from a material that
(2) Install bridge on tool and tap the seal down into
expands quickly when oiled.
position with Tool C-3625 for 383 Cubic Inch Engines
(1) Apply mineral spirits or diesel fuel to the side
or Tool C-3743 for 440 Cubic Inch Engines until tool
seals.
is seated.
(2) Install seals immediately in the seal retainer
(3) Trim off that portion of the seal that protrudes
above the cap (Fig. 49). grooves.
(3) Install seal retainer and tighten screws to 25
S id e S e a ls In s ta lla tio n foot-pounds.
Perform the following operations as rapidly as pos Failure to pre-oil the seals will result in an oil leak.
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ROCKER A R M
RIGHT B A N K < LEFT B A N K ROCKER
LUBRICATION LUBRICATION SHAFT
RIGHT ROCKER SHAFT
OIL SUPPLY
NO. 4 CAMSHAFT TO PUSH ROD Q|L FE£D HOLE
BEARING
O IL FILTER
OIL PRESSURE
OIL PUMP RELIEF VALVE
NU257
GASKET
<4
"O'* RING
' FEELER
KR173 GAUGE
mm I
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STRAIGHT EDGE -
9
*
8
{
FEELER G AUGE' KR175
KB67A
Fig. 5 4 —Measuring Inner Rotor Thickness
OUTER ROTOR
PUMP BODY
KR176
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new oil seal rings between filter base and pump body. R em o val
Use care so as not to damage transmission oil cooler
In s ta lla tio n lines.
(1) Install a new “0 ” ring seal on the pilot of oil (1) Using Tool C-4065 unscrew the filter from the
pump before attaching oil pump to cylinder block. base on bottom side of engine and discard (Fig. 58).
(2) Install oil pump on engine, using a new gasket (2) Wipe base clean.
on engine and tighten attaching bolts to 30 foot
pounds. Install oil filter element. In s ta lla tio n
(1) Install the “spin” oil filter by hand, finger
OIL FILTER REPLACEMENT tight. Do not use tool.
(2) To obtain an effective seal, tighten filters by
The “spin on” oil filter should be replaced prefer hand the additional num ber of turns indicated on the
ably to coincide with every second oil change. replacem ent filter. Start engine and inspect for leaks.
SERVICE PROCEDURES
TUNE-UP “Ignition System Secondary Circuit Inspection” Elec
trical Section.
(1) Test battery specific gravity, add w ater if nec (7) Inspect the breaker plate contacts, prim ary wire
essary, clean and tighten battery connections. and vacuum advance operation. Test coil output volt
(2) Test cranking voltage. See “Starting Motor age, prim ary and secondary resistance. Test Conden
Cranking Voltage” E lectrcal Section of this manual. ser. Replace parts as necessary. Refer to Ignition Sys
(3) Tighten the intake manifold bolts to specifica tem and make necessary adjustments.
tions. (8) Reset the ignition timing with the vacuum ad
(4) Perform cylinder compression test. Compres vance line disconnected. The ignition timing should
sion should not be less than 110 pounds and not vary be set to compensate for altitudes an d /o r gasoline
more than 40 pounds. The recommended compression grades.
pressures are to be used only as a guide to diagnosing (9) Set carburetor idle m ixture adjustment. Adjust
engine problems. An engine in good condition may ex engine RPM to specifications. Perform a combustion
hibit higher pressures. Many conditions which are analysis.
difficult to control cause variations in compression (10) Test the fuel pump for pressure and vacuum.
readings. An engine should not be disassembled to Refer to “Fuel System” Group 14, Specifications.
determ ine the cause of low compression unless some (11) Inspect the manifold heat control valve in
other malfunction is present. the right exhaust manifold for proper operation and
(5) Clean or replace spark plugs as necessary and apply Manifold Heat Control Valve Solvent Number
adjust gap to .035 inch. Tighten to 30 foot-pounds. 2525054 or equivalent to the bushing and shaft.
Aluminum spark plug tubes serve as spark plug (12) Every oil change remove filter element and
gaskets. blow out dirt gently with air hose. Direct air from
(6) Test resistance of spark plug cables. Refer to inside out, and keep nozzle 2 inches away from ele-
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m ent to avoid damaging. Clean the metal housing engine.
and replace the element. Every year install a new (3) Remove extension housing mounting bolts,
factory recommended filter element. Service the crossmember attaching bolts and remove crossmem
unit more frequently when driving under severe con ber.
ditions, such as in dusty areas. (4) Remove insulator from crossmember.
(13) Inspect crankcase ventilation system as out
lined on page 85. In s ta lla tio n
(14) Inspect and adjust the accessory belt drives (1) Install insulator to crossmember.
referring to “Cooling System” Group 7 for proper (2) Install crossmember, tightening attaching bolts
adjustments. to specifications.
(15) Road test vehicle as a final check. (3) Install extension housing mounting bolts tight
ening to specifications (Fig. 2).
FRONT ENGINE MOUNTS (4) Remove transmission jack and lower vehicle.
2780673
BRACKET RIGHT ^
2780672
BRACKET
LEFT 2468184
INSULATOR
ASSEMBLY
LEFT SCREW AN D WASHER
ASSEMBLY (2)<§>
RIGHT SIDE
<$> 20 FT. LB.
FT. LB.
<§> 30
35 FT. LB.
<£>
<§> 50 FT. LB.
CROSS MEMBER „ - ^
<i> 75 FT. LB. CROSS MEMBER NR 4 3 B BOLT ^ PY433
E-Bodies.org
strap to front of left cylinder head and rear strap ... STUD NUTS (4) EACH HEAD
to rear of right cylinder head.
Caution: Do not use intake manifold to remove en . i :■ ... 'f- '
gine assembly. " . '•* 1 "r:. l !.,i t -K-•m m;
Remove carburetors to prevent damage.
(9) Attach hydro-crane lifting hooks to lifting
straps, remove engine assembly from chassis and in / % ? '
stall engine in a repair stand.
A - f W m ( I
In s ta lla tio n P P *
(1) Attach hydro-crane lifting hooks to lifting
rn m m M m
r : > / /
straps and remove engine from repair stand.
(2) Lower engine into chassis until the front en
NN 972
gine mounts line up with “K” member support. Install
attaching bolts and stud nuts, do not tighten at this Fig. 4 —Removing or Installing Cylinder H ead
time. Stud Nuts
(3) Install engine support fixture C-3487A, engaging
oil to aid in break-in. The oil mixture should be left
the hooks in holes in frame side members. Be sure
in engine for a minimum of 500 miles and drained at
support ends are up against the underside of the oil
pan flange. next normal oil change.
(13) Start engine, adjust engine idle and timing
(4) Remove hydro-crane lifting hooks. Raise ve
hicle on a hoist. to specifications, install air cleaner and road test ve
(5) Install transmission as outlined in Group 21 of hicle.
this service manual.
(6) Install clutch torque shaft, linkage and adjust CYLINDER HEADS
clutch pedal to 1 inch free play if so equipped. Each chrome alloy cast iron cylinder head is held
(7) Install exhaust pipes to manifolds. Torque front in place by 13 bolts (Fig. 3) and 5 studs, nuts and
engine mounts to specifications. Lower vehicle. washers (Fig. 4). The stud nuts are tightened from
(8) Connect electrical connections to alternator, inside of the tappet chamber. Aluminum spark plug
coil, temperature and oil pressure sending units, fuel tubes (shown in cross section in Figure 5) serves as
line. spark plug gaskets. The tubes project through the cyl
(9) Install carburetors, linkage, throttle cable and inder head cover and are sealed against oil leaks.
adjust.
(10) Install radiator, connect heater hoses, cooler C y lin d e r H e a d C o v e r R e m o v a l
lines and fill cooling system. (1) Disconnect battery ground cable at battery.
(11) Install hood using scribe marks for proper (2) Remove air cleaner, distributor cap with spark
alignment. plug cable and coil secondary cable as an assembly.
(12) Install battery, fill crankcase to capacity. (3) Grasp secondary cables at spark plug covers
Whenever an engine has been rebuilt and/or a and pull covers straight out.
new camshaft and/or new tappets are installed, one
quart of engine supplement Chrysler Part Number
1879406 or equivalent should be added to the engine
SUPPORT BRACKET BOLTS
. '* / * " ? j ^ ’X
j* JSs
..
1
■ S i
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(4) Remove spark plugs. loose, the studs will have to be coated with Chrysler
(5) On left bank, disconnect brake lines at m aster Sealer Part Number 1057794 or equivalent and
cylinder, remove cotter pin and clevis pin from link torqued to 20 foot-lbs.
age in back of power brake. (3) Coat new gasket lightly with Chrysler Sealer
(6) Remove the 4 nuts attaching booster to m ount Part Number 1057794 or equivalent. With the raised
ing bracket and remove power brake and m aster cyl bead toward cylinder block, install gasket and cylin
inder assembly. der head.
(7) Remove cylinder head covers and gaskets. (4) Install the cylinder head stud nuts inside of
tappet chamber and the eight short outer cylinder
R o c k e r A rm s a n d S h a fts R e m o v a l head bolts. Do not tighten at this time.
(1) With cylinder head cover removed, remove the
five bolts, (3/4 inch hexagon) that attach the rocker R o c k e r A rm s a n d S h a ft In s ta lla tio n
arm support brackets to the cylinder head and block (1) Install push rods through push rod holes in
(Fig. 3). head. The short rods in upper holes (intake) and long
(2) Remove rocker arm assemblies. rods in lower holes (exhaust).
(3) Remove push rods and identify to insure instal If the rocker arm assembly had been disassembled
lation in original location. for cleaning, inspection or replacement, refer to Fig
ure 6 for proper reassembly noting oil holes in num
C y lin d e r H e a d R e m o v a l ber two and four brackets.
(1) With cylinder head cover and rocker arm as (2) Position the rocker shaft support brackets on
semblies removed, remove alternator, disconnect ac the cylinder head and install the five long cylinder
celerator cable and transmission throttle rod from head bolts into rocker shaft support brackets and cyl
upper bellcrank. Drain cooling system. inder head, lining up all push rods to their respective
(2) Disconnect fuel line at tee fitting. rocker arms.
(3) Disconnect intake manifold heat tubes located (3) Starting at the center, tighten all head bolts
at rear of manifold. Remove air tube between auto and stud nuts to 50 foot-pounds in sequence shown
matic choke and exhaust manifold. in Figure 7 then repeat the procedure, tightening to
(4) Remove the intake manifold attaching screws. 75 foot-pounds in the same sequence.
(There are three locating dowels at each end of m ani (4) Adjust tappets. See “Tappet Adjustm ent Pro
fold.) cedure.”
(5) Remove intake manifold with ignition coil, both (5) Install exhaust headers with new gaskets and
carburetors, fuel lines, fuel filters, throttle linkage tighten to 35 foot-pounds.
and upper bellcrank as an assembly. (6) Place new cylinder head cover gaskets in posi
(6) Disconnect exhaust headers from cylinder heads tion and install cylinder head covers. Tighten nuts to
and tie out of way. 40 inch-pounds.
(7) Remove the lower eight cylinder head bolts (7) Adjust spark plug gaps to .035 inch. Slide spark
(Fig. 3). plug tube seals over tubes. With a six inch extension
(8) Remove the four stud nuts, (9/16 inch hexa on a spark plug socket insert spark plug, slide spark
gon) from cylinder head studs inside of tappet cham plug tube over assembly, insert assembly in cover and
ber (Fig. 4).
cylinder head, being careful not to drop plug as this
(9) Remove cylinder heads and place in holding fix
would change gap setting. Tighten spark plugs to 30
ture tool C-3626. To protect studs do not set cylinder
foot-pounds.
head down on studs at any time.
der head.
(2) Inspect all surfaces with a straightedge if there
is any reason to suspect leakage. If out of flatness
exceeds .00075 times the span length in any direction;
either replace head or lightly machine the head gasket
surface. As an example, if a 12 inch span is .004" out
of flat, allowable is 12 x .00075 = .009". Head is OK. ;* r ,y
/H
The cylinder head surface finish should be 70-180 Vt
NN 1040
micro-inches.
If the cy l inder head studs were removed or come
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R em o val
(1) With cylinder head removed, compress valve
springs with Tool C-3422A (Fig. 9).
(2) Remove valve retaining locks, valve spring re
tainers, valve stem cup seals (intake valves only) and
valve springs. Remove any burrs from the valve stem
lock grooves to prevent damage to the valve guide
when valves are removed. Identify valves to insure in
stallation in original location.
© ® ® © ® © @ © V a lv e In s p e c tio n
(1) Clean valves thoroughly and discard burned,
NN1036
warped or cracked valves.
Fig. 7—Cylinder H ead Tightening Sequence (2) Measure valve stems for wear. New intake valve
stem diam eter should m easure .3085 to .3095 inch
(8) Install new intake manifold gaskets and intake
and exhaust valve stem diameter should m easure
manifold; make sure end gaskets are positioned over
.3075 to .3085 inch. If w ear exceeds .002 inch, replace
locating dowels marked “A” in Figure 8. Tighten
valve.
screws marked “B” to 72 inch-pounds, and screws
(3) Remove carbon and varnish deposits from in
marked “C” to 48 inch-pounds. Repeat the tightening
side of valve guides with a reliable valve guide
procedure in the sequence shown until all screws
cleaner.
maintain their specified torque.
(4) Measure valve stem guide clearance as follows:
(9) Connect fuel line, automatic choke, intake mani
(a) Install sleeve Tool C-3973 over valve stem
fold heat tubes, transmission throttle rod to upper bell
(Fig. 10) and install valve. The special sleeve places
crank, accelerator cable and adjust as necessary.
the valve at the correct height for checking with a
(10) Install crankcase ventilation hose, distributor dial indicator.
cap with spark plug cables, and coil wire and cable. (b) Attach dial indicator Tool C-3339 to cylinder
(11) Install alternator, battery ground cable and head and set it at right angle to the valve stem being
heater hoses if removed. m easured (Fig. 11).
(12) Connect power brake booster, if so equipped (c) Move valve to and from the indicator. The total
and bleed brakes. dial indicator should not exceed .017 inch. Ream
(13) Fill the cooling system. Start engine and check guides for valves with oversize stems if dial indicator
for leaks. reading is excessive or if the valve stems are scuffed
(14) Adjust ignition timing and carburetors to spec or scored.
ifications. Road test vehicle. (d) Service valves with oversize stems are avail
able in .005, .015 and .030 inch oversize.
VALVES AND VALVE SPRINGS
® ®
© © C D ® ® ® © ©
© © ® ® ® ® @ ©
® ®
N N 1037
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FACE ‘ >
FACE
EXHAUST VALVE
INTAKE VALVE
VALVE SPRING
RETAINER LOCK
GROOVES
NP119
(e) Slowly turn ream er by hand and clean guide Fig. 12—In tak e and Exhaust Valves
thoroughly before installing a new valve. Do not at
coat valve seat lightly with Prussian Blue then set
tempt to ream the valve guides from standard directly
the valve in place. Rotate the valve with light pres
to .030 inch. Use step procedure of .005, .015 and
sure. If the blue is transferred to the center of the
.030 inch so the valve guides may be reamed true in
valve face, contact is satisfactory. If the blue is trans
relation to the valve seat. ferred to the top edge of valve face, lower the valve
seat with a 30° stone. If the blue is transferred to
R e fa c in g V a lv e s a n d V a lv e S e a ts the bottom edge of valve face, raise the valve seat
(1) The intake and exhaust valve seats and valve
with a 60° stone.
faces have a 45 degree angle.
(6) When the seat is properly positioned, the width
(2) Inspect the rem aining margin after the valves
of intake seats should be 1/16 to 3/32 inch. The
are refaced (Fig. 12). Valves with less than 3/64 inch
width of exhaust seats should be 3/64 to 1/16 inch.
margin should be discarded.
(3) When refacing valve seats, it is im portant that T e s tin g V a l v e S p r in g s (F ig . 1 3 )
the correct size valve guide pilot be used for reseat (1) Whenever valves have been removed for in
ing stones. A true and complete surface must be ob spection, reconditioning or replacement, valve springs
tained. should be tested. As an example, the compressed
(4) Measure the concentricity of valve seat using length to be tested is 1-1/2 inches. Turn table of
dial indicator No. 13725. Total runout should not Tool C-647 until surface is in line with the 1-1/2 inch
exceed .002 inch (total indicator reading).
(5) Inspect valve seat with Prussian Blue to deter
mine where the valve contacts the seat. To do this,
^ ’ m m
Fig. 11 —M e a s u r i n g V a l v e Guide W e a r
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mark on the threaded stud and the zero mark to the in the following procedure and adjust only the tappets
front. Place spring over stud on the table and lift indicated in the chart.
compressing lever to set tone device. Pull on torque Set the rocker adjusting screw so that there is no
wrench until ping is heard. Take reading on torque clearance (zero lash) in the system. Then turn the
wrench at this instant. Multiply this reading by two. screw into the rocker 1-1/2 turns. Torque the lock nut
This will give the spring load at test length. Fraction to 25 ft. lbs.
al m easurements are indicated on the table for finer When adjusting tappets on the 426 cu. in. engine
adjustments. The valve spring (with surge damp (cold setting) it is very im portant that the setting be
er removed) should test 110 to 120 pounds when made with each tappet at the lowest point of the cam
compressed to 1-55/64 inches (valve closed), and shaft; that is on the base circle.
300 to 320 at 1-3/8 inches (valve open). Discard The procedure used on standard engines cannot be
springs that do not m eet these specifications. used because of the overlap and duration with the
(2) Inspect each valve spring for squareness with special camshaft. The following procedure will assure
a steel square and surface plate, test springs from proper position of the camshaft when making the
both ends (Fig. 14). If the spring is more than 1/16 adjustment. An indicating light may be used in the
inch out of square, install a new spring. ignition primary circuit to more clearly define the
various positions of the camshaft.
In s ta lla tio n Intake Exhaust
(1) Coat valve stems with lubrication oil and insert A. Adjust ignition timing to TDC,
them in cylinder head. chalk mark TDC and 180° op
(2) Install new seals on intake valve stems and over posite TDC on the front crank
valve guides. Install valve springs and retainers. shaft damper.
B. Set crankshaft so No. 1 cylinder
(3) Compress valve springs with Tool C-3422A, is at TDC (Compression stroke,
install locks and release tool. If valves and/or seats points opening).
are reground, measure the installed height of springs. Adjust 2 and 7 4 and 8
Make sure measurement is taken from bottom of C. Rotate crankshaft 180° in nor
spring retainer (if spacers are installed, m easure from mal running direction until
points open for No. 4 cylinder.
the top of spacer). If height is greater than 1-59/64 Adjust "1 and 8 3 and 6
inch, install a 1/16 inch spacer in head counterbore to D. Rotate crankshaft an additional
bring spring height back to the normal 1-53/64 to 180° until points open for No.
1-57/46 inches. 6 cylinder.
Adjust 3 and 4 5 and 7
E. Rotate crankshaft an additional
TAPPET ADJUSTMENT 180° until points open for No.
7 cylinder.
The 426 cu. in. engine is equipped with adjustable Adjust 5 and 6 1 and 2
rockers and special hydraulic tappets with limited F. Reset ignition timing to oper
plunger travel and a heavy duty snap ring for more ating specifications and install
valve covers.
reliability in high speed operation.
To adjust tappets, postion crankshaft as indicated HYDRAULIC TAPPETS
P r e lim in a r y to C h e e k in g th e H y d r a u lic
T a p p e ts
(1) Before disassembling any part of the engine to
correct tappet noise, read the oil pressure at the
gauge (Install a reliable gauge at pressure sending
unit if vehicle has no oil pressure gauge) and check
the oil level in the oil pan. The pressure should be
between 45 and 65 pounds at 1000 R.P.M.
(2) The oil level in the pan should never be above
the “full” mark on dipstick, or below the “add oil”
mark. Either of these two conditions could be respon
sible for noisy tappets.
O il L e v e l T o o H ig h
If oil level is above the “full” m ark on dipstick,
it is possible for the connecting rods to dip into the oil
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while engine is running and create foam. Foam in oil insure installation in original location.
pan would be fed to the hydraulic tappets by the oil A diamond shaped marking stamped on the engine
pump causing them to lose length and allow valves to numbering pad indicates that some tappet bodies are
seat noisily. .008 inch oversize.
O il L e v e l T o o L o w DISASSEMBLY
Low oil level may allow oil pump to take in air
which, when fed to the tappets, causes them to lose The tappets in the 426 Hemi engine are a special
length and allows valves to seat noisily. Any leaks on design with limited plunger travel and a special heavy
intake side of pump through which air can be drawn duty snap ring. The snap ring is designed to remain
will create the same tappet action. When tappet noise in place at high engine speeds.
is due to aeration, it may be interm ittent or constant, These tappets are not to be disassembled for clean
and usually more than one tappet will be noisy. When ing.
oil level and leaks have been corrected, engine should If the tappet or bore in cylinder block is scored,
be operated at fast idle for sufficient time to allow all scufFed or shows signs of sticking, ream the bore to
of the air inside of the tappets to be bled out. next oversize.
T a p p e t N o is e D ia g n o s is In s ta lla tio n
(1) To determine source of tappet noise, operate (1) Lubricate tappets.
engine at idle with cylinder head covers removed. (2) Install tappets and push rods in their original
(2) Feel each valve spring or rocker arm to detect positions.
noisy tappet. The noisy tappet will cause the affected (3) Install rocker arm and shaft assembly.
spring an d /o r rocker arm to vibrate or feel rough in (4) Install intake manifold.
operation. (5) Start and operate engine. Warm up to normal
Worn valve guides or cocked springs are sometimes operating tem perature.
mistaken for noisy tappets. If such is the case, noise CAUTION: To prevent damage to valve mechanism,
may be dampened by applying side thrust on the engine must not be run above fast idle until all hy
valve spring. If noise is not appreciably reduced, it draulic tappets have filled with oil and have become
can be assumed the noise is in the tappet. Inspect the quiet.
rocker arm push rod sockets and push rod ends for
wear. VALVE TIMING
(3) Valve tappet noise ranges from light noise to
a heavy click. A light noise is usually caused by exces (1) Turn crankshaft until NO. 6 exhaust valve is
sive leakdown around the unit plunger which will closing and No. 6 intake valve is opening.
necessitate replacing the tappet, or by the plunger (2) Insert a 1/4 inch spacer between rocker arm pad
partially sticking in the tappet body cylinder. A heavy and stem tip of NO. 1 intake valve (First valve on top
click is caused either by a tappet check valve not rocker shaft on right bank as viewed from front of
seating, or by foreign particles becoming wedged be engine).
tween the plunger and the tappet body, causing the (3) Install a dial indicator so plunger contacts valve
plunger to stick in the down position. This heavy click spring retainer as nearly perpendicular as possible.
will be accompanied by excessive clearance between (4) Allow spring load to bleed tappet down giving
the valve stem and rocker arm as valve closes. In in effect a solid tappet. Zero the indicator.
either case, tappet assembly should be removed for (5) Rotate crankshaft clockwise (normal running
inspection and cleaning. direction) until valve has lifted .094 inch.
CAUTION: Do not turn crankshaft any further clock
T ap p et R em oval wise, as the valve spring might bottom and result in
(1) The tappet can be removed by removing the serious damage.
intake manifold or cylinder heads by following this The timing of the crankshaft pulley should now read
recommended procedure. Remove cylinder head cov from 10 degrees before top dead center to 2 degrees
ers. after top dead center.
(2) Remove rocker arms and shaft assembly. (6) If reading is not within specified limits:
(3) Remove push rods and identify to insure instal (a) Check accuracy of DC m ark on crankshaft
lation in original location. pulley.
(4) Remove intake manifold. (b) Check sprocket index marks.
(5) Pull tappet out of bore with a twisting motion. (c) Inspect timing chain for wear.
If all tappets are to be removed, identify tappets to (7) Turn crankshaft counterclockwise until valve is
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closed and remove the indicator and spacer. TORQUE WRENCH
C over R em o val
(1) Drain cooling system and remove radiator, fan
belt and w ater pump housing. Remove power steer
ing pump and tie out of the way, if so equipped.
(2) Remove pulley from vibration damper, bolt and
washer securing vibration damper on crankshaft.
(3) Install Tool C-3688, and pull dam per assembly
off end of crankshaft (Fig. 15).
(4) Remove the two front pan bolts.
(5) Remove chain case cover and gasket using
extrem e caution to avoid damaging oil pan gasket. 1 KR151A
It is normal to find particles of neoprene collected be
tween the crankshaft seal retainer and crankshaft oil Fig. 16—Measuring Timing Chain Stretch (Typical)
slinger.
(6) Slide crankshaft oil slinger from end of crank ceeds 3/16 inch.
shaft. (5) If chain is satisfactory, slide crankshaft oil
slinger over shaft and up against sprocket (flange
away from sprocket).
M e a s u r in g T im in g C h a in fo r S tre tc h
(1) Place a scale next to the timing chain so any (6) If chain is not satisfactory; remove camshaft
movement of the chain may be measured. sprocket attaching bolts and remove timing chain
(2) Place a torque wrench and socket over cam with crankshaft and camshaft sprockets.
shaft sprocket attaching bolt and apply torque in the When installing timing chain, use Tool C-3509 to
direction of crankshaft rotation to take up slack; 30 prevent camshaft from contacting the welch plug in
foot-pounds (with cylinder heads installed) or 15 the rear of engine block. Remove distributor and oil
foot-pounds (cylinder heads removed). pump-distributor drive gear. Locate tool against rear
With torque applied to the camshaft sprocket bolt, side of cam gear and attach tool with distributor re
crankshaft should not be permitted to move. It may tainer plate bolt (Fig. 17).
be necessary to block crankshaft to prevent rotation. (7) Place camshaft sprocket and crankshaft sprock
(3) Holding a scale with dimensional reading even et on the bench with timing marks on exact imaginary
with edge of a chain link, apply torque in the reverse center line through both camshaft and crankshaft
direction 30 foot-pounds (with cylinder heads in sprocket bores.
stalled) or 15 foot-pounds (cylinder heads removed), (8) Place tim ing chain around both sprockets.
and note amount of chain movement (Fig. 16). (9) Turn crankshaft and camshaft to line up with
keyway location on crankshaft sprocket and dowel
(4) Install a new timing chain, if its movement ex-
hole in camshaft sprocket.
(10) Lift sprockets and chain (keep sprockets tight
TOOL'
ARM (TOOL)
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Fig. 2 0 —Removing O il Seal
(4) Place flat washer and nut on the remover screw.
Hold center screw and tighten remover nut to remove
Fig. 18 —Alignment of Timing M arks
the seal (Fig. 20).
against chain in position as described). (5) Insert remover screw through the removing and
(11) Slide both sprockets evenly over their respec installing plate so thin shoulder will be facing up.
tive shafts. (6) Insert remover screw with the plate through
(12) Use a straight edge to measure alignm ent of seal opening (inside of chain case cover facing up).
timing marks (Fig. 18). (7) Place seal in cover opening, with neoprene down.
(13) Install camshaft sprocket bolts and tighten Place seal installing plate into the new seal, with pro
to 40 foot-pounds. Slide the crankshaft oil slinger tective recess toward lip of seal retainer (Fig. 21).
over shaft and up against sprocket (flange away from The lip of the neoprene seal must be toward source
sprocket). of oil.
(8) Install flat washer and nut on remover screw,
O il S e a l R e p la c e m e n t (C o v e r R e m o v e d ) hold screw and tighten nut (Fig. 22).
(1) Position rem over screw of Tool C-3506 through (9) The seal is properly installed when the neoprene
case cover, inside of case cover up. Position remover is tight against face of cover. Try to insert a .0015
blocks directly opposite each other, and force the inch feeler gauge between the neoprene and the cover
angular lip between the neoprene and flange of seal (Fig. 23). If the seal is installed properly, feeler
retainer. gauge cannot be inserted. Do not over compress neo
(2) Place washer and nut on rem over screw. Tighten prene.
nut, forcing the blocks into the gap to a point of dis
torting the seal retainer lip (Fig. 19). This is im C o v e r In s ta lla tio n
portant, remover is on ly positioned at this point. (1) Be sure mating surfaces of chain case cover and
(3) Place sleeve over retainer and place removing cylinder block are clean and free from burrs.
and installing plate into the sleeve. (2) Using a new gasket slide chain case cover over
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m f m m
v KR155B
Fig. 2 4 —In s ta llin g V ib r a tio n D a m p e r Assem bly
Fig. 2 2 —In s ta llin g N e w S e a l
removed, remove distributor and lift out oil pump
locating dowels. Install and tighten bolts 15 foot
and distributor drive shaft.
pounds.
(2) Remove fuel pump to allow fuel pump push
(3) Lubricate seal lip with lubriplate, place damper
rod to drop away from cam eccentric.
hub slot on key in crankshaft, and slide vibration
(3) Remove camshaft, being careful not to damage
damper on crankshaft.
camshaft bearings with the cam lobes.
(4) Place installing tool part of Tool C-3688 in
position and press damper on the crankshaft (Fig. 24).
In s ta lla tio n
(5) Install damper retainer washer and bolt. Tight (1) Lubricate camshaft lobes and camshaft bearing
en to 135 foot-pounds. journals and insert camshaft to within 2 inches of its
(6) Slide belt pulley over shaft and attach with final position in cylinder block.
bolts and lockwashers. Tighten bolts to 200 inch- (2) Modify Tool C-3509 by grinding off index lug
pounds. holding the upper arm on the tool and rotate arm 180
CAMSHAFT degrees.
(3) Install Tool C-3509 in place of distributor
The camshaft has an integral oil pump and distrib drive gear and shaft, as shown in Figure 17.
utor drive gear and fuel pump eccentric. (4) Hold tool in position with distributor lock plate
The rearw ard camshaft thrust is taken by the rear screw. This tool will restrict camshaft from being
face of the cast iron camshaft sprocket hub, bearing pushed in too far and prevent knocking out the welch
directly on the front of cylinder block, eliminating plug in the rea r of cylinder block.
need for a thrust plate. The helix of the oil pump The tool should remain installed until camshaft and
and distributor drive gear and camshaft lobe taper crankshaft sprockets and timing chain have been in
both tend to provide a rearw ard thrust. stalled.
Whenever an engine is rebuilt and/or a new cam
R em oval
(1) With tappets and the timing chain and sprockets shaft and/or new tappets are installed, one quart of
engine supplement, Chrysler Part Number 1879406 or
j _ V F E rlR G A l'i; . /
equivalent 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 at
the next normal oil change.
Whenever camshaft is replaced, all of tappet faces
must be inspected for crown with a straight edge. If
any contact surface is dished or worn, tappet must be
im F w L ilk replaced.
CAMSHAFT BEARINGS
(Engine Removed from Vehicle)
CHAIN CASE COVER KR156A
R em oval
(1) With engine completely disassembled, drive out
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camshaft rear bearing welch plug.
(2) Install proper size adapters and horse shoe BUSHING
washers (part of Tool C-3132A) at the back of each
bearing to be removed and drive out bearings (Fig.
25).
in s ta lla tio n
(1) Install new camshaft bearings with Tool C-
3132A. Place new camshaft bearing over proper adap
ter.
(2) Position bearing in the tool. Install the horse
shoe lock and by reversing removal procedure, care
fully drive bearing into place (Fig. 25).
(3) Install remaining bearings in like manner.
Install the No. 1 camshaft bearing 1/32 inward Fig. 2 6 —Removing Distributor Drive Shaft Bushing
from the front face of cylinder block.
In s ta lla tio n
The oil holes in camshaft bearings and the cylinder (1) Slide a new bushing over burnishing end of
block must be in exact register to insure proper lubri Tool C-3053 and insert tool bushing into the bore.
cation. (2) Drive bushing and tool into position, using a
The camshaft bearing index can be inspected after hammer (Fig. 27).
installation by inserting a pencil flashlight in the (3) As the burnisher is pulled through the bushing
bearing. The camshaft bearing oil hole should be per by tightening remover nut, the bushing is expanded
fectly aligned with the drilled oil passage from the tight in the block and burnished to correct size
main bearing. Other oil holes in the camshaft bear (Fig. 28). DO NOT REAM THIS BUSHING.
ings should be visible by looking down on the left
D is trib u to r T im in g
bank oil hole above and between No. 6 and No. 8 cyl
Before installing distributor and oil pump drive
inders to No. 4 camshaft bearing and on the right shaft, time the engine as follows:
bank above and between No. 5 and 7 cylinders to No. (1) Rotate crankshaft until No. 1 cylinder is at top
4 camshaft bearing. If camshaft bearing oil holes dead center on the firing stroke.
are not in exact register, remove and reinstall them (2) When in this position, the straight line on the
correctly. Install a new welch plug at rear of cam vibration dam per should be under “O” on timing indi
shaft. Be sure this plug does not leak. cator.
(3) Coat shaft and drive gear with engine oil. In
DISTRIBUTOR DRIVE SHAFT BUSHING stall the shaft so that after gear spirals into place,
it will index with the oil pump shaft, so slot in top
R em oval of drive gear will be parallel with center line of
(1) Insert Tool C-3052 into the old bushing and crankshaft (Fig. 29).
thread down until tight fit is obtained (Fig. 26).
(2) Hold rem over screw and tighten nut until bush In s ta lla tio n o f D is trib u to r
(1) Hold distributor over mounting pad on cylinder
ing is removed.
BUSHING
,:w
7 1
Ills
a
CRANKSHAFT MAIN BEARING OIL HOLE
CAMSHAFT BEARING OIL HOLE
KR164
KR160
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P is to n R e m o v a l
BUSHING (1) Remove top ridge of cylinder bores with a reli
TOO L able ridge ream er before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered
during this operation.
The pistons and connecting rods must be removed
from the top of the cylinder block. When removing
piston and connecting rod assemblies from the engine,
rotate the crankshaft so each connecting rod is cen
tered in cy l inder bore.
(2) Inspect connecting rods and connecting rod caps
for cylinder identification. Identify them if necessary.
Remove connecting rod cap.
. KR161 (3) Install suitable connecting rod guides on rod
Fig. 2 8 —Burnishing Distributor Drive Shaft Bushing
bolts and push each piston and rod assembly out of
cylinder bore: (Connecting rod guides to cover the
block with vacuum chamber pointing toward center complete threaded area can be made from copper or
of engine. aluminum tubing and the inside threaded with a
(2) Turn rotor until it points forward and to ap 7/16"-20 tap.)
proximate location of No. 1 tower term inal in the (4) After removal, install the corresponding bear
distributor cap. ing cap on the rod.
(3) Place distributor gasket in position.
(4) Lower the distributor and engage the shaft in C le a n in g a n d In s p e c tio n
the slot of distributor drive shaft gear. (1) Clean cylinder block thoroughly and inspect all
(5) Turn distributor clockwise until breaker con core hole plugs for evidence of leaking.
tacts are just separating, install and tighten hold down (2) If new core plugs are installed, coat edges of
clamp. plug and core hole with Number 1057794 Sealer or
equivalent. Drive the core plug in so that the rim lies
CYLINDER BLOCK at least 1/64" below the lead-in chamfer.
(3) Examine block for cracks or fractures.
The cylinder block is of the deep block design
which eliminates the need for a torque converter C y lin d e r B o re In s p e c tio n
housing adapter plate. The cylinder block reinforced The cylinder walls should be measured for out-of
in the vicinity of the main bearing web. Number 2, 3 round and taper with Tool C-119. If the cylinder bores
show more than .005" out-of-round, or a taper of more
and 4 main bearing caps receive added support from
than .010" or if the cylinder walls are badly scuffed
a pair of horizontal tie-bolts which anchor the bearing
or scored, the cylinder block should be rebored and
caps to the sides of the cylinder block. The sides ex honed, and new pistons and rings fitted. W hatever
tend three inches below the crankshaft center line. type of boring equipment is used, boring and honing
operation should be closely coordinated with the fit
DISTRIBUTOR A N D OIL ting of pistons and rings in order that specified clear
PUMP DRIVE ance may be maintained.
G EAR SLOT
it'-
H o n in g C y lin d e r B o re s
Before honing, stuff plenty of clean rags under the
4 }/ bores, over the crankshaft to keep the abrasive ma
terials from entering the crankcase area.
(1) Use carefully, the cylinder bore resizing hone
r C-823 equipped with 220 grit stones and 390 exten
y ■vtwu*
& sions necessary with the 426 cubic inch engine is the
%■ best tool for this job. In addition to deglazing, it will
reduce taper and out-of-round as well as removing
light scuffing, scoring or scratches. Usually, a few
strokes wili clean up a bore and maintain the re
CENTER LINE OF CRANKSHAFT KR163A
quired limits.
(2) Deglazing of the cylinder walls may be done
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using a cylinder surfacing hone, Tool C-3501, F in is h e d P is to n s
equipped with 280 grit stones (3501-3810) if the cylin All pistons are machined to the same weight in
der bore is straight and round. 20 to 60 strokes de grams, regardless of oversize so piston balance can
pending on the bore condition will be sufficient to be maintained. For cylinder bores which have been
provide a satisfactory surface. Inspect cylinder walls honed or rebored, pistons are available in standard
after each 20 strokes. Use honing oil C-3501-3880 or and the following oversizes: .005, .020, and .040
a light honing oil available from m ajor oil distribu inch.
tors. Do not use engine or transmission oil, mineral
oil or kerosene. F ittin g P is to n s
(3) Honing should be done by moving the hone up Piston and cylinder wall must be clean and dry.
and down fast enough to get a cross-hatch pattern. Specified clearance between the piston and the cyl
When hone marks intersect at 60°, cross hatch angle inder wall is .0025 to .0035 inch.
is most satisfactory for proper seating of rings (see Piston diam eter should be measured at the top of
Fig. 30). skirt 90 degrees to piston pin axis. Cylinder bores
(4) After honing, it is necessary that the block be should be measured halfway down the cylinder bore
cleaned again to remove all traces of abrasives. Wash and transverse to the engine crankshaft center line.
cylinder block and crankshaft thoroughly. Pistons and cylinder bores should be measured at
CAUTION: Be sure all abrasives are removed from normal room temperature, 70 degrees F.
the engine parts after honing. It is recommended All service pistons include pins, and are available
that a solution of soap and water be used with a brush in standard and the following oversizes: .005, .020
and .040 inch.
and the parts then thoroughly dried. The bore can be
considered clean when it can be wiped clean with a
F ittin g R in g s
white cloth and the cloth remains clean. Oil bores (1) Measure piston ring gap about two inches from
after cleaning to prevent rusting. bottom of cylinder bore in which it is to be fitted.
(An inverted piston can be used to push rings down
PISTONS, PINS AND RINGS to insure positioning rings squarely in cylinder wall
before measuring.)
P is to n s (2) Insert feeler stock in the gap. Ring gap should
The pistons are cam ground so that the diam eter at be between .013 to .025 inch for the compression
the pin boss is less than its diam eter across the thrust rings and .015 to .062 inch for the oil ring steel rails
face. This allows for expansion under normal operat in standard size bores. Maximum gap on .005 inch
ing conditions. Under operating tem peratures, ex O/S bores should be .060 inch for compression rings
pansion forces the pin bosses away from each other, and .070 inch for the oil ring steel rails.
thus causing the piston to assume a more nearly (3) Measure side clearance between piston ring and
round shape. It is im portant that old or new pistons ring groove. Clearance should be .0015 to .003 inches
be m easured for taper and elliptical shape before for the top compression ring and interm ediate ring.
they are fitted into the cylinder bore. Steel rail service oil ring should be free in groove,
but should not exceed .005 inch side clearance.
(4) Install the three piece oil ring in lower ring
groove using instructions in ring package.
(5) Install compression rings in middle and top
groove as shown on instruction sheet. Be sure the
m ark “top” on each compression ring faces top of
piston.
(6) For the two top rings use ring installer Tool
C-3673.
P is to n P in s
(1) The piston pin should be a tight thumb press
fit in connecting rod and piston at normal room
tem perature, 70°F. If proper fit cannot be obtained
with standard pins, hone or ream piston and connect
ing rod, and install oversize piston pin. Piston pins
are supplied in standard and the following oversizes:
.003 and .008 inch.
(2) Position the left cylinder bank (1-3-5-7) pistons
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so the arrow indicating front is to the left of the oper is satisfactory. Correct clearance is from. .0015 to
ator and the connecting rod insert locating tang or .0025 inch.
num ber is facing the operator. Install piston pin and (4) Side play should be from .009 to .017 inch.
lock rings with the bevel edge away from the piston
pin, using Tool C-3915. INSTALLING PISTON AND CONNECTING
(3) Assemble the right cylinder bank (2-4-6-8) so ROD ASSEMBLY IN CYLINDER BLOCK
the arrow is to the right of the operator with the con
necting rod insert locating tang or num ber is facing (1) Before installing pistons, rods, and rod assem
the operator. Install piston pin and lock rings with blies in the bore, be sure that the compression ring
the bevel edge away from the piston pin using Tool gaps are staggered so that neither are in line with
C-3915. oil ring rail gaps.
(2) The oil ring expander ends should be positioned
CRANKSHAFT IDENTIFICATION toward the outside of the “V” of the engine. The oil
ring rail gaps should be positioned opposite each
IMPO RTANT: A Maltese Cross stamped on the engine other and above the piston pin holes.
numbering pad indicates that engine is equipped (3) Immerse piston head and rings in clean engine
with a crankshaft which has one or more connecting oil, slide ring compressor, Tool C-385, over the piston
rods and/or main bearing journal finished .001 inch and tighten with special wrench (part of Tool C-385).
undersize. The position of the undersize journal or (4) Be sure the position of rings does not change
journals is stamped on a machine surface of the No. 3 during this operation. Screw connecting rod bolt pro
counterweight. A Maltese Cross with an X indicates tectors on rod bolts.
.010 inch undersize journals. Rotate crankshaft so connecting rod journal is on
The connecting rod journals are identified by the center of cylinder bore.
letter “R” and main bearing journals by the letter (5) Insert rod and piston into cylinder bore. Guide
“M”. For example “M -l” indicates that No. 1 main the rod over crankshaft journal.
bearing is .001 inch undersize. (6) Tape piston down in cylinder bore, using handle
of a hammer. At the same time, guide connecting rod
CONNECTING RODS into position on crankpin journal.
(7) The arrow on top of piston must be pointing
In s ta lla tio n o f C o n n e c tin g R o d B e a rin g s toward front of engine and the num ber or the con
Fit all rods on one bank until complete. Do not necting rod insert locating tang must face outboard.
alternate from one bank to another, because when (8) Install rod caps, tighten nuts to 75 foot-pounds.
rods are assembled to the pistons correctly, they are
not interchangeable from one bank to another. CRANKSHAFT MAIN JOURNALS
The bearings should always be installed so that
the small formed tang fits into the machined grooves Crankshaft main bearing journals should be inspect
of the rods. The end clearance should be from .009 ed for excessive wear, taper and scoring. Journal
to .017 inch (two rods). grinding should not exceed .012 inch under the stand
Limits of taper or out-of-round on any crankshaft ard journal diameter. DO NOT grind the thrust faces
journals should be held to a maximum of .0005 inch. of the No. 3 main bearing. Do not nick crankpin or
Bearings are available in .001, .002, .003, .010, .011 main bearing fillets. After regrinding, remove rough
and .012 inch undersize. edges from crankshaft oil holes and clean out all oil
Install the bearings in pairs. Do not use a new passages.
bearing half with an old bearing half. Do not file
the rods or bearing caps. CRANKSHAFT MAIN BEARINGS
MEASURING CONNECTING ROD The num ber 2, 3 and 4 main bearing caps have two
BEARING CLEARANCE horizontal tie-bolts which anchor the bearing caps to
the sides of the block (Fig. 31).
S h im S to c k M e t h o d New lower main bearings halves Number 1, 2, 4, 5
(1) Place an oiled .002 inch brass shim stock (1/2 are interchangeable (Fig. 32). New upper main bear
inch wide and 3/4 inch long) between the bearing and ing halves Number 2, 4 and 5 are also interchange
connecting rod journal. able. Upper and lower bearing halves are not inter
(2) Install bearing cap and tighten to 75 foot changeable because upper bearing is grooved and
pounds. lower bearing is not.
(3) Turn connecting rod 1/4 tu rn in each direction. The No. 1 upper main bearing IS NOT INTER
A slight drag should be felt which indicates clearance CHANGEABL E AND IS CHAMFERED on the tab
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TOOL :W BEARING '
f* v ■ (1
N N 1038A
BRIDGE
UPPER (PART OF TOOL)
«-
‘ THRUST BEARING
B m fim
LOWER
SIDE SEAL.
v5B!R> GROOVES KR237
NU256
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clearance is .002 inch or less and is considered satis
factory.
If, however, no drag is felt, the bearing is too large
or crankshaft cannot be rotated, bearing is too small
and should be replaced with the correct size.
(4) Measure crankshaft end play .002 to .007 inch.
If end play is less than .002 inch or more than .007
inch, install a new num ber 3 main bearing.
(5) Fit rem aining bearings in same manner.
It is permissable to use one .001 inch undersize
bearing shell with one standard bearing shell or one
.002 inch undersize bearing shell with one .001 inch
undersize shell. A lways use the smaller diameter
bearing half as the upper. Never use an upper bear
ing half more than .001 inch smaller than the lower
bearing half and never use a new bearing half with a KR238
REAR MAIN BEARING OIL SEAL into position with Tool C-3743 until tool is seated.
(Crankshaft Removed) (3) Trim off that portion of the seal that protrudes
above the cap (Fig. 35).
U p p e r R e a r M a in S e a l In s ta lla tio n
(1) Install a new rear main bearing oil seal in S id e S e a ls In s t a lla t io n
cylinder block so that both ends protrude. Perform the following operations as rapidly as pos
(2) Tap seal down into position, using Tool C-3743 sible. These side seals are made from a material that
with bridge removed until tool is seated in bearing expands quickly when oiled.
bore. (1) Apply m ineral spirits or diesel fuel to the side
(3) Hold the tool in this position and cut off por seals.
tion of seal that extends above the block on both sides. (2) Install seals immediately in the seal retainer
grooves.
L o w e r R e a r M a in S e a l In s ta lla tio n (3) Install seal retainer and tighten screws to
(1) Install a new seal in seal retainer so ends pro 25 foot-pounds.
trude (Fig. 34). Failure to pre-oil the seals will result in an oil
(2) Install bridge on tool and tap the seal down leak.
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PLUG ’ BOLTS AND WASHERS
GASKET * COVER /O IL FILTER
SPRING
OUTER ROTOR
RELIEF VALVE
PLUNGER INNER ROTOR
AND SHAFT
BODY
,4 DRIVE SHAFT
N r
SEAL RING 1 AND GEAR
KB67A
GASKET
“ O ” RING Fig. 3 9 —Measuring Inner Rotor Thickness
KR173
surface (Fig. 37). If a .0015 inch feeler gauge can be
inserted between the base and straightedge, filter
base should be replaced.
Fig. 36—Oil Pump and Filter Assembly
(Disassembled View )
(3) If outer rotor length measures less than .943
inch (Fig. 38) and diameter less than 2.469 inches,
Inspection a n d A ssem bly replace outer rotor.
(1) Clean all parts thoroughly. The mating face of (4) If inner rotor length measures less than .942
filter base (oil pump cover) should be smooth. Replace inch (Fig. 39), a new inner rotor should be installed.
filter base if it is scratched or grooved. (5) Install outer rotor into pump body, pressing to
(2) Lay a straightedge across oil pump filter base one side with fingers and measure clearance between
COVER outer rotor and pump body (Fig. 40). If measurement
is more than .014 inch, replace oil pump body.
(6) Install inner rotor into pump body and place a
straightedge across the face between bolt holes (Fig.
41). If a feeler gauge of more than .004 inch can be
STRAIGHT
EDGE
inserted between the rotors and straightedge, replace
pump body.
OUTER ROTOR
FEELER
GAUGE
KR] 74
STRAIGHT EDGEv
JM ‘
i
DIAMETER
KB66B FEELER GAUGE""" KR175
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-OUTER ROTOR
T '
A
- INNER ROTOR
's 9-.
4,
A ■ : f o FEELER
GAUGE
I 9 g
NN 359
rotors (Fig. 42) is more than .010 inch, replace inner
Fig. 4 3 —Removing O il Filter
and outer rotor.
CRANKCASE VENTILATION SYSTEM
S e rv ic in g O il P re s s u re R e lie f V a lv e A fully closed crankcase ventilation system is in
Inspect oil pump relief valve plunger for scoring
stalled on all vehicles. The fully closed crankcase ven
and free operation in its bore. Small scores may be
removed with 400 grit wet or dry paper providing tilation system operates by unfiltered air drawn in
extreme care is used not to round off the sharp edge from the air cleaner (ahead of the filter) through the
portion of the valve. crankcase inlet air cleaner (where it is filtered) by
The relief valve spring has a free length of 2-9/32 means of a hose (Fig. 1). Air is circulated through the
to 2-19/64 inch and should test 22.3 to 23.3 lbs. when engine and drawn out of the cylinder head cover by
compressed to 1-19/32 inch. Discard spring that fails manifold vacuum into the combustion chambers and
to meet specifications. dispelled with the exhaust gases.
If the oil pressure is low, inspect for worn bearings, A ventilation valve is installed in the outlet vent of
or look for other causes of possible loss of oil the cylinder head cover, and a hose. The hose it con
pressure. When assembl ing the oi l pump, be sure to nected between the outlet vent and the lower part of
use new oil seal rings between filter base and pump the carburetor body. The function of the valve is to
body. regulate the flow of crankcase ventilation at various
throttle positions. If the ventilation valve is plugged,
In s ta lla tio n fumes flow into the air cleaner and are burned in the
(1) Install a new “0 ” ring seal on the pilot of oil combustion chamber prior to reaching the atmosphere
pump before attaching oil pump to cylinder block.
to prevent atmospheric contamination.
(2) Install oil pump on engine, using a new gasket
The valve and hose are subject to fouling with
on engine and tighten attaching bolts to 30 foot
sludge and carbon formation due to the nature of the
pounds. Install oil filter element.
m aterial carried by the ventilation system. The valve
will operate effectively as long as normal maintenance
OIL FILTER REPLACEMENT is applied.
A plugged vent system may in turn cause excessive
The “spin on” oil filter should be replaced prefer
engine crankcase sludge formation and may also cause
ably to coincide with every second oil change.
rough or erratic engine idle or excessive oil leakage.
The ventilation system should be cleaned every six
R em oval
Use care so as not to damage transmission oil cooler months and valve replaced every year in average
lines. service and more frequently if the vehicle is used ex
(1) Using Tool C-4065 unscrew the filter from the tensively for short trips—driving less than 10 miles—
base on bottom side of engine and discard (Fig. 43). with frequent idling, such as city traffic.
(2) Wipe base clean. See the “Lubrication and Maintenance” section,
Group 0 of this manual for proper service procedures.
In s ta lla tio n
(1) Install the “spin” oil filter by hand, finger REPAIR OF DAMAGED OR WORN THREADS
tight. Do not use tool.
(2) To obtain an effective seal, tighten filters by Damaged or worn threads can be repaired by the
hand the additional num ber of turns indicated on the use of Heli-Coils. Essentially, this repair consists of
replacem ent filter. Start engine and inspect for leaks. drilling out worn or damaged threads, tapping the
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NP125B
SPECIFICATIONS
SIX CYLINDER ENGINE
170-198-225 Cubic Inch Engines
Type ........................................................................................... In-Line OHV
Number of C ylin d ers.............................................................. 6
Bore ......................................................................................... . 3.40"
Stroke— 170 Cubic Inch ............................... ......................... 3.125"
198 Cubic In c h .......................................................... 3.640"
225 Cubic Inch ........................................................ 4.125"
Piston Displacement 170-198-225 Cu. In.
Compression Ratio— 170 Cubic Inch ................................. 8.50 to 1
198 Cubic In c h ................................... 8.40 to 1
225 Cubic Inch ................................. 8.40 to 1
Minimum Compression Pressure with Engine Warm,
Spark Plugs Removed, Wide-Open T h ro ttle ................... 100 psi
Maximum Variation Between Cylinders (any one engine) 25 psi
Firing O rd e r.......................................................... ................... 1-5-3-6-2-4
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Basic Timing— 170 Cubic In c h ........................................... 5° B T C ± 2 -l/2 °
198 Cubic In c h ........................................... T D C ± 2 -l/2 °
225 Cubic In c h ........................................... T D C ± 2 -l/2 °
CRANKSHAFT
Type ....................................................................................... Fully Counter-Balanced
Bearings ............................................................................... Steel-Backed Babbitt
Main Bearing Journal D iam eter........................................ 2.7495" to 2.7505"
Connecting Rod Journal D iam eter.................................... 2.1865" to 2.1875"
Maximum Out-of-Round Perm issible............................... . .001"
Number Main B earings...................................................... 4
Clearance Desired .............................................................. .0005" to .0015"
Maximum Clearance Allowance Before Reconditioning .0025"
End Play ............................................................................. .002" to .007"
Thrust Taken b y .................................................................. No. 3 Main Bearing
Finish at Rear Seal S u rfa c e ....................... ..................... Diagonal Knurling
Interchangeability of Bearings ......................................... Upper Nos. 2, 4
Lower Nos. 1, 2, 4
MAIN BEARING (service)
All available in Standard and the following Undersizes .001, .002, .003, .010, .012"
CONNECTING RODS AND BEARINGS
Type ....................................................................................... Drop Forged “I” Beam
Length (Center to Center) ................................................ 170— 5.705" to 5.709"
198— 7.003" to 7.007"
225— 6.697" to 6.701"
Weight (Less Bearing Shells) 170— 25.3 oz.
198-27 oz.
225—26.8 oz.
Bearings .................................................................................................... Steel-Backed Babbitt
Diameter and Length ............................................................................. 2.1870" x 1.015"
Clearance Desired ................................................................................... .0005" to .0015"
Maximum Allowable before Reconditioning....................................... .0025"
Side Clearance ......... . ............................................................................. .006" to .012"
Bearings for Service ............................................................................... Standard .001, .002,
.003, .010, .012" O.S.
Piston Pin Bore D iam eter......................... ............................................. .8995" to .9000"
CAMSHAFT
Drive .......................................................................................................... Chain
Bearings .................................................................................................... Steel-Backed Babbitt
Number ...................................................................................................... 4
Thrust Taken b y ....................................................................................... 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. 2 ...................................................................................................... 1.984" to 1.985"
No. 3 ................... ................................................................................. 1.969" to 1.970"
No. 4 ...................................................................................................... 1.953" to 1.954"
TIMING CHAIN
Number of L in k s ....................................................................................... 50
Pitch ......................................................................................................... .50"
Width ........................................................................ ............................... .88"
TAPPETS
Type ............... .......................................................................................... Mechanical
Clearance in B lo c k ................................................................................. . .0012" to .0025"
Body Diameter ....................................................................................... .9040" to .9045"
Clearance Between Valve Stem and Rocker Arm Pad (Engine Hot) .010" Intake
.020" Exhaust
PISTONS
Type .......................................................................................................... Aluminum Alloy Tin Coated
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Material ...................................................................................................................... Horizontal Slot w/Steel Struts
Land Clearance (diametral) ................................................................................. t0
Clearance at Top of S k ir t....................................................................................... £-,-t0
Weight (std. through .040 oversize) ..................................................................... 465 gms.
Piston Length (overall) ........................................................................................... 3.51"
Ring Groove Depth „„„
No. 1 ...................................................................................................................... 179
No. 2 ...................................................................................................................... -179;
No. 3 ................... ................................................................................................. 181
Piston for S ervice................................................................................................ Std. .005, .020, .040" O.S.
PISTON PINS
Type .......................................................................................................................... Press Fit in Rod
Diameter .................................................................................................. ................. .9007"— .9009"
Length ..................................................................................................................... 2.955"-—2.975"
Clearance in P is to n ................................................................................................ .00045" to .00075"
Interference in Rod ................................................................................................ .0007" to .0012"
Piston Pins for S e rvice........................................................................................... Standard Only
Direction Offset in P isto n ....................... ............................................................... Toward Right Side of Engine
PISTON RINGS 198-225 Cubic Inch 170 Cubic Inch
Number of Rings per P iston ........................... ................. 3 3
Compression .................................................................. 2 2
Oil ............................. ............................................................ 1 1
Oil Ring T y p e .................................................................... 3-piece Cast iron
steel rail with
chrome-face expander
Ring Width
Compression .................................................................... .0775"-.0780" .0775"-.0780"
Oil— Cast iron ................................................................. ....................... ,1860"-.1865"
Steel rails ............................. .................................. .025" ----- --------------
Ring Gap
Compression .................................................................... .010"-.020" .010"-020"
Oil— Cast iron .................................................................. ............... ,010"-020"
Steel rails ................................................................ .015"-.055" -------
Ring Side Clearance
Compression ............................... .................................... .0015"-.0030" .0015"-.0030"
Oil— Cast iron .................................................................. ....................... .0015"-.0030"
Steel rails ................................................................ .0002"-.005"
Service Rings
Ring Gap
Compression ......................... ........... .......................... .010"-.047" .010"-.047"
Oil (Steel rails) Cast Iron not av aila b le ................. .015"-.062" .015"-.062"
Ring Side Clearance
Compression ................................................................ .0015"-.004" .0015"-.004"
Oil (Steel rails) Cast Iron not a v a ila b le................. .0002"-.005" .0002"-.005"
VALVE TIMING
Intake Opens (BTC) ............................................................................................... 10°
Closes (ABC) ............................. ................................................................. 50°
Exhaust Opens (BBC) ............................................................ ............................... 50°
Closes (ATC) ............................. ............................................................... 6°
Valve Overlap ........................................................ ................................................. 16°
Intake Valve Duration ......................... ................................................................ 240°
Exhaust Valve D uration........................................................................................... 236°
VALVES— Intake
Material .................................................................................................................... . Carbon Manganese Steel
Head Diameter ........................................................................................................ 1.615"— 1.625"
Length (to gauge dim. L in e )................................................................................. 4.6878"— 4.7028"
Stem Diameter ................................................................................... .................... .372" to .373"
Stem to Guide C learance........................................................ ............................. .001" to .003"
Maximum Allowable Before Reconditioning...................................................... .017"*
Valve Face Angle ..................................................................................................... 45°
A d ju s tm e n t.............................................................................................................. Rocker Arm Screw
Lift .............................................................................................................................. .395"
VALVES— Exhaust
M a te ria l...................................................................................................................... Nitrogen Treated Manganese
Chromium Nickel Steel
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Head Diameter ............................. .................................. ........................................ v>
1.355"— 1.365'
Length (to gauge dim. L in e )................................................................................ 4.6878"— 4.7028'
Stem Diameter ..................................................................................... ................... .371" to .372"
Stem to Guide Clearance....................................................................................... -002" to .004"
Maximum Allowable Before Reconditioning .......................................... ........... .017"*
Valve Face Angle .................................................................................................. . 43°
A djustm ent................................................................................................................ Rocker Arm Screw
Lift ............................. ............................................................................................... -395"
VALVE SPRINGS
Number ................................................................. .................................................... 12
Free Length .............................................................................................................. !-92"
Load when Compressed to (valve closed ).......................................................... 49—57 lbs. @ 1- 11/16"
Load when Compressed to (valve o p e n ).............................................................. 137-150 lbs. @ 1-5/16"
Valve Springs I.D....................................................................................................... 1.010" to 1.030"
Valve Spring Installed Height (spring seat to re ta in e r)................................... 1- 5/8"— 1-11/16"
Use 1/16 inch spacer to reduce spring height when over specifications
CYLINDER HEAD
Combustion Chamber ............................................................................................ Wedge Type
Valve Seat Run-Out (maximum) ........................................................................... .002"
Intake Valve Seat A n g le ......................................................................................... 45°
Seat Width (finished).............................................................................................. .070" to .090"
Exhaust Valve Seat Angle ..................................................................................... 45°
Seat Width (finished) ............................................ ................................................ .040" to .060"
Cylinder Head Gasket Compressed (thickness) ................................................ -022"
CYLINDER BLOCK
Cylinder Bore (standard) ....................................................................................... 3.4000"
Cylinder Bore Out-of-Round (Max. allowable before reconditioning) ............ -005"
Cylinder Bore Taper (Max. allowable before reconditioning)......................... -010"
Reconditioning Working Limits (for taper and out-of-round)......................... .001"
Maximum Allowable Oversize Cylinder Bore .................................................... .040"
Tappet Bore D iam eter............................................................................................ .9050"— .9058"
Distributor Lower Drive Shaft Bushing (press fit in b lo c k )............................. .0005"— .0040"
Ream to ................................................................................................ .................. .4865"— .4880"
Shaft to Bushing Clearance ................................................................................. .0007"— .0027"
ENGINE LUBRICATION
Pump T y p e ................................................................................................................ Rotary, Full Pressure
Capacity (qts.) .......................................................................................................... 4 U.S. or 3- 1/4 Imperial **
Pump Drive ..................... ....................................................................................... Camshaft
Operating Pressure at 1000 RPM ......................................................................... 45 to 60 lbs.
Pressure Drop Resulting from Clogged F ilte r .................................................... 7 to 9 lbs.
OIL FILTER
Type ........................................................................................................................... Full Flow
Spin O n ..................................................................................................................... Replaceable
* With Tools C-3973 & C-3339 using wobble method.
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OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
Engine
Displacement Condition Identification Location of Identification
170 cu. in.
198 cu. in.
225 cu. in. .001" U /S Crankshaft Maltese Cross Top of front pad— Right
side of block
M-2-3 etc. (indicating Crankshaft counterweight
No. 2 & 3 main bearing
journal)
and/or
R-l-4 etc. (indicating
No. 1 & 4 connecting rod
journals)
.010" U /S Crankshaft Maltese Cross and X Top of front pad— Right
side of block
CYLINDER BLOCK
Cylinder Bore (standard) ............. ......... . ................. .. 3.910"-3.912" 4.040"-4.0420"
Cylinder Bore Out-of-Round
(Max. allowable before reconditioning) ................ .005" .005"
Cylinder Bore Taper
(Max. allowable before reconditioning) ................ .010" .010"
Reconditioning Working Limits
(for taper and out-of-round)................................. .001" .001"
Maximum Allowable Oversize (cylinder b o re ).......... .040" .040"
Tappet Bore D iam eter.................................................. .9050"-.9058" .9050"-.9058"
Distributor Lower Drive Shaft Bushings
(press fit in block) .................................................... .0005"-.0040" .0005"-.0040"
Ream to ................................................................. .4865"-.4880" .4865"-.4880"
E-Bodies.org
______________ _____________________ “318”__________
Shaft to Bushing Clearance ................................................ ,0007"-.0027" ,0007"-.0027"
PISTONS
Type Material ......................................................................... Autothermic Autothermic
Alloy Tin Coated Alloy Tin Coated
Land Clearance (diametral) ................................................ .019"-.027" .019"-.027"
Clearance at Top of S k ir t...................................................... .0005"-.0015" .0005"-.0015"
Weight (Std. through .040" oversize)................................... 592 gms. 719 gms.
Piston Length (overall) .......................................................... 3.21" 3.545"
Ring Groove Depth
No. 1 ............................................................................... .. .205" .210"
No. 2 ..................................................................................... .205" .210"
No. 3 ..................................................................................... .194" .198"
Pistons for S ervice.............................................................. Std. .005", .020", Std. .005", .020",
.040" Oversize .040" Oversize
PISTON PINS
Type ........................................................................................... Full Floating Full Floating
D ia m e te r............................................................................................... 9841"-.9843" .9841"-.9843"
Length ....................................................................................... 2.990"-3.000" 2.990"-3.000"
Clearance in Piston (Light Thumb Push @ 7 0 ° F .)............ ,0000"-.0005" .0000"-.0005"
End P la y ................................................................................... ,004"-.026" .004"-.026"
Clearance in Rod ................................................................... .0000"-.0005" .0000"-.0005"
Pins for Service ..................................................................... Std. .003", .008" Std. .003", .008"
Oversize Oversize
PISTON RINGS
Number of Rings per Piston ................................................ ................... 3 3
Compression.................................................... ............................................ 2 2
Oil ................................................................... .............................................. 1 1
Oil Ring Type .............................................. ........................... 3-piece 3-piece
steel rail steel rail
chrome-face chrome-face
Ring Width
Compression ....................................................................... ,0775"-.0780" .0775"-.0780"
Oil— Steel rails .................................................................... .025" .025"
Ring Gap
Compression ......................... .............................................. 010"-020" .010"-. 020"
Oil— Steel rails ........................................................ ........... 015"-055" .015"-.055"
Ring Side Clearance
Compression ....................................................................... nm,„
.0015"-.0030"
O il-S te e l rails .................................................................... r S ! " M 5 '' .0002"-.005"
Service Rings •0002 ‘ ■00b
Ring Gap
Compression .................................................................... „„„„ „„„„
Oil— Steel rails ................................................................ .010" .020"
-
E-Bodies.org
Thrust Taken By ...................................................... No. 3 Main Bearing No. 3 Main Bearing
End P la y ..................................................................... .002"-.007" .002"-.007"
Maximum Allow able.............................................. .010" .010"
Diametral Clearance D esired................................... .0005"-.0015" .0005"-.0015"
Diametral Clearance Allow ed................................... .0025" .0025"
Finish at Rear Oil Seal S u rface............................... Diagonal Knurling Diagonal Knurling
MAIN BEARING JOURNALS
Diameter ..................................................................... 2.4995"-2.5005" 2.4995"-2.5005"
Maximum Allowable Out-of-Round and/or Taper . .001" .001"
Bearings for Service Available in Standard and
the following undersizes....................................... .001", .002", .003", .001", .002", .003",
.010", .012" .010", .012"
CONNECTING ROD JOURNALS
Diameter ..................................................................... 2.124"-2.125" 2.124"-2.125"
Maximum Allowable Out-of-Round and/or Taper . .001" .001"
CAMSHAFT
Drive ........................................................................... Silent Chain Roller Chain
Bearings ..................................................................... Steel Backed Babbitt Steel Backed Babbitt
Number ....................................................................... 5 5
Diametrical C learance.............................................. .001"-.003" .001"-.003"
Maximum Allowable before Reconditioning . . . .005" .005"
Thrust Taken b y ........................................................ Thrust Plate Thrust Plate
End Play ..................................................................... .002"-.006" .002"-.006"
Maximum Allow able.............................................. .010" .010"
CAMSHAFT JOURNALS
D iam eter..................................................................... No. 1 1.998"-1.999" 1.998"-1.999"
No. 2 1.982"-1.983" 1.982"-1.983"
No. 3 1.967"-1.968" 1.967"-1.968"
No. 4 1.951"-1.952" 1.951"-1.952"
No. 5 1.5605"-1.5615" 1.5605"-1.5615"
CAMSHAFT BEARINGS
D ia m eter..................................................................... No. 1 2.000"-2.001" 2.000"-2.001"
No. 2 1.984"-1.985" 1.984"-1.985"
No. 3 1.969"-1.970" 1.969"-1.970"
No. 4 1.953"-1.954" 1.953"-1.954"
No. 5 1.5625"-1.5635" 1.5625"-1.5635"
VALVE TIMING ..............................................................
CM
CM
O
Intake Opens (BTC) .................................................. 10°
Intake Closes (ABC) ................................................ 50° 66°
Exhaust Opens (BBC) .............................................. 58° 74°
Exhaust Closes (ATC) .............................................. 10° 22°
Valve Overlap ............................................................ 20° 44°
Intake Valve Duration .............................................. 240° 268°
Exhaust Valve D uration............................................ 248° 276°
TIMING CHAIN
Number of Links ...................................................... 68 68
P itc h ............................................................................. .375" .375"
Width ........................................................................... .625" .870"
TAPPETS
Type ............................................................................. Hydraulic Hydraulic
Body D iam eter............................................................ .9035"-9040" .9035"-9040"
Clearance in B lo c k .................................................... .0010"-.0023" .0010"-.0023"
Service Tappets Available ...................................... Std., .001", .008", .030" Std., .001", .008", .030'
CYLINDER HEAD
Valve Seat Run-Out (Maximum) ............................. .002" .002"
Intake Valve Seat A n g le .......................................... 45° 45°
Seat Width (finish) .............................................. .060"-.085" .060"-.085"
Exhaust Valve Seat A n g le ........................................ 45° 45°
Seat Width (finish) ............................................. .04CT-.060" .040"-.060"
Cylinder Head Gasket (Thickness compressed) . .029" .030"
VALVE GUIDES
Type ........................................................................... Cast in Head Cast in Head
Guide Bore D iam eter.............................................. .374"-.375" Std. .374"-.375" Std.
E-Bodies.org
VALVES— (INTAKE)
Head Diameter ....................................................................... 1.780" 2.02"
Length (to center of valve f a c e )........................................... 4.90" 4.90"
Stem Diameter (Standard) .................................................... .372"-.373" .3715"-.3725"
Stem to Guide Clearance ...................................................... ,001"-.003" .0015"-.0035"
Maximum Allowable .......................................................... .017"* .017"*
Face Angle ............................................................................... 45° 45°
Valve for Service (Oversize Stem D ia m .)............................. Std., .005", .015", .030" Std., .005", .015", .030"
Lift (Zero Lash) ....................................................................... .373" .429"
VALVES— (EXHAUST)
Head Diameter ....................................................................... 1.563" 1.60"
Length to (center of valve face) .......................................... 4.90" 4.90"
Stem Diameter (Standard) .................................................. .371"-.372" .3705"-.3715"
Stem to Guide Clearance ...................................................... .002"-.004" ,0025"-.0045"
Maximum A llow able............................................................ .017"* .017"*
Face Angle ............................................................................... 43° 43°
Valve for Service (Oversize Stem D ia m .)............................. Std., .005", .015", .030" Std., .005", .015", .030"
Lift (Zero L a s h )....................................................................... .399" .444"
VALVE SPRINGS
Number ..................................................................................... 16 16
Free Length............................................................................... 2.00" 1.94"
Load when Compressed to (valve closed
with surge damper rem oved)............................................ 78-88 lbs. @ 1- 11/16" 80-90 lbs. @ 1-11/16"
Load when Compressed to (valve open
with surge damper rem oved)............................................ 170-184 lbs. @ 1-5/16" 235-249 lbs. @ 1- 7/32"
Valve Springs I.D..................................................................... 1.010"-1.030" 1.070"-1.090"
Maximum Allowable Out of Plumb ..................................... 1/16" .080"
Valve Spring Installed Height (spring seat to retainer)___ 1-5/8"-1-11/16" 1-5/8"-1-11/16"
Using 1/16" Spacer to Reduce Spring Height When Over
Specifications .........................................................................
ENGINE LUBRICATION
Pump Type ............................................................................. ...... Rotary Full Pressure Rotary Full Pressure
Capacity (qts.) ......................................................................... ...... 4 U.S. or 3-1/4 4 U.S. or 3-1/4
I mperial** Imperial**
Pump Drive ............................................................................. ...... Camshaft Camshaft
Minimum Pump Pressure @ 500 R.P.M...................................... 20 PSI 20 PSI
Operating Pressure at 1000 R.P.M......................................... ...... 45-65 lbs. 45-65 lbs.
Pressure Drop Resulting from Clogged Filter ................. ...... 7-9 lbs. 7-9 lbs.
Oil Filter Type ......................................................................... ......Fuli-Flow Full-Flow
* With tools C-3973 & C-3339 using wobble method.
**When Filter Element is Replaced, Add 1 U.S. Quart or 3/4 Imperial Quart.
E-Bodies.org
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
Displacement Condition Identification Location of Identification
318 cu. in.
340 cu. in. .001" U /S Crankshaft R or M Milled flat on number eight
M-2-3 etc. (indicating crankshaft counterweight
No. 2 & 3 main bearing
journal)
and/or
R-l-4 etc. (indicating
No. 1 & 4 connecting rod
journal)
E-Bodies.org
Reconditioning Working Limits
(for taper and out-of-round)................................... .001" .001"
Maximum Allowable Oversize (cylinder b o re )----- .040" .040"
Tappet Bore D iam eter................................................ .9050"-.9058" .9050"-.9058"
Distributor Lower Drive Shaft Bushing
(press fit in b lo c k ).................................................. .0005"-.0040" .0005"-.0040"
Ream t o ........................................ ......................... .4865"-.4880" .4865"-.4880"
Shaft to Bushing Clearance ........ .............................. .0007"-.0027" .0007"-.0027"
PISTONS
Type Material ............................................................. Autothermic Autothermic
W/Steel Struts W/Steel Struts
Land Clearance (diametral) ............................. .021"-.029" .023"-.030"
Clearance at Top of S k ir t.......................................... .0003"-.0013" ,0003"-.0013"
Weight (Std. through .040" oversize)....................... 770 gms. 857.5 gms.
Piston Length (overall) .............................................. 3.874" 3.650"
Ring Groove Depth
No. 1 ........................................................................... .220" .220"
No. 2 ........................................................................... .220" .220"
No. 3 ................. .................................. ....................... .208" .208"
Pistons for Service ................................................... Std., .005", .020", Std., .005", .020",
.040" Oversize .040" Oversize
PISTON PINS
Type ............................................................ .................. Press Fit in Rod Press Fit in Rod
Diameter ........................................................................ 1.0935"-1.0937" 1.0935"-1.0937"
Length ........................................................ ................... 3.555"-3.575" 3.555"-3.575"
Clearance in Piston (Light Thumb Push @ 70°F.) .00045"-.00075" .00045"-.00075"
Interference in Rod .................................................. .0007"-.0012" .0007"-.0012"
Pins for Service .......................................................... Standard Only Standard Only
PISTON RINGS
Number of Rings per P is to n ..................................... 3 3
Compression ............................................................... 2 2
Oil ................................................................................. 1 1
Oil Ring T y p e ............... ............................................... 3-piece 3-piece
Chrome-plated Chrome-plated
rails with rails with
Stainless steel Stainless steel
expander-spacer expander-spacer
Ring Width
Compression ........................... ............. .............................. .0775"-.0780” .0775"-.0780”
Oil (Steel rails) ................................................................... .025" .025"
Ring Gap
Compression ....................................................................... .013"-.023" .013"-.023"
Oil (Steel r a ils )........................................................ ........... .015"-.055" .015"-.055"
Ring Side Clearance
Compression ................................................................... . .0015"-.0030" .0015"-.0030"
Oil (Steel r a ils )............................................................ . .0000"-.005" .0000"-.005"
Service Rings
Ring Gap
Compression ..................................................... ............ .013"-023" .013"-023"
Oil (Steel rails) ................................................................ .015"-.062" .015"-.062"
Ring Side Clearance
Compression ................................. .................................. .0015"-.004" .0015"-.004"
Oil (Steel rails) ................................................................ .0000"-.005" .0000"-.005"
CONNECTING RODS
Length (Center to C e n te r)................................................... 6.356"-6.360" 6.766"-6.770"
Weight (less bearing shells)................... .............................. 812 ± 4 gms. 846 ± 4 gms.
Side Clearance (two rods) ............................... ..................... .009"-.017" .009"-.017"
Piston Pin Bore Diameter .................................................. 1.0923"-1.0928" 1.0923"-1.0928"
CONNECTING ROD BUSHING
Type .......................................................................................... None None
CONNECTING ROD BEARINGS (T y p e )..............2 BBI. Carb. Steel Backed Babbitt -
4 BBI. Carb. Tri-metal Steel Backed Tri-metal Steel Bad
Diameter and W id th ................................................................ 2.376"-.927" 2.376"-.927"
E-Bodies.org
“383" “440”
Clearance desired.............................................. 2 BBI. Carb. .0005"-.0015" ——
E-Bodies.org
Intake Valve Seat Angle ...................................... 45° 45°
Seat Width (fin is h )............................................ .060"-.080" .060"- .080"
Exhaust Valve Seat A n g le .................................... 45° 45°
Seat Width (finish) ................................................ ,040"-.060" .040"-.060"
Cylinder Head Gasket (Thickness Compressed) .021" .021"
VALVE GUIDES
Type ....................................................................... . Cast in Head Cast in Head
Guide Bore D iam eter............................................ .374"-.375" Std. .374"-.375" Std.
VALVES— (INTAKE)
Head Diameter ...................................................... 2.08" 2.08"
Length (to center of valve f a c e )........................ 4.87" 4.87"
Stem D iam eter........................................................ 2 BBL. 4 BBL. ALL
.3723"-.3730" .3718"-.3725" .3718"-.3725"
Stem to Guide C learance....................... .0010"-.0027" .0015"-.0032" .0015"-.3725"
Maximum Allowable ........................... .017"* .017"*
Face Angle ................................................ 45° 45°
Valve for Service (Oversize Stem Diam.) Std., .005", .015", .030" Std., .005", .015", .030"
Lift (Zero L a s h )........................................ .425" .425" f
.450" f t .450" f f
VALVES— (EXHAUST)
Head Diameter ........................................ 1.75" 1.75"
Length to (center of valve f a c e ) ............ 4.87" 4.87"
Stem Diameter 2 BBL 4 BBL ALL
Hot End .................................................. .3713"-.3720" .3708"-.3715" .3708"-.3715"
Cold End ................................................ .3723"-.3730" .3718"-.3725" .3718"-.3725"
Stem to Guide Clearance
Hot End .................................................. .0020"-.0037" .0025"-.0042" .0025"-.0042"
Cold End ................................................ .0010"-.0027" ,0015"-.0032" .0015"-.0032"
Maximum A llow able............................. .017"* .017"*
Face Angle ................................................ 45° 45°
Valve for Service (Oversize Stem Diam.) Std., .005", .015" , .030" Std., .005", .015", .030"
Lift (Zero Lash) ......................................... .435" 435"f
.458" ff .458" f t
VALVE SPRINGS
Number .......... 16 16
2 BBL. 4 BBL 4 BBL. 3.2 BBL
Free Length ................................. 2.58" 2.23" 2.23" 2.15"
Load when Compressed to
Valve C losed............. ........... 121-129@l-55/64" 100-•110@l-55/64" 100-110@l-55/64" 110-120@l-55/64"
Valve Open ........................... 192-208@l-7/16" 236--256@l-23/64" 236-256@l-23/64" 300-320@l-3/8"
Valve Spring I.D........................... 1.01"-1.03" 1.07"-1.09" 1.07"-1.09" 1.07"- 1.09"
Maximum Allowable Out of
Plumb ....................................... .060" .080" .080" .080"
Valve Spring Installed Height (spring seat
to retainer) ......................................................................... l-53/64"-l- 57/64" l - 53/64"-l-57/64"
Use 1/16" Spacer to Reduce Spring Height when
Over Specifications
ENGINE LUBRICATION
Rotary Full Rotary Full
Pump Type . . . Pressure Pressure
Capacity (qts.) 4 U.S. or 3-1/4 6 U.S. or 5
Imperial** Imperial**
Pump Drive ...................................................... Camshaft Camshaft
Minimum Pump Pressure @ 500 R.P.M......... 20 PS I 20 PSI
Operating Pressure at 1000 R.P.M.................. 45-65 lbs. 45-65 lbs.
Pressure Drop Resulting from Clogged Filter 7-9 lbs. 7-9 lbs.
Oil Filter Type .................................................. Full-Flow Full-Flow
E-Bodies.org
OIL PUMP—INSPECTION LIMITS FOR REPLACEMENT
383 and 440
Cu. In- Engines
Oil Pump Cover ....................... .0015 inch or more
Outer Rotor Leftgth ................. .943 inch or less
Outer Rotor D ia m e te r.............. 2.469 inch or less
Inner Rotor Length................... .942 inch or less
Clearance Over Rotors— Outer .004 inch or more
Inner .004 inch or more
Outer Rotor Clearance . . . ___ .014 inch or more
Tip Clearance Between Rotors .010 inch or more
E-Bodies.org
Tappet Bore Diameter ........................................................... .9050"-.9058"
Distributor Lower Drive Shaft Bushing (press fit in block) .0015"-.0040" (Interference)
Ream to ............................................................................... .4865"-.4880"
Shaft to Bushing Clearance .................................................. .0007"-.0027"
PISTONS
Type Material ..................... ............................................. ....... Forged Aluminum
(Tin Plated)
Land Clearance (diametrical) .............................................. .033"-.041"
Clearance at Top of S k ir t ...................................................... .0025"-.0035"
Weight (Std. through .040" oversize)....................... .......... 841-845 gms.
Piston Length (overall) ........................................................... 4.060"
Ring Groove Depth
No. 1 ................................................................... ................. .220"
No. 2 ................................................................................. . .220"
No. 3 ...................................................................................... .186"
Pistons for Service ................................................................ Std., .005", .020"
.040" Oversize
PISTON PINS
Type .......................................................................................... Full Floating
Diameter .............................................. ............... ................... 1.0310"-1.0312"
Length ............. .......................................... .............................. 3.395"-3.405"
Weight ....................................................................................... 204 gms.
Clearance in Piston (Tight Thumb Push @ 7 0 °F .)............ .0001"-.0006"
End Play ........................................................................... ......... .006"-.012"
Clearance in Rod .................................................................... .0002"-.0007"
Pins for Service ...................................................................... Std., .003", .008" Oversize
PISTON RINGS
Number of Rings per Piston .......................................... . 3
Compression ......................... ........................................... . 2
Oil ....................................... ..................................................... 1
Oil Ring Type .................................................. ....................... 3-piece
Chrome-Plated Rails with
Stainless Steel
Expander-Spacer
Ring Width
Compression ................................. .0075"-.0780"
Oil (Steel Rails) ........................... .025"
Ring Gap
Compression ................................. .013"-.023"
Oil (Steel Rails) ........................... ,015"-.055"
Ring Side Clearance
Compression ................................. .0015"-.0030"
Oil (Steel Rails) ........................... .0002"-.005"
Service Rings
Ring Gap
Compression ............................. .013"-.023"
Oil (Steel Rails) ....................... .015"-.062"
Ring Side Clearance
Compression ............................. .0010"-.003"
Oil (Steel Rails) ....................... .0002"-.005"
CONNECTING RODS
Length (center to c e n te r)............... 6.859"-6.863"
Large End W e ig h t............................. 770 gms. ± 2 gms.
Small End W e ig h t............................. 314 gms. ± 2 gms.
Side Clearance (two rods) ............. .009"-.017"
Piston Pin Bushing Bore Diameter 1.0314"-1.0317"
CONNECTING ROD BUSHING
Type .................................................. Steel Backed Bronze
CONNECTING ROD BEARINGS
Type .................... ............ ............... Tri-metal Steel Backed
Diameter and Width ..................... 2.376" x .927"
Clearance Desired ......................... .0015"-.0025"
Maximum A llow able....................... .0025"
Bearings for Service ..................... Std., .0005", .001", .002",
.003", .010", .011", .012"
E-Bodies.org
CRANKSHAFT
Type ........................................................................................................................... Fully Counter-Balanced
Bearings ................................................................................................................... Tri-metal Steel Backed
Thrust Taken B y ...................................................................................................... No. 3 Main Bearing
End Play ................................................................................................................... ,002"-.007"
Maximum A llow able............................................................................................ .010"
Clearance Desired .................................................................................................. ,0015"-.0025"
Clearance Allowed .................................................................................................. .0025"
Finish at Rear Oil Seal S u rfa c e ........................................................................... Diagonal Knurling
MAIN BEARING JOURNALS
Diameter ................................................................................................................... 2.7495"-2.7505"
Maximum Allowable Out-of-Round....................................................................... .0003"
Maximum Allowable Taper ................................................................................... .0005"
Bearings for Service Available in Standard and the following undersizes . . . .001", .002", .003",
.010", .011", .012"
E-Bodies.org
Exhaust Valve Seat A n g le....................................................................................... 45°
Seat Width (Finish) ............................................................................................... ,050"-.070"
Cylinder Head Gasket (thickness compressed) ................................................ .025"
Combustion Chamber Volumes (with valves and plugs) ................................. 172.2-174.2 cc
VALVE GUIDES
Type ................................................ Cast in Head
Guide Bore Diameter ! ...... ............................................................... .3115"-.3125" Std.
VALVES— (Intake)
Head Diameter ........................................................................................................ 2.250"
Length (to center of valve fa c e )........................................................................... 5.316"-5.331"
Stem Diameter (Standard) ................................................................................... .3085"-.3095"
Stem to Guide C learance....................................................................................... .002"-.004"
Maximum Allowable ........................................................................................... .017"*
Face Angle ................................................................................................................ 45°
Valve for Service .................................................................................................... Std., .005", .015", .030"
Oversize Stem Diam.
Lift (Zero L a s h )........................................................................................................ -490"
VALVES— (Exhaust)
Head Diameter ........................................................................................................ 1.940"
Length (to center of valve fa c e )........................................................................... 4.7543"-4.7693"
Stem Diameter (Standard) ................................................................................... .3075"-.3085"
Stem to Guide Clearance ....................................................................................... .003"-.005"
Maximum Allowable .......................................................................................... .017"*
Face Angle .................................................................................................... ........... 45°
Valve for Service .................................................................................................... Std., .005", .015", .030"
Oversize Stem Diam.
Lift (Zero L a s h )........................................................................................................ -481"
VALVE SPRINGS
Number ..................................................................................................................... ............................. 16
Free Length .............................................................................................................. 2.15"
Load when Compressed to (valve closed less surge d am p er)......................... 110-120 @ 1-55/64"
Load when Compressed to (valve open less surge d a m p e r)........................... 300-320 @ 1- 3/8"
Valve Springs I.D....................................................................................................... 1.070"-1.090"
Maximum Allowable Out of P lu m b ...................................................................... -080"
Valve Spring Installed Height (spring seat to re ta in e r)................................... 1-53/64" - 1- 57/64"
Use 1/16" spacer to reduce spring height when over specifications.
E-Bodies.org
FOR IDENTIFICATION ENGINES WILL BE STAMPED ON CYLINDER BLOCK BOSS AS SHOWN BELOW
EXAMPLE
F H 426
MONTH DAY
TIGHTENING REFERENCE
170-198-225 CUBIC INCH ENGINES
Torque Thread
Foot-Pounds Size
Connecting Rod Nut ............................... 45 3/8-24
Cylinder Head B o lt................................... 65 7/16-14
Main Bearing Cap B o lt ....................... . 85 1/2-13
Spark Plug ........................................ 30 14mm
Camshaft Lo ckb olt................................... 35 7/16-14
Carburetor to Manifold N u t ................... 200 in.-lbs. 3/8-16
Chain Case Cover B o lt............................. 200 in.-lbs. 5/16-18
Torque Converter Housing B o l t ............ 30 3/8-16
Converter Brace to Aluminum Housing 40 9/16-14
Converter Brace to Engine B lo c k .......... 30 3/8-16
Clutch Housing Bolt ............................... 30 3/8-16
Crankshaft Rear Bearing Seal Retainer 30 3/8-16
Cylinder Head Cover B o lt ....................... 40 in.-lbs. 1/4-20
Distributor Clamp Bolt ........................... 200 in.-lbs. 5/16-18
Engine Front Mounting to Frame Nut .. 85 1/2-20
Engine Front Mounting to Block Nut . . . 45 7/16-20
Engine Rear Mount B o lts ....................... 35 7/16-14
3/8-24
Exhaust Manifold N u t ............................. 10 5/16-24
Exhaust Pipe Flange N u t ....................... 35 7/16-20
Exhaust Pipe Clamp B o lt ....................... 20 3/8-24
Exhaust Pipe Support Clamp B o lt ........ 20 3/8-24
Fan Attaching Bolt ................................. 200 in.-lbs. 5/16-18
Flywheel to Crankshaft........................... 55 7/16-20
E-Bodies.org
Flex Plate to C rankshaft............................. 55 7/16-20
Flex Plate to C onverter............................... 270 in.-lbs. 5/16-24
Flywheel Housing to Cylinder Block Bolt 50 7/16-14
Flywheel Housing Cover B o lt ..................... 7 1/4-20
Fuel Pump Attaching B o lt ......................... 30 3/8-16
Alternator Bracket Bolt — . . ................... 30 3/8-16
Alternator Mounting Nut ........................... 200 in.-lbs. 5/16-18
Alternator Adjusting Strap B o lt................. 15 5/16-18
Alternator Adjusting Strap Mounting Bolt 30 3/8-16
Intake to Exhaust Manifold Bolt ............. 240 in.-lbs. 5/16-18
Oil Pan Drain P lu g ................................. 20 1/2-20
Oil Pan S c re w ....................... ...................... 200 in.-lbs. 5/16-18
Oil Pump Cover B o lt .................................. 95 in.-lbs. 1/4-20
Oil Pump Attaching Bolt ............................. 200 in.-lbs. 5/16-18
Oil Filter Attaching Stud ........................... 10 3/4-16
Oil Pressure Gauge Sending U n it ............. 60 in.-lbs. 1/8 N.P.T.F.
Rocker Shaft Bracket B o lt......................... 25 3/8-16
Starter Mounting Bolt ................................. 50 7/16-14
Temperature Gauge Sending U n it ............ 180 in.-lbs. 1/4 N.P.T.F.
Water Pump to Housing Bolt ................... 30 3/8-16
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Exhaust Pipe Flange N u t ............................................................. ................... 50 7/16-20
Exhaust Pipe Clamp B o lt................................................................................. 20 3/8-24
Exhaust Pipe Support Clamp B o lt........................... ...................................... 20 3/8-24
Fan Attaching Bolt .......................................................................................... 15-18 5/16-18
Flywheel to Crankshaft................................................ .................................... 55 7/16-20
Flex Plate to Crankshaft................................................................................... 55 7/16-20
Flex Plate to Converter..................................................................................... 270 in.-lbs. 5/16-24
Fan Belt Idler Pulley N u t ............... ................................................................ 45 7/16-20
Fan Belt Idler Pulley Bracket B o lt................................................................ 30 3/8-16
Flywheel Housing to Cylinder Block B o lt .................................................... 50 7/16-14
Flywheel Cover Bolt ........................................................................................ 7 1/4-20
Fuel Pump Attaching B o lt............................................................................... 30 3/8-16
Alternator Mounting Bolt ................................................................................. 30 3/8-16
Alternator Adjusting Strap B o lt....................................................................... 200 in.-lbs. 5/16-18
Alternator Adjusting Strap Mounting B o lt.................................................... 30 3/8-16
Intake Manifold Bolt ...................................................................................... 40 3/8-16
Oil Pan Drain P lu g ............................................................................................ 20 1/2-20
Oil Pan Screws .................................................................................................. 200 in.-lbs. 5/16-18
Oil Pump Cover B o lt ............................................................................................... 10 5/16-18
Oil Pump Attaching B o lt.................................. ................................................ 30 3/8-16
Rocker Shaft Bracket B o lt.............................................................................. 25 3/8-16
Starter Mounting B o lt ................. .................................................................... 50 7/16-14
Vibration Damper Pulley Bolts ...................................................... ................. 200 in.-lbs. 5/16-18
Valve Tappet Cover End B o lt ............................................................................................. 9 1/4-20
Water Pump to Housing B o lt ......................... ................................................ 30 3/8-16
Water Pump Housing to Cylinder Block B o lt................................................ 30 3/8-16
A/C Compressor to Engine B o lt ..................... , .............................................. 30 3/8-16
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CLEANER AIR SYSTEM
CONTENTS
Page Page
CLEANER AIR SYSTEM ........ 1 LOWER COMPRESSION RATIOS . 5
HEATED AIR SYSTEM ............ 1 DISTRIBUTOR SOLENOID 5
CARBURETORS AND CHOKE 4 EVAPORATOR CONTROL SYSTEM 5
IDLE SPEED SOLENOID........ 5
CLEANER AIR SYSTEM (CAS) CID 3-2V or engines equipped with the fresh air scoop
option have a heated air intake system. This system
The Federal government has imposed more strin provides a faster more efficient engine warm up with
gent exhaust emissions requirem ents on all U.S. and improved fuel economy and reduced exhaust emis
most imported cars. These new standards require that sions (Fig. 2).
exhaust emissions from all cars not exceed 2.2 grams The HEATED AIR SYSTEM is basically a two air
of hydrocarbons and 23 grams of carbon monoxide flow circuit system.
per vehicle mile as measured during a prescribed (1) When the under hood air tem perature is 10° F
test. This constitutes about a 33% decrease in exhaust or lower, the air flow will be through the stove, into a
emission levels. The new grams per mile standards flexible connector, into the adaptor on the bottom of
take into consideration that total emission levels are the snorkel and into the air cleaner.
a function of vehicle weight. (2) When the under hood air tem perature is above
Several changes have been made to our engines to 100° F, the air flow will be through the snorkel into
m eet these new standards and m aintain or improve the air cleaner.
vehicle driveability (Fig. 1). When the under hood air tem perature is between
approximately 10° F and 100° F, there will be air
HEATED AIR SYSTEM
flow through both circuits after the engine has been
All engines except the 340 CID, 426 Hemi and 440 started and the exhaust manifold starts to give off
IMPROVED MANIFOLD HEAT VALVE CARBURETOR
• IMPROVED DISTRIBUTION
. LEANER MIXTURES
. FASTER ACTING CHOKE
• EXTERNAL IDLE MIXTURE LIMITER
• SOLENOID THROTTLE STOP
CRANKCASE
VENTILATOR VALVE
HEATED
INTAKE AIR
INTAKE MANIFOLD
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VACUUM THERMOSTAT diaphragm on the snorkel.
DIAPHRAGM The sensor is simply a bimetalic strip attached
rigidly at one end and controls a small air valve at
the other end. This valve is connected into the same
vacuum chamber on the bottom of the sensor that the
2 hoses connect into. When the tem perature at the
sensor is less than 95° F the valve is closed and the
intake manifold vacuum is communicated to the
vacuum diaphragm which in turn lifts the heat con
trol door and allows heated air from the exhaust
manifold stove to enter the air cleaner. When the
tem perature at the sensor is above 105° F, the valve
COLD in the sensor opens and decreases the vacuum at the
AIR vacuum diaphragm and the spring in the diaphragm
AIR HEATED ENTERS housing pushes the heat control door downward de
BY MANIFOLD
creasing the heated air flow from the stove and in
creases the air flow through the snorkel.
The vacuum diaphragm is simply a bellows type
diaphragm mounted in a housing with a spring be
HEATED AIR
ENTERS
tween the diaphragm and the top of the housing and
CARBURETOR PY944 a hose nipple in the side of the housing to connect to
the vacuum hose from the sensor. Perm anently con
Fig. 2 — H eated In le t Air System
nected to the piston of the vacuum diaphragm is a
heat. The colder the under hood air the greater the link which hooks into the heat control door. Since the
flow of air through the stove, and the warmer the air diaphragm is opposed by a spring, it requires not less
the greater the flow through the snorkel. The quantity than 5" Hg to lift the heat control door off the floor
of air through each circuit is controlled by a heat of the snorkel and not greater than 9" Hg to raise the
control door in the snorkel so as to m aintain a tem door to the top of the snorkel.
perature of 95° to 105° F at the tem perature sensor With the vacuum diaphragm opposed by a spring
m ounted inside the air cleaner housing. it is obvious that tem perature modulation will occur
The modulation of the induction air tem perature is only at road load throttle positions or when the intake
perform ed by intake manifold vacuum, a tem per manifold vacuum is above the operating vacuum of
ature sensor and a vacuum diaphragm which operates the vacuum diaphragm. But should a burst of power
the heat control door in the snorkel. be required, and the throttle is opened wide, the in
A vacuum hose connects to a hose nipple on the take manifold vacuum drops and the heat control door
base of the carburetor and leads to one side (either drops to the floor of the snorkel closing off the hot
side) of the sensor and another hose connected to the air and opens the snorkel to eliminate any undue
opposite side of the sensor and leads to the vacuum resistance to free breathing of the engine.
SERVICE PROCEDURES
HEATED AIR SYSTEM (3) With the engine warmed up and running, check
the air tem perature entering the snorkel or at the
Im proper functioning of this system will affect sensor. When the air tem perature entering the outer
driveability as well as affecting the vehicle exhaust end of snorkel is 105 degrees F. or higher the door
emission control system and may result in failure of should be in the down position (heat off).
the vehicle to m eet Federal Emission regulations. (4) Remove the air cleaner from the engine and
To determ ine whether the system is functioning allow it to cool down to 90 to 95 degrees F. With 20"
properly, the following procedure should be used: Hg vacuum applied to the sensor the door should be
(1) Make sure all vacuum hoses (Figs. 3 and 4), and in the up position (heat on position). Should the door
the stove to air cleaner flexible connector are prop not rise to the heat on position, check the vacuum
erly attached and are in good condition. diaphragm for proper operation.
(2) With a cold engine and ambient tem perature (5) Check the vacuum diaphragm by applying vacu
in the engine com partm ent of less than 100 degrees um directly to the vacuum diaphragm (with Tool C-
F., the heat control door (valve plate) in the snorkel 3707 and vacuum pump C-4081) with a vacuum gauge
should be in the up position or heat on position. in the line and a bleed valve to control the vacuum
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VACUUM PUMP
/
VACUUM TEST
SET C-3707
vacuum d ia p h r a g m
tuit**''-
TO CARBURETO R
quately but proper tem perature is not maintained,
VACUUM FITTING replace the sensor and repeat the tem perature checks
in steps 2 and 3.
PY945
FRONT
LOCK
TAB
OPERATING
TO C A ^ j ^ Z T O a ROD
VACUUM FITTING
PY946
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VACUUM DIAPHRAGM
PY949
SENSOR
R em o val
With air cleaner housing removed from vehicle.
(1) Disconnect vacuum hoses from sensor, remove
retainer clips (Fig. 8), and discard (new clips are sup
plied with a new sensor).
(2) Remove sensor with gasket and discard.
In s ta lla tio n
(1) Position gasket on air cleaner housing and in
stall sensor (Fig. 9).
(2) Supporting sensor on outer diam eter, install
new retainer clips securely being sure gasket is com
pressed to form an air seal. Supporting sensor on plas
tic guard could damage bi-metal strip. No attempt
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fuel economy and reduced emissions. This is achieved LOWER COMPRESSION RATIOS
by using a removable, thin stamped, stainless-steel
The 318, 383 and 440 CID engines (except the 426
cup between the therm ostatic choke control unit and
Hemi and 440 CID 3-2V) have new pistons to reduce
the exhaust passage gases in place of the thicker cast-
compressions by about 0.5. The lower compression
in manifold pocket used previously. A gasket is in
ratio reduce hydrocarbon emissions by producing a
stalled between the steel cup and manifold to ensure
better combustion chamber shape and by leaving more
that no exhaust leak occurs. Also a part of the heated
heat in the exhaust to assist the after combustion
air system is a heat insulating spacer between the in
reaction.
take manifold and carburetor. This is used in place of
a gasket and is essential for correct operation. DISTRIBUTOR SOLENOID
All 383 and 440 engines (except the 440 3-2V) have
IDLE SPEED SOLENOID
a solenoid incorporated in the distributor vacuum ad
The high performance engines (340, 440, 440 3-2V vance mechanism to retard the ignition timing when
and 426 Hemi) employ idle speeds between 800 and the throttle is closed. At closed throttle, electrical
1000 rpm to obtain acceptable lower emissions during contacts on the carburetor throttle stop and with idle
idle and deceleration. In order to prevent “after run adjusting screw in the closed position, causes the dis
ning” with such high idle speeds, these engines have tributor solenoid to energize. This retards the ignition
an electrical solenoid throttle stop which holds the timing to provide reduced exhaust emissions under
throttle at the correct idle position when energized hot idle conditions. Cold or part throttle starting is
but de-energizes when the ignition is turned off, al not penalized because the distributor solenoid is not
lowing the throttle blades to close more completely. energized unless the hot idle adjusting screw is against
Refer to “Fuel System” Group 14 for service pro the throttle stop contact. Timing must be set at closed
cedures. throttle to give ignition full retard.
SERVICE PROCEDURES
IGNITION TIMING (383 Cu. ln.440Cu. In.) plate. The timing is advanced. To adjust turn distribu
tor housing (Not Vacuum Chamber) Counter clockwise.
(S o le n o id D is t r ib u t o r ) Do not use vacuum chamber as a turning handle. If
To obtain maximum engine performance, the dis the timing light flash occurs when the tim ing m ark on
tributor must be correctly positioned on the engine the vibration damper is located past the specified de
to give proper ignition timing. The ignition timing
gree m ark on the timing plate. The timing is retarded.
test will indicate the timing of the spark at No. 1 To adjust turn distributor housing clockwise. Timing
cylinder at curb idle (Hot only). may vary from the specified specifications a plus or
Test procedure as follows:
minus 2-1/ 2 ° and still fall within range, but if the
(1) Disconnect vacuum hose at distributor, and plug timing is checked it should be adjusted to the specifi
hose. cation shown on the distributor charts.
(2) Connect the secondary lead of a power timing (6) To check the distributor solenoid for proper
light to No. 1 spark plug, red prim ary lead to positive operation, disconnect the wire at the carburetor. Aim
term inal of the battery and the black prim ary lead to the power timing light at the timing marks on the
the negative battery term inal. Do not puncture cables, chain case. The timing should advance above 5-1/2°
boots or nipples with test probes. Always use proper
and the engine speed should increase.
adapters. Puncturing the spark plug cables with a (7) Stop the engine and tighten the distributor hold-
probe will damage the cables. The probe can separate
down screw.
the conductor and cause high resistance. In addition (8) Reconnect the wire at the carburetor throttle
breaking the rubber insulation may permit secondary
stop.
current to arc to ground.
(9) Reconnect the vacuum hose to the distributor.
(3) Loosen the distributor hold-down mounting
(10) Remove the timing light.
screw just enough so distributor housing can be ro
tated in its mounting. EVAPORATION CONTROL SYSTEM
(4) S tart the engine and set the curb idle as shown
in “Specifications.” (Transmission in N eutral and En Chrysler Corporation cars sold in California have
gine Hot). an Evaporation Control System (ECS) to reduce the
(5) Aim the power tim ing light at the timing m arks loss of fuel from the fuel system to the atmosphere
on the chain case cover. If the timing light flash occurs by evaporation. This is a closed system which controls
when the timing m ark on the vibration dam per is fuel expansion and feeds fuel evaporation emissions
located ahead of specified degree m ark on the timing from the carburetor or fuel tank. The vapors pass
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CRANKCASE
AIR CLEANER
VAPOR-LIQUID
SEPARATOR
VENT-LIQUID
RETURN LINE
PRESSURE -
VACUUM
RELIEF CAP
THERMAL -
EXPANSION
VOLUME TANK
PY940
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SERVICE DIAGNOSIS
The ECS system should not require any mainte (3) All ECS lines plugged between fuel tank and
nance in normal service. Any loss of fuel or vapor vapor separator.
from the fuel filler cap would indicate one or more (4) Plugged ECS line between the vapor separator
of the following: and the crankcase air inlet filter.
(1) An unsatisfactory seal between cap and filler (5) Plugged fuel tank expansion chamber inlet hole
neck. in main tank. A removable plug is provided in th e top
(2) A malfunction of ECS cap release valve. A quick surface of ECS fuel tanks, for access to expansion
check of the ECS fuel cap may be made by placing chamber in event of plugging of its fill-drain hole. If
against the mouth and blowing into the hole in the purging of the fuel tank is required, the expansion
release valve housing. An immediate leak with light chamber must be purged separately through the top
blowing or lack of release with hard blowing indicates access plug hole.
a defective or incorrect unit.
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EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
Page Page
CARBURETOR AIR HEATER........................ 7 INTAKE MANIFOLD (383, 440 Cu. In.
COUNTERWEIGHT, THERMOSTAT Engines)...................................................... 9
(426 HEMI ENGINE) ................................ 14 INTAKE MANIFOLD (426 Hemi Engine) .. 10
EXHAUST HEADERS (426 Hemi Engine) .. 11 INTAKE MANIFOLD HEAT TUBES
EXHAUST MANIFOLD (318, 340 Cu. In. (426 Hemi Engine).................................... 10
Engines)...................................................... 9 MANIFOLD HEAT CONTROL VALVE
EXHAUST MANIFOLD (383, 440 6 Cylinder Engine ...................................... 11
Cu. In. Engines) ........................................ 10 318 Cubic Inch Engine ............................ 12
EXHAUST PIPES, MUFFLERS AND 340 Cubic Inch Engine.............................. 13
T A IL P IP E S .............................................. 4 383-440 Cubic Inch Engine .................... 13
GENERAL INFORMATION .......................... 1 426 Hemi Engine ...................................... 14
INTAKE AND EXHAUST MANIFOLD MANIFOLD HEAT CONTROL VALVE
ASSEMBLY (6 Cyl. Engines).................... 8 REPLACEMENT (426 H e m i).................... 15
INTAKE MANIFOLD (318, 340 SERVICE DIAGNOSIS .......... .................... 3
Cu. In. Engine) .......................................... 9 SERVICE PROCEDURES.............................. 4
TIGHTENING REFERENCE ........................ 15
GENERAL INFORMATION
U-NUT
TAIL PIPE
GASKET
TIGHTENING TORQUE
PLAIN
< s> 35 FT. LB. 95 IN. LB.
<€> BRACE INSULATOR WASHER (2)
50 FT. LB. 150 IN. LB. ASSEMBLY N u > (2)<g>
<§> SADDLE
EXHAUST PIPE v x
200 IN. LB. U-BOLT
VIEW A
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U-NUT PLATE
EXHAUST P IPE
ASSEMBLY PLAIN
WASHER
TAIL PIPE
NR332B
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SCREW <^> PLATE ASSEMBLY U-NUT
ASSEMBLY
PLAIN WASHER
REFERENCE
BOLT<§> SUPPORT
BRACKET ASSEMBLY-
INSULATOR VIEW E TAIL PIPE
ASSEMBLY EXTENSION
DUAL (RIGHT SIDE SHOWN) - A
TAIL PIPE TAIL PIPE
PLAIN VIEW G
WASHER (2) (RIGHT AND LEFT SIDE)
VIEW D
DUAL (RIGHT AND LEFT SIDE)
TIGHTENING
TORQUE
24 IN. LB.
95 IN. LB.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
EXCESSIVE EXHAUST (a) Leaks at pipe joints. (a)
Tighten clamp at leaking joints.
NOISE (b) Burned or blown out muffler. (b)
Replace muffler assembly.
(c) Burned or rusted out exhaust pipe. (c)
Replace exhaust pipe.
(d) Exhaust pipe leaking at manifold (d)
On 318 cu. in. engines, tighten ball
flange. joint connection attaching bolt nuts
to 24 foot-pounds. On 426 Hemi en
gines, tighten the nuts to 24 foot
pounds. On all other engines, install
a new gasket and tighten flange bolt
nuts to 50 foot-pounds.
(e) Exhaust manifold cracked or broken. (e) Replace manifold.
(f) Leak between manifold and cylinder (f) Tighten manifold to cylinder head
head. stud nuts or bolts to specifications.
(g) Leaks at heat tube pipe connections. (g) Replace gaskets as required. Tighten
bolts and nuts and clamp bolt nut to
specifications.
LEAKING EXHAUST (a) Leaks at pipe joints. (a) Tighten U-bolt nuts at leaking joints
GASES to 150 inch-pounds.
(b) Damaged or improperly installed gas (b) Replace gaskets as necessary.
kets.
(c) Restrictions in muffler or tail pipe. (c) Remove restriction, if possible, or
replace as necessary.
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(d) Loose heat tube connections. (d) Replace gaskets as required. Tighten
stud nuts or bolts to specifications.
(e) Burned or rusted out heat tubes. (e) Replace heat tubes as required.
ENGINE HARD TO (a) Heat control valve frozen in the open (a) Free up manifold heat control valve
WARM UP OR WILL position. using a suitable manifold heat con
NOT RETURN TO trol solvent.
NORMAL IDLE
MANIFOLD HEAT (a) Thermostat broken. (a) Replace thermostat.
CONTROL VALVE (b) Broken, weak or missing anti-rattle (b) Replace spring,
RATTLE spring.
SERVICE PROCEDURES
EXHAUST PIPES, MUFFLERS AND (2) Remove extension bracket support screw attach
TAIL PIPES ing bracket to side rail.
(3) Slide extension and support as an assembly
R e m o v a l— G e n e ra l from the tail pipe.
(1) Raise vehicle on hoist and apply penetrating (4) Withdraw extension bracket from rubber block
oil to all clamp bolts and nuts to loosen rust and cor in support.
rosion.
If only the muffler is to be replaced, cut the exten I n s t a l l a t i o n ( A l l M o d e l s w i t h 1 9 8 ,2 2 5 ,
sion pipe just forward of the muffler with a hack saw 3 1 8 , 3 4 0 ,3 8 3 a n d 4 4 0 C u . I n . E n g i n e s )
or cutter. It is not necessary to remove the exhaust (1) Assemble exhaust pipe, muffler and tail pipe
pipe. The replacem ent muffler can be installed, using loosely to perm it proper alignment (Figs. 1, 2, 3, 4
a U-bolt and saddle clamping arrangem ent at the and 5).
front of the muffler. (Challenger replacem ent mufflers (2) Assemble exhaust pipe to exhaust manifold. On
m ust be the same as original equipment). engines without ball joint seating connections, use
(2) Remove clamps and support from exhaust pipe, new flange gaskets and tighten bolt nuts to 50 foot
muffler and tail pipe (Figs. 1, 2, 3, 4 and 5). pounds. On models with 318 cubic inch engines, do
(3) Disconnect exhaust pipe at exhaust manifolds not tighten ball joint bolt nuts at this time.
and remove exhaust pipe. On models using gaskets at (3) Adjust tail pipe and muffler supports to provide
exhaust pipe flanges, discard gaskets and carefully proper clearance with underbody and adjacent parts.
clean manifold flanges of any gasket particles. Do not fully tighten attaching bolts and screws at this
On models with the 426 Hemi engine, also remove time.
heat tube clamp bolt, nut, clamp and heat tube from (4) Tighten all slip joints working from rear to
exhaust connection (Fig. 5). front. Tighten the extension pipe slip joint on Dart
(4) Remove muffler and extension pipe assembly. with 318, which must use a heavier “U” bolt (3-8"-16
(5) Raise rear end of vehicle to relieve the body thread), to 30 foot-pounds.
weight from rear springs and remove tail pipe. (5) Tighten tail pipe support attaching clamp screws
to 95 inch-pounds, at same time maintaining proper
R e m o v a l— C h a lle n g e r clearance with adjacent parts.
To remove the exhaust system, follow the same in (6) Tighten exhaust pipe ball joint connection bolt
structions outlined for regular models with the fol nuts to 24 foot-pounds. Alternately tightening nuts to
lowing addition steps: insure parallelism of flanges.
(1) The muffler support bolt is to be removed and
the blade moved to allow lowering of the muffler.
I n s t a l l a t i o n (M o d e l s w i t h 4 2 6 H e m i E n g in e )
(2) Cars equipped with chrome extensions should
(1) Assemble exhaust pipes, mufflers, resonators
have special attention to avoid paint damage to the
and tail pipes loosely to perm it proper alignment
stone deflector panel.
(Fig. 5).
(2) Assemble exhaust pipes to exhaust headers, but,
R e m o v a l— D a r t w it h 3 4 0 C u . In . E n g in e
To remove the exhaust system, follow the same in do not tighten ball joint nuts at this time.
structions outlined for regular models with the follow (3) Adjust muffler and tail pipe supports to provide
ing additional steps: proper clearance with underbody and adjacent parts.
(1) At the extension, remove the U-bolt and saddle Do not fully tighten attaching bolts and nuts at this
clamping arrangem ent (Fig. 3). time.
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EXHAUST PIPE MUFFLER ASSEMBLY SCREW PLATE
ASSEMBLY ASSEMBLY
HEAT
SHIELD
FLOOR P A N -
REAR
(REFERENCE)
EXHAUST
HEAT SHIELD‘D ^
SYSTEM
<8>
200 IN. LB. 50 FT. LB.
<§> <S>
24 FT. LB. <£> 95 IN. LB
<€>
NUT (2)<§>
100 IN LB
225 CUBIC INCH ENGINE <$> 35 FT. LB <$> PY205
11-5
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HEAT SHIELD GASKET TAIL PIPE HANGER
11-6
BRACKET (REFERENCE)
PLATE
BOLT (2)<B>\
ASSEMBLY
EXHAUST
FLOOR PAN—
REAR
(REFERENCE)
PIPE ASSEMBLY HEAT SHIELD
SUPPORT
ASSEMBLY
SYSTEM
CLAMP
LOCKWASHER
BOLT<B,
NUT<H> TAIL PIPE
NUT<^> NUT AND EXTENSION
EXHAUST PIPE WASHER ASSEMBLY <^>
ASSEMBLY ' NUT <m >
VIEW IN DIRECTION OF ARROW Z
VIEW IN DIRECTION OF ARROW ¥
VIEW IN DIRECTION OF ARROW X
SCREW (3)<F>
VIEW IN DIRECTION OF ARROW U
TIGHTENING TORQUE
50 FT. LB
<s> 150 IN. LB. <S>
-SADDLE
95 IN. LB.
-PLAIN WASHER <$> 200 in . LB. <S>
EXHAUST PIPE ASSEMBLY 24 IN. LB
'N U T < ^> 24 FT. LB. <§>
<s>
LB. 100 IN. LB.
426 HEMI ENGINE VIEW IN DIRECTION OF ARROW W <§> 35 FT. <8 > PY204
Pig. 5 —Hi#®! Exh&mt System (Challenger 3 4 0 , 383*4V , 4 40 -4 V , 440 -6 V and 42 6 Hemi Enginesi
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(4) Tighten front resonator slip joint U-bolt nuts A IR CLEANER
V A C U U M LINE TO
to 150 inch-pounds. HEAT
SHIELD FLEXIBLE CARBURETOR
(5) Tighten muffler and tail pipe attaching bolts to C O N N EC TO R
150 inch-pounds, at same time maintaining proper
BATTERY
clearance with adjacent parts.
(6) Tighten tail pipe U-bolt nuts to 150 inch-pounds.
(7) Tighten exhaust pipe ball joint bolt nuts to 24 M A N IF O L D
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CARBURETOR AIR HEATER AIR CLEANER
CONNECTOR
VACUUM
LINE TO
CARBURETOR
► NUT MANIFOLD
AND - .
WASHER ASSEMBLY 2<$>
SCREW A N D DART V/
,,, / WASHER , ------- TIGHTENING
/V i\ ASSEMBLY 2 < $ > TORQUE
MANIFOLD TIGHTENING TORQUE 45 IN.LB.
Y
NUT A N D 40 IN.LB.
WASHER ASSEMBLY 3
PY418 SCREW UT A N D WASHER ASSEMBLY 2<§>PY422
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to exhaust manifold to 240 inch-pounds, starting with folds to cylinder heads. Remove manifolds from cyl
inner screw. inder heads.
(5) Install carburetor air heater.
(6) Attach exhaust pipe to manifold flange, using a C le a n in g a n d In s p e c tio n
new gasket and tighten stud nuts to 35 foot-pounds. (1) Clean m ating surfaces on cylinder heads and
(7) Install carburetor and connect fuel line, auto manifolds, wash with solvent and blow dry with com
matic choke rod and throttle linkage. pressed air. Inspect manifolds for cracks.
(8) Install distributor vacuum control line and car (2) Inspect mating surfaces of manifold for paral
buretor bowl vent line if so equipped. lelism with a straightedge. Gasket surfaces must be
(9) Install air cleaner and connect breather cap to flat within .008 inch.
air cleaner line. (3) O n right hand manifold, test manifold heat con
(10) Install air cleaner vacuum line to carburetor trol valve for free operation. If necessary to free up,
and flexible connector between air cleaner and carbu apply a suitable manifold heat control valve solvent to
retor air heater. both ends of valve shaft. A suitable solvent is avail
able under P art Number 2525054, Manifold Heat
INTAKE MANIFOLD (318, 340 Cu. In. Engines) Control Valve Solvent or equivalent. Be sure manifold
is COOL and solvent is allowed to soak a few minutes
Remove intake manifold as outlined in Group 9, to dissolve deposits. Then, work valve back and forth
"Engine." until it turns freely.
S e rv ic in g In s ta lla tio n
(1) Clean manifold in solvent and blow dry with CAUTION: If studs came out with the nuts, install
compressed air. Inspect manifold for cracks. new studs, applying sealer on the coarse thread
(2) Inspect mating surfaces of manifold for paral ends. If this precaution is not taken, water leaks may
lelism with a straightedge. develop at the studs.
(3) Inspect exhaust crossover passages through (1) Position two outboard arm s of manifolds on the
manifold (Fig. 9). If passages are coated with hard, two studs on cylinder heads, using new gaskets. In
stall conical washers and nuts on studs (Fig. 10).
black carbon, they should be scraped clean and sand
(2) Install two screws and conical washers at inner
blasted to remove the carbon deposits.
ends of outboard arm s of manifold. Install two screws
(4) Install intake manifold, using new gaskets.
without washers on center arm of manifold (Fig. 10).
Tighten manifold bolts to 35 foot-pounds. Tighten screws and nuts, starting at center arm and
working outward, to 20 foot-pounds.
EXHAUST MANIFOLD (318, 340 Cu. In. Engines) (3) Assemble exhaust pipe to manifold, and secure
with bolts, nuts and washers. On 318 cubic inch en
R em o val gine, tighten to 24 foot-pounds. On 340 cubic inch
(1) Remove bolts and nuts attaching exhaust pipe engine, tighten nuts to 50 foot-pounds.
to manifold.
(2) Remove bolts, nuts and washers attaching mani- INTAKE MANIFOLD (383, 440 Cu. In. Engines)
CARBURETOR MOUNTING FLANGE EXHAUST Remove the Intake Manifold as outlined in Group 9,
CROSSOVER
7 5 "Engine."
S e rv ic in g
(1) Clean manifold in solvent and blow dry with
compressed air.
[^ ^ •-** ^,.5
8 6
AUTOMATIC CHOKE WELL
4 2
EXHAUST CROSSOVER ^ ^ \ /V '■ ^
PASSAGE NK120
'* m SCR-WS
. ' fj& f/ £ ; PY423
Fig. 9 —In tak e M an ifo ld —3 1 8 Cubic Inch Engine
(Typical)
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(2) Inspect exhaust crossover passages and pres INTAKE MANIFOLD HEAT TUBES (426 Hemi
sure test for any leakage into intake passages. Engine)
(3) Inspect mating surfaces for parallelism.
(4) Use new gaskets when installing manifold. Re R e m o v a l— In le t T u b e
install manifold as outlined in Group 9, “Engine.” (1) To remove inlet tube, remove two stud nuts and
washers from right hand exhaust header (Fig. 11).
EXHAUST MANIFOLD (383, 440 Cu. In. Engines) (2) Remove screws attaching upper end of inlet tube
to rear face of intake manifold.
R em oval (3) Remove tube and gaskets and discard gaskets.
(1) Remove spark plugs.
(2) Remove alternator. O u tle t T u b e
(3) Disconnect exhaust pipe at exhaust manifolds. (1) To remove outlet tube, remove nut, washer
(4) Remove stud nuts attaching exhaust manifolds and bolt from tube clamp at exhaust pipe (Fig. 11).
to cylinder heads. Slide manifolds off studs and away Remove clamp from tube.
from cylinder heads. (2) Remove two screws attaching heat shield and
outlet tube to rear face of intake manifold and remove
tube.
C le a n in g a n d In s p e c tio n
(1) Clean manifolds in solvent and blow dry with In s ta lla tio n — In le t T u b e
compressed air. (1) Clean gasket surfaces of exhaust header and
(2) Inspect manifolds for cracks and distortion. intake manifold of all old gasket particles.
(3) On right hand manifold test manifold heat con (2) Place new gaskets in position on studs and
trol valve for free operation. If necessary to free up, install inlet tube on exhaust header studs.
apply a suitable manifold heat control valve solvent (3) Install washers and nuts on studs and tighten
to both ends of valve shaft. A suitable solvent is nuts to 200 inch-pounds.
available under P art Number 2525054, Manifold Heat (4) Secure upper end of tube with screws and
Control Valve Solvent or equivalent. Be sure manifold washers. Tighten screws to 200 inch-pounds.
is COOL and solvent is allowed to soak a few minutes
to dissolve deposits. Then, work valve back and forth O u tle t T u b e
until it turns freely. (1) Install tube and clamp on exhaust pipe connec
tion.
In s ta lla tio n (2) Install new gasket and tube at upper end of
CAUTI ON: If studs came out with the nuts, install outlet tube.
new studs, applying sealer on the coarse thread
ends. If this precaution is not taken, water leaks may
develop at the studs.
(1) Install manifolds on cylinder heads. No gaskets
are required. Tighten stud nuts to 30 foot-pounds.
(2) Install exhaust pipes on exhaust manifolds,
using new gaskets. Tighten nuts to 50 foot-pounds.
(3) Install alternator and adjust belt tension.
(4) Install spark plugs and tighten to 30 foot-pounds.
S e rv ic in g
(1) Clean manifold in solvent and blow dry with
compressed air.
(2) Inspect exhaust passages and pressure test for
any leakage into intake passages.
(3) Inspect mating surfaces for parallelism.
(4) Use new gaskets when installing manifold.
Reinstall manifold as outlined in Group 9, “Engine”.
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(3) Install heat shield and outer screw and washer be inspected periodically. With engine idling, ac
on outlet tube flange. Install inner screw and washer. celerate momentarily to wide open throttle. The coun
Tighten screws to 200 inch-pounds. terweight on six cylinder and 426 Hemi engines
(4) Install clamp bolt, washer and nut and tighten should respond by moving counterclockwise approx
nut to 100 inch-pounds. imately 1/2 inch and to its original position. On all
other engines, the counterweight should move clock
EXHAUST HEADERS (426 Hemi Engine) wise. If no movement is observed, shaft is binding due
to accumulation of deposits or therm ostat is weak or
R em o val broken.
(1) On right hand exhaust header, disconnect car The application of a suitable manifold heat control
buretor choke heat tube. valve solvent, every oil change, to both ends of mani
(2) Disconnect choke intake heat tube from lower fold heat control valve shaft at bushings, will keep
inside surface of right hand exhaust header. valve working freely. A suitable solvent is available
(3) Remove ball joint bolts connecting exhaust under P art Number 2525054, Manifold Heat Control
pipes to exhaust headers and separate pipes from Valve Solvent or equivalent. The solvent should be
headers. applied when manifold is COOL and allowed to soak
(4) Remove screws attaching inlet heat tube to a few minutes to dissolve deposits. Then, work valve
exhaust header and separate tube from header. back and forth until it turns freely.
(5) Remove screws and washers attaching exhaust
headers to cylinder heads. Remove headers and gas SIX CYLINDER
kets from cylinder heads.
Remove intake and e x haust manifolds as outlined on
C le a n in g a n d In s p e c tio n page 8.
(1) Clean gasket surfaces on cylinder heads and (1) Position valve plate, grind off spot welds from
headers, wash with solvent and blow dry with com valve plate and shaft.
pressed air. Inspect headers for cracks. (2) Remove counterweight and shaft assembly,
(2) Inspect mating surfaces of headers for paral valve plate.
lelism with a straightedge. Gasket surfaces must be (3) Press out bushings and cup seals from manifold
flat within .008 inch. (Fig. 12).
(3) On right hand header test heat control valve (4) Inspect vent holes and clean out if necessary.
for free operation. If necessary to free up, apply a
suitable manifold heat control valve solvent to both In s ta lla tio n
ends of valve shaft. A suitable solvent is available (1) Press in cup seals flush with inside walls (Fig.
under P art Num ber 2525054, Manifold Heat Control 12) with cupped ends facing outward.
Valve Solvent or equivalent. Be sure header is COOL (2) Press in bushings flush with outer edge of ex
and solvent is allowed to soak a few minutes to dis haust manifold.
solve deposits. Then, work valve back and forth until (3) Line ream bushings and seals .3095 to .3110
it turns freely. inch diameter. Test for free fit of shaft in bushings
and seals.
In s ta lla tio n (4) Mark one end of shaft with a suitable dye at
(1) Place headers in position on cylinder heads, 1.240 inches, press counterweight on m arked end of
using new gaskets. Install conical washers and screws. shaft until flush with end of shaft.
Position washers with concave side toward bolting (5) Install therm ostatic spring on counterweight
flanges. Tighten screws to 35 foot-pounds. with center end or tab pointing right and outer end or
(2) Assemble exhaust pipes to exhaust headers. hook pointing left.
Secure ball joints with bolts and nuts. Tighten nuts (6) Install valve stop on counterweight with looped
to 24 foot-pounds. ends facing away from therm ostatic spring hook end.
(3) Assemble inlet heat tube to right hand header, (7) Holding therm ostatic spring wrapped 215 de
using new gasket. Tighten screws to 200 inch-pounds. grees in a clockwise direction viewed from counter
(4) Connect choke intake heat tube to lower inside weight end, install shaft assembly in manifold and
surface of exhaust header. valve plate with strap facing outboard; attach hook
(5) Connect heat tube to exhaust header. end of thermostatic spring to stop pin (Fig. 12).
(8) With counterweight end of shaft positioned
MANIFOLD HEAT CONTROL VALVE 1.240 inches (previously identified) away from mani
(All Engines)
fold, valve plate centered between seals and posi
tioned 2.05 inches from center of inside tapped hole
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VALVE STOP (4) Remove counterweight and shaft assembly,
VALVE valve plate. Press out bushings and seals from mani
fold (Fig. 13).
(5) Inspect vent holes and clean out if necessary.
PIN
In s ta lla tio n
(1) Press in cup seals until seals extend into mani
fold .100 inch on each side with cupped ends facing
outward (Fig. 13).
(2) Press in bushings flush with outer edge of ex
haust manifold.
(3) Line ream bushings and seals, .3095 to .3110
inch diameter. Test for free operation of shaft in bush
WITH
ings and seals.
VALVE PLATE PLATE MUST (4) Mark one end of shaft with a suitable dye at
SET TO CLOSED BE CENTERED 1.240 inches, press counterweight on marked end of
POSITION INDEX BETWEEN SEALS
shaft until flush with end of shaft.
COUNTERWEIGHT TO PUT STOP
AGAINST PIN AS SHOWN (5) Position therm ostat so center end or tab is
pointing left and hook or outer end points down, in
PRESS COUNTERWEIGHT
FLUSH WITH END OF
stall therm ostat on counterweight.
SHAFT (6) Install valve stop on counterweight so looped
ends face away from therm ostatic spring hook end.
(7) Holding thermostatic spring wrapped 140 de
ANTI-RATTLE
SPRING grees in a counterclockwise direction viewed from
counterweight end, install shaft assembly through
outer bushing, seal and valve plate with center strap
PIN
VALVE
ARC WELD
WITH
STAINLESS
BUSHING STEEL ROD
COUNTERWEIGHT DO NOT RUN ARC CURRENT
THRU BUSHINGS WHEN WELDING pY4 i4
COUNTER
Fig. 12—Proper M a n ifo ld H eat Control V alve WEIGHT
Installation Six Cylinder Engines
BUSHING
(intake to exhaust manifold attaching screw) (Fig. 12).
(9) Arc weld valve plate to shaft with stainless
steel rod. Arc welding ground must be made at coun
terweight.
(10) Test for free operation. Install anti-rattle
spring.
(11) Complete assembly and installation as outlined
on page 8.
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facing flange end of manifold; attach hook end of th er depth of 7/16 inch.
mostatic spring to stop pin. (3) Line ream bushings, .3095 to .3110 inch diam
(8) With counterweight end of shaft positioned eter, test for free fit of shaft in bushings.
1.240 inches (previously identified) away from mani (4) Press in plug (with cupped end facing inner
fold, valve plate centered between seals and valve bushing) until flush with manifold.
plate closed (Fig. 13). (5) Mark shaft with suitable dye at 1.240 inches at
(9) Arc weld valve plate to shaft with stainless one end, press counterweight on m arked end of shaft
steel rod. Arc w e lding ground must be made at coun until flush with end of shaft.
terweight. (6) Position spring so center end or tab is pointing
(10) Test for free operation. Install anti-rattle left and hook or outer end points down, install spring
spring. on counterweight.
(11) Position new gasket on studs, install exhaust (7) Install spring stop on counterweight so looped
manifold and tighten to 20 foot-pounds. ends face away from therm ostatic spring hook end.
(12) Install exhaust pipe to manifold (no gasket (8) Install seal in manifold in counterbore on coun
used) and tighten to 24 foot-pounds. terweight side.
(9) Holding therm ostatic spring wrapped a 140 de
340 CUBIC INCH ENGINE grees in a counterclockwise direction viewed from
counterweight end install shaft assembly through
R em oval outer bushing, seal, valve plate with strap facing
(1) Remove exhaust pipe from manifold. flange end of manifold and attach hook end of ther
(2) Remove exhaust manifold from engine. mostatic spring on stop pin.
(3) Position valve plate, grind off spot welds from (10) With counterweight end of shaft positioned
valve plate and shaft. 1.240 inches (previously identified) away from mani
(4) Remove counterweight and shaft assembly, fold and valve plate closed, arc weld valve plate to
valve plate. Press out bushings and plug from mani shaft. Arc welding ground must be made at counter
fold (Fig. 14). weight.
(11) Test for free operation.
In s ta lla tio n (12) Position new gasket on studs, install exhaust
(1) Press in new outer bushing flush with outer manifold and tighten to 20 foot-pounds.
edge of manifold (Fig. 14). (13) Assemble exhaust pipe with a new gasket to
(2) Press in new inboard or inner bushing to a manifold and tighten to 50 foot-pounds.
R em o val
Remove exhaust manifold as outlined on page 9.
(1) Position valve plate, grind off spot welds from
valve plate and shaft.
(2) Remove counterweight and shaft assembly,
valve plate.
(3) Press out bushings and cup seals from mani
fold (Fig. 15).
(4) Inspect vent holes and clean out if necessary.
In s ta lla tio n
(1) Press in cup seals until seals extend into mani
fold .100 inch on each side with cupped ends facing
outward (Fig. 15).
(2) Press in bushings flush with outer edge of ex
haust manifold.
(3) Line ream bushings and seals .3095 to .3110
inch diameter. Test for free fit of shaft in bushings
and seals.
(4) Mark one end of shaft with a suitable dye at
1.240 inches, press counterweight on marked end of
shaft until flush with end of shaft.
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VALVE STOP WITH VALVE PLATE SET TO CLOSED COUNTERWEIGHT, THERMOSTAT
POSITION INDEX COUNTERWEIGHT
UNTIL STOP MAKES CONTACT 426 HEMI ENGINE
WITH PIN
Removal
PIN
(1) Remove counterweight from outer end of valve
THERMOSTAT shaft by loosening clamp bolt (Fig. 16).
(2) Unhook therm ostat from stop pin and slide
from valve shaft slot.
(3) If fabric bum per on counterweight is worn, it
may be replaced by sliding it off the tab and sliding
on a new one.
In s ta lla tio n
CLOSED (1) Be sure shaft retainers (Fig. 16) are in place in
grooves in valve shaft and stop pins. Then, turn shaft
MANIFOLD in the extreme counterclockwise position.
PLATE MUST BE (2) Install a new therm ostat in slot in shaft (Fig. 17)
CENTERED BETWEEN SEALS
with outer end of therm ostat in lower left hand posi
X
tion. Press inner end of therm ostat into shaft and
seat firmly.
ANTI-RATTLE (3) Wrap outer end of therm ostat counterclockwise
SPRING
and engage under stop pin.
(4) Install counterweight on outer end of valve
shaft with lock engaged in valve shaft slot and bum per
on right hand side of stop pin (Fig. 18).
(5) Tighten clamp bolt to 50 inch-pounds with
C-3380 Torque Wrench. Test operation of valve for
freedom of movement.
DO NOT RUN ARC
ARC WELD
CURRENT THRU BUSHINGS
PRESS COUNTERWEIGHT FLUSH
WHEN WELDING RETAINER
WITH END OF SHAFT
PY415
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INSTALLED POSITION STOP PIN BUMPER
\ THERMOSTAT
FREE \ !■
POSITION \
l\ - !\ *L f. A1, '
v
RETAINER
NN965 LOCK CLAMP BOLT
VALVE SHAFT .NN967
Fig • I J —installing Thermostat (42 6 H em i Engine) Fig. 18—Installing Counterweight (42 6 H em i Engine)
MANIFOLD HEAT CONTROL VALVE will be necessary to hone bushings to shaft size.
REPLACEMENT (Hemi Only) (3) Pull shaft out far enough to position valve
plate on shaft, then slide shaft into position in both
R em oval bushings.
(1) Remove alternator. (4) Align hole in valve plate with hole in shaft and
(2) Remove exhaust pipe from manifold. insert a drift into both holes to m aintain correct posi
(3) Remove exhaust manifold from engine. tioning of valve plate while it is being welded to shaft.
(4) Remove counterweight, therm ostat, shaft re (5) Remove drift from valve plate and shaft.
tainers and anti-rattle spring. (6) Install new therm ostat, anti-rattle spring shaft
(5) Cut valve plate off shaft. retainers and counterweight assembly on shaft, as
(6) Remove shaft and press bushings from mani outlined for respective engine.
fold. (7) Install manifold on engine assembly.
(8) Attach exhaust pipe to manifold, using a new
In s ta lla tio n gasket where required.
(1) Install new bushings in exhaust manifold. (9) Install alternator and adjust belt tension.
(2) Install shaft in manifold and check shaft for (10) Start engine and test operation of manifold
freedom of movement. If shaft fails to turn freely, it heat control valve assembly.
T I GHTENING REFERENCE
6-Cyl inder 8*Cylinder
Ft. Lbs. In. Lbs. Ft. Lbs. In. Lbs.
Exhaust Header Ball Joint Bolt Nut (426 Hemi
Engine) .................................................. ....................... 24
Exhaust Manifold to Cylinder Head Stud Nut, 198,
225 Cu. In. Engine ...................................................... 10
318, 340, 383, 440 Cu. In. Engines............................. 30
Exhaust Manifold to Pipe Flange Ball Joint Bolt Nut. 24
Exhaust Pipe Flange Bolt Nut Singl e Exhaust___ 35 35
Dual Exhaust ........ 50
Exhaust Pipe U-Bolt Nut ............................................... 150 150
Heat Control Valve Counterweight Clamp Bolt Nut .. 50
Heat Tube Clamp Bolt Nut (426 Hemi E ng in e).......... 95
Heat Tube Screw and Stud Nut (426 Hemi Engine) . . . 200
Intake Manifold to Cylinder Head S c re w .............. 10
318, 340 Cu. In. Engines ............................................. 35
383, 440 Cu. I n. Engines............................................. 40
Intake to Exhaust Manifold S c re w ............................... 240
Rear Muffler Support Bolt and N u t ............................. 200
Rear Muffler Support to Underbody B o lt..................... 200 200
Support Clamp S c re w .................................................... 95 95
Tail Pipe Support to Underbody B o lt ......................... 200 200
Tail Pipe U-Bolt Nut (426 Hemi E n g in e )................... 95
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FUEL SYSTEM
CONTENTS
Page Page
AFB— SERIES CARBURETORS.................. 81 HOLLEY CARBURETOR (2200 SER IES)... 38
AVS— SERIES CARBURETORS ................ 50 HOLLEY CARBURETOR (2300 SER IES)... 62
BBD— SERIES CARBURETORS.............. 22-30 HOLLEY CARBURETOR (4160 S E R IE S )... 91
BBS— SERIES CARBURETORS.................. 6 SERVICE DIAGNOSIS 4
FUEL P U M P S ................................................ 109 SPECIFICATIONS 122
FUEL TANKS ................................ ............ 113 THROTTLE LINKAGE 120
HOLLEY CARBURETOR (1920 SERIES) . . . 15
GENERAL INFORMATION
The fuel system consists of the fuel tank, fuel spring housing and at the choke shaft. Move the choke
pump, fuel filter, carburetor, fuel lines and vacuum rod up and down to check for free movement in the
lines. coil housing. If unit binds, a new unit should be in
The fuel tank assembly consists of the tank, filler stalled. The well type choke is serviced as an assem
neck cap, air vent, and a fuel gauge sending unit. bly. Do not attempt to repair or change the setting,
In operation, the fuel pump draws fuel from the unless authorized by service literature. Changes of
tank and forces it to the filter and carburetor. The the choke setting materially affect summer temper
carburetor m eters the fuel into the air stream drawn ature cold starting and seldom are a satisfactory cor
into the engine, in quantities suitable for all engine rection of driveability problems, which are generally
speed and load conditions. associated with carburetors or vacuum diaphragms.
The fuel filter is a paper elem ent sealed, disposable Two types of wells are in general usage. One is cast
type unit, located in the fuel line between the fuel as an integral part of the manifold. The second is a
pump and the carburetor. The filter unit should be stainless steel cup fastened over a port in the mani
replaced every 24,000 miles. fold. (Figs. 1 or 2.)
When checking parts removed from the carburetor, The stainless steel well cups are held in place by
it is at times difficult to be sure they are satisfactory choke retainer bolts. A steel-asbestos gasket seals the
for further service. It is therefore recommended that exhaust gas within the manifold. Loosening or re
in such case, new parts be installed. moving the choke retainer bolts will allow exhaust
All the carburetors referred to in the Fuel System gases to escape into the engine compartment. DO NOT
are either equipped for use with a Cleaner Air System RUN THE ENGINE WITHOUT THE CHOKE FIRMLY
(C.A.S.) or an Evaporation Control System, (E.C.S.) BOLTED TO THE MANIFOLD. FIRE OR HEAT DAM
depending on the area in which the vehicle is to be AGE MAY OCCUR.
used. The servicing procedures covering these car When installing the steel well cup, make certain the
buretors are nearly identical. Differences between the gasket is in good condition and is in place to prevent
two types of carburetors are covered (where applic exhaust leakage.
able) in the service procedures. Do not lubricate any of the choke parts or the con
trol unit. This causes dirt to accumulate, and would
AUTOMATIC CHOKE—WELL TYPE result in binding of the choke mechanism.
The choke control unit is accurately adjusted when
A new design well for the automatic choke has first assembled. Under normal servicing do NOT
been incorporated in all engines except the 440 cu. change the setting or disassemble the control unit. If
in. tricarb installation and the 426 cu. in. Hemi. This however, the setting has been disturbed, reset as fol
new design allows faster opening of the choke mech lows: Loosen locknut and turn shaft with screwdriver
anism resulting in leaner fuel mixtures during the until index m ark on disc is in alignment with correct
warm-up period for reduced emissions and fuel con m ark on the fram e. Hold in this position with screw
sumption. (Figs. 1 or 2.) driver while tightening nut, (Refer to Specifications
for indexing).
To function properly, it is im portant that all parts
be clean and move freely. Other than an occasional
CLEANER AIR SYSTEM (C.A.S.)
cleaning, the automatic choke control requires no
servicing. However, it is very im portant that the choke The cleaner air system consists of a special air
control unit works freely at the therm ostatic coil cleaner, breather cap, ventilation valve, carburetor,
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distributor and various other automatic control de
vices, (Fig. 3.) as required.
The function of the cleaner air system is to reduce
the unburned hydro-carbons emitted by the vehicle’s
engine. Fresh air is drawn into the air cleaner, for
consumption by the engine. A portion of this fresh
air is diverted through a hose to the breather cap and
into the crankcase. Manifold vacuum causes crank
case vapors (including fresh air and unburned hydro
carbons) to flow through the crankcase ventilation
Fig. 1—Choke Control (open w ell) 8 Cylinder
valve to the base (or throttle body) of the carburetor.
These vapors are joined with the fuel m ixture in the (1) The carburetor must be completely disas
intake manifold and are delivered into the combustion sembled.
chamber, from which they are ejected as essentially (2) All parts (except choke diaphragm assembly)
completely burned exhaust products. should be cleaned in a suitable solvent then inspected
for damage or wear.
EVAPORATION CONTROL SYSTEM (E.C.S.) (3) Use air pressure only, to clean the various ori
fices or channels.
The evaporation control system consists of the (4) Replace questionable parts with NEW ONES.
C.A.S. system plus, a special vented fuel tank, sepa
rator, fuel tank vapor tube, breather cap, enclosed CLEANING CARBURETOR PARTS
bowl vent valve, a vacuum pressure relief fuel tank
cap and hoses. (Fig. 4). The recommended solvent for gum deposits is de
The function of the evaporation control system is to natured alcohol which is easily obtainable. However,
reduce the loss of fuel from the fuel system to the there are other commercial solvents which may be
atmosphere by evaporation and reduce the unburned used with satisfactory results.
hydro-carbons em itted by the vehicle’s engine. W hen The choke diaphragm can be damaged by solvents.
fuel evaporates from the carburetor or fuel tank, it Avoid placing the diaphragm assembly in ANY liquid.
passes through vent hoses or tubes to the crankcase. Clean the external surfaces with a clean cloth or a
With the engine running, vapors are purged from the soft wire brush. Shake dirt or other foreign m aterial
from the stem (plunger) side of the diaphragm. De
crankcase through the crankcase ventilation system,
pressing the stem to the retracted position, will pro
as in the Cleaner Air System previously described.
vide an additional hole for the removal of dirt. Com
The fuel tank contains a one gallon overfill lim iter
pressed air can be used to remove loose dirt but
tank. When the fuel tank is filled, the overfill lim iter should not be connected to the vacuum diphragm
tank remains essentially empty, to allow for therm al fitting.
expansion. Each corner of the fuel tank is vented and IMPORTANT: If the commercial solvent or cleaner
each of the hoses from these vents are connected to recommends the use of water as a rinse, it should be
the separator. A tube from the separator leads to the "HOT." After rinsing, all trace of water must be
breather cap. Thus evaporated fuel vapor from the blown from the passages with air pressure. It is
fuel tank, flows through the separator, to the engine further advisable to rinse all parts in clean kerosene
crankcase and then through the crankcase ventilation or gasoline to be certain no trace of moisture remains.
system. In addition, the carburetor fuel bowl vent
valve is also included, by a tube from the vent valve
to the breather cap, or fuel pump. (6 cylinder engines.)
This completely seals the fuel system.
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Never clean jets with a wire, drill, or other mechani carburetor is leaned out if carburetor is set too lean.
cal means, because the orifices may become enlarged, (c) When it has been established that the m eter is
making the mixture too rich for proper performance. indicating a lower reading (richer m ixture) when the
idle mixture screws are turned in the richer direction,
Idle Speed Adjustment (Curb Idle) proceed to adjust the carburetor to give 14.2 air/fu el
To make the idle speed adjustm ent on carbure ratio, turning the screws counterclockwise (richer) to
tors, secure an accurate ignition tachom eter and a lower the m eter reading and clockwise (leaner) to in
Sun Electric Combustion-Vacuum Unit, Model 80, Ex crease the m eter reading. Do not remove plastic cap
haust Condenser, Model EC, and Hose 669-14 or in order to obtain an over-rich mixture.
equivalent. (The above analyzer is recommended; (d) If the idle speed changes as the m ixture screws
however, other reliable makes of analyzers in good are turned, adjust the speed to the specified value
condition may be used.) and readjust the m ixture as required so that 14.2
(1) Engine running at norm al operating tem pera air/fuel ratio is obtained at the specified idle speed.
ture, and timing checked to the specifications shown
in the Electrical Group. ROUGH IDLE AND LOW SPEED SURGE
(2) Air Cleaner installed.
(3) Six cylinder engines only—turn headlights on Rough idle and low speed surge on vehicles (using
high beam position. 1-1/2" BBD, AVS, and Holley 4160 carburetors) may
(4) Automatic transmissions in neutral position (not be the result of im proper idle setting balance between
in park position). the right and left carburetor bores. To correct this
(5) On air conditioned cars, turn air conditioning condition the following steps should be followed.
off. (1) Remove the plastic caps from the two idle
(6) Connect ignition tachometer. screws in base of carburetor (1-1/2" BBD, and AVS)
(7) Insert probe of exhaust gas analyzer in the or in the sides of the prim ary m etering block (Holley).
tail pipe as far as possible (2 ft. minimum distance). (Fig. 1, BBD, AVS and Holley).
On dual exhaust cars use left side tail pipe (side (2) With engine thoroughly warmed up, install an
opposite heat valve). It is very im portant that the approved exhaust gas analyzer for carburetor idle
probe and connecting tubing be free of leaks to pre speed and m ixture adjustm ent as described under
vent erroneous readings. If a garage exhaust system “Idle Speed A djustm ent”.
is used to conduct the exhaust gases away, a plenum (3) With a screw driver, turn the two idle screws
chamber or other means m ust be used to reduce clockwise until they are both seated.
vacuum of the exhaust system to 1/2 inch w ater or (4) Turn both idle screws 1-1/2 turns counter
less. clockwise for 1-1/2" BBD carburetors and 2 to 3
(8) Connect exhaust gas analyzer, warm up and turns counterclockwise for AVS carburetors as a start
calibrate according to m anufacturer’s instructions. ing point (experience may dictate more or less turns
(9) Set the idle speed to specified value for the as a rough setting but both screws should be turned
specific engine-transmission combination as follows: equally).
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Fig. 4 —Evaporation Control System (E.C.S.)
(5) Start engine and set specified idle speed for From this point on, follow instructions for idle setting
engines with 300 or more miles. Set 75 rpm below until 14.2 air/fuel ratio is obtained at appropriate idle
specifications if under 50 miles or 50 rpm below speci speed. It is very im portant that both idle screws be
fications if 50 to 300 miles are on engine. turned the same amount on each adjustm ent so that
(6) Observe a ir/fu el ratio reading of exhaust gas as finally set both screws will be the same num ber
analyzer. Turn each screw 1/16 turn richer (counter of turns from the seated position.
clockwise) and note change in a ir/fu el m eter reading. (8) Install plastic caps over idle screws.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
POOR IDLING (a) I dle air bleed carbonized or of in (a) Disassemble carburetor. Then, use
correct size. compressed air to clear idle bleed
after soaking it in a suitable solvent.
(b) Idle discharge holes plugged or (b) Disassemble carburetor. Then, use
gummed. compressed air to clear idle discharge
holes after soaking main and throttle
bodies in a suitable solvent.
(c) Throttle body carbonized or worn (c) Disassemble carburetor. Check throt
throttle shaft. tle valve shaft for wear. If excessive
wear is apparent, replace throttle
body assembly.
(d) Damaged or worn idle mixture needle. (d) Replace throttle body assembly.
(e) Low grade fuel or incorrect float (e) Test fuel level in carburetor. Adjust
level. as necessary to obtain correct float
level.
(f) Loose main body to throttle body (f) Tighten main body to throttle body
screws. screws securely to prevent air leaks.
(g) Worn or corroded needle valve and (g) Clean and inspect needle valve and
seat. seat. If found to be in questionable
condition, replace assembly. Then,
test fuel pump pressure. Refer to
Specifications for correct fuel pump
pressure.
(h) Incorrect valve lash. (h) Adjust valves.
(i) Engine miss (ignition.) (i) Check ignition system.
POOR ACCELERATION (a) Accelerator pump piston (or plunger) (a) Disassemble carburetor. Replace ac
leather too hard, worn, or loose on celerator pump assembly if leather
stem. is hard, cracked or worn. Test follow-
up spring for compression.
(b) Faulty accelerator pump discharge (b) Disassemble carburetor. Use com
ball. pressed air to clean discharge nozzle
and channels after soaking main body
in a suitable solvent. Test fuel pump
capacity.
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(c) Faulty accelerator pump inlet check (c) Disassembl e carburetor. Check accel
ball. erator pump inlet, check ball for poor
seat or release. If part is faulty, re
place.
(d) Incorrect fuel or float level. (d) Test fuel or float level in carburetor.
Adjust as necessary to obtain correct
float level.
(e) Worn accelerator pump and throttle (e) Disassemble carburetor. Replace
linkage. worn accelerator pump and throttle
linkage and measure for correct posi
tion.
(f) Manifold heat valve sticking. (f) Free up manifold heat control valve,
using recommended solvent.
(g) Incorrect pump setting. (g) Reset pump.
CARBURETOR FLOODS (a) Cracked body. (a) Disassemble carburetor. Replace
OR LEAKS cracked body. Make sure main to
throttle body screws are tight.
(b) Faulty body gaskets. (b) Disassemble carburetor. Replace de
fective gaskets and test for leakage.
Be sure screws are tightened se
curely.
(c) High float level. (c) Test fuel level in carburetor. Make
necessary adjustment to obtain cor
rect float level.
(d) Worn needle valve and seat. (d) Clean and inspect needle valve and
seat. If found to be in a questionable
condition, replace complete assembly
and test fuel pump pressure. Refer to
specifications for correct fuel pump
pressure.
(e) Excessive fuel pump pressure. (e) Test fuel pump pressure. If pressure
is in excess of recommended pres
sure (refer to Specifications), replace
fuel pump.
POOR PERFORMANCE (a) Restricted air cleaner. (a) Remove and clean air cleaner or re
MIXTURE TOO RICH place element.
(b) Leaking float. (b) Disassemble carburetor. Replace
leaking float. Test float level and cor
rect as necessary, to proper level.
(c) High float level. (c) Adjust float |evel as necessary to se
cure proper level.
(d) Excessive fuel pump pressure. (d) Test fuel pump pressure. Refer to
specifications for recommended pres
sure. If pressure is in excess of rec
ommended pressure, replace fuel
pump assembly.
(e) Worn metering jet. (e) Disassemble carburetor. Replace
worn metering jet, using a new j'et of
the correct size and type.
CARBURETOR MIX (a) Air leak bypassing carburetor. (a) Repair.
TURES LEAN
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EXCESSIVE STALLS AFTER COLD START
(a) Choke System L ean (a) Check items under “Poor Starting-
Choke Valve Fails to Close.”
(b) Choke vacuum diaphragm adjust- (b) Adjust to specifications,
ment lean.
ENGINE OUTPUT LOW (a) Fast idle speed low. (a) Adjust to specification.
(b) Fast idle cam position adjustment (b) Adjust to Specifications,
incorrect.
(c) Engine lubrication oil of incorrect (c) Recommend No. 5W-20.
viscosity.
CARBURETOR LEAN (a) Curb idle set very lean. (CAS Carbs.) (a) Adjust to CAS Specifications.
(b) Air leak bypassing the carburetor. (b) Repair.
LOW ENGINE OUTPUT (a) Engine lubricating oil or incorrect (a) Recommended 5W-20.
(10°F or lower) viscosity.
(b) Valve lash incorrect. (b) Readjust.
(c) Choke thermostat adjustment incor- (c) Adjust to correct setting,
rect, rich.
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GENERAL INFORMATION
The Ball and Ball single throat carburetor models these carburetors are equipped with a hot idle com
C.A.S. (Cleaner Air System) BBS-4715S and BBS- pensator valve, which is a thermostatically operated
47168 are used on the 198 cu. in. engines when the air bleed, to relieve an overrich condition at idle. This
vehicles are equipped with manual or automatic condition is the result of excessive heat and resultant
transmissions respectively. (Fig. 1.) The BBS-4715S is overrich mixtures. The BBS-4717S is equipped with a
equipped with a dash pot which retards the return of dash pot which retards the return of the throttle to
the throttle to idle position. (Manual Transmission idle position. (Manual Transmission Only.)
Only). The proper adjustment of the dash pot is very im
The Ball and Ball single throat carburetor models portant! (See carburetor adjustments.)
E.C.S. (Evaporation Control System) BBS-4717S and Since the service procedures are identical on all
BBS-4718S are also used on the 198 cu. in. engines BBS carburetors, the illustrations showing the various
when the vehicles are equipped with manual or auto disassembly procedures will not always show any one
matic transmissions respectively. (Fig. 2.) Both of specific carburetor.
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Figs. 1 or2) disengage link from diaphragm plunger (stem) and
choke lever. (Fig. 1). Remove link.
(1) Place carburetor assembly on repair block, Tool (5) Remove vacuum diaphragm and bracket assem
C-3225. bly and place to one side to be cleaned as a special
(2) Remove hairpin clip and disengage accelerator item. A liquid cleaner may damage diaphragm ma
pump operating rod. terial.
(3) Remove vacuum hose between carburetor main (6) Remove air horn retaining screws. Remove
body and vacuum diaphragm. dash pot. (If so equipped.)
(4) Remove clip from choke operating link and (7) Tilt air horn toward throttle lever far enough to
CHOKE VALVE CHOKE VALVE
ACCELERATOR PUMP
ACCELERATOR
ROCKER ARM
CHOKE VACUUM PUMP ROD
CHOKE VACUUM
DIAPHRAGM DIAPHRAGM DASH POT
M O UNTING
AIR HORN
m BRACKET
MAIN BODY
CHOKE
OPERATING
CHOKE 1
OPERATING
LINK
LINK
FAST IDLE
CAM LINK DISTRIBUTOR VACUUM
-— ADVANCE TUBE
FITTING
•THROTTLE
i: BODY
THROTTLE
LEVER \
GASKET
FAST IDLE CAM
\
IDLE LIMITER CAP
(IDLE MIXTURE FAST IDLE SPEED
IDLE LIMITER CAP
(IDLE MIXTURE
ADJUSTING SCREW)
ADJUSTING SCREW) ADJUSTING SCREW
FAST IDLE SPEED CLOSED CRANKCASE
CLOSED CRANKCASE VENT IDLE SPEED ADJUSTING VENT TUBE FITTING
ADJUSTING SCREW
TUBE FITTING SCREW (CURB IDLE)
IDLE SPEED ADJUSTING DASH POT
THROTTLE LEVER CMANUAL TRANSMISSION ONLY)
SCREW (CURB IDLE)
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ACCELERATOR PUMP CHOKE VALVE
ROCKER ARM
AIR H O RN
BOWL VENT VALVE
CHOKE VALVE \ ACCELERATOR PUMP
OPERATING LEVER CHOKE V A C U U M
\ ROCKER ARM
D IA PHR A G M
\ I BOWL VENT VALVE
CHOKE LEVER CHOKE
OPERATING LINK
\ \ OPERATING LEVER
BOW L VEN T VALVE
PLUNGER STEM \ \ \ BOWL VENT VALVE
H O T IDLE COMPENSATOR
\ EVAPORATIO N
VALVE COVER |
TUBE FITTING
CHOKE V A C U U M ;1 % \
^ D IA P H R A G M
“EM CLIP
FAST IDLE
C A M LINK
^ FAST IDLE CAM
I K VACUUM ACCELERATOR
CHOKE TUBE PUMP ROD
M A IN BODY
HOT IDLE
■ ■ NEEDLE VALVE,
COMPENSATOR VALVE
SEAT A N D GASKET
PY373
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.IDLE ORIFICE TUBE
ft
PY376
Fig. 5 —Removing or Installing Step-up Piston It is usually not advisable to remove the throttle
shaft or valve from the throttle body, unless wear or
(11) Remove step-up piston retaining screw, and
damage necessitates the installation of new parts.
slide step-up piston and rod out of well, (Fig. 5).
Now lift out the step-up piston spring. Remove step-
up piston gasket from bottom of the well.
INSPECTION AND REASSEMBLY
(12) Remove main m etering jet (Fig. 6).
T h ro ttle B o d y
(13) Unscrew and remove idle orifice tube (Fig. 7). (1) Check throttle shaft for excessive wear in the
(14) Invert carburetor and drop out accelerator throttle body. If w ear is extreme, it is recommended
pump check balls from their respective seats. that throttle body assembly be replaced rather than
(15) Using Tool T-109-43 plug remover, remove ac installing a new shaft in the old body.
celerator pum p je t plug. Using Tool T-109-59T, re
During m anufacture, location of idle transfer port
move accelerator pump jet, (Fig. 8).
and spark advance control ports to the throttle valve
(16) Remove plastic lim iter cap from idle air
is carefully established for one particular assembly.
m ixture screw. (Be sure and count num ber of turns
to seat screw, as the same num ber of turns (from the (Fig. 9).
If a new shaft should be installed in an old, worn
seat) must be m aintained at installation.) Remove
screw and spring from throttle body. throttle body, it would be very unlikely that the origi
nal relationship of the ports to the valve would be
The carburetor now has been disassembled into
obtained. Changing the relationship of the valve to
three main units; air horn, main body and throttle
the ports would adversely affect norm al car operation
body and the component parts of each disassembled
as far as necessary for cleaning and inspection. ACC ELER A TOR PUMP
IN LET CHECK BALL
(AT BOTTOM OF C YLINDER)
•m i * ACCELERATOR PUMP
.................... D IS C H A R G E C HEC K BALL
•* (A T B O T T O M O F
V « ,! V WELL)
10-
ACCELERATOR
PUM P JET
PY377
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IDLE TRANSFER SPARK ADVANCE ' ACCELERATOR PUMP i
PORT CONTROL PORT INLET CHECK BALL #j
(AT BOTTOM OF CYLINDER) M
*J m \ .$ t If -ACCELERATOR PUMP
DISCHARGE
CHECK BALL
THROTTLE”
VALVE
V
IDLE SPEED ADJUSTING
SCREW (CURB IDLE)
/
FAST IDLE SPEED
ADJUSTING SCREW
PY378
between the speeds of 15 and 30 miles per hour. If a Fig. 10 —Installing Accelerator Pump Discharge and
new shaft or valve is to be installed, adhere to the In ta k e Check Balls
following instructions: (3) Using a small clean brass rod, hold discharge
(2) Mark position of throttle valve in bore, so that check ball down firmly on its seat. Again raise
it can be reinstalled in the same position. plunger and press downward. No fuel should be
(3) Remove screws that hold throttle valve to shaft, em itted from either intake or discharge passage,
then slide valve out of bore. (Fig. 11).
CAUTIO N: These screws are staked on the opposite If any fuel does emit from either passage, it indi
side and care should be used at removal so as not to cates the presence of d irt or a damaged check ball.
break them off in the shaft. Clean the passage again and repeat test. If leakage is
(4) Slide throttle shaft out of throttle body. still evident, install a NEW check ball. The fuel inlet
(5) Install new throttle shaft and lever (or new check ball is located at the bottom of the plunger
valve). well. Invert carburetor and remove both check balls.
(6) Install NEW screws but do not tighten. Hold (4) Install accelerator pump jet, (Fig. 8). Tighten
valve in place, with fingers pressing on high side securely, using Tool T-109-59T. Install a new plug
of valve. Tap valve lightly with a screwdriver to seat and drive tightly in place.
in throttle bore. Tighten screws lightly. Hold up to a (5) Install idle orifice tube, (Fig. 7). Tighten secure
strong light to check for proper position in bore. (The
ly*
valve may have to be rotated slightly as it is elip- (6) Install main m etering jet, (Fig. 6). Tighten se
tical.) When properly positioned, tighten screws se
curely.
curely and stake, using pliers.
(7) Before installing step-up piston, be sure step-up
(7) Install idle m ixture screw and spring in body.
(The tapered portion m ust be straight and smooth. If rod is able to move freely each side of vertical
tapered portion is grooved or ridged, a new idle mix ACCELERATOR
tu re screw should be installed to insure having cor BRASS R O D j^V PUMP PLUNGER
rect idle m ixture control.) DO NOT USE A SCREW (PRESS DOWN .
TO SEAT ' * f
DRIVER. Turn screw lightly against its seat with the BALL) C-
fingers. Back off num ber of turns counted at disas
sembly. Install new plastic cap (blue) with tab against 4 . ^
stop.
M a in B o d y
(1) Install accelerator pum p discharge and intake
check balls in their respective passages, (Fig. 10).
To check accelerator pum p system; fuel inlet and
discharge check balls, proceed as follows: N O FUEL TO BE EMITTED
(2) Pour clean gasoline into carburetor bowl, ap FROM PUMP INTAKE
proxim ately 1/2 inch deep. Remove pump plunger \ APPROX. 1 /2 INCH
OF FUEL IN BOWL
from jar of gasoline and slide down into pump cylin PY380
der. Raise plunger and press lightly on plunger shaft Fig. V T esting Accelerator Pump In ta k e a n d
to expel air from pump passage. D ischarge Check Balls
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position, (Fig. 12). The step-up rod must be straight FLOAT FULCRUM PIN GAUGE TO JUST TOUCH
RETAINER FLOATS AT CROWN
and smooth.
(8) Slide step-up piston gasket down into position in
piston well, then install step-up piston spring and
step-up piston and rod (Fig. 5). Install retaining screw
and tighten securely. (Carefully guide step-up rod into
main m etering jet.) Be sure step-up piston slides
freely in its cylinder. A step-up piston stuck in UP
S iS 6 FLOAT
GAUGE
F~
position will cause a rich m ixture at part throttle,
whereas a piston stuck in DOWN position will cause
a lean m ixture at wide open throttle and poor ac
celeration.
C h o k e V a c u u m D ia p h ra g m
Inspect the vacuum diaphragm fitting to be sure
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CHOKE VALVE CARBURETOR ADJUSTMENTS
**% . - , WIDE OPEN
BOWL VENT
1 “> 1 DRILL OR G A U G E
It is very im portant that the following adjustm ents
be made on a reconditioned carburetor, and in the
VALVE sequence listed:
\h,
SOWL VENT A c c e le r a t o r P u m p a n d B o w l V e n t (C .A .S .)
VALVE SEAT When assembling the accelerator pump to the air
*99
horn, note that the hairpin clip (which opens the bowl
THROTTLE VALVE
IN CLOSED vent) can be placed in any one of three positioning
POSITION notches. These notches correspond to the long, medi
um and short pump stroke holes in the throttle lever.
BOWL VENT
VALVE OPERATING (Refer to Air Horn Paragraph for correct position
LEVER of the pump stem clip and the pump rod.)
PUMP ROCKER The proper procedure is to adjust the amount of
ARM AIR CLEANER
MOUNTING SURFACE
bowl vent opening instead of measuring and setting
PIVOT the height of the pump plunger.
SCREW ACCELERATOR To check or set the adjustment, proceed as follows:
PUMP TRAVEL (1) Open choke valve, so that when throttle valve is
'9 U closed, fast idle adjusting screw will not contact fast
BEND , V-*>- idle cam.
TANG TO !*<""’ • ' 9 9 DRILL OR GAUGE (2) Be sure pump operating rod is in the correct
ADJUST"'." % y. ,;j 9 stroke hole in throttle lever, and that bowl vent clip
BOWL VENT on pump stem is in proper location.
‘VENT
0WL ‘
VALVE PLUNGER
STEM
(3) Close throttle valve tightly. It should be just
j * . , * * , . /f> .,^ V possible to insert a #69 drill (.030 + or — .010") be
’ “E" CUP tween bowl vent and air horn, (Fig. 14).
BEND AT ANGLE If an adjustm ent is necessary, bend the pump oper
E.C.S. CARBURETOR
FOR PUMP PY382 ating rod, using Tool T-109-213, at the lower angle,
ADJUSTMENT until correct bowl vent opening has been obtained.
This is an im portant adjustment, since too much
Fig. 14 —Checking Bowl Vent Opening lift at the bowl vent will result in considerable loss in
that the passage is not plugged with foreign m aterial. low speed fuel economy.
Leak test diaphragm to determ ine if it has internal Remember that if the pump operating rod is moved
leaks. To do this, depress diaphragm stem, then place to either the short or long stroke position, a corres
a finger over fitting to seal opening. Release stem. If ponding change must be made in the location of the
stem moves more than 1/16 inch in 10 (ten) seconds, bowl vent clip, and the amount of lift of the bowl vent
leakage is excessive and the assembly m ust be re rechecked and adjusted.
placed. The accelerator pump travel is automatically taken
Install the diaphragm on the carburetor as fol care of when the bowl vent is properly adjusted.
lows:
(1) Place diaphragm on mounting surface. Install A c c e le ra to r P u m p a n d B o w l V e n t V a lv e
and tighten attaching screws securely. (E .C .S .)
(2) Install choke operating link in position between On the E.C.S. BBS carburetor, it is necessary to
the diaphragm plunger (stem) and choke lever. Install check or set the accelerator pump travel before check
clip to secure. ing the bowl vent valve opening.
(3) Inspect rubber hose for cracks before placing
it on correct carburetor fitting. Do not connect vacu A c c e le ra to r P u m p T ra v e l
um hose to diaphragm fitting until after vacuum kick (1) Be sure the accelerator pump rod is in outer
adjustment has been made. (See C arburetor A djust hole (long stroke) of throttle lever.
ments.) (2) Close throttle valve to curb idle.
(4) Place hot idle compensator valve gasket in posi (3) Using a straight edge placed on flat surface (air
tion in recess in air horn, followed by valve. (Be sure cleaner mounting surface), measure distance between
valve is positioned with legs toward outside of car straight edge and top of accelerator pump plunger.
buretor.) Place cover over opening and install attach (Fig. 14.) This m easurem ent should be 5/16 inch.
ing screws. Tighten securely. (Fig. 4.) If so equipped. (4) If an adjustment is necessary, bend accelerator
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pump rod at angle until correct pump travel has been choke valve within the air horn by action of the link
obtained. Use Tool T109-213. age between the choke shaft and th e diaphragm. The
diaphragm m ust be energized to m easure the vacuum
B o w l V e n t V a lv e kick adjustm ent. Use either a distributor test machine
This adjustm ent to be made after accelerator pump with a vacuum source, or vacuum supplied by another
adjustment. vehicle. Adjust as follows:
(1) With throttle valve at closed curb idle, it should (1) If adjustm ent is to be made with engine run
be possible to insert a 9/64 inch drill between under ning, back off fast idle speed screw until choke can be
side of bowl vent valve lever and air horn. (Fig. 14.) closed to the kick position with engine at curb idle.
(2) If an adjustm ent is necessary, bend lower tang (Note num ber of screw turns required so that fast
on bowl vent valve operating lever (at pivot) until cor idle can be returned to original adjustment). If an
rect opening has been obtained. auxiliary vacuum source is to be used, open throttle
valve (engine not running) and move choke to closed
F a s t Id le S p e e d a n d C a m P o s itio n position. Release throttle first, then release choke.
A d ju s tm e n t (2) When using an auxiliary vacuum source, dis
The fast idle engine speed adjustm ent should be connect vacuum hose from carburetor and connect
made on the vehicle, as described in the Fast Idle it to hose from vacuum supply with a small length of
Speed Adjustm ent (On the Vehicle) Paragraph. How tube to act as a fitting. Removal of hose from dia
ever, the Fast Idle Cam Position Adjustm ent can be phragm may require forces which damage the system.
made on the bench. This adjustm ent is im portant to Apply a vacuum of 10 or more inches of mercury.
assure that the speeds of each cam step occur at the (3) Insert specified drill (refer to Specifications)
proper time during engine warm-up. Adjust as between choke valve and wall of air horn (Fig. 16).
follows: Apply sufficient closing pressure on lever to which
(1) With fast idle speed adjusting screw contacting choke rod attaches to provide a minimum choke
second highest step on fast idle cam, move choke valve valve opening without distortion of diaphragm link.
toward closed position with light pressure on choke Note that the cylindrical stem of diaphragm will ex
shaft lever. tend as internal spring is compressed. This spring
(2) Insert specified drill between choke valve and must be fully compressed for proper m easurem ent
wall of air horn (See Specifications at rea r of Fuel of vacuum kick adjustment.
System Group). (4) An adjustm ent will be necessary if a slight drag
(3) If an adjustm ent is necessary, bend fast idle rod is not obtained as drill is being removed. Shorten or
at upper angle, using Tool T-109-213, until correct lengthen diaphragm link to obtain correct choke
valve opening has been obtained. (Fig. 15). opening. Length changes should be made carefully
by bending (open or closing) the bend provided in
V a c u u m K ic k A d ju s t m e n t — (T h is te s t c a n b e diaphragm link. CAUTION: DO NOT APPLY TWIST
m a d e O N o r O F F v e h ic le .) ING OR BENDING FORCE TO DIAPHRAGM.
The choke diaphragm adjustm ent controls the fuel (5) Reinstall vacuum hose on correct carburetor
delivery while the engine is running. It positions the fitting. Return fast idle screw to its original location
DR!U OR GAUGE ■Hi% • DRILL OR GA U GE
CHOKc VALVE
/ SEND FAST IDLE
FAS-' :-v ; SPccD C A M LINK AT A M IN IM U M OF 10
ADJUSTING SCsVtW "ANGLE FOR INCHES OF V A C U U M
O N SECOND HIGH':S’’ .ADJUSTMENT REQUIRED O N
STEP CAM DIAPHRAGM
PLUNGER ST -M RETRACTED
BY VACUUM
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if disturbed as suggested in Step No. 1. positioned on second highest-speed step of fast idle
(6) Make following check. With no vacuum applied cam (Fig. 18).
to diaphragm, the CHOKE VALVE SHOULD MOVE (3) Start engine and determine stabilized speed.
FREELY between open and closed positions. If move Turn fast idle speed screw in or out to secure speci
m ent is not free, examine linkage for misalignment fied speed. (See Specifications.)
or interferences caused by bending operation. Repeat (4) Stopping engine between adjustm ents is not
adjustm ent if necessary to provide proper link opera necessary. However, reposition fast idle speed screw
tion. on cam after each speed adjustm ent to provide cor
rect throttle closing torque.
C h o k e U n lo a d e r ( W id e O p e n K ic k ) Before adjusting idle an d /o r fast idle speeds and
The choke unloader is a mechanical device to par mixtures, make sure that the basic timing and the
tially open the choke valve at wide open throttle. It distributor control valve are correctly adjusted, as
is used to eliminate choke enrichm ent during crank outlined under Idle Speed Adujstm ent (Curb Idle).
ing of an engine. Engines which have been flooded or
stalled by excessive choke enrichm ent can be cleared Id le S p e e d A d ju s tm e n t (C u rb Id le )
by use of the unloader. Adjust the choke unloader as (Refer to General Information at Front of Section.)
follows:
(1) Hold throttle valve in wide open position. In D a s h p o t S e ttin g a n d A d ju s tm e n t
sert specified drill (see Specifications) between upper With the curb idle speed and m ixture properly set
edge of choke valve and inner wall of air horn. and a tachom eter installed, position the throttle lever
(2) With a finger lightly pressing against valve, a so that the actuating tab on the lever is contacting the
slight drag should be felt as drill is being withdrawn. stem of the dashpot but not depressing it. The ta
If an adjustm ent is necessary, bend unloader tang chometer should read 2000 rpm if the setting is cor
on throttle lever until correct opening has been ob rect. To adjust the setting if necessary, screw the
tained. (Fig. 17.) dashpot in or out as required. When the desired
setting is obtained, tighten the lock nut on the dash-
F a s t Id le S p e e d A d ju s tm e n t (O n V e h ic le ) pot against the bracket.
Fast idle engine speed is used to overcome cold
engine friction, stalls after cold starts and stalls be C h e c k in g th e F lo a t S e ttin g
cause of carburetor icing. Set this adjustm ent after (O n th e V e h ic le )
the vehicle odometer indicates over 500 miles to in (1) Remove accelerator pump operating rod.
sure a norm al engine friction level. Prepare engine by (2) Remove two long air horn attaching screws
driving at least 5 miles. Connect a tachom eter and set and two short screws, then install two short screws
the curb idle speed and m ixture, then proceed as fol in place of two long screws removed. This will hold
lows: main body to throttle body. Tighten screws securely.
(1) With engine off and transmission in PARK or (3) Remove remaining air horn screws, then tilt air
NEUTRAL position, open throttle slightly. horn far enough to disengage fast idle cam link from
(2) Close choke valve until fast idle screw can be fast idle cam. Remove air horn and gasket.
DRILL OR GAUGE CHOKE VALVE
,> /C H O K E VALVE
K /
LIGHT CLOSING
PRESSURE AGAINST
CHOKE LEVER
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Check float setting as follows: bottom of the bowl, then bend the float lip toward or
(4) Seat float fulcrum pin by pressing on fulcrum away from the needle. Recheck the 1/4 inch setting
pin retainer. again, then repeat the lip bending operation as
There should be enough fuel in the bowl to raise required.
float so that lip bears firmly against needle. Addi CAUTION: When bending the float lip, do not allow
tional fuel may be admitted by slightly depressing the lip to push against the needle as the tip can be
float. If the fuel pressure in line is insufficient to compressed sufficiently to cause a false setting which
force additional fuel into the bowl, add the necessary will affect correct level of the fuel in the bowl.
fuel from a clean container. A fter being compressed, the tip is very slow to
CAUTIO N: Since the manifolds may be hot, it is dan recover its original shape.
gerous to spill fuel on these surfaces. Therefore, take It is very im portant that the float lip be perpen
the necessary precautions to avoid spillage. dicular to the needle or slanted not more than 10
(5) With only pressure of buoyant float holding degrees away from the needle when the float is cor
float lip against inlet needle, check float setting, using rectly set.
Tool T-109-239 or a “T” scale. There should be 1/4 (6) Reassemble air horn as described previously.
inch from surface of bowl (gasket removed) to crown To set the idle speed, refer to the Fuel System Gen
of floats at center. eral Information Paragraph.
If an adjustm ent is necessary, hold the float on the
HOLLEY MODEL N O . 1 9 2 0
SERIES CARBURETOR
INDEX
Page Page
Automatic Choke (well type) ................................... 1 Dashpot Adjustment ............................................ 22
Carburetor Adjustments .......................................... 20 Cleaning Carburetor P arts........................................ 2
Accelerator Pump and Bowl Vent ..................... 22 Disassembling Carburetor........................................ 16
Choke Vacuum Kick ............................................ 20 General Information .................................................. 15
Fast Idle Cam Position ......................................... 20 Inspection and Reassembly..................................... 17
Fast Idle Speed (On V eh icle)............................... 21 Specifications.............................................................. 122
Idle Speed Adjustm ent......................................... 21
GENERAL INFORMATION
The Holley single throat carburetor models C.A.S. The proper adjustment of the dash pot is very im
(Cleaner Air System) R-4351A, R-4352A and Taxi ap portant! (See C arburetor Adjustments.)
plication R-4355A are used on the 225 cu. in. engines Fuel from the bowl flows into the four basic fuel
when the vehicles are equipped with manual or auto metering systems, which are: the idle system, the
matic transmissions respectively. (Fig. 1.) The R-4351A main metering system, the power enrichm ent system
is equipped with a dash pot which retards the return and the accelerating pump system.
of the throttle to idle position. (Manual Transmission The choke valve located in the bore of the carbu
Only). retor is connected to a well-type automatic choke.
The Holley single throat carburetor models E.C.S. Additional fuel for acceleration is supplied by a
(Evaporation Control System) R-4353A, R-4354A and diaphragm type, spring driven pump. The pump is
Taxi application R-4363A are also used on the 225 operated by a lever connected by linkage to the
cu. in. engines when the vehicles are equipped with throttle shaft.
manual or automatic transmissions respectively. (Fig. A two stage power valve mounted in the m etering
2.) These carburetors are equipped with a hot idle block, actuated by manifold vacuum, delivers the addi
compensator valve, which is a thermostatically oper tional fuel necessary for full power and high speed
ated air bleed, to relieve an overrich condition at idle. operation.
This condition is the result of excessive heat and Since the service procedures are identical on all
resultant overrich mixtures. The R-4353A is equipped Holley carburetors, the illustrations showing the vari
with a dash pot which retards the return of the ous disassembly procedures will not always show any
throttle to idle position. (Manual Transmission Only). one specific carburetor.
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CHOKE VACUUM
DIAPHRAGM
CHOKE VACUUM BOWL VENT VALVE
DIAPHRAGM LINK OPERATING LEVER
CHOKE VALVE CHOKE VALVE
ft
-ACCELERATOR PUMP ■
/ D IA PHR A G M STEM
THROTTLE
LEVER
/
/
IDLE LIMITER CAP
(IDLE MIXTURE )
ADJUSTING SCREW)
_
FUEt BOWL
' \
FAST IDLE SPEED
ADJUSTING SCREW
ACCELERATOR
PUMP LEVER
\ CLOSED CRANKCASE
CLO
VENT TUBE FITTING
/
IDLE SPEED
\ Ve ECONOMIZER COVER
ADJUSTING SCREW
DISTRIBUTOR VACUUM ADVANCE
TUBE FITTING AIR CLEANER TO CARBURETOR
DASH POT ASSEMBLY VACUUM TUBE FITTING
(MANUAL TRANSMISSIONS ONLY) PY387
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Figs. 1 or2) clip, then slide float off fulcrum pin.
(9) Remove screws that attach metering block, then
(1) Place carburetor assembly on repair stand, Tool remove m etering block (Fig. 7).
C-3866, and remove dashpot (if so equipped). (10) Tilt pump lever on its pivot until hook on
(2) Remove vacuum hose between carburetor th ro t pump diaphragm stem can be released. Slide pump
tle body fitting and vacuum diaphragm. diaphragm and spring out of fuel bowl. (Fig. 8).
(3) Remove choke vacuum diaphragm, link and (11) Using Tool C-3748, remove main jet from
bracket assembly. Disengage link from slot in choke m etering block. (Fig. 9).
lever; place to one side to be cleaned as a special item. (12) Using a suitable tool, remove pump lever re
(Figs. 1 or 2). As the vacuum diaphragm bracket is taining clip. Slide lever off pivot and disengage link
being removed, the bowl vent valve rod and spring from throttle lever.
will fall out. (Fig. 3). (13) Remove fast idle cam retaining screw, then
(4) Remove screws that attach hot idle compensator remove cam, and at same time, disengage fast idle
valve cover to air horn. Lift off cover, then remove cam rod.
valve and gasket. (Fig. 4.) If so equipped. (14) Remove plastic lim iter cap from idle air mix
(5) Using a 5 /8 " wrench, remove fuel inlet needle ture screw. (Be sure and count num ber of turns to
valve and seat. seat the screw, as the same num ber of turns (from the
(6) Remove economizer retaining screws, then lift seat) must be maintained at installation.) Remove
economizer cover, diaphragm and stem out of carbu screw and spring from throttle body. Discard plastic
retor, (Fig. 5). cap.
(7) Remove fuel bowl attaching screws, then re (15) Remove fast idle and curb idle speed screws
move fuel bowl, baffle and gasket, (Fig. 6). Slide baffle and spring from throttle lever.
out of bowl. Discard gasket. Remove float dam per (16) Remove screws that retain bowl vent valve
spring. cover to air horn. Remove cover, then lift out valve
(8) Using a suitable tool, remove float retaining and spring. (If so equipped.)
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CHOKE VALVE
BOWL VENT VALVE
OPERATING LEVER
CHOKE VACUUM
DIAPHRAGM LINK
BOWL VENT VALVE FAST IDLE CAM LINK
PLUNGER STEM ECONOMIZER COVER
CHOKE
CHOKE VACUUM VACUUM 30WL VENT VALVE
DIAPHRAGM
BOWL VENT DIAPHRAGM
VALVE TUBE CHOKE DIAPHRAGM
VACUUM HOSE
FAST IDLE
CAM
THROTTLE
LEVER
ECONOMIZER
COVER
HOT IDLE
COMPENSATOR CLOSED
VALVE COVER CRANKCASE
(H.I.C.) VENT TUBE
FITTING
FUEL BOWL
\
FAST IDLE SPEED
ADJUSTING SCREW DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
IDLE SPEED ADJUSTING a i d CLEANER TO
SCREW (CURB IDLE) CARBURETOR VACUUM / \ THROTTLE LEVER
HOT IDLE COMPENSATOR TUBE FITTING / IDLE SPEED ADJUSTING
AIR CLEANER TO CARBURETOR VALVE COVER FAST IDLE SPEED SCREW
VACUUM TUBE FITTING ADJUSTING SCREW (CURB IDLE)
PY388
Fig. 2 —C arburetor Assembly (Holley 1920 Series) C.C.S.
The carburetor assembly now has been disassem assembly be replaced rath er than installing a new
bled as far as necessary for cleaning and inspection. It shaft in old body.
is usually not advisable to remove the throttle shaft During m anufacture, the location of the idle trans
and valve from the throttle flange, unless wear or fer port and the spark advance control ports to the
damage necessitates the installation of new parts. throttle valve is carefully established for one particu
lar assembly.
INSPECTION AND REASSEMBLY
T h ro ttle S h a ft a n d V a lv e
(1) Check throttle shaft for excessive wear in body.
If wear is extreme, it is recommended that carburetor
B O W l VENT
ROD
m
”m
EC O N O M IZER
D IA PHR A G M COVER
COVER
HOT IDLE
SCREWS COMPENSATOR
/ A j m VALVE
s ' rurwc
CHOKE V A C U U MA
WArniik
PY506
D IA PHR A G M TUBE
FITTING HH754A
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ECON OMIZER
COVER
ECONOMIZER
% DIAPHRAGM
PUMP
D IA PHR A G M
FUEL /
'5 » ECONOMIZER
BODY
FLOAT
MAIN JET
^ B O W l SCREWS PY508
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If tapered portion is grooved or ridged, a new idle
mixture screw should be installed to insure having , , ' / FLOAT SPRING
correct idle m ixture control.) Do not use a screw
driver. Turn screw lightly against its seat with fingers. ; >*% CARBURETOR
FLOAT — - ' INVERTED
Back off num ber of turns counted at disassembly. In
GAUGE . t
stall new plastic cap (blue) with tab against stop. ( ;
A s s e m b lin g C a r b u r e to r
■j| 71 E
(1) Loosen choke valve attaching screws slightly. FLOAT-.. • ' ””
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attaching screws. Tighten securely. (If so equipped.) kick adjustment. Use either a distributor test machine
with a vacuum source or vacuum supplied by another
CARBURETOR ADJUSTMENTS vehicle. Adjust as follows:
(1) If adjustm ent is to be made with engine ru n
It is very im portant that the following adjustm ents ning, back off fast idle speed screw until choke can
be made on a reconditioned carburetor. be closed to the kick position with engine at curb idle.
(Note num ber of screw turns required so that fast
F a s t Id le S p e e d a n d C a m P o s itio n A d ju s tm e n t idle can be returned to original adjustment). If an
The fast idle engine speed adjustm ent should be auxiliary vacuum source is to be used, open throttle
made on the vehicle, as described in “Fast Idle Speed valve (engine not running) and move choke to closed
Adjustm ent.” (On the Vehicle) Paragraph. However, position. Release throttle first, then release choke.
the Fast Idle Cam Position Adjustm ent can be made (2) When using an auxiliary vacuum source, discon
on the bench. This adjustm ent is im portant to assure nect vacuum hose from carburetor and connect it to
that the speeds of each cam step occur at the proper hose from vacuum supply with a small length of tube
time during engine warm-up. Adjust as follows: to act as a fitting. Removal of hose from diaphragm
(1) With fast idle speed adjusting screw contacting may require forces which damage the system. Apply
second highest step on fast idle cam (Fig. 11), move a vacuum of 10 or more inches of mercury.
choke valve toward closed position with light pres (3) Insert specified drill (refer to Specifications) be
sure on choke shaft lever. tween top of choke valve and wall of air horn (Fig. 12).
(2) Insert specified drill between top of choke valve Apply sufficient closing pressure on lever to which
and wall of air horn. (See Specifications at rear of choke rod attaches to provide a minimum choke valve
Fuel System Group.) opening without distortion of diaphragm link. Note
(3) If an adjustm ent is necessary, bend fast idle that the cylindrical stem of diaphragm will extend as
link at lower angle, using Tool T-109-213, until correct internal spring is compressed. This spring must be
valve opening has been obtained. (Fig. 11).
fully compressed for proper m easurem ent of vacuum
When the correct fast idle position cam adjustment
kick adjustment.
has been made, the choke unloader (wide open kick)
(4) An adjustm ent will be necessary if a slight
adjustment has also been obtained. No further ad
justment is required. drag is not obtained as drill is being removed. Shorten
or lengthen diaphragm link to obtain correct choke
opening. Length changes should be made carefully
V a c u u m K ic k A d ju s t m e n t — (T h is te s t c a n b e
by bending (open or closing) the bend provided in
m a d e O N o r O F F v e h ic le .)
The choke diaphragm adjustm ent controls the fuel diaphragm link. CAUTION: DO NOT APPLY TWIST
delivery while the engine is running. It positions the ING OR BENDING FORCE TO DIAPHRAGM.
choke valve within the air horn by action of the link (5) Reinstall vacuum hose on correct carburetor
age between the choke shaft and the diaphragm. The fitting. Return fast idle screw to its original loca
diaphragm must be energized to m easure the vacuum tion if disturbed as suggested in Step No. 1
DRILL OR GAUGE
FAST IDLE SPEED CHOKE VALVE _—-DRILL OR GAUGE
ADJUSTING SCREW
ON SECOND HIGHEST A MINIMUM OF 10 CHOKE VALVE
STEP OF CAM INCHES OF VACUUM
REQUIRED
LIGHT CLOSING
* PRESSURE ON
CHOKE LEVER
1'x 7**.* BEND FAST IDLE
ft CAM LINK AT
THIS ANGLE
m T TO VACUUM
SOURCE
\ fASTIDLE
CAM DIAPHRAGM STEM
PY510 RETRACTED BY VACUUM PY511
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FAST IDLE SPEED CHOKE VALVE -*‘T" SCALE
ADJUSTING SCREW WIDE OPEN
O N SECOND ^ |
HIGHEST ^
STEP OF CAM ” l i i i ,
Wm
*'M38*^-
A Wmmmw
— L,
Ml
MACHINED
PY512 SURFACE OF / if.
CARBURETOR /
C h e c k in g W e t F u e l L e v e l (E.C.SJ
CARBURETOR PY514
With engine running and car on a level floor, the
fuel level can be checked or m easured through the
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B o w l V e n t A d ju s t m e n t (C .A .S . C a r b u r e t o r s )
With throttle valve at curb idle speed, it should
be possible to insert a 3/32" (.0937") drill between
bowl vent and the seat, (Fig. 15). This measurem ent
should never exceed .125 inch. (1/8" drill). S~5*V
t-
B o w l V e n t A d j u s t m e n t (E .C .S . C a r b u r e t o r s ) THROTTLE LEVER .
With throttle valve at curb idle speed, it should be CONTACTING STEM
-W IT H O U T DEPRESSING IT
possible to insert a 1/32 (.030) in. drill or gauge be
tween bowl vent and the seat. (Fig. 15.) , STEM
If an adjustm ent is necessary, bend vent rod at
horizontal portion until correct clearance has been • LOCKNUT
obtained. Be sure vent rod does not bind in guide
after adjusting. * 1
D a s h p o t S e ttin g a n d A d ju s tm e n t
With the curb idle speed and m ixture properly set THROTTLE LEVER \ PY515
and a tachom eter installed, position the throttle lever
Fig. 16—Adjusting Dash Pot
so that the actuating tab on the lever is contacting the
stem of the dashpot but not depressing it. The ta setting is obtained, tighten the lock nut on the dash-
chometer should read 2500 rpm if the setting is cor pot against the bracket. (Fig. 16).
rect. To adjust the setting if necessary, screw the To set the idle speed, refer to the Fuel System Gen
dashpot in or out as required. When the desired eral Information Paragraph.
GENERAL INFORMATION
Ball and Ball dual throat 1-1/4 inch carburetor engines when the vehicles are equipped with manual
models C.A.S. (Cleaner Air System) BBD-4721S, BBD- and automatic transmissions respectively. (Fig. 2.)
4722S and BBD-4895S are used on the 318 cu. in. en Both of these carburetors are equipped with a hot idle
gines when the vehicles are equipped with m anual or compensator valve, which is a thermostatically oper
automatic transmissions respectively. (Fig. 1.) The ated air bleed, to relieve an over rich condition at
BBD-4721S is equipped with a dash pot which retards idle. This condition is the result of excessive heat and
the retu rn of the throttle to idle position. (Manual resultant overrich mixtures. The BBD-4723S is
Transmission Only). BBD-4722S is used on vehicles equipped with a dash pot which retards the return of
without air conditioning. BBD-4895S is used on ve the throttle to idle position. (Manual Transmission
hicles with air conditioning only and is equipped with Only).
a hot idle compensator valve, which is a therm ostatic The proper adjustment of the dash pot is very im
ally operated air bleed, to relieve an overrich condi portant! (See carburetor adjustments.)
tion at idle. This condition is the result of excessive Since the service procedures are identical on all
heat and resultant overrich mixtures. BBD carburetors, the illustrations showing the var
Ball and Ball dual throat 1-1/4 inch carburetor ious disassembly procedures will not always show
models E.C.S. (Evaporation Control System) BBD- any one specific carburetor.
4723S and BBD-4724S are also used on the 318 cu. in.
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SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Figs. 1 or2) spring. (C.A.S. Carburetors). On E.C.S. Carburetors,
remove “E” clip and washer from plunger stem, then
(1) Place carburetor assembly on repair block Tool slide accelerator pum p plunger out of air horn. Re
C-3225. move screws attaching bowl vent housing to air horn.
(2) Remove hairpin clips and disengage accelerator Remove housing, vent valve spring and vent valve.
pump operating rod. If the old plunger can be used again, or if a new
(3) Remove clips and disengage fast idle connector plunger is to be installed, place plunger in a ja r of
rod from fast idle cam and choke lever. clean gasoline or kerosene to prevent leather from
(4) Remove vacuum hose between carburetor main drying out.
body and choke vacuum diaphragm. (9) Remove fuel inlet needle valve, seat and gasket
(5) Remove clip from choke operating link and dis from main body.
engage link from diaphragm plunger (stem) and (10) Lift out float fulcrum pin retainer, then lift
choke lever. out floats and fulcrum pin.
(6) Remove choke vacuum diaphragm and bracket (11) Remove step-up piston retaining screw, and
assembly and place to one side to be cleaned as a slide step-up piston and rods out of well, (Fig. 5).
special item. A liquid cleaner may damage diaphragm Now, lift out step-up piston spring. Remove step-up
material. piston gasket from th e bottom of well.
(7) Remove air horn retaining screws and lift air (12) Remove main m etering jets, (Fig. 6).
horn straight up and away from main body, (Fig. 3). (13) Remove venturi cluster screws, then lift ven
Discard gasket. Remove dash pot and bracket (if so turi cluster and gaskets up and away from main body,
equipped). (Fig. 7). Discard gaskets. Do not remove the idle orifice
(8) Disengage accelerator pump plunger from tubes or main vent tubes from the cluster. They can
rocker arm by pushing up bottom of plunger and be cleaned in a solvent and dried with compressed air.
sliding plunger shaft off hook. Slide plunger out of air (14) Invert carburetor and drop out accelerator
horn and remove bowl vent valve, spring seat and pump discharge and intake check balls.
ACCELERATOR PUMP
C O NNECT O R ROD CH O KE OPERATING
LINK ROCKER A R M ACCELERATOR PUMP
ROD
'' DASH POT CHOKE V A C U U M
(MANUAL TRANSMISSION CHOKE LEVER
DIAPHRAGM
ONLY) CHOKE VALVE
DISTRIBUTOR V A C U U M
| ACCELERATOR / AD VA N C E TUBE \ FAST IDLE
PJMP ROD FITTING C O N N EC TO R ROD
1 ‘
mm
AIR HORN
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FAST IDLE FAST IDLE CHOKE OPERATING
CHOKE LEVER DISTRIBUTOR V A C U U M
C O N N EC TO R ROD C O N N EC TO R ROD LINK A D VA N C E TUBE
ACCELERATOR PUMP FITTING
PLUNGER CHOKE DIA PHR A G M
V A C U U M TUBE
CLOSED BOW L
VENT VALVE
H O U S IN G THROTTLE
LEVER
FAST IDLE
SPEED A D JU STIN G
SCREW
ACCELERATOR
PUMP ROD
IDLE SPEED
AD JU STIN G SCREW
(CURB IDLE)
CHOKE
D IAPHRAG M
THROTTLE
LEVER VACUUM
ACCELERATOR PUMP
ROCKER ARM REPAIR
STAND
FAST IDLE
IDLE LIMITER CAP
SPEED A D JUSTING CHOKE DIAPHRAGM
(IDLE MIXTURE
SCREW V A C U U M TUBE
A D JU STIN G SCREW 2)
AIR CLEANER TO AIR CLEANER TO CLOSE CRANKCASE
CHOKE UNLOADER CARBURETOR V A C U U M CARBURETOR V A C U U M VENT TUBE
TANG TUBE FITTING TUBE FITTING FITTING PYJ491
HO T IDLE
COMPENSATOR
PLUNGER VALVE ■" H a t/
SPRING , ACCELERATOR
PUMP PLUNGER
VENTURI
CLUSTER COVER
FLOATS
STEP-UP
PISTON
PY492
SCREW
N N 694B
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STEP-UP PISTON SPRING VENTURI CLUSTER GASKET
COVE!'?
VENTURI
CLUSTER
PUMP DISCHARGE
? . CHECK BALL
NN697
Fig. 5 —Removing or Installing Step-up Piston Fig. 7 —Removing or Installing Venturi Cluster
valve cover to main body. Remove cover, then lift out throttle body, it would be very unlikely that the origi
compensator valve and gasket. (Fig. 4.) (If so nal relationship of the ports to the valves would be
equipped.) obtained. Changing the relationship of the valves to
The carburetor now has been disassembled into the ports would adversely affect normal vehicle oper
three main units, namely, the air horn, main body ation between the speeds of 15 and 30 miles per hour.
and throttle body and the component parts of each However, if it has been determ ined that a new shaft
disassembled as far as necessary for cleaning and or valves is to be installed, adhere to the following
inspection. instruction:
It is usually not advisable to remove the throttle (2) Mark position of throttle valves to shaft, then
shaft or valves from the throttle body, unless wear or slide valves out of bores. CAUTIO N: These screws
damage necessitates the installation of new parts. are staked on the opposite side and care should be
used at removal so as not to break off in the shaft.
INSPECTION AND REASSEMBLY (3) Slide throttle shaft out of throttle body.
(4) Slide new throttle shaft into throttle body.
T h ro ttle B o d y (5) Install throttle valves in their respective bores
(1) Check throttle shaft for excessive wear in throt (with valve num bers toward manifold flange). Install
tle body. (If wear is extreme, it is recommended that new screws but do not tighten. Hold valves in place
throttle body assembly be replaced rath er than in (idle position) with fingers pressing on high sides of
stalling a new shaft in old body.) valves. Tap valves with a screwdriver to seat in
During m anufacture, the location of the idle trans throttle bores. Tighten screws lightly. Hold up to a
fer port and the spark advance control ports to the strong light to check for a proper position in bore.
throttle valve, is carefully established for one particu (They may have to be rotated slightly as the valves
lar assembly. (Fig. 8). are eliptical.) When properly positioned, tighten
If a new shaft should be installed in an old, worn screws securely and stake, using pliers.
(6) Install idle m ixture screws and springs in body.
IDLE TRANSFER
IP PORTS SPARK ADVANCE
CONTROL PORT
MAIN METERING
JET /
/
A | MAIN METERING
' - JET
N N 696B NN698A VALVES
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(The tapered portion must be straight and smooth. If
NO FUEL TO BE
tapered portion is grooved or ridged, a new idle mix
ture screw should be installed to insure having correct
idle m ixture control). DO NOT USE A SCREW
DRIVER. Turn screws lightly against th eir seats with
fingers. Back off num ber of turns counted at disas
sembly. Install new plastic caps (blue) with tab against
stop.
M a in B o d y
(1) Invert main body and place insulator in posi
tion, then place throttle body on main body and align.
Install screws and tighten securely.
(2) Install accelerator pump discharge check ball
(5/32 inch diameter) in discharge passage, (Fig. 9).
Fig. 10 —Testing Accelerator Pump In ta k e and
Drop accelerator pump intake check ball (3/16 Discharge Check Balls
inch diameter) into bottom of the pump cylinder.
To check the accelerator pump system; fuel inlet step-up piston and rods. Carefully guide step-up rods
and discharge check balls, proceed as follows: into main m etering jets. (Fig. 5). Install retaining
(3) Pour clean gasoline into carburetor bowl, ap screw and tighten securely.
proximately 1/2 inch deep. Remove pump plunger (8) Install hot idle compensator valve gasket in posi
from ja r of gasoline and slide down into pump cyl tion in recess in main body, followed by valve. (Be
inder. Raise plunger and press lightly on plunger sure valve is positioned with legs toward outside of
shaft to expel air from pump passage. main body.) (Fig. 4.) Place cover over opening and in
(4) Using a small clean brass rod, hold discharge stall attaching screws. Tighten securely. (If so
check ball down firmly on its seat. Again raise plunger equipped.)
and press downward. No fuel should be emitted from A step-up piston stuck in the UP position will cause
either intake or discharge passage, (Fig. 10). a rich m ixture at part throttle, whereas a piston stuck
If any fuel does emit from either passage, it indi in the DOWN position will cause a lean m ixture at
cates the presence of dirt or a damaged check ball or wide open throttle and poor acceleration.
seat. Clean passage again and repeat test. If leakage is
still evident, install new check balls. The fuel inlet C h e e k in g F lo a t S e ttin g
check ball is located at bottom of the plunger well. The carburetors are equipped with a synthetic
Remove fuel from bowl. rubber tipped fuel inlet needle. The needle tip is a
(5) Install new gaskets on venturi cluster, then in rubber m aterial which is not affected by gasoline and
stall in position in main body. (Fig. 7). Install cluster is stable over a wide range of tem peratures. The tip is
screws and tighten securely. flexible enough to make a good seal on the needle
(6) Before installing step-up piston, be sure step-up seat, and to give increased resistance to flooding.
rods are able to move freely each side of vertical The use of the synthetic rubber tipped inlet needle
position, (Fig. 11). The step-up rods m ust be straight requires that care be used in adjusting the float set
and smooth. ting. Care should be taken to perform this accurately
(7) Slide step-up piston gasket down into position in >
piston well, then install step-up piston spring and
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in order to secure the best performance and fuel
economy. BOWL VENT VALVE PLUNGER
To correctly set the float height, when the carbu SPRING SEAT CLIP POSITIONS
reto r is being overhauled, proceed as follows:
(1) Install floats with fulcrum pin and pin retainer
in main body.
(2) Install needle, seat and gasket in body and
tighten securely.
(3) Invert main body (catch pump intake check
ball) so that weight of floats only, is forcing needle
BOWL VENT VALVE SPRING
against seat. Hold finger against retainer to fully seat OPERATING CLIP
fulcrum pin. NK688
(4) Using Tool T-109-282 or a “T” scale, check the
float, (Fig. 12). There should be 1/4 inch from sur Fig. 13 —Accelerator Pump Assembly
face of fuel bowl to crown of each float at center. air horn. (Fig. 3). Install attaching screws and tighten
If an adjustm ent is necessary, hold the floats on the securely. (When installing air horn be sure leather on
bottom of the bowl and bend the float lip toward or plunger does not fold back.) Install dash pot (if so
away from the needle. Recheck the 1/4 inch setting equipped).
again then repeat the lip bending operation as re (3) Engage fast idle connector rod in choke lever
quired. CAUTION: When bending the float l ip, do not and fast idle cam. Secure with clips.
allow the lip to push against the need l e as the syn (4) Engage accelerator pump operating rod in prop
thetic rubber tip can be compressed sufficiently to er hole in rocker arm (depending on carburetor)
cause a false setting which will affect correct level of and in center hole in throttle lever. Install clips to
fuel in the bowl. After being compressed, the tip is secure.
very slow to recover its original shape.
It is very im portant that the float lip be perpendicu
lar to the needle or slanted not more than ten degrees C h o k e V a c u u m D ia p h ra g m
Inspect the diaphragm vacuum fitting to insure
away from the needle when the float is set correctly.
that the passage is not plugged with foreign material.
Leak check the diaphragm to determ ine if it has in
A ir H o rn ternal leaks. To do this, first depress the diaphragm
(1) Assemble pump plunger, spring and spring
stem, then place a finger over the vacuum fitting to
seat, (Fig. 13). Slide plunger shaft through opening in
seal the opening. Release the diaphragm stem. If the
air horn. Install bowl vent valve over plunger shaft,
stem moves more than 1/16 inch in 10 seconds, the
then engage with pump rocker arm. (C.A.S. Carbure leakage is excessive and the assembly must be re
tors.)
placed.
On E.C.S. carburetors, slide pump plunger spring Install the diaphragm assembly on the air horn as
over plunger stem, then slide plunger up through air follows:
horn. Slide bowl vent valve down over plunger stem (1) Assemble to air horn and tighten the attaching
(with convex side down). Slide valve spring over stem, screws securely.
followed by valve housing. Install attaching screws (2) Install choke operating link in position between
and tighten securely. diaphragm plunger (stem) and choke lever. Install
(2) Place a new gasket on main body, then install clip to secure.
(3) Inspect rubber hose for cracks before placing
FUEL INLET B l/it
NEEDLE VA'.V/ . it on correct carburetor fitting. (Fig. 1). Do not con
SEAT AND IB iP T ^ n nect vacuum hose to diaphragm fitting until after
gasket vacuum kick adjustm ent has been made. (See Carbure
FLOAT FULCRUMl ^ H S M P w l ^ ^ M i l ^ B H i M tor Adjustments.)
PIN RETAINER (4) Loosen choke valve attaching screws slightly.
Hold valve closed, with fingers pressing on high side
of valve. Tap valve lightly with a screw driver to seat
in air horn. Tighten attaching screws securely and
stake by squeezing with pliers.
CARBURETOR ADJUSTMENTS
GxQVv'j^ O r r iG V f ’S
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be made on a reconditioned carburetor, and in the assure that the speeds of each cam step occur at the
sequence listed: proper time during engine warm-up. Adjust as fol
lows:
A c c e le r a t o r P u m p a n d B o w l V e n t (C .A .S .) (1) With fast idle speed adjusting screw contacting
When assembling the accelerator pump to the air second highest speed step on fast idle cam, move
horn, note that the hair pin clip (which opens the choke valve towards closed position with light pres
bowl vent) can be placed in any one of the three sure on choke shaft lever.
positioning notches. These notches correspond to the (2) Insert specified drill (see specifications) be
long, medium and short pump stroke holes in the tween choke valve and wall of air horn. An adjust
throttle lever. Normally, the bowl vent clip on the m ent will be necessary if a slight drag is not obtained
pump stem will be at the middle notch and the pump as drill or gauge is being removed.
operating rod in the medium stroke hole. (3) If an adjustm ent is necessary, bend fast idle
The proper procedure is to adjust the amount of connector rod at angle, using Tool T-109-213, until
bowl vent opening instead of m easuring and setting correct valve opening has been obtained. (Fig. 15).
the height of the pump plunger.
To check or set the adjustment, proceed as follows: V a c u u m K ic k A d ju s t m e n t — (T h is te s t c a n be
(1) Open choke valve so that fast idle cam allows m a d e O N o r O F F v e h ic le .)
throttle valves to be completely seated in bores. The choke diaphragm adjustm ent controls the fuel
(2) Be sure pump operating rod is in medium delivery while the engine is running. It positions the
stroke hole in throttle lever, and that bowl vent clip choke valve within the air horn by action of the link
on pump stem is in center notch. age between the choke shaft and the diaphragm. The
(3) Close throttle valves tightly. It should be just diaphragm must be energized to m easure the vacuum
possible to insert a #69 (.030 + or — .010") drill be kick adjustment. Use either a distributor test machine
tween bowl vent and its seat, (Fig. 14).
If an adjustm ent is necessary, bend the pump oper
ating rod, using Tool T-109-213, at lower angle, until DRILL OR GAUGE
the correct bowl vent opening has been obtained.
This is an im portant adjustment, since too much lift
at the bowl vent will result in considerable loss in low
speed fuel economy.
Remember that if the pump operating rod is moved
to either the short or long stroke position, a corres
ponding change m ust be made in the location of the
bowl vent clip, and the amount of lift of the bowl vent
rechecked and adjusted. m
A c c e l e r a t o r P u m p a n d B o w l V e n t (E .C .S .)
(1) Back olf idle speed adjusting screw to com THROTTLE IN
pletely close throttle valves. Open choke valve so that CLOSED POSITION *
NN699B
fast idle cam allows throttle valves to seat in bores.
(2) Be sure accelerator pump operating rod is in
medium stroke hole in throttle lever.
THROTTLE IN
(3) Close throttle valves tightly. Measure distance
CLOSED PO SITIO N
between top of vent valve plastic housing and end of
pump plunger stem. (Fig. 14). This m easurem ent
should be 9/16 inch.
(4) To adjust pump travel, bend accelerator pump
operating rod, using Tool T-109-213, at lower angle,
until correct pump travel has been obtained.
F a s t Id le S p e e d a n d C a m P o s itio n A d ju s tm e n t
The fast idle engine speed adjustm ent should be
made on the vehicle, as described in the Fast Idle
Speed Adjustm ent (On the Vehicle) Paragraph. How
ever, the Fast Idle Cam Position Adjustm ent can be
made on the bench. This adjustm ent is im portant to
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the cylindrical stem of diaphragm will extend as
DRILL OR GAUGE CHOKE VALVE internal spring is compressed. This spring m ust be
fully compressed for proper m easurem ent of vacuum
\ &£\.
FAST IDLE
CONNECTOR ROD kick adjustm ent.
■> SBEND AT ANGLE) (4) An adjustm ent will be necessary if a slight drag
*/ /,■ is not obtained as drill is being removed. Shorten or
lengthen diaphragm link to obtain correct choke
FAST IDLE SPEED
I-.- ADJUSTING SCREW ON opening. Length changes should be made carefully
ie-
SECOND HIGHEST STEP by bending (open or closing) the bend provided in dia
. OF CAM
LIGHT CLOSING PRESSURE
phragm link. CAUTION: DO NOT APPLY TWIST
ON CHOKE LEVER I NG OR BENDING FORCE TO DIAPHRAGM.
(5) Reinstall vacuum hose on correct carburetor
fitting. R eturn fast idle linkage to its original condi
tion if disturbed as suggested in Step No. 1.
(6) Make following check. W ith no vacuum ap
PY494 plied to diaphragm, the CHOKE VALVE SHOULD
MOVE FREELY between open and closed positions.
fig . i 5 —Fast Id le Cam Position Adjustment If movement is not free, examine linkage for mis
with a vacuum source or vacuum supplied by another alignm ent or interferences caused by bending oper
vehicle. Adjust as follows: ation. Repeat adjustm ent if necessary to provide
(1) If adjustm ent is to be made with engine run proper link operation.
ning, disconnect fast idle linkage to allow choke to
close to the kick position with engine at curb idle. C h o k e U n l o a d e r (W id e O p e n K i c k )
If an auxiliary vacuum source is to be used, open The choke unloader is a mechanical device to par
throttle valves (engine not running) and move choke tially open the choke valve at wide open throttle. It
to closed position. Release throttle first, then release is used to eliminate choke enrichm ent during crank
choke. ing of an engine. Engines which have been flooded or
(2) When using an auxiliary vacuum source, dis stalled by excessive choke enrichm ent can be cleared
connect vacuum hose from carburetor and connect by use of the unloader. Adjust the choke unloader as
it to hose from vacuum supply with a small length of follows:
tube to act as a fitting. Removal of hose from dia (1) Hold throttle valves in wide open position. In
phragm may require forces which damage the system. sert specified drill (see Specifications) between upper
Apply a vacuum of 10 or more inches of m ercury. edge of choke valve and inner wall of air horn.
(3) Insert specified drill (refer to Specifications) be (2) With a finger lightly pressing against valve, a
tween choke valve and wall of air horn (Fig. 16). Ap slight drag should be felt as drill is being withdrawn.
ply sufficient closing pressure on lever to which choke If an adjustm ent is necessary, bend unloader tang on
rod attaches to provide a minimum choke valve open throttle lever until correct opening has been ob
ing without distortion of diaphragm link. Note that tained. (Fig. 17).
D IA PHR A G M STEM j
TO V A C U U M RETRACTED BY
SOURCE VACUUM PY495 * PY496
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Id le S p e e d A d j u s t m e n t ( C u r b I d l e ) CHOKE VALVE FAST IDLE SPEED
(Refer to General Information at Front of Section). WIDE OPEN ADJUSTING SCREW ON
SECOND HIGHEST STEP
ON CAM
F a s t Id le S p e e d A d ju s tm e n t (O n V e h ic le )
Fast idle engine speed is used to overcome cold
engine friction, stalls after cold starts and stalls be
cause of carburetor icing. Set this adjustm ent after
the vehicle odometer indicates over 500 miles to in
sure a normal engine friction level. Prepare engine by
driving at least 5 miles. Connect a tachom eter and set
the curb idle speed and mixture, then proceed as
follows:
(1) With engine off and transmission in PARK or
NEUTRAL position, open throttle slightly.
(2) Close choke valve until fast idle screw can be
positioned on second highest-speed step of fast idle
cam (Fig. 18). FAST IDLE CAM
(3) Start engine and determine stabilized speed. PY497
Turn fast idle speed screw in or out to secure
specified speed. (See Specifications.) Fig. 18—Fast Idle Speed Adjustment (on Vehicle)
(4) Stopping engine between adjustm ents is not
necessary. However, reposition fast idle speed screw and a tachom eter installed, position the throttle lever
on cam after each speed adjustm ent to provide cor so that the actuating tab on the lever is contacting the
rect throttle closing torque. stem of the dashpot but not depressing it. The ta
Before adjusting idle an d /o r fast idle speeds and chometer should read 2000 rpm if the setting is cor
mixtures, make sure that the basic timing and the rect. To adjust the setting if necessary, screw the
distributor control valve are correctly adjusted as out dashpot in or out as required. W hen the desired
lined under Idle Speed Adjustm ent (Curb Idle). setting is obtained, tighten the lock nut on the
dashpot against the bracket.
D a s h p o t S e ttin g a n d A d ju s tm e n t To set the idle speed, refer to the Fuel System Gen
M a n u a l T ra n s m is s io n O n ly eral Information Paragraph.
With the curb idle speed and m ixture properly set
INDEX
Page Page
Automatic Choke (well type) ................................... 1 Choke Unloader (Wide Open Kick) ................... 36
Carburetor Adjustments .......................................... 35 Idle Speed Adjustm ent........................................ 37
Accelerator Pump and Bowl V e n t ................. 35-37 Cleaning Carburetor Parts ...................................... 2
Choke Vacuum Kick ............................................ 36 Disassembling Carburetor........................................ 31
Fast Idle Cam Position........................................ 36 Inspection and Reassembly.................................... 33
Fast Idle Speed (On V e h ic le )............................... 38 Specifications........................................ ..................... 123
GENERAL INFORMATION
The Ball and Ball dual throat 1-1/2 inch Carburetor idle. This condition is the result of excessive heat and
Models C.A.S. (Cleaner Air System) BBD-4725S, BBD- resultant overrich mixtures. These three carburetors
4726S and BBD-4894S are used on the 383 cu. in. En are also equipped with a distributor ground switch,
gines when the vehicles are equipped with manual or which retards the distributor when the carburetor is
automatic transmissions respectively. (Fig. 1). BBD- at curb idle, for better emission control.
4726S is used only on vehicles without air condition The Ball and Ball dual throat 1-1/2 inch carburetor
ing while BBD-4894S is used only on vehicles with air models E.C.S. (Evaporation Control System) BBD-
conditioning. This carburetor is equipped with a hot 4727S and BBD-4728S are used on the 383 cu. in. en
idle compensator valve, which is a therm ostatically gines when the vehicles are equipped with manual and
operated air bleed, to relieve an overrich condition at automatic transmissions respectively. Both of these
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carburetors are equipped with a hot idle compensator The Ball and Ball carburetor is of the dual down
valve which is a thermostatically operated air bleed draft type. Each throat has its own throttle valve and
to relieve an overrich condition at idle. This condition main m etering systems and are supplem ented by the
is the result of excessive heat and resultant overrich float, accelerating, idle and power systems.
mixtures. These two carburetors are also equipped On each BBD series carburetor, the model num ber
with a distributor ground switch, which retards the is stamped on metal tag attached to air horn. Do not
distributor when the carburetor is at curb idle, for remove or destroy this tag, as it is the only means
better emission control. provided for carburetor model identification. Before
Since the service procedures are identical on all attem pting to repair or overhaul carburetor, refer to
BBD carburetors, the illustrations showing the vari model num ber and secure a repair kit for num ber
ous disassembly procedures will not always show any indicated on tag.
one specific carburetor.
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Fig. 1 or2) tle body fitting and vacuum diaphragm.
(5) Remove clip from choke operating link and dis
(1) Insert three Tool T109-287S and one Tool T- engage link from diaphragm plunger and choke lever.
109-288S elevating legs through carburetor throttle (Fig. 1 or 2).
body stud holes. (These tools are used to protect (6) Remove vacuum diaphragm and bracket assem
throttle valves from damage and to provide a suitable bly and place to one side, to be cleaned as a special
base for working.) item. A liquid cleaner may damage the diaphragm
(2) Remove hairpin clips and disengage fast idle material.
connector rod from fast idle cam and choke lever. (7) Remove screws that attach hot idle compensator
(3) Remove hairpin clip and disengage accelerator valve cover to main body. Remove cover and lift out
rod from throttle lever and pump rocker arm. hot idle compensator valve and gasket. (Fig. 3).
(4) Remove vacuum hose between carburetor throt (8) Remove air horn retaining screws and lift air
ACCELERATO R PUMP
RO CKER ARM
ACCELERATOR DISTRIBUTOR GROUN D
BOWL VENT PUMP SWITCH TERMINAL
VALVE CHOKE LEVER
CHOKE VALVE
CHOKE OPERATING
AIR LINK
HORN
FAST IDLE /
CONNECTOR ROD
DIAPHRAGM
\ I
'
STEM
"C
CHOKE VACUUM H
■ ■ ■ I DIAPHRAGM
*
FUEL INLET
^ *
CHOKE VACUUM
HOSE
=NEEDLE, VALVE,*
SEAT J MAIN y FAST IDLE /
A N D GASKET f BODY f
.THROTTLE
CAM T
CLOSED CRANKCASE
IDLE LIMITER CAP (2)
: (IDLE MIXTURE ADJUSTING
BODY THROTTLE LEVER VENT TUBE FITTING SCREWS 2) .
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CHOKE VALVE BOW L VENT
VALVE COVER
FAST IDLE SPEED ACCELERATOR PUMP
AD JU STIN G SCREW CHOKE OPERATING ROCKER ARM
LINK
THROTTLE LEVER CHOKE VALVE ACCELERATOR PUMP
BOW L VENT
ARM
VALVE VENT BOW L VENT
FAST IDLE
TUBE FITTING VALVE COVER
C O N N EC TO R ROD FAST IDLE
BOW L VENT VALVE CONNECTOR ROD
/ VENT TUBE
DISTRIBUTOR
GROUND
AIR H O R N SWITCH
TERMINAL
CHOKE LEVER
/
CURB IDLE
M A IN BODY
SPEED
A D JU STIN G FUEL INLET
SCREW
M l
NEEDLE, VALVE, SEAT
A N D GASKET
AIR GLEANER TO
CARBURETOR IDLE LIMITER CAP (2) FAST IDLE
H OT IDLE (IDLE MIXTURE ADJUSTING CAM
VACUUM
COMPENSATOR SCREWS 2)
TUBE FITTING
VALVE COVER
THROTTLE LEVER
CHOKE V A C U U M ' DISTRIBUTOR VACUUM THROTTLE BODY
TUBE ADVANCE TUBE FITTING UNLOADER TANG
CLOSED CRANKCASE
VENT TUBE CHOKE VACUUM ACCELERATOR PUMP
FITTING DIAPHRAGM ROD PY499
HOT IDLE
GASKET
COMPENSATOR VALVE J r ^ S;s f J step-up PISTON
I “ ^ S . SPR|ng (GASKET AT
PY500
MAINl(^ 4r!O v BOTTOM OF WELL)
METERING JETS ^
US# ’ NR379
f ig . 3 —Removing or Installing H ot Id le Compensator
V a lv e
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VENTURI CLUSTER VENTURI CLUSTER
SCREWS X , . /C A P
VENTURI CLUSTER
GASKET
M A IN
METERING JETS
ACCELERATOR
PUMP DISCHARGE
HOLES GASKET
NR380A
Fig. 5—Removing or Installing M ain M eterin g Jets ACCELERATOR /
PUMP DISCHARGE '
tubes or main vent tubes from cluster. They can be CHECK BALL NR381
cleaned in a solvent and dried with compressed air.
(15) Invert carburetor and drop out accelerator Fig. 6—Removing or Installing Venturi Cluster
pump discharge check ball and intake check ball. valves is to be installed, adhere to the following in
(The intake check ball is the largest.) structions:
(16) Remove screws that attach throttle body to (2) Mark position of throttle valves in bores.
main body. Separate the bodies and discard gasket. (3) Remove screws that hold throttle valves to shaft
(17) Remove plastic limiter caps from idle air mix and slide valves out of bores. These screws are staked
ture screws. (Be sure and count num ber of turns to on the opposite side and care should be used at re
seat the screws, as the same num ber of turns (from moval so as not to break them off in the shaft.
the seat) must be maintained at installation.) Remove Remove the staked end of the screws with a file.
screws and springs from throttle body. (4) Slide throttle shaft and lever out of body.
The carburetor now has been disassembled into (5) Install new throttle shaft and lever.
three sub-assemblies, the air horn, main body and (6) Install throttle valves in their respective bores
throttle body and the components of each disassem (with valve num bers toward manifold). Install new
bled as far as necessary for cleaning and inspection. screws but do not tighten. Hold valves in place (idle
It is usually not advisable to remove the throttle position) with fingers pressing on high sides of valves.
shaft or valves from the throttle body, unless wear or Tap valves lightly with a screwdriver to seat in
damage necessitates the installation of new parts. throttle bores. Tighten screws lightly. Hold up to a
There is about .005 inch clearance between the strong light to check for a proper position in bore.
throttle shaft and the throttle shaft bores in the throt (They may have to be rotated slightly as the valves
tle body. Any clearance over .010 inch, a new throttle are eliptical.) When properly positioned tighten
shaft an d /o r throttle body should be installed. screws securely and stake, using pliers.
(7) Install idle m ixture screws and springs in body.
INSPECTION AND ASSEMBLY (The tapered portion must be straight and smooth. If
tapered portion is grooved or ridged, a new idle mix
T h ro ttle B o d y ture screw should be installed to insure having correct
(1) Inspect the throttle shaft and throttle body for
ide m ixture control.) DO NOT USE A SCREWDRIV
excessive wear. If either or both are worn to the point
ER. Turn screws lightly against their seats with fin-
where the carburetor operation will be affected, re
place as required. IDLE TRAt i'ORTS SPARK
During m anufacture, the location of the idle trans -AD VA N C E
fer port and the spark advance control ports to the PORT
throttle valve, is carefully established for one particu
lar assembly, (Fig. 7).
If a new shaft should be installed in an old, worn
throttle body, it would be very unlikely that the origi
nal relationship of the ports to the valves would be
obtained. Changing the relationship of the valves to II* V T lp k ■ ■ !
the ports would adversely affect normal car operation | p y ^ I p
between the speeds of 15 and 30 miles per hour. If it y,-.:; NR38?
has been determined, however, that a new shaft or Fig. 7—Ports in R e la tio n to Throttle Wolves
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gers. Back off the num ber of turns counted at disas rods are able to move freely, each side of the vertical
sembly. Install new plastic caps with tab against stop. position, (Fig. 9). The step-up rods must be straight,
This screw has a left hand thread. Turn counterclock smooth and free to move forward and backward
wise (Richer) and clockwise (Leaner.) from vertical.
(8) Slide step-piston gasket down into position in
M a in B o d y piston well, then install the step-up piston spring,
(1) Invert main body and place a new gasket in
step-up piston and rods. Carefully guide step-up rods
position and place throttle body on main body and
into main m etering jets (Fig. 4). Install retaining
align. Install screws and tighten securely.
screw and tighten securely. Check piston for free
(2) Install accelerator pump discharge check ball in
operation in well.
discharge passage and check accelerator pum p sys
A step-up piston stuck in the Up position will cause
tem; fuel inlet and discharge check balls as follows:
a rich m ixture at part throttle, whereas a piston stuck
(3) Pour clean gasoline into carburetor bowl, ap in the Down position will cause a lean m ixture at wide
proximately 1/2 inch deep. Remove pump plunger
open throttle and poor acceleration.
from jar of gasoline, flex leather several times, then
slide down into pump cylinder. Raise plunger and
M e a s u r in g F lo a t S e ttin g
press lightly on plunger shaft to expel all air from
pump passage. The carburetors are equipped with a rubber-tipped
(4) Using a small clean brass rod, hold discharge fuel inlet needle. The rubber tip is flexible enough to
check ball down firmly on its seat. Again raise plung make a good seal on the needle seat, and to give
er and press downward. No fuel should be emitted increased resistance to flooding. Care should be taken
from either intake or discharge passage, (Fig. 8). to perform this operation accurately in order to
If any fuel does emit from either passage, it indi secure the best performance and fuel economy.
cates the presence of dirt or a damaged check ball (1) To correctly set float height when carburetor is
seat. Check the passage again and repeat test. If leak being overhauled, install floats with fulcrum pin and
age is still evident, install a new check ball. The fuel pin retainer in main body.
inlet check ball is located at the bottom of the plunger (2) Install rubber-tipped needle, seat and gasket in
well. body and tighten securely.
(5) Install new gaskets on venturi cluster, and in (3) Invert main body so that weight of float only
stall in position in main body. Install cluster screws is forcing needle against seat. Hold finger against re
and tighten securely. Test pump discharge by press tainer to fully seat fulcrum pin.
ing pump plunger down. Two fine streams of fuel (4) Using Tool T-109-280 or a “T” scale, measure
should be forced from cluster. If either stream is float, (Fig. 10). There should be 5/16 inch from sur
restricted or diverted, remove cluster and reclean. face of fuel bowl to crown of each float at center.
After test, pour fuel from the bowl and remove pump If an adjustm ent is necessary, hold the floats on
plunger. bottom of the bowl and bend float lip toward or away
(6) Install main m etering jets. Tighten securely. from needle. Recheck the 5/16 inch setting again and
(Fig. 5). repeat the lip bending operation as required.
(7) Before installing step-up piston, be sure step-up CAUTION: When bending the float lip, do not allow
the lip to push against the needle as the synthetic
rubber tip can be compressed sufficiently to cause a
false setting which will affect correct level of fuel in
ACCELERATOR the bowl.
PUMP PLUNGER*'
-BRASS ROD
/
N O PUR. TO 8! / -.>'*• *VV
E M IT rtD l-A S i PUM P/
IN TAKi. CH fXK BALI GUIDE SIZE
R O A D IO A D STEP.
N U FUEL TO BE EMITTED
INTERMEDIATE
PAST DISCHARGE CHECK
POWER
BALL I STAGED)
MIXTURE STEP
Fig. S—Testing Accelerator P um p In ta k e and
D ischarge Cheek Balls
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excessive and the assembly m ust be replaced.
Install the diaphragm assembly on th e air horn as
follows:
(1) Assemble diaphragm to air horn and tighten
attaching screws securely.
(2) Install choke operating link in position between
diaphragm plunger (stem) and choke lever. Install
clip to secure.
(3) Inspect rubber hose for cracks before placing it
on correct carburetor fitting. (Fig. 1). Do not connect
vacuum hose to diaphragm fitting until after vacuum
FLOAT GAUGE ONLY WEIGHT OF FLOATS kick adjustm ent has been made. (See Carburetor Ad
NR384 AGAINST INLET NFEDIE
justments.)
Fig. 10—Checking flo a t Setting (4) Loosen choke valve attaching screws slightly.
After being compressed, the tip is very slow to re Hold valve closed, with fingers pressing on high side
cover its original shape. of valve. Tap valve lightly with a screw driver to seat
CAUTI ON: It is very important that the float lip be in air horn. Tighten attaching screws securely and
perpendicular to the needle or s l anted not more than stake by squeezing with pliers.
ten degrees away from the needle when the float
height is correct. CARBURETOR ADJUSTMENTS
It is very im portant that the following adjustm ents
A ir H o rn are made on a reconditioned carburetor and in the
(1) Test freeness of choke mechanism in air horn. sequence listed:
The choke shaft must float free to operate correctly.
If choke shaft sticks in bearing areas, or appears to A c c e le ra to r P u m p
be gummed from deposits in air horn, a thorough (1) Back off idle speed adjusting screw. Open
cleaning will be required. choke valve so that fast idle cam allows throttle valves
(2) Remove accelerator pump plunger from gaso to be completely seated in bores. Be sure that pump
line, slide compression spring and spring seat over connector rod is installed in outer hole of throttle
shaft. Install assembly in air horn and engage with lever.
accelerator pump arm. (2) Close throttle valves tightly. Measure the dis
(3) Place a new gasket on main body, and install air tance between top of air horn and end of plunger
horn. Install attaching screws and tighten securely. shaft, (Fig. 11). This m easurem ent should be 1.00 inch.
(When installing air horn, be sure leather on plunger (3) To adjust pump travel, bend pump operating
does not wrinkle or fold back.) rod using Tool T-109-213, at lower angle of rod, until
(4) Engage accelerator pump rod with pump rocker correct setting has been obtained.
arm and install loose end in outer hole of throttle
lever. Install hairpin clip to secure (Fig. 1).
(5) Engage fast idle connector rod (loop at top) in
fast idle cam and in slotted choke lever. Install retain
ing clips to secure.
(6) Install hot idle compensator valve gasket in
position in recess in main body, followed by valve. (Be
sure valve is positioned with legs toward outside of
main body.) (Fig. 3.) Place cover over opening and in
stall attaching screws. Tighten securely. (If so
equipped.)
C h o k e V a c u u m D ia p h ra g m
Inspect the diaphragm vacuum fitting to be sure
th at the passage is not plugged with foreign material.
Leak check the diaphragm to determ ine if it has in
ternal leaks. To do this, first depress the diaphragm
stem, then place a finger over the fitting to seal the
opening. Release the stem. If the stem moves more
than 1/16 inch in ten (10) seconds, the leakage is
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F a s t Id le S p e e d a n d C a m P o s itio n A d ju s tm e n t (2) When using an auxiliary vacuum source, dis
The fast idle engine speed adjustm ent should be connect vacuum hose from carburetor and connect it
made on the vehicle, as described in the Fast Idle to hose from vacuum supply with a small length of
Speed Adjustm ent (On the Vehicle) Paragraph. How tube to act as a fitting. Removal of hose from dia
ever, the Fast Idle Cam Position Adjustm ent can be phragm may require forces which damage the sys
made on the bench. This adjustm ent is im portant to tem. Apply a vacuum of 10 or more inches of m er
assure that the speeds of each step of the cam occur cury.
at the proper time during engine warm-up. (3) Insert specified drill (refer to Specifications) be
(1) With fast idle speed adjusting screw contacting tween choke valve and wall of air horn (Fig. 13). Ap
second highest speed step on fast idle cam, move ply sufficient closing pressure on lever to which choke
choke valve toward closed position with light pres rod attaches to provide a minimum choke valve open
sure on choke shaft lever. ing without distortion of diaphragm link. Note that
(2) Insert specified drill (see specifications) be the cylindrical stem of diaphragm will extend as in
tween choke valve and wall of air horn. An adjust ternal spring is compressed. This spring must be
m ent will be necessary if a slight drag is not obtained fully compressed for proper m easurem ent of vacuum
as drill is being removed. kick adjustment.
(3) If an adjustm ent is necessary, bend fast idle (4) An adjustm ent will be necessary if a slight drag
connector rod at lower angle, using Tool T-109-213, is not obtained as drill is being removed. Shorten or
until correct valve opening has been obtained. (Fig. lengthen diaphragm link to obtain correct choke
12.) opening. Length changes should be made carefully
by bending (open or closing) the bend provided in
Vacuum K i c k A d j u s t m e n t — ( T h i s t e s t c a n b e diaphragm link. CAUTION: DO NOT APPLY TWIST-
m a d e O N o r OFF v e h i c l e . ) ING OR BENDING FORCE TO DIAPHRAGM.
The choke diaphragm adjustm ent controls the fuel (5) Reinstall vacuum hose on correct carburetor
delivery while the engine is running. It positions the fitting. Return fast idle linkage to its original con
choke valve within th e air horn by action of the link dition if disturbed as suggested in Step No. 1.
age between the choke shaft and the diaphragm. The (6) Make following check. With no vacuum applied
diaphragm must be energized to m easure the vacuum to diaphragm, the CHOKE VALVE SHOULD MOVE
kick adjustment. Use either a distributor test machine FREELY between open and closed positions. If move
with a vacuum source, or vacuum supplied by another m ent is not free, examine linkage for misalignment
vehicle. or interferences caused by bending operation. Re
(1) If adjustm ent is to be made with engine run peat adjustm ent if necessary to provide proper link
ning, disconnect fast idle linkage to allow choke to operation.
close to the kick position with engine at curb idle.
If an auxiliary vacuum source is to be used, open C h o k e U n lo a d e r (W id e O p e n K ic k )
The choke unloader is a mechanical device to par-
throttle valves (engine not running) and move choke
to closed position. Release throttle first, then release LIGHT CLOSING ‘
choke. PRESSURE AGAINST
CHOKE LEVER
DRILL OR GAUGE DRILL OR GAUGE
CHOKE VALVE
DIAPHRAGM STEM
'"'"’i ADJUSTING SCREW to : \ • RETRACTED
' ‘ - O N SECOND STEP VACUUM . X
AND AGAINST FACE SOURCF ' APPLY 10 OR MORE
g INCHES OF VACUUM
OF NEXT STEP OF PY503
^ / O N DIAPHRAGM
LIGHT CLOSING PRESSURE FAST IDLE CAM
AGAINST CHOKE LEVER PY502
Fig* f 3—Cfieck in g Choke Vacuum Kick Setting
(W id e O p en Mick)
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tially open the choke valve at wide open throttle.
It is used to eliminate choke enrichm ent during
cranking of an engine. Engines which have been flood
ed or stalled by excessive choke enrichm ent can be
cleared by use of the unloader. A djust the choke ft
unloader as follows:
(1) Hold throttle valves in wide open position. In
sert specified drill (see Specifications) between upper
edge of choke valve and inner wall of air horn. (Fig.
14).
(2) With a finger lightly pressing against shaft
lever, a slight drag should be felt as drill is being UNLOADER
withdrawn. If an adjustm ent is necessary, bend un TA N G O N '
loader tang on throttle lever until correct opening has THROTTLE LEVER-..... - .....
m
been obtained. (Fig. 15.) Use Tool T109-214.
B o w l V e n t A d j u s t m e n t (E .C .S .)
(1) Open choke valve so that fast idle cam allows - 9 SPECIAL TOOL
valves to close, (curb idle). 9 ^
(2) Be sure that pump operating rod is in long PY517
stroke hole in throttle lever. Remove bowl vent valve Unloader Tang
Fig. I S —Bending C hoke
cover if not previously done.
lifter arm until correct clearance has been obtained.
(3) Close throttle valves tightly. Using a narrow
ruler, m easure the distance from top of bowl vent
valve (rubber tip) to top of air horn casting. (Fig. 16.) Id le S p e e d A d ju s tm e n t (C u rb Id le )
This m easurem ent should be 5/32 inch. (Refer to General Information at Front of Section).
(4) If an adjustm ent is necessary, bend bowl vent
lift arm, using a suitable tool, until correct opening M e a s u r in g F lo a t S e ttin g (O n V e h ic le )
has been obtained. (WARNI NG: DO NOT BEND (1) Remove hairpin clip and disengage accelerator
BOWL VENT VALVE LEAF SPRING DURING BEND pum p rod from throttle lever and pump rocker arm.
I NG OPERATION OR I MPROPER VENT VALVE Disconnect automatic choke rod by unsnapping clip.
OPERATI ON WILL RESULT.) Install bowl vent valve (2) Remove air horn attaching screws and lift air
cover and secure with attaching screws. horn straight up and away from main body. Remove
(5) On C.A.S. Carburetors, with the throttle valves gasket.
closed, (curb idle.) there should be 1/16 inch clear B O W l VENT VALVE LIFT ARM
ance between bowl vent valve and seat on air horn.
(Fig. 16). (When m easured at outerm ost or largest
dimension with a drill shank.)
(6) If an adjustm ent is necessary, bend vent valve
V BEND SHIrT„
THRO" TIE
riHLD CLOSfcC
ARM FOR CU-6 'Dv:
BOWL VENT ■'I
ADJUSTMENT
(C.A.S.) ,r„
CARBURETORS V'
Fig. 16—M easuring Bowl Vent Valve Opening
(C.A.S.) (EX.S.)
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(3) Set float fulcrum pin by pressing a finger FAST IDLF. CAM
against fulcrum pin retainer.
There should be enough fuel in the bowl to raise
&
floats so that the lip bears firmly against needle. Ad CHO KE VALVE
ditional fuel may be admitted by slightly depressing WIDE OPEN
float. If fuel pressure in the line is insufficient to
force additional fuel into bowl, add necessary fuel
from a clean container.
WARNING: Since the manifold may be hot, it is dan
gerous to spi l l fuel onto these surfaces. Take the nec
essary precautions to avoid spillage. ijs * •
(4) With only pressure from buoyant float holding
FAST IDLE SPEED
lip against inlet needle, check float setting, using Tool ADJUSTING SCREW
T-109-280, or a “T” scale. There should be 5/16 inch O N SECOND HIGHEST
from surface of bowl (gasket removed) to crown of STEP O F CAM PY505
floats at center.
If an adjustm ent is necessary, hold the floats on the Fig. 17—Fast Idle Speed Adjustment (on Vehicle)
bottom of the bowl, then bend the float lip toward or the vehicle odometer indicates over 500 miles to in
away from the needle. Recheck the 5/16 inch setting sure a normal engine friction level. Prepare engine
again, then repeat the lip bending operation as re by driving at least 5 miles. Connect a tachom eter and
quired. When bending the float lip, do not allow the set the curb idle speed and mixture, then proceed as
lip to push against the needle as the rubber tip can be follows:
compressed sufficiently to cause a false setting which (1) With engine off and transmission in PARK or
will affect correct l evel of fuel in the bowl. After NEUTRAL position, open throttle slightly.
being compressed, the rubber tip is very slow to re (2) Close choke valve until fast idle screw can be
cover its origina l shape. It is very important that the positioned on second highest-speed step of fast idle
float lip be perpendicular to the needle or slanted not cam (Fig. 17).
more than 10 degrees away from the needle when the (3) Start engine and determine stabilized speed.
float is set correctly. Turn fast idle speed screw in or out to secure speci
(5) A fter float has been correctly set, reassemble fied speed. (See Specifications.)
the air horn. (4) Stopping engine between adjustm ents is not
necessary. However, reposition fast idle speed screw
F a s t Id le S p e e d A d ju s tm e n t (O n V e h ic le ) on cam after each speed adjustm ent to provide cor
Fast idle engine speed is used to overcome cold rect throttle closing torque.
engine friction, stalls after cold starts and stalls be To set the idle speed on vehicles, refer to Fuel Sys
cause of carburetor icing. Set this adjustm ent after tem General Information Paragraph.
GENERAL INFORMATION
The Holley dual throat, 2200 series carburetor with a distributor ground switch, which retards the
model C.A.S. (Cleaner Air System) R-4371A, (Fig. 1) distributor when the carburetor is at curb idle, re
is used on the 383 cu. in. engines when the vehicles sulting in better emission control.
are equipped with an automatic transmission and with Each throat of the carburetor has its own throttle
out air conditioning only. This carburetor is equipped valve and main m etering systems and are supple-
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ACCELERATOR PUMP ROCKER ARM CHOKE OPERATING LEVER
ACCELERATOR PUMP ROD FAST IDLE C O N N EC TO R ROD
BOWL VENT VALVE OPERATING LEVER FAST IDLE SPEED ADJUSTING SCREW
FAST IDLE C AM CURB IDLE SPEED AD JU STIN G SCREWS
FAST IDLE C O N N EC TO R /:R O D CRANKCASE VENT CARBURETOR AIR
C H O K IiV A L V i: '' TUBE FITTING CLEANER VENT TUBE
w FITTING
CHOKE VACUUM
D IAPHRAGM ’
CHOKE OPERATING
LINK
CHOKE LEVER
DISTRIBUTOR
VACUUM ADVANCE
TUBE FITTING
CRANKCASE VENT
TUBE FITTING
DISTRIBUTOR
G R O U N D SWITCH
L O N G AIR
C O N TA C T '
H O R N SCREW
F u e l In le t S y s t e m (F ig . 2 )
All fuel enters the fuel bowl through the fuel inlet
fitting in the bowl cover.
The “Viton” tipped fuel inlet needle seats directly
in the fuel inlet seat. The fuel inlet needle is con
trolled by a nitrophyl float (a cellular buoyant m aterial
ADJUSTING TAB
which cannot collapse or leak) and stainless steel float
lever which is hinged by a “Delrin” float fulcrum pin. Fig. 2—Fuel Inlet System
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horn. An external vent actuated by the pump lever is
opened at curb idle or when the engine is not running
to release fuel vapors from the bowl.
Id le S y s t e m (F ig . 3 )
Fuel used during curb idle and low speed operation
flows through the main m etering jet into the main
well.
A horizontal connecting passage perm its the fuel
to flow from the main well into the idle well. Fuel
continues up the idle well and through an idle feed
restriction into an idle channel where the fuel is
mixed with air which enters through idle air bleeds
located in the air horn.
At curb idle the fuel and air m ixture flows down
the idle channel and is further mixed or broken up
by air entering the idle channel through the transfer
slot which is above the throttle valve at curb idle.
Fig. 4 —M ain M eterin g System
During low speed operation the throttle valve moves
exposing the transfer slot and fuel begins to flow The m ixture of fuel and air being lighter than raw
through the transfer slot as well as the idle port. As fuel responds faster to changes in venturi vacuum
the throttle valves are opened further and engine and is also more readily vaporized when discharged
speed increases the air flow through the carburetor into the venturi.
also increases. This increased air flow creates a vacu The main discharge nozzle passage is a part of the
um or depression in the venturi and the main m eter booster venturi which is an integral part of the main
ing system begins to discharge fuel. body casting. Distribution tabs in the main venturi
provide further vaporization of the fuel and air mix
M a i n M e t e r i n g S y s t e m (F ig . 4 ) ture.
As the engine approaches cruising speed the in The main m etering system is calibrated to deliver a
creased air flow through the venturi creates vacuum lean mixture for best overall economy. When addi
(low pressure area) in the venturi of the carburetor. tional power is required a vacuum operated power
N ear atmospheric pressure present in the bowl in the system enriches the fuel-air mixture.
area above the fuel causes the fuel to flow to the
lower pressure area created by the venturi and mag P o w e r E n r ic h m e n t S y s t e m (F ig . 5 )
nified by the booster venturi. The power enrichment system consists of a power
Fuel flows through the main jet into the main well; valve installed in the center of the carburetor body be
air enters through the main well air bleeds and into tween the main jets and a vacuum piston installed in
the main well through holes in the main well tube. the bowl cover. A vacuum passage leads from the top
V A C U U M PASSAGE POWER VALVE PISTON
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of the piston down to the manifold flange. m ixture required for starting and operating a cold
When manifold vacuum is high the vacuum piston engine. A bi-metal spring inside the choke housing,
is raised to the top of its cylinder and the spring on which is installed in a well in the intake manifold,
the piston stem is compressed. holds the choke valve in the closed position.
When manifold vacuum drops to a predeterm ined When the engine starts, manifold vacuum is applied
level the spring overcomes the vacuum and pushes to the choke diaphragm through a rubber hose from
the piston stem down. the throttle body to the choke diaphragm assembly.
The piston stem in turn pushes the power valve The adjustm ent of the choke valve opening, when
stem down opening the power valve and perm itting the engine starts and vacuum is applied to the choke
fuel to flow through the power valve through power diaphragm, is called vacuum kick.
valve channel restrictions and into the main well on Manifold vacuum alone is not strong enough to pro
either side of the power valve. vide the proper degree of choke opening during the
entire choking period. The impact of in rushing air
A c c e le r a t in g P u m p S y s t e m (F ig . 6 ) past the offset choke valve provides the additional
When the throttle valves are opened suddenly the opening force.
air flow through the carburetor responds almost im As the engine warms up manifold heat transm itted
mediately. However, there is a brief time interval or to the choke housing relaxes the bi-metal spring until
lag before the fuel can overcome its inertia and main it eventually perm its the choke to open fully.
tain the desired fuel-air ratio.
The piston type accelerating pump system mechani D is trib u to r V a c u u m A d v a n c e
cally supplies the fuel necessary to overcome this de As engine speed increases, the spark timing must
ficiency for a short period of time. be advanced so that the burning in the cylinder may
Fuel enters the pump cylinder from the fuel bowl be completed at the proper time to achieve maximum
through a slot in the pump well above the normal pressure and efficiency.
position of the pump piston. When the engine is A vacuum spark port located in the throttle bore,
turned off, fuel vapors in the pump cylinder are vented just above the closed throttle valve, is connected to
through the area between the pump rod and pump the distributor vacuum chamber by a series of pas
plunger. sages to a fitting in the carburetor body and a flexible
As the throttle lever is moved the pump link operat hose.
ing through a system of levers and a pump override As the throttle is opened, this port is exposed to
spring pushes the pump piston down. Fuel is forced manifold vacuum which varies with changes in engine
through a passage around the pump discharge needle speed and load.
valve and out the pump discharge jets which are This changing vacuum is applied to the distributor
drilled in the main body. vacuum diaphragm.
The diaphragm, in turn rotates the distributor
A u t o m a t ic C h o k e S y s t e m (F ig . 7 ) breaker plate through a connecting rod changing the
The automatic choke provides the richer fuel-air spark timing to meet engine demands.
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At curb idle, the curb idle screw contacts the dis distributor to maximum retard for improved emission
tributor retarding solenoid. This in turn retards the control at idle.
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR damage diaphragm material.
(6) Remove “E” clip that retains bowl vent valve
(1) Insert three Tool T109-287S and one Tool T109- operating lever on stub shaft of air horn. Slide lever
288s elevating legs through carburetor throttle body off shaft, being careful not to lose lever spring. (Note
mounting stud holes. (These tools are used to protect position of spring). (Fig. 5).
throttle valves from damage and to provide a suitable (7) Remove eight air horn attaching screws, then
base for working.) (Fig. 1). lift air horn straight up and away from main body.
(2) Remove nut and washer attaching accelerator (Long screw in center). USE EXTREME CARE WHEN
pump rocker arm to accelerator pump shaft. Remove HANDLING AIR HORN SO AS NOT TO BEND OR
arm from flats on pump shaft, then disengage accel DAMAGE MAIN WELL TUBES. (Fig. 6).
erator pump rod from center slot in arm and from (8) Disengage accelerator pump plunger from pump
hole in throttle lever. (Fig. 2). shaft by pushing up on bottom of plunger, then tilt
(3) Remove nut and washer that attaches choke ing slightly toward center, then slide off pump shaft.
lever to choke shaft. Disengage fast idle connector Slide plunger stem out of air horn and remove com
rod from lever and fast idle cam. (Fig. 3). pression spring. (Fig. 7).
(4) Remove choke vacuum diaphragm hose from (9) Slide accelerator pump shaft out of air horn.
throttle body tube fitting. Remove screws that attach (Fig. 8).
choke diaphragm and mounting bracket to air horn. (10) Remove fuel inlet fitting and gasket from air
(5) Remove choke diaphragm and at the same time, horn.
disengage choke operating link from slot in choke (11) With air horn inverted, remove screw that at
operating lever. (Fig. 4). Place choke unit to one side taches fuel baffle to air horn. (Fig. 9).
to be cleaned as a special item. A liquid cleaner may (12) Slide nylon float fulcrum pin out of air horn,
THROTTLE
LEVER
CHOKE OPERATING
LEVER
LIMITER CAP
(IDLE MIXTURE
ADJUSTING
SCREW) ACCELERATOR
PUMP ROD
DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
CHOKE VACUUM
DIAPHRAGM FUEL INLET FITTING
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Jkr
-SLOT IN LEVER
CHOKE
OPERATING LINK
ACCELERATOR
PUMP ROD • CHOKE DIAPHRAGM
/
THROTTLE LEVEH — NUt
LOCKWASHER —* 0 PY836 ATTACHING SCREWS
♦ I - /
ENDS OF
SPRING
CHOKE,,''
LEVER BOWL V E N T '
VALVE
FAST IDL-
CAM
FAST IDLE
LOCKWASHE1 CONNECTOR ROD SPRING -
\
?
* HUT 1
PY837 "E" CLIP* . PY839
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FUEL
-AIR H O R N BAFFLE
GASKEV.^ . . ,
LUGS
ACCELERATOR PUMP
PLUNGER \
M A IN WELL TUBES.
D O N O T BEND
M M FULCRUM PIN
. CENTERED
M A IN BODY A TTA C H IN G SCREW *
PY843
ACCELERATOR PUMP
PLUNGER STEM
FLOAT
PY841
AD JUSTING TAB
Fig. 7 —Removing o r Installing Accelerator
(FLOAT DROP)
Pump Plunger
\
SCREWDRIVER
PUMP
PLUNGER
SEAT A N D GASKET
I
/
SMALL END FUEL INLET NEEDLE ------- ► - j p PY844
OF SPRING
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MAIN WELL TUBES SPECIAL
D O -N O T REMOVE. '* TOOL
SERVICED IN AIR*
HORN CASTING ONLY STUB SHAFT
VACUUM
^ POWER
PISTON
11
-FAST IDLE CAM
s.
I
“ i
Ng. I I —i Piston noted at this time, that the num bered side is on the
bottom (or carburetor mounting flange side) and op
posite the idle m ixture screw ports.
DISCHARGE PASSAGE
S»1«
1
• SPECIAL TOOL
f . ■ I
^ POWER VALVE
PY849
PY847
Fig. 15—Installing Accelerator Pump Discharge
Check N eedle
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throttle valves should be replaced if the edges have
been nicked or if the protective plating has been re
moved. Be sure that the choke and throttle shafts
are not bent or scored. Replace any broken or dis
torted springs. Replace all screws and lockwashers
that show signs of stripped threads or distortion.
T h ro ttle B o d y
If the throttle valves were removed because of dam
age, install new valves as follows:
(1) Slide new valves into position in throttle shaft,
with the valve num ber on the bottom, (or mounting
flange side,) and away from idle air m ixture adjusting
screw ports. EMITTED FROM PASSAGE
(2) Install new valve screws but do not tighten. OR PARTS PY850
(3) Hold valves in place with fingers. (Fingers press
ing on high side of valves.) Fig. J6—Testing Accelerator Pump Discharge
(4) Tap valve lightly with a screw driver to center Check N eedle
in bores. Now, tighten valve attaching screws se a piece of drill rod down on needle. Lightly tap drill
curely. Operate the throttle shaft. From closed to open rod with a hammer to form a new seat. Remove and
position, they must operate smoothly without drag or discard old needle and install a new one. Retest as
sticking. Hold throttle body up to a strong light. The described previously. If service fix does not correct
light which is visible around the outer diam eter of the condition, a new main body should be installed.
valves in bore should be uniform. Stake screws, using Remove accelerator pump plunger, discharge check
a pair of pliers. needle and fuel from main body.
(5) Install idle m ixture screws and springs in body. (6) Install power valve, using Tool T109-73S (Fig.
(The tapered portion must be straight and smooth. If 13). Tighten securely.
the tapered portion is grooved or ridged, a new idle (7) Install main m etering jets, using Tool TMC-
m ixture screw should be installed to insure having 36A (Fig. 12). Tighten securely. (Number 65 on throt
correct idle m ixture control.) DO NOT USE A SCREW tle lever side and num ber 63 on other side of bowl.)
DRIVER. Turn screws lightly against their seat with (8) Install accelerator pump discharge check needle
fingers. Back off the num ber of turns (from the seat) in pump discharge passage. (Fig. 15).
counted at disasesmbly. Install new plastic caps with
tab against stop. A ir H o rn
(1) Test freeness of choke mechanism in air horn.
M a in B o d y The choke shaft must float free to operate correctly.
(1) Invert main body and place a new gasket in If choke sticks in bearing bores, or appears to be
position. Place throttle body on main body and align. gummed from deposits in air horn, a thorough clean
Install attaching screws and tighten securely. ing will be required.
(2) Install accelerator pump discharge check needle (2) Install vacuum power piston in its cylinder (Fig.
in discharge passage. (Fig. 15). Check accelerator 17). Lock in position by prick punching rim of cylin
pump, fuel inlet and discharge systems as follows: der (at least three places.) Do not over-stake. Com
(3) Pour clean gasoline into fuel bowl, approximate press piston to be sure no binding exists. If piston
ly 1 inch deep. Slide accelerator pump plunger into sticks or binds enough to hinder smooth operation, a
cylinder. Raise plunger and press down lightly on new piston should be installed.
plunger stem to expell all air from pump passage. (3) Slide accelerator pump plunger compression
(4) Using a small clean brass rod, hold discharge spring over plunger stem, with small diam eter toward
check needle down on its seat. Again raise plunger plunger. Install pump shaft in air horn. (Fig. 8).
and press downward. No fuel should be emitted from (4) As plunger is being installed in air horn, slight
pump discharge passage. (Fig. 16). ly tilt plunger to engage with plunger shaft.
If any fuel does emit from discharge passage, it (5) Install fuel inlet needle valve seat and gasket
indicates the presence of dirt or a damaged or worn in air horn. Tighten securely, using a wide blade
check needle, or seat. Clean the passage again and screwdriver. Install fuel inlet needle in seat. (Fig. 10).
retest as above. If leakage is still evident, attem pt to (6) Install float in position, then slide delrin fulcrum
form a new seat as follows: pin through float hinge to retain float. Center fulcrum
(5) With discharge check needle installed, insert pin. (Fig. 9).
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FLOAT RAISED
FLOAT
PY853
FLOAT STOP
■Wt;,
FLOAT
'^^FLO A T BOTTOM EDGE
OF FLOAT
DRILL OR GAUGE FLOAT SHOULD BE PARALLED
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assembly over stub shaft on air horn. Align spring and (3) If an adjustm ent is necessary, bend fast idle
arm with stub shaft and end of spring over raised connector rod at angle, using Tool T109-213, until
portion of fuel inlet fitting. Install “E” slip to secure. correct valve opening has been obtained.
Vent valve should be in closed position.
(6) Install fast idle cam on air horn stub shaft, with V a c u u m K ic k A d ju s t m e n t — (T h is te s t c a n b e
steps toward fast idle adjusting screw. Install “E” m a d e O n o r O ff v e h ic le .)
clip to secure. (Fig. 14). The choke diaphragm adjustm ent controls the fuel
(7) To install fast idle connector rod, engage plain delivery while the engine is running. It positions the
end in slot of fast idle cam (from inside). Engage other choke valve within the air horn by action of the link
end of rod in choke lever. With choke valve wide open, age betwen the choke shaft and the diaphragm. The
slide lever over choke shaft; (aligning flats) and point diaphragm must be energized to measure the vacuum
ing directly to fast idle cam stub shaft. (Fig. 3). Install kick adjustment. Use either a distributor test machine
attaching lockwasher and nut. Tighten securely. with a vacuum source, or vacuum supplied by another
vehicle.
C h o k e V a c u u m D ia p h ra g m (1) If adjustm ent is to be made with engine running,
Inspect the diaphragm vacuum fitting to be sure
disconnect fast idle linkage to allow choke to close
that the passage is not plugged with foreign material.
to the kick position with engine at curb idle. If an
Leak check the diaphragm to determ ine if it has in
ternal leaks. To do this, first depress the diaphragm auxiliary vacuum source is to be used, open throttle
stem, then place a finger over the fitting to seal the valves (engine not running) and move choke to closed
opening. Release the stem. If the stem moves more position. Release throttle first, then release choke.
than 1/16 inch in 10 (ten) seconds, the leakage is (2) When using an auxiliary vacuum source, dis
excessive and the assembly must be replaced. connect vacuum hose from carburetor and connect it
Install choke diaphragm assembly on the air horn to hose from vacuum supply, with a small length of
as follows: tube to act as a fitting. Removal of hose from dia
(1) Engage free end of choke operating link in slot phragm may require forces which can damage the
of choke lever. system. Apply a vacuum of 10 or more inches of
(2) Install choke diaphragm and mounting bracket mercury.
on air horn. Install attaching screws and tighten se (3) Insert specified drill (refer to Specifications) be
curely. tween top of choke valve and wall of air horn (Fig.
(3) Inspect rubber hose for cracks before placing it 22). Apply sufficient closing pressure on lever to
on correct carburetor fitting, (Fig 1) after vacuum which choke rod attaches to provide a minimum choke
kick adjustm ent has been made. valve opening, without distortion of diaphragm link.
Note that the cylindrical stem of diaphragm will ex
CARBURETOR ADJUSTMENTS tend as internal spring is compressed. This spring
It is very im portant that the following adjustm ents
LIGHT CLOSING a
are made on a reconditioned carburetor and in the PRESSURE O N &
sequence listed: CHOKE LEVER------T . ! * “» ...
F a s t Id le S p e e d a n d C a m P o s itio n A d ju s tm e n t
The fast idle engine speed adjustm ent should be
made on the vehicle, as described in the Fast Idle
Speed Adjustm ent (On Vehicle) paragraph. However,
the Fast Idle Cam Position Adjustm ent can be made DRILL OR GAUGE
on the bench. This adjustm ent is im portant to assure FAST IDLE SPEED
ADJUSTING SCREW
that the speeds of each step of the cam occur at the
O N SECOND HIGHEST
proper time during engine warm-up. * STEP OF C A M
(1) With fast idle speed adjusting screw contacting (ADJUST SCREW TO
OBTAIN FAST IDLE
second highest speed step on the fast idle cam, move
SPEED) - CAM
choke valve toward closed position with light pressure
on choke shaft lever.
BEND ROD
(2) Insert specified drill (see Specifications) between A T AN G LE FOR
top of choke valve and wall of air horn. (Fig. 21). An ADJUSTM ENT SCREW PY855
adjustm ent will be necessary if a slight drag is not Fig. 2 1 —Fast Id le Speed and Cam Position
obtained as drill shank is being removed. Adjustment
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DRILL OR GAUGE
DRILL OR GAUGE —
M IN IM U M OF
10 INCHES , . J :*
OF VACUUM W± V%
,If
OR DIAPHRAGM* W &
(REQUIRED) i. V
1
LIGHT BEND T A N G O N
LOSING PRESSURE
THROTTLE LEVER
ON CHOKE LEVER
TO ADJUST
BEND LINK
FOR ADJUSTMENT
PY856 PY857
Fig. 2 2 —Vacuum Kick Adjustment Fig. 2 3 —Choke U nloader Adjustment
(W ide Open Kick)
must be fully compressed for proper m easurem ent of
vacuum kick adjustment. choke valve so that fast idle cam allows throttle valves
(4) An adjustm ent will be necessary if a slight drag to be completely seated in bores. Be sure that pump
is not obtained as drill is being removed. Shorten or connector rod is installed in center slot of accelera
lengthen diaphragm link to obtain correct choke open tor pump rocker arm.
ing. Length changes should be made carefully by (2) Close throttle valves tightly. Measure the dis
bending (open or closing) the bend provided in dia tance between top of air horn and end of plunger
phragm link. CAUTION: DO NOT APPLY TWISTING shaft, (Fig. 24). This m easurem ent should be 9/16 inch.
OR BENDING FORCE TO DIAPHRAGM. (3) To adjust pump travel, bend pump operating
(5) Reinstall vacuum hose on correct carburetor rod, using Tool T109-213, at loop of rod, until correct
fitting. R eturn fast idle linkage to its original condi setting has been obtained.
tion if disturbed as suggested in Step No. 1.
(6) Make following check. With no vacuum applied B ow l V en t
to diaphragm, the choke valve should move freely (1) With curb idle speed adjusting screw at curb
between open and closed positions. If movement is idle, there should be 5/64 inch clearance between
not free, examine linkage for misalignment or inter bowl vent valve and seat on air horn when throttle
ferences caused by bending operation. Repeat adjust valves are closed. (Fig. 25).
ment if necessary to provide proper link operation. (2) If an adjustm ent is necessary, bend tang on ac
celerator pump rocker arm, using Tool T109-41, until
C h o k e U n lo a d e r (W id e O p e n K ic k )
The choke unloader is a mechanical device to par C ACCELERATOR PUMP
i PLUNGER STEM
tially open the choke valve at wide open throttle. It is
used to eliminate choke enrichm ent during cranking
of an engine. Engines which have flooded or stalled
by excessive choke enrichm ent can be cleaned by use
of the unloader. Adjust the choke unloader as fol E H I t!
lows:
(1) Hold throttle valves in wide open position. Insert
specified drill (see Specifications) between upper edge
of choke valve and inner wall of air horn. (Fig. 23). *fr mr N •if
(2) With a finger slightly pressing against shaft lev
er, a slight drag should be felt as drill is being with ROD IN CENTER
SLOT OF A R M
drawn. If an adjustm ent is necessary, bend unloader
tang on throttle lever until correct opening has been BEND^
ACCELERATOR PUMP v THROTTLE AT FULLY
obtained. (Fig. 23). Use Tool T109-213. ROD FOR A D JU S TM E N T^ ■ CLOSED POSITION
PY858
A c c e le ra to r P u m p
(1) Back olf curb idle speed adjusting screw. Open
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DRILL OR GAUGE CHOKE VALVE
THROTTLE AT WIDE OPEN
I CURB IDLE
FAST IDLE
SPEED
ADJUSTING
SCREW O N
SECOND
HIGHEST
STEP OF
CAM
(ADJUST
SCREW TO
SEAT O BTAIN
FAST IDLE
BOWL VENT VALVE SPEED)
(C.A.S. CARBURETOR)
FAST IDLE
C AM SCREW
PY859 PY860
Fig. 2 5 —Bowl V e n t Adjustment Fig. 2 6 —Fast Idle Speed Adjustment (On Vehicle)
correct vent valve opening has been obtained. (1) With engine off and transmission in PARK or
NEUTRAL position, open throttle slightly.
fefle S p e e d A d j u s t m e n t ( C u r b I d l e ) (2) Close choke valve until fast idle screw can be
(Refer to General Information at Front of Section.) positioned on second highest speed step of fast idle
cam. (Fig. 26).
F a s t I d l e S p e e d A d j u s t m e n t (O n V e h i c l e ) (3) Start engine and determ ine stabilized speed.
Fast idle engine speed is used to overcome cold Turn fast idle speed screw in or out to secure speci
engine friction stalls, after cold starts and stalls be fied speed. (See Specifications.)
cause of carburetor icing. Set this adjustm ent after (4) Stopping engine between adjustm ents is not
the vehicle odometer indicates over 500 miles to in necessary. However, reposition fast idle speed screw
sure a normal engine friction level. Prepare engine on cam after each speed adjustm ent to provide cor
by driving at least 5 miles. Connect a tachom eter and rect throttle closing torque.
set the curb idle speed and m ixture, then proceed as To set idle speed on vehicles, refer to Fuel System
follows: General Information Paragraph.
INDEX
Page Page
Automatic Choke (well type) ................................... 2 Idle S p e e d ............................................................... 60
Carburetor A djustm ents........................................ 57 Secondary Throttle L e v e r..................................... 59
Accelerator Pump and Bowl V e n t..................... 59-60 Secondary Throttle L ockout........................... 59
Air Valve S e c o n d a ry ........................... ................... 60 Cleaning Carburetor Parts ..... ........................... . 2
Bowl Vent Valve .................................................... 60 Closed Crankcase Vent System (Group 9—Engine)
Choke Unloader (Wide Open Kick) .................... 58 Disassembling Carburetor ...................................... 53
Choke Vacuum K ic k ............................................... 58 General Information .................................................. 50
Fast Idle Cam Position ........................................ 58 Inspection and R eassem bly.................................... 55
Fast Idle Speed (On Vehicle) ............................. 60 S pecifications............................................................. 124
GENERAL INFORMATION vehicles equipped with air conditioning only, and has
a hot idle compensator valve. This valve is a therm o
3 4 0 C u b ic In c h E n g in e statically operated air bleed, to relieve an overrich
The Carter four barrel carburetor models C.A.S. condition at idle. This condition is the result of ex
(Cleaner Air System) AVS-4933S, AVS-4934S and AVS- cessive heat and resultant overrich mixtures. (Fig. 2).
4935S are used on the 340 cu. in. engines, when the The Carter four barrel carburetor models E.C.S.
vehicles are equipped with manual or automatic (Evaporation Control System) AVS-4936S and AVS-
transmissions respectively. AVS-4935S is used with 4937S are also used on the 340 cu. in. engines when
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CHOKE VALVE SECONDARY
AIR VALVE
BOWL
VENT VALVE
VACUUM CHOKE MEASURING
DIAPHRAGM HOLE PLUG CHOKE VALVE
STEP-UP PISTON
COVER PLATE
ACCELERATOR BOWL VENT
DISTRIBUTOR /P U M P LINK
:VACUUM
I VALVE TUBE
AIR HORN
ACCELERATOR FITTING
ADVANCE / 'PUMP PLUNGER
TUBE FITTING
CHOKc \
FAST IDLE
CONNECTOR LEVER
KUI
ROD
X-
CLOSED
CHOKE BOWL
CRANKCASE
OPERATING VENT VALVE
VENT TUBE
■ FITTING
A LINK ' OPERATING
ROD
IDLE MIXTURE /
ADJUSTING SCREWS
\uNLOADI-.V r * CHOKE VACUUM
TANG / -
ACCELERATOR P U M P / X
ROCKER ARM - THROTTLE 'x BOWL VENT VALVE
LEVER OPERATING LEVER
, / SOLENOID
FAST IDLE SPEED SOLENOID OPERATING
ACCELERATOR PUMP ROD ADJUSTING SCREW FAST CURB PLUNGER LEVER
. IDLE
SOLENOID FAST CURB IDLE
CURB IDLE SPEED
ADJUSTING SCREW
ADJUSTING SCREW
PY725
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CHOKE VALVE ACCELERATOR PUMP
PLUNGER STEM;
CHOKE VALVE
ACCELERATOR
ACCELERATOR PUMP PUMP ROCKER
■ROCKER ARM ARM
STEP-UP PISTON COVER
PLATE (2) STEP-UP PISTON
COVER PLATE (2)
CHOKE VACUUM
DIAPHRAGM BOWL VENT FUEL INLET
VALVE ARM TUBE FITTING
DISTRIBUTOR ACCELE
VACUUM \ BOWL VENT VALVE
RATOR
ADVANCE
iu-PUMP
■TUBE FITTING mm rod
CHOKE CONTROL (CENTER
CLOSED FAST IDLE LE¥ER & fyy \ HOLE)
✓CONNECTOR CHOKE
CRANKCASE
VENT ROD DIAPHRAGM* \ CURB IDLE
TUBE FITTING ^ FAST IDLE LINK, v \ SPEED
^ CAM A \ ADJUSTING
UNLOADER \ SCREW
TANG ACCELERATOR
IDLE MIXTURE ADJUSTING SECONDARY THROTTLE
SCREW LIMITER CAPS THROTTLE LEVER THROTTLE PUMP ROD
4 BODY
CONNECTOR LINK DIAPHRAGM
ACCELERATOR V \ FAST IDLE SPEED
VACUUM HOSE IDLE MIXTURE ADJUSTING
PUMP ROD ADJUSTING SCREW SCREW LIMITER CAPS
CHOKE
ACCELERATOR PUMP VACUUM'
.CURB IDLE SPEED PLUNGER STEM DIAPHRAGM DISTRIBUTOR VACUUM -
ADJUSTING SCREW
CARBURETOR ASSEMBLY AVS -CAS. ADVANCE TUBE ■FITTING
ACCELERATOR PUMP CHOKE VALVE STEP-UP PISTON CHOKE'
PLUNGER STEM COVER PLATE (2) VALVE ACCELERATOR
\ ACCELERATOR PUMP BOWL VENT VALVE PUMP
ACCELERATOR! PLUNGER LINK AIR VALVE AIR VALVE | ROCKER ARM
(CHECKING OPENING)
PUMP \ PLUG
BOWL VENT VALVE / throttle
ROCKER ARM
TUBE FITTING FUEL INLET J LEVER
TUBE FITTING
FUEL INLET
CHOKE
LEVER
TUBE FITTING ^ y / CURB
l IDLE
~ ADJUSTING
CHOKE CONTROL
r ^ . ^SCREW
ACCELERATOR LEVER
PUMP ROD BOWL VENT VALVE
\ DISTRIBUTOR
TUBE FITTING
THROTTLE | \ GROUND '
LEVER CHOKE SWITCH
DIAPHRAGM LINK TERMINAL
AIR CLEANER TO CLOSED
* CARBURETOR - I \ \ CRANKCASE
CURB IDLE VENT TUBE BOWL VENT VALVE DISTRIBUTOR \ \ VENT TUBE
SPEED VACUUM \ \ FITTING
OPERATING LEVER
ADJUSTING ADVANCE \ \
SCREW
FAST IDLE
rHrwe TUBE FITTiNG >
S IDLE MIXTURE
FAST IDLE CONNECTOR ROD ADJUSTING SCREW
SPEED DIAPHRAGM LIMITER CAPS
ADJUSTING
SCREW BOWL VENT VALVE
CHOKE UNLOADER TANG OPERATING LEVER
(BEND TO ADJUST (BEND TO ADJUST)
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the throttle to close to a low idle speed throttle posi removing the air horn o r the carburetor from the
tion when the ignition key is turned off, to prevent engine. The prim ary venturi assemblies are replace
“after running.” able and contain many of the calibration points for
Since the service procedures are identical on all both the high and low speed system. One fuel bowl
Carter AVS carburetors, the illustrations showing the feeds both the prim ary and secondary nozzles on the
various disassembly procedures will not always show right side while the other fuel bowl takes care of the
any one specific carburetor. prim ary and secondary nozzles on the left side. This
The throttle valves of the secondary half of the provides improved perform ance in cornering, quick
carburetor are mechanically connected to th e prim ary stops and acceleration.
valves and open with the prim ary after an approxi All the m ajor castings of the carburetor are alumi
mate 60° lag; and continue to open until both prim ary num, with the throttle body cast integral with the
and secondary throttle valves reach the wide open main body. This allows an overall height reduction in
position simultaneously. As engine speed increases, the carburetor. The section containing the accelerator
the forces exerted by the velocity of intake air down pump is term ed the prim ary side of the carburetor.
through the venturis of the carburetor increases and The rear section is the secondary. The five conven
tends to overcome the air valve spring attached to the tional systems used in previous four barrel carburet
air valve, perm itting the air valve to position its self ors are also used in this unit. The five conventional
according to engine requirem ents. systems are, two float systems, two low speed systems,
The AVS (air valve secondary) carburetor con (primary side only) two high speed systems, one
tains many features, some of which are the locations accelerator pump system and one automatic choke
for the step-up rods and pistons. The step-up rods, control system.
pistons and springs are accessible for service without
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Fig. 1) (9) Remove eight screws that attach air horn to
main body. Lift air horn straight up and away from
(1) Place carburetor assembly on repair stand Tool main body. When removing air horn, use care so as
C-3400 or T-109-287S elevating legs. These tools are not to bend or damage floats. Remove accelerator
used to protect throttle valves from damage and to pump, plunger lower spring from pump cylinder.
provide a suitable base for working. (10) Remove hot idle compensator and gasket, (if so
(2) Remove hairpin clip that attaches fast idle con equipped).
nector rod to fast idle cam. Disengage rod from cam
then swing rod at an arc until it can be disengaged D is a s s e m b lin g A ir H o r n
from choke operating lever. Place air horn in an inverted position on bench (to
(3) Remove hairpin clip that holds throttle connec protect the floats) then proceed to disassemble as fol
tor rod in center hole of accelerator pump arm. Dis lows:
engage rod from arm and throttle lever, then remove (1)) Using a suitable tool, remove float fulcrum
from carburetor.
(4) Remove screws attaching step-up piston and rod A 'lS f c If STEP UP
cover plates. Hold cover down w ith a finger to prevent 'ON a n d
*■ ; ..........— H'-.TNG ROD
piston and rods from flying out. Lift off plates and
slide step-up pistons and rods out of air horn, (Fig. STEP UP
PISTON
3). Remove step-up piston springs. ' • SPRING
(5) Remove vacuum hose between carburetor throt
tle body and vacuum diaphragm.
(6) Remove clip from choke operating link and dis STEP UP
PISTON
engage link from diaphragm plunger (stem) and
choke lever. (Fig. 2).
(7) Remove vacuum diaphragm and bracket assem (STEP UP
PISTON
bly and place to one side to be cleaned as a special SPRING
item. A liquid cleaner may damage diaphragm ma SCREW
terial. "C
COVER PLATE 3 STAGE METERING ROD NR513A
(8) Remove screws that attach idle solenoid bracket
and solenoid to air horn and main body. Remove
solenoid assembly from carburetor. (If so equipped.)
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, ACCELERATOR PUMP
JET HOU SIN G
SFECIAL TOOL
G a S.CET
PRIMARY *DISCHARGE PASSAGE
VENTURI
CLUSTER PRIMARY :
{PUMP SIDE) ; - VENTURI * ,;r *
CLUSTER
< (Si-4-' * ■ ■ (CHOKE SIDE) V
/ #
f. INTAKE
■J/V '.f £ ?\ CHECK ASSEMBLY
- 1,
ACCELERATOR — M AIN
PUMP WELL '"‘-•'METERING
JET
\
INTAKE CHECK BALL
M A IN METERING
JET PRIMARY (2)
t SECONDARY
!2 )
I ASSEMBLY
INTAKE CHECK ASSEMBLY '
NR514 NR515
Fig. 4 —Removing or Installing Accelerator Pump Fig. 5 —Removing or Installing M ain M etering Jets
Jet Housing
ing jets (secondary side), (Fig. 5). Remove intake
pins, (left and right) then lift float up and out of check.
bosses on air horn. It is suggested that the float on the (4) Remove screws that attach prim ary venturi
pump side be m arked so that floats can be reinstalled (choke and pump side) to main body. Lift venturi
in th eir respective positions. straight up and away from main body, (Fig. 6). Dis
(2) Remove two needle valves from their respective card gaskets. The venturi assemblies are not inter*
seats, after m arking one on pump side for identifica changeable, side for side and must be reinstalled in
tion. Using a wide blade screw driver, remove needle their original locations at reassembly.
valve seats. Be sure each needle valve is returned to (5) Using Tool T-109-59, screw driver bit, remove
its original seat at reassembly. accelerator pump intake check valve located inside
(3) Remove shoulder screw and spring holding ac fuel bowl, adjacent to accelerator pump cylinder.
celerator pump rocker arm and bowl vent arm to air (6) Remove plastic limiter caps from idle air mix
horn. (C.A.S.) Remove arms and disengage pump link ture screws. (Be sure and count num ber of turns to
from pump stem. Slide acelerator pump plunger and seat the screws (from stop), as the same num ber of
spring out of air horn. Remove gasket. turns (from seat) must be maintained at installation.)
(4) Place accelerator pump plunger in a ja r of Remove screws and springs from throttle body.
clean gasoline or kerosene, to prevent leather from The carburetor now has been disassembled into two
drying out. units, namely air horn and the main and throttle body
(5) Remove fuel inlet fitting and filter screen from casting. The component parts of each have been dis
air horn. assembled as far as necessary for cleaning and in
(6) Test freeness of choke mechanism in air horn. spection.
The choke shaft must float free to operate correctly.
^G A S K E T
If choke shaft sticks in bearing area, or appears to be
gummed from deposits in air horn, a thorough clean
ing will be required. / PRi/ViARY VENTURI
CLUSTER
I’ * " :?UMP SIDE)
M a in B o d y D is a s s e m b ly
(1) Remove screws th at attach accelerator pum p jet ^ P R I M A R Y VENTURI
housing to main body. Lift out jet housing and gasket CLUSTER
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It is usually not advisable to remove the throttle ECONDARY
shafts or valves unless wear or damage necessitates VALVE
the installation of new parts. During the m anufacture
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, (Fig. 7).
The valves are milled to give proper port relation.
If new throttle shafts should be installed in an old
worn body, it would be very unlikely that the original
relationship of these ports to the valves would be ob PRIMARY
/
tained. A very slight change in the port relationship VALVE
to the valves would adversely affect normal carbu
KF946C
retor operation, between the speeds of 15 and 30
miles per hour. Fig. 8 —Throttle V a lv e Identification
It is recommended that if the throttle shafts are (2) Tap valves lightly in this position, tighten
excessively worn, that a new carburetor be installed. screws securely. Stake screws by squeezing with
However, if the throttle valves have become nicked, pliers.
burred or damaged, new valves may be installed, pro (3) Install idle mixture screws and springs in throt
viding the following instructions are carefully fol tle body. (The tapered portion must be straight and
lowed. The screws that attach the throttle valves are smooth. If tapered portion is grooved or ridged, a
staked on the opposite side and care should be used in new idle m ixture screw should be installed to insure
removal so as not to break the screws in the throttle having correct idle m ixture control.) DO NOT USE A
shaft. Remove the staked portion of the screws with a SCREW DRIVER. Turn screws lightly against their
file. seats with fingers. Back off the num ber of turns
Remove the screws that attach the prim ary throttle counted at disassembly. Install new plastic caps with
valves to the throttle shaft and slide valve (or valves) tab against stops. This screw has a left hand thread.
out of bores. Turn counterclockwise (Richer) and clockwise (Lean
Remove the screws that attach the secondary throt er).
tle valves to the throttle shaft and slide valve (or (4) Be sure all the metering holes and vent tubes
valves) out of bores. are clean, in the primary venturi. Place new prim ary
The prim ary valves and secondary valves are not venturi gaskets in position, then install the prim ary
interchangeable and should be kept separate in order venturi (pump and choke side) by lowering straight
that each may be returned to its respective bore. (Fig. down on gaskets (Fig. 6). Install attaching screws and
8 ). tighten securely.
(5) Install prim ary and secondary main m etering
INSPECTION AND REASSEMBLY jets, using Tool T-109-58. (Fig. 5). Tighten jets se
curely. Install intake check.
(1) Slide primary throttle valve (or valves) into (6) Install accelerator pump intake check ball using
their respective bores, install new screws, but do not Tool T-109-59.
tighten. Be sure idle speed adjusting screw is backed (7) Install hot idle compensator and gasket, (if so
out. Hold valves in place with fingers. (Fingers press equipped). Tighten screws securely.
ing on high side of valves.)
A c c e le ra to r P u m p T e s t
SPARK ADVANCE PORT IDU; DISCHARGE POP! 3 (1) Pour clean gasoline into carburetor bowl (ap
PRIMAL . 'i * 1 ' v ,/ \ proximately 1/2 inch deep). Remove accelerator pump
THROTTLE | o plunger from jar of gasoline. Flex leather several
vAi vi \ — ; r~\ * . - , % , .1 ,
times, then slide into pump cylinder.
(2) Install accelerator pump discharge check needle
in discharge passage. Raise pump plunger and press
lightly on plunger shaft to expel air from pump pas
sages. Using a small clean brass rod, hold discharge
check needle firmly on its seat. Again raise plunger
and press downward. No fuel should be emitted from
either the intake or discharge passage.
!0 !.r 1 -'Ai-i'.B-.? PORTS NR517 (3) If fuel does emit from intake passage, remove
Fig. 7 —Ports in Relation to Throttle Valves intake check ball and reclean the passage. Fuel leak
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age at discharge check needle indicates presence of affect correct level of fuel in the bowl.
dirt or a damaged check needle. Clean again and (4) Place a new air horn to main body gasket in
then install a new check needle. Retest for leakage. position on air horn, then install float needle valve
(4) If either intake check assembly or discharge seats. (Be sure each needle seat and needle is rein
check needle leaks after above test and service fix, stalled in its original position.)
attempt to reseat as follows: (5) Slide right and left floats into position in air
horn, then install float fulcrum pins. (Be sure marked
In ta k e Check Ball float is installed on pump side of the air horn.) See
Remove the intake check assembly from the throt disassembly procedures.
tle body. Install a new check assembly, then retest as (6) After floats have been installed, check float
described previously (Fig. 5). alignment, level and drop settings as follows:
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fuel economy without sacrificing performance in the
intermediate speed range. To do this, there is a
step-up piston, new metering rods with two diam
eters, and primary metering jets, (Fig. 12).
(5) Slide step-up piston spring into piston cylinders,
followed by step-up pistons and step-up rods. Install
cover plates and attaching screws while holding step-
up pistons down in position. Tighten screws securely.
(6) Check fit of choke valve in air horn. The valve
should be evenly spaced on all sides. Loosen screws
Fig. 10—Checking Float Height and reposition if necessary.
(7) Engage throttle connector rod with hole in throt
Float Drop Setting
Float drop is the distance the floats move from the tle lever. Install other end in accelerator pump rocker
inverted air horn (float level setting position) to the arm, (center hole) and install hairpin clip to secure.
airhorn in upright position. (8) Engage upper end of fast idle connector rod in
(1) With air horn inverted (upside down) place air slot of choke operating lever. Swing rod in an arc
horn in upright position and measure the distance and engage with fast idle cam. Secure with hairpin
floats move from inverted to upright position. This clip.
measurement should be 1/2 inch. (Fig. 11). Air horn
gasket installed. If an adjustment is necessary, bend Installing Vacuum D iap h rag m
Inspect the diaphragm vacuum fitting to be sure
stop tabs on float levers until correct drop setting that the passage is not plugged with foreign material.
has been obtained. Bend tab toward needle seat to Leak check the diaphragm to determine if it has in
lessen drop, or away from seat to increase drop. ternal leaks. To do this, first depress the diaphragm
(2) After floats have been checked and adjusted, stem, then place a finger over the vacuum fitting to
continue to assemble carburetor as follows: seal the opening. Release the diaphragm stem. If the
(3) Place accelerator pump plunger lower spring in stem moves more than 1/16 inch in ten (10) seconds,
pump cylinder, then lower air horn carefully down the leakge is excessive and the assembly must be
on main body. Care must be taken to center small replaced. Install the diaphragm assembly on the car
brass main bleed tubes so that they will pass through
buretor as follows:
holes in air horn without being damaged. Be sure
(1) Assemble to carburetor and tighten attaching
the fuel baffles on the air horn, slide down in front,
screws securely.
(bowl side) of the float chamber baffles, or the air
(2) Install choke operating link in position between
horn will not index correctly with the main body and
diaphragm plunger (stem) and choke lever. Install
can cause the floats to hang up. Be sure the leather
clip to secure. Secure choke lever end with spring
on the plunger does not curl or wrinkle. Accelerator
clip.
pump operation will be affected if this precaution is (3) Inspect rubber hose for cracks, before placing it
not observed. Place curb idle solenoid in position on on correct carburetor fitting. (Fig. 2). Do not connect
carburetor. Install attaching screws and tighten se the vacuum hose to the diaphragm fitting until after
curely. (If so equipped.) the vacuum kick adjustment has been made. (See Car
(4) Install air horn attaching screws and tighten buretor Adjustments.)
securely.
The change from low speed, best fuel economy, CARBURETOR ADJUSTMENTS
road load mixtures to richer wide open throttle full
power mixtures is now accomplished in two steps. The following adjustments should be made with the
This has made it possible to secure best low speed carburetor on the bench for ease of working, and,
yCOVER
SCREW
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should be made in the following order: closed position. Release throttle first, then release
choke.
Fast Idle Speed Cam Position Adjustment (2) When using an auxiliary vacuum source, dis
The fast idle engine speed adjustment should be connect vacuum hose from carburetor and connect it
made on the vehicle, as described in the Fast Idle to hose from vacuum supply with a small length of
Speed Adjustment (On Vehicle Paragraph.) However, tube to act as a fitting. Removal of hose from dia
the Fast Idle Cam Position Adjustment can be made phragm may require forces which damage the system.
on the bench. Apply a vacuum of 10 or more inches.
This adjustment is important to assure that the (3) Insert specified drill (refer to Specifications)
speeds of each cam step occur at the proper time between choke valve and wall of air horn. (Fig. 14).
during engine warm-up. Adjust as follows: Apply sufficient closing pressure on lever to which
(1) With fast idle speed adjusting screw contacting choke rod attaches to provide a minimum choke
second highest speed step on fast idle cam, move valve opening without distortion of diaphragm link.
choke valve toward closed position with light pressure Note that on most units, a cylinderical stem extends
on choke shaft lever. as an internal spring is compressed. This spring
(2) Insert specified drill (refer to Specifications), be must be fully compressed for proper measurement
tween choke valve and wall of air horn (Fig. 13). An of vacuum kick adjustment.
adjustment will be necessary if a slight drag is not (4) An adjustment will be necessary if a slight drag
obtained as the drill is being removed. is not obtained as drill is being removed. Shorten or
(3) To adjust, bend fast idle connector rod at angle, lengthen diaphragm link to obtain correct choke
using Tool T-109-213 until correct valve opening has opening. Length changes should be made by care
been obtained. (Fig. 13). fully opening or closing the bend provided in dia
phragm link. CAUTION: DO NOT APPLY TWISTING
Vacuum Kick Adjustm ent—(This test can be OR BENDING FORCE TO DIAPHRAGM.
m ad e O N or OFF vehicle.) (5) Reinstall vacuum hose on correct carburetor
The choke diaphragm adjustment controls the fuel fitting. Return fast idle linkage to its original condi
delivery while the engine is running. It positions the tion if disturbed as suggested in step no. 1.
choke valve within the airhorn by use of the link (6) Make following check. With no vacuum applied
age between the choke shaft and the diaphragm. The to diaphragm. CHOKE VALVE SHOULD MOVE
diaphragm must be energized to measure the vacuum FREELY between open and closed positions. If move
kick adjustment. Use either a distributor test machine ment is not free, examine linkage for misalignment
with a vacuum source, or vacuum supplied by the or interferences caused by bending operation. Repeat
vehicle. adjustment if necessary to provide proper link opera
(1) If adjustment is to be made with engine run tion.
ning, disconnect fast idle linkage to allow choke to
close to kick position with engine at curb idle. If an Choke Unloader Adjustment
The choke unloader is a mechanical device to par-
auxiliary vacuum source is to be used, open throttle
valves (engine not running) and move choke valve to
DRILL OR GAUGE
LIGHT CLOSING .............
PRESSURE O N v ’ DRILL OR GAUGE
t " V i CHOKE LEVER
MINIMUM OF
Nr V; BEND FAST IDLE 10 INCHES
FAST IDLE X CONNECTOR CHOKE* OF VACUUM
CAM V ROD AT THIS LEVER. O N DIAPHRAGM
/ ‘tm ANGLE SLOT REQUIRED
5*
CHOKE TO
LEVER '' VACUUM
SOURCE
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tially open the choke at wide open throttle. It is
used to eliminate choke enrichment during cranking
TOP OF PLUNGER
of an engine. Engines which have been flooded or TO TOP OF
stalled by excessive choke enrichment can be cleared AIR HORN 'ft?
by use of the unloader. Adjust the system as follows:
(1) Hold throttle valves in wide open position. In
sert specified drill (refer to Specifications), between 1 _ 9 .
upper edge of choke valve and inner wall of air horn.
(Fig. 15).
(2) With a finger lightly pressing against choke
BEND ACCELERATOR ■'i
lever, a slight drag should be felt as drill is being PUMP ROD-
withdrawn. If an adjustment is necessary, bend un AT ANGLE
loader tang on fast idle cam, using Tool T-109-22,
until correct opening has been obtained. (Fig. 15). CURB IDLE SPEED ADJUSTING * \
SCREW BACKED OFF TO ALLOW THROTTLE CLOSED
VALVES TO FULLY SEAT PY729
Accelerator Pump Adjustm ent
Move the choke valve to wide open position, to re Fig. 1 6 —Cheeking Accelerator Pump Adjustment
lease the fast, idle cam. Back off the idle speed adjust With primary and secondary throttle valves in tight
ing screw (curb idle) until the throttle valves are ly closed position, it should be possible to insert
seated in the bores. Tool T-109-29 (.020") wire gauge, between positive
Measure the distance from the top of the air horn closing shoes on the secondary throttle levers, (Fig.
to the top of the plunger shaft, using a “T” scale, 18).
(Fig. 16). This distance should be 7/16 inch. If an adjustment is necessary, bend the shoe on the
If an adjustment is necessary, bend the throttle secondary throttle lever, using Tool T-109-22, until
connector rod at the lower angle, using Tool T-109- correct clearance has been obtained.
213, until correct travel has been obtained.
Secondary Throttle Lever Adjustment Secondary Throttle Lock Out Adjustm ent
To check the secondary throttle lever adjustment, Crack the throttle valves, then manually open and
block the choke valve in the wide open position and close the choke valve. The tang on the secondary
invert the carburetor. Slowly open the primary throt throttle lever should freely engage in the notch of the
tle valves until it is possible to measure 21/64 inch lockout dog. (Fig. 17).
between the lower edge of the primary valve and the If an adjustment is necessary, bend the tang on the
bore (opposite idle port) (Fig. 17). At this measure secondary throttle lever, until engagement has been
ment, the secondary valves should just start to open. made. Use Tool T-109-22 for this operation.
If an adjustment is necessary, bend the secondary After adjustments have been made, reinstall carbu
throttle operating rod at the angle, using Tool T-109- retor on engine, using a new gasket.
213, until correct adjustment has been obtained. It is suggested that the carburetor be filled with
.. o:< GAUGE BEND ROD AT
THIS ANGLE . PRIMARY
■. '.V I. CLOSING 1 ^THROTTLE
A S S U R E UP VALVES
r-*
O N CHOKE
lever ■■S E P
«h p b i
SCALE
SECONDARY.
9QW LY OPEN
THROTTLE /.-HROTTLE
SEND UNLO Al: VALVES VALVES
TANG FOR SHOULD JUST
CORRECT OPEK. START TO
OPEN
NOTCH OF
THROTTLE IN W
LOCKOUT, DOG .MVE WIDE O PEN
OPEN POSITIC.
NR523A TANG ON SECONDARY LEVER NR525A
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VENT VALVE
DRILL GAUGE
m i
■■■ ’% . & ■ '■ j *
THROTTLE
VALVES CLOSED
ON
AIR HORN NR528A
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SECONDARY AIR VALVE WIDE OPEN
LOCK SCREW
\
j*
\ * TERMINAL
\ ADJUSTING SLEEVE
FAST CURB
FAST CURB IDLE
ADJUSTING SCREW
IDLE SOLENOID
SOLENOID PLUNGER
SECONDARY AIR VALVE JUST CLOSED
PY733
Fig. 22—Idle Speed Solenoid Adjustment
LOCK SCREW- (340 Cu. In. Eng.)
>■, i - Before adjusting idle and/or fast idle speeds and
%
mixtures, make sure that the basic timing and the
distributor control valve are correctly adjusted as
— outlined under Idle Speed Adjustment (Curb Idle).
I
,>5 >
Id le Speed Solenoid Adjustm ent
■ r ja p i (340 Cu. In. Engine)
TURN 2 FULL TURNS
FROM WIDE OPEN POSITION
To set the idle speed solenoid for correct engine
r.p.m., proceed as follows:
(1) Warm up engine to normal operating tempera
PY732 ture, then attach a tachometer.
Fig. 20—Secondary Air Valve Adjustment (2) With engine running, turn idle speed solenoid
adjusting screw in or out to obtain 950 r.p.m. for
(3) Start engine and determine stabilized speed.
Turn fast idle speed screw in or out to secure manual transmission equipped vehicles and 900 r.p.m.
specified speed. (Refer to Specifications). for automatic transmission equipped vehicles. (Fig.
22).
(4) Stopping engine between adjustments is not
necessary. However, reposition fast idle speed screw (3) After specified r.p.m. has been obtained and
on came after each speed adjustment to provide cor with engine still running (to energize solenoid), adjust
rect throttle closing torque. FAST
T
/? *
■1
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curb idle speed screw until end of screw just touches (2) With engine running, turn idle speed solenoid
stop on carburetor throttle body. Now, back off 1 full adjusting screw in or out to obtain 900 r.p.m. for
turn to obtain slow curb idle speed setting. (Approxi manual transmission equipped vehicles and 800 r.p.m.
mately 650 to 700 r.p.m.) for automatic transmission equipped vehicles. (Fig.
23).
Idle Speed Solenoid Adjustment (3) After specified r.p.m. as been obtained and with
(If so equipped) engine still running (to energize solenoid), adjust curb
To set idle speed solenoid for correct engine r.p.m. idle speed screw until end of screw just touches stop
proceed as follows: on carburetor throttle body. Now, back off 1 full turn
(1) Warm up engine to normal operating tempera to obtain slow curb idle speed setting. (Approximately
ture, then attach a tachometer. 650 to 700 r.p.m.)
GENERAL INFORMATION easier servicing and adjusting (Fig. 1). Each barrel has
its own venturi, idle system, main metering system,
Three two barrel Holley 2300 and 2300C Series booster venturi and throttle valve. The carburetor is
carburetors are mounted on a cast iron intake mani equipped with a diaphragm type cam operated, ac
fold and are used on the 440 cubic inch engine. C.A.S. celerating pump, located on the bottom of the fuel
Models (Cleaner Air System) R-4375A and R-4376A bowl. The pump functions when the pump lever is
(Center) are used when the vehicle is equipped with a activated by a cam on the throttle lever. An override
Standard or Automatic Transmission respectively. spring on the pump lever adjusting screw, allows a
E.C.S. Models (Evaporation Control System) R-4374A prolonged discharge of fuel for smooth acceleration.
and R-4144A are used when the vehicle is equipped The supply of fuel necessary for high speed or full
with Standard or Automatic Transmissions respective power operation, is delivered by a fully automatic
ly. The two Outboard Carburetors C.A.S. Models power enrichment system. Manifold vacuum on the
(Cleaner Air System) R-4382A and R-4383A are used power valve diaphragm actuates the power enrich
with either Standard or Automatic Transmissions. ment system.
E.C.S. (Evaporation Control System) Models R-4175A The choke used only on the center carburetors
and R-4365A are used with either Standard or Auto (only) is the well type with a thermostatic coil spring.
matic Transmission. (Refer to Specifications.) (Fig. 1). The well is located in the intake manifold and over
The two outboard carburetors contain all the usual the exhaust crossover passage. Heat generated in the
systems except choke, power enrichment, accelerat well acts on the thermostatic coil spring so that as the
ing pump, idle, and spark advance. Each carburetor engine warms up, the choke valve moves toward the
is equipped with a throttle control vacuum diaphragm open position.
(Fig. 1). The two outboard carburetors are connected There are four major sub-assemblies of the center
to the center carburetor’s slotted throttle lever by carburetors and they are: the main body assembly,
two adjustable connector rods. The slotted throttle the fuel bowl, the metering body assembly and the
lever of the center carburetor allows the throttle throttle body.
valves to open on the outboard carburetors as vacuum
requires and close mechanically with the controlling O p eration (R-4375A, R-4376A, R-4374A
center carburetor (Fig. 1). a n d R-4144A)
The center (or controlling carburetor) provides for The carburetor uses the four basic systems re-
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: enter carbureto r
REAR OUTBOARD
CARBURETOR
FR O N T O U TB O A R D
CARBURETOR
* .SLOTTED
ADJUSTER LINK
P' - '‘‘Ht*
<€#' ASSIST SPRING
.RETURN
SPRING
REAR C O N N E C T O R
* 9 9 9 / 9 ROD
^ SLOTTED
N>*THROTTLE
FRONT N LEVER
CONNECTOR
ROD
DISTRIBUTOR V A C U U M
BOW L .A D V A N C E TUBE
V EN T
C R AN K C A SE
V EN T VACUUM
1APHRAOM
SUPPLY TUBE
FUEL
SUPPLY TUBE
NU942A
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Fig. 2—Fuel Inlet S y ste m
ment of the float, opening or closing the fuel inlet
needle valve to immediately restore or hold the
proper fuel level. The fuel inlet system must constant
ly maintain the specified level of fuel as the basic fuel Fig. 3—Choice System
metering systems are calibrated to deliver the proper inlet check ball on its seat preventing fuel from flow
mixture only when the fuel is at this level. ing back into the float chamber. The fuel flows from
A float spring is incorporated under the float to the short horizontal passage in the fuel bowl into the
assist in minimizing float vibration. The float chamber long diagonal passage in the metering body. The fuel
is vented internally by the vent tube at all times. passes into the main body and then in the pump
discharge chamber. The pressure of the fuel causes
Choke System the discharge needle to raise and fuel is discharged
The choke permits a richer fuel-air mixture re into the venturi.
quired for starting and operating a cold engine. Most As the throttle is moved toward the closed posi
of the vaporized fuel condenses to a liquid upon con tion, the linkage returns to its original position and
tact with the cold surfaces of intake manifold. In this the diaphragm spring forces the diaphragm down. As
liquid form it burns too slowly and incompletely in the diaphragm returns to its original position the
the cylinders and will cause stalling and loss of power. pump inlet check ball is moved off its seat and the
The choke valve is normally closed during the crank diaphragm chamber is filled with fuel from the bowl.
ing period and partially open during warm up, con
fining manifold vacuum below the choke valve. This Main M etering System
greater vacuum causes both main metering system When the engine is running, it draws air through
and idle system to discharge fuel into the manifold the carburetor venturi and booster venturi. The air
(Fig. 3).
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passing through the throat of a venturi, creates a low
pressure called a vacuum. The strength of this low RESTRICTION
pressure is determined primarily by the velocity of
the air flowing through throat of the venturi. This, in IDLE AIR BLEED
FUEL
turn, is regulated by the speed and power output of BOWL
the engine. The difference, between the pressure in
IDLE
the booster venturi and the normal air pressure in the TRANSFER
float chamber, causes fuel to flow through the main PASSAGE MAIN JET
metering system (Fig. 5).
At cruising speed, the fuel flows from the float IDLE DISCHARGE
IDLE DISCHARGE PASSAGE
chamber through the main jet, which measures or HOLE
meters the fuel flow, into the bottom of the main IDLE TRANSFER SLOT
NU729
well. The fuel moves up the main well past the main
well air bleed hole in the side of the well. Filtered Fig. 6—Idle System
air, enters through the air bleed in the main body The fuel flows up this vertical passage, (idle well)
and then into the main metering body by inter past the idle feed restriction and then it is mixed
connecting passages. This mixture of fuel and air, with air coming in from the idle air bleed. This
being lighter than raw fuel, responds faster to any fuel-air mixture flows through a short horizontal pas
change in venturi vacuum and vaporizes more readily sage and then down another vertical passage. At the
when discharged into the air stream of the venturi. bottom of this vertical passage the fuel-air mixture
The mixture of fuel and air moves up the main branches in two directions, one through the idle dis
metering passage and passes into the short horizontal charge passage and the other to the idle transfer
passage leading to the main body, then through the passage.
horizontal channel of the discharge nozzle. The fuel in the idle discharge passage flows through
Idle System a short passage, down another passage in the main
At idle and low speeds, the air flow through the body and into the throttle bore below the throttle
carburetor is not sufficiently strong enough to draw valve.
fuel through the venturi for the main metering sys During off-idle operation when the throttle valve
tem. Intake manifold vacuum is high because of the is moved slightly, the fuel flows through the idle
greater restriction to the air flow by the nearly transfer passage from the metering body into the
closed throttle valves. This high manifold vacuum is throttle body passage. As the idle transfer slot is ex
used to provide the pressure differential to operate posed to manifold vacuum, fuel is discharged into
the idle system (Fig. 6). the throttle bore.
The carburetor utilizes two identical idle systems, As the throttle valve is opened still wider and en
one for each bore. Since, the two passages function gine speed increases, the air flow through the car
identically, only one side will be considered in this buretor is also increased. This creates an increased
explanation. vacuum in the venturi to bring the main metering
At idle, the normal air pressure in the float cham system into operation. The flow from the idle system
ber causes the fuel to flow through the idle system to tapers off as the main metering system begins dis
the greatly reduced pressure area below throttle charging fuel. The two systems are engineered to
valve. Fuel flows from the float chamber through the provide smooth gradual transition from idle to cruis
main jet then into the small angular but horizontal ing speeds.
passage that leads across to a vertical passage. This fuel is discharged into the booster venturi and
then in the air stream of the carburetor venturi.
BOOSTER VENTURI
The throttle valve controls the amount of fuel-air
MAIN WELL
AIR BLEED
mixture admitted to the intake manifold, regulating
the speed and power output of the engine in ac
cordance with accelerator pedal movement.
TO IDLE
WELL DISCHARGE
NOZZLE Pow er Enrichment System
During high speed (or low manifold vacuum) the
MAIN JET carburetor must provide a mixture richer than is
MAIN WELL
needed when the engine is running at cruising speed
under no great power requirements. The added fuel
NU731 for power operation is supplied by the power enrich
ment system (Fig. 7).
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This system is controlled by manifold vacuum
which gives an accurate indication of the power de
mands placed upon the engine. Manifold vacuum is
strongest at idle and decreases as the load on the
engine increases. As the load on the engine is in
creased, the throttle valve must be opened wider to
maintain a given speed. Manifold vacuum is thus re
duced because the opened throttle valve offers less
restriction to air entering the intake manifold.
A vacuum passage in the throttle body transmits
manifold vacuum to the power valve chamber in the
main body. The power valve which is located in the
main metering body is affected by this manifold
vacuum. The manifold vacuum, acting on the dia Fig. 7—Power Enrichment System
phragm at idle or normal load conditions, is strong off the added supply of fuel which is no longer
enough to hold the diaphragm closed, and overcomes required.
the tension of the power valve spring. When high
power demands, place a greater load on the engine Spark Advance
and manifold vacuum drops below a predetermined The carburetor is teamed with the distributor to
point, the power valve spring overcomes the reduced effect spark timing that will satisfy all engine speed
vacuum opening the power valve. Fuel flows from and load conditions.
the float chamber, through the valve and out the The spark must be advanced as the engine speed is
small holes in the side of the valve through the dia increased since a definite time is required for the
gonal restrictions in the main metering body and fuel-air mixture to burn and reach its maximum pres
then into the main well. Here the fuel joins the fuel sure at the right time for highest efficiency of the
flow in the main metering system, enriching the engine cycle. Because the fuel-air mixture induced
mixture. into the intake manifold at light loads is not as dense
As engine power demands are reduced, manifold as that during high load operation, it bums more
vacuum increases. The increased vacuum acts on the slowly, hence the spark under these conditions must
diaphragm, overcoming the tension of the power also be advanced.
valve spring. This closes the power valve and shuts
SERVICE PROCEDURES
DISASSEMBLING CARBURETOR (Center Unit) at the same time, disengage choke rod from bottom
hole of lever (Fig. 7). (Note position of fast idle cam
To disassemble the carburetor (Figs. 1, 2 or 3) for
in choke control lever).
cleaning or overhaul, proceed as follows:
(7) Remove accelerator pump discharge nozzle re
(1) Install four elevating legs Tool T109-287S in
taining screw, then lift out discharge nozzle (Fig. 8).
mounting flange holes in throttle body, or use Car
Remove nozzle and retaining screw gaskets and dis
buretor stand C-3886. (These tools are used to pro
card. Remove vacuum diaphragm hose. (To outboard
tect the throttle valves from damage and to provide
carburetors.)
a suitable base for working.)
(8) Invert main body and drop out accelerator
(2) Remove screws and seal washers that attach
pump check needle from discharge passage (Fig. 9).
fuel bowl and metering body to main body. Remove
(9) With carburetor inverted, remove five screws
fuel bowl (Fig. 4). Discard screw seal washers.
that attach throttle body to main body (Fig. 10).
(3) Remove metering body, then discard gaskets
Remove throttle body and discard gasket.
(Fig. 5).
(4) Remove screw and washer that retains choke Disassembling Fuel Bowl
unloader lever to throttle shaft. Slide lever off flats (1) Remove screw that retains bowl vent valve,
on end of shaft (Fig. 6). plate, spring and rod to fuel bowl (Fig. 11). Remove
(5) Disconnect choke diaphragm hose from throttle bowl vent valve assembly. (If so equipped).
body fitting. Remove choke diaphragm attaching (2) Remove fuel level adjusting nut lock screw,
screws, then remove choke diaphragm after disen then remove adjusting nut. Slide needle valve and
gaging link from choke control lever. seat out of fuel bowl (Fig. 12). Discard needle seat
(6) Remove “E” clip that retains choke control “O” ring.
lever and cam. Slide lever and cam off stub shaft, and (3) Remove screws that attach float lever bracket
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OUTBOARD CARBURETOR BOWL VENT CENTER CARBURETOR OUTBOARD CARBURETOR
(FRONT) VALVE \ (REAR)
(C.A.S, ONLY) CHOKE ^
\ VALVE v \ BOWL VENT ROD
IDLER *JM;TER \ *
LOCK SCREW
CAP \ THROTTLE CONTROL
\ \ VACUUM DIAPHRAGM
FUEL LEVEL V*
rm
ADJUSTING'N UT ■11
/ PUMP LEVER'
PULL BACK
SPRING TH.?OTTlc
LEVER
r THROTTLE
CONNECTOR
;: C D (REAR)
\
FAST CURB
/ /
SOLENOID J
I 'V"“~—
THROTTLE
•ALUMINUM
MANIFOLD
IDLE SPEED PLUNGER FAST CURB IDLE CONNECTOR
ADJUSTING SCREW SPEED SOLENOID ROD (FRONT) THREADED SLEEVE NU948A
Disassembling M a in M ete rin g Body The recommended solvent for gum deposits is de
(1) Using Tool C-3747, remove power valve as natured alcohol which is easily obtainable. However,
sembly from metering body (Fig. 15). there are other commercial solvents, (such as Metal-
(2) Using Tool C-3748, remove main metering clene) which may be used with satisfactory re
jets (Fig. 16). sults.
(3) Using a suitable tool, pry plastic limiter caps The choke diaphragm can be damaged by solvents.
off the two idle air mixture screws. Remove screws Avoid placing the diaphragm assembly in ANY liq
and gaskets. (Be sure and count the number of turns uid. Clean the external surfaces with a clean cloth or
to seat screws, as the same number of turns from the soft wire brush. Shake dirt or other foreign material
seat must be maintained at installation) (Fig. 17). from the stem side of the diaphragm. Depressing the
diaphragm stem to retracted position, will provide an
Disassembling Throttle Body additional hole for the removal of dirt. Compressed
Caution: In normal routine cleaning and overhaul air can be used to remove loose dirt, but should not
of the carburetor, do not remove throttle valves un be connected to the vacuum inlet fitting.
less they are nicked or damaged. If necessary to IMPORTANT: If the commercial solvent or cleaner
remove, proceed as follows: recommends the use of water as a rinse, it should
(1) Remove screws that hold throttle valves to be "HOT". After rinsing, all trace of water must be
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LOCK
SCREW BOWL VENT
... VALVE OPERATING
-m ROD
— IDLE LIMITER
FUEL BOWL __ *r;■ •:
ATTACHING SCREW'—-—'—
Mill ADJUSTING SCREW
CAP (2)
AND SEAL WASHERS /
FUEL LEVEL /
ADJUSTING NUT
m
THROTTLE LEVER
BOWL VENT VALVE /
(C.A.S. ONLY) .
FAST CURB
IDLE ADJUSTING
ACCELERATING PUMP SCREW
ADJUSTING SCREW ACCELERATING
PUMP LEVER
■CHOKE VALVE
LOCK SCREW
CHOKE DIAPHRAGM
CHOKE ROD
CURB IDLE SPEED
ADJUSTING SCREW CHOKE LINK
THROTTLE
BODY
FAST IDLE
FAST IDLE CAM*
CAM LEVER
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?**
.VACUUM DIAPHRAGM
—i
MAIN BODY
LOCK 'SCREW
FUEL LEVEL
ADJUSTING NUT
VACUUM DIAPHRAM
THROTTLE VALVE *
CONTROL
FUEL BOWL
^9 <?^ .f
9%
F i g . 3 — C a r b u r e t o r A sse m bly (O u tb o a rd ) F r o n t o r R e a r
r
SPRING ■J
- MAIN METERING
\
? ' JETS . (, i \
I ,
METERING BODY \
THROTTLE METERING BODY
)Y \
LEVER GASKET
BOWL SCREW (4)
ACCELERATOR
PUMP COVER SEAL (4) POWER VALVil
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ACCELERATING PUM P
DISCHARGE
-CHECK NEEDLE
FAST IDLE CAM
"IA:"i
ATTACHING SCREWS- NU1005
&
- -%-t
GASKET'
CHOKE
/
CONTROL
LEVER
RETAINER- f §
fast
"E " CLIP M i
IDLE CAM
NU100#
""•V , |, - — GASKET
-GASKET " ^ -c-. | <t‘ 4 ^ ------------FUEL LEVEL
ADJUSTING NUT
V i: ■
\
BOWL VENT
VALVE
\ ^OPERATING
SPRING
ROD
VACUUM. ,
\
DIAPHRAGM v
'/A V u E L LEVEL
HOSE K SIGHT PLUG
(OUTBOARD
CARBURETORS) gasket
'ATTACHING SCREW
NU! 007 KOI 010
Fig* 8—Removing or imstallimg Pmmp Discharge
Nozzle
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r
9 •NEEDLE VALVE A N D
SEAT ASSEMBLY
.j METERING BODY
"O" RING
NEEDLE V A i> J
METERING SPEClAi TOOL
GASKET
BLOCK %
|H f
•■
1 GASKET
.Si
■4
\ „ J __
"~T ~ I
x.
■H'fL BOWL ... ...aw—
! 1 ;
COVER ^UMP DIAPHRAGM
DIAPHRAGM
ACCELERATING'
SPRING
PUMP
DIAPHRAGM PUMP COVER- M A IN METERING JET
PUMP SPRING
CLUTCH HEAD SCREW— * — NU1015
NU1013
Fig. 14—Removing or Installing As<§®S<2 :jating Pump Fig. 16—Removing or installing Main Metering Jets
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Fig. 17—Removing Idle Air Mixture Screws Fig. 19—Installing Idle Air Mixture Screws
and Gaskets and Gaskets
(4) Install new plastic caps over idle screws, with throttle body gasket. Place throttle body in position
tabls on caps against stops in bore (Fig. 19). on gasket. Install attaching screws and tighten se
curely.
Reassembling Fuel Bowl (8) Install bowl vent valve on fuel bowl. Install
(1) Place a new gasket over fuel inlet fitting, then attaching screw and tighten securely. (Be sure spring
install fitting in fuel bowl. Tighten securely. short loop enters hole in plate from underneath and
(2) Install accelerator pump spring in position in long end hooked under rod (Fig. 11). (If so equipped).
fuel bowl, followed by diaphragm and pump cover. (9) Engage fast idle cam with choke control lever.
(When installing diaphragm, be sure contact button Be sure cam steps are toward lever side (Fig. 7). Slide
rivet head is toward pump lever in cover (Fig. 14). cam and lever over pivot pin and at the same time
Install clutch head screws and tighten securely, using engage choke rod in bottom hole of lever. Secure
Tool CL-13. with “E” clip.
(3) Install sight plug and new gasket in bowl. (10) Slide fast idle cam lever over flats on throttle
(4) Slide float and hinge bracket in position in shaft. (Be sure lever is installed in such manner so
bowl, with fulcrum pin seated in slot. Install at that tab rides on cam steps (Fig. 6).
taching screws and tighten securely (Fig. 20). (11) Engage choke link in slot on choke control
(5) Coat a new “O” ring with vasoline and slide lever, then place choke diaphragm on main body. In
over fuel inlet needle seat and down into position. stall attaching screws and tighten securely.
Install needle and seat in fuel bowl (Fig. 12). (12) Install new gaskets on front and rear of meter
(6) Using a new gasket, install fuel level adjusting ing body, then install in position on main body with
nut over threaded end of needle seat, with flats jets toward outside (Fig. 21).
aligned. Place a new gasket over lockscrew and in
(13) Slide new seal washers over fuel bowl mount-
stall in needle seat and over adjusting nut.
(7) Invert main body and install new main to
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POWER VALVE . ,* , * * * * * * * FUEL BOWL Checking the Bowl Vent Valve Clearance
' gasket m a in Checking the Pump Lever Clearance
METERING Idle Speed Adjustment (curb Idle)
^ BODY Adjusting the Float
Outboard Carburetor Throttle Rod Adjustment
Checking Wet Fuel Level
\ J - f l I
Checking the Bowl Vent V a lv e Clearance
To check the bowl vent valve clearance (Fig. 23),
VACUUM proceed as follows:
P n IDLE
SPARK
LIMITER CAP (1) With throttle valves at curb idle, it should be
ADVANCE! possible to insert a 1/16 inch drill shank between
TUBE FITTING
bowl vent valve and top of primary fuel bowl, with
VACUUM MAIN METERING JETS
the idle speed properly set.
DIAPHRAGM VACUUM CHOKE
TUBE FITTING TUBE FITTING
(2) If an adjustment is necessary, bend rod to
NU1020
change arc of contact with throttle lever, using Tool
Fig. 21—Metering Body Installed T109-213 until correct clearance has been obtained.
ing screws. Install screws through fuel bowl and
metering body. (Be sure all gaskets are aligned, then Checking Accelerator Pump Lever Clearance
tighten screws to 50 inch pounds). Make sure ac To check accelerator pump lever clearance (Fig.
celerator pump lever is under adjusting screw of 24), proceed as follows:
accelerating pump operating lever. (1) With throttle valves wide open, and the pump
(14) Install new keystone clamp over vacuum dia ** BOWL VENT VALVE
phragm hose (with tee for outboard carburetors), then
slide hose over tube fitting (Fig. 22). Clamp with
keystone pliers.
CARBURETOR ADJUSTMENTS
It is very important that the following adjustments
be mades on a reconditioned carburetor:
Qualifying the Choke Control Lever
Choke Unloader Adjustment (wide open kick)
Fast Idle Cam Position Adjustment
Vacuum Kick Adjustment (on or off vehicle) THROTTLE VALVES
ADJUST BOWL
Fast Idle Speed Adjustment (on the vehicle) SURFACE OF VENT VALVE IN CLOSED
FUEL BOWL ROD HERE POSITION
KEYSTONE CLAMP (C.A.S.) NU949A
-~ r ' f . a d ju s t ro d HERE
THROTTLE
•U \ VALVES CLOSED
/ r r . L - r -
£4 ! v -*7
VACUUM DIAPHRAGM HOSE PLUNGER -
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PUMP OVERIDE THROTTLE ADJUST AT SCALE TO TOP rDGE
SPRING VALVES |jTHIS POINT. ; ./ Or LEVER HOLE
\ - IN WIDE
\ OPEN
POSITION iX . \ *v
/ - s&it
■i* ; 9
* . ’ ■«
o
ct 9- ’“-V*
W ,J m
. ^v.
3-49/64" J- 1/64"
(TO TOP OF LEVER < - *
HOLE--CARBURETOR Mia*
MOUNTED ON MANIFOLD)
: •-.,'9 9 9 9 y , : ¥ * %
HOLD PUMP'"
LEVER DOWN DRILL OR
GAUGE
NU950 NU951
Fig. 24—Checking Accelerator Pump Lever Clearance Fig. 25—Qualifying Choke Control Lever
lever held down, it should be possible to insert a .015 of the unloader. Adjust the system as follows:
inch (min.) .0625 (max.) gauge between adjusting nut (1) Qualify the choke control lever, if necessary.
and lever. (See Qualifying Choke Control Lever Paragraph).
(2) If an adjustment is necessary, adjust pump (2) Hold the throttle valves in the wide open po
over-ride screw until correct clearance has been ob sition. Insert the specified drill between the upper
tained. edge of the choke valve and the inner wall of the air
(3) There must be no free movement of pump horn (see specifications).
leverage when throttle is at curb idle. (3) With a finger lightly pressing against the choke
control lever, a slight drag should be felt as the
Q u a lify in g Choke Control Lever drill is being withdrawn. If an adjustment is neces
Adjustment of the choke control lever is necessary sary, bend the indicated tang until correct opening
to provide correct relationship between choke valve, has been obtained (Fig. 26).
thermostatic coil spring and the fast idle cam. It
should be checked and adjusted (if necessary) after Fast Idle Adjustment (On Vehicle)
carburetor assembly or as preparation of the choke Fast idle engine speed is used to overcome cold
system linkage before making the Vacuum Kick, engine friction, stalls after cold starts and stalls be
Cam Position or Unloader adjustment. These three cause of carburetor icing. Set this adjustment after
adjustments must and should be made after qualifi the vehicle odometer indicates over 500 miles to in
cation of the choke control lever. sure a normal engine friction level. Prepare the
(1) Open the throttle to mid-position.
(2) Close the choke valve by slight pressure on THROTTLE VALVES DRILL OR
choke control lever. WIDE OPEN GAUGE
(3) The top of choke rod hole in control lever
should be 3-49/64 ± 1/64 inch above choke assembly
(carburetor on engine) or 1-23/32 ± 1/64 inch above
carburetor base (carburetor on bench) (Fig. 25).
(4) Adjust if necessary by bending choke shaft
rod at point indicated.
CAUTION: I mproper bending will cause binding of
rod. Test for free movement between open and closed
choke positions and rebend if necessary to eliminate
any interferences.
BEND UNLOADFR
Choke Unloader Adjustm ent (w id e open kick) TANG • • ' ' **'• f
The choke unloader is a mechanical device to par \ • , : W ' [ ■'* :
tially open the choke at wide open throttle. It is used / CHOKE CONTROL LEVrF ***
to eliminate choke enrichment during cranking of an
engine. Engines which have been flooded or stalled
by excessive choke enrichment can be cleared by use
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engine by driving at least 5 miles. Connect a tachom ... CHOKE VALVE
eter and set the curb idle speed and mixture, then ORILt OR
proceed as follows: • GAUGE
(1) With the engine off and the transmission in I
the PARK or NEUTRAL position, open the throttle
slightly.
S-'AST IDLE ;rE=r
(2) Close choke valve until fast idle screw tang ADJUSTING YA,-
can be positioned on the second highest-speed step
of the fast idle cam (Fig. 27). FAST ! D li CAM
(3) Start the engine and determine the stabilized
speed. Bend the fast idle tang by use of a screwdriver CAM POSITION
placed in the tang slot to secure the specified speed. ADJUSTING TANG
CAUTION: Bend only in a direction perpendicular
to the contact surface of the cam. Movement in any
other direction changes the CAM POSITION ADJUST
MENT described earlier.
(4) Stopping the engine between adjustments is
not necessary. However, reposition the fast idle tang CHOKE CCNYRC!, IHV5R
(LIGHT CLOSING PRESSURE) NU954
on the cam after each speed adjustment to provide
correct throttle closing torque. Fig. 28—Fast Idle Cam Position Adjustment
*2ND HIGHEST
SPEED STii:5
. f
1. W " m
•V
w ■
■ ! P
:V- :
FAST IDLE
SPEED TO VACUUM
ADJUSTING SUPP1Y
TANG
'
Ai
... W “. ' i f ... “ \
FAST IDLE
TH»S POINT W m
SP'iED IFVER C . i s i r ' : 'O N '.
(LIGHT CLOSING PRESSURE)
NU953
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SIGHT PLUG SIGHT PLUG
g asket\ SIGHT PLUG
~ '-f %*¥ • * I
t M IM
r •;
M
i-W «
FRONT ■ CURB IDLE
ROD / ADJUSTING
m m m m \ SCREW
.SOLENOID * \i
/ PLUNGER REAR ROD CENTERED
FAST CURB IDLE ^ " IN THROTTLE LEVER
ADJUSTING *v
SCREW m & « ~ ROD CLIP tm956
Fig « 30—Outboard Carburetor Throttle Rod
A d ju s tm e n t
Fig . 3 1—Adjusting Fuel Level (On Vehicle)
gine running, position the fast idle tang (Fig. 29)
(Cam position adjustment) to allow choke closure to the hose from the diaphragm may require forces
kick position. If auxiliary vacuum source is to be which could damage diaphragm. Apply a vacuum of
used, open throttle valves, (engine not running) and 10 or more inches.
move choke to closed position. Release throttle first, (3) Insert the specified drill (see specifications)
then release choke. between the choke valve and the wall of the air horn
(2) When using an auxiliary vacuum source, dis (Fig. 29). Apply sufficient closing pressure on the
connect the vacuum hose from the carburetor and lever to which the choke rod attaches to provide a
connect it to the hose from the vacuum supply with minimum choke valve opening without distortion of
a small length of tube to act as a fitting. Removal of the diaphragm link. Note that the cylindrical stem of
LEGENDS (Fig. 32)
1. Carburetor Assembly (Front or Rear) 40.Screw (Throttle Rod) 79. Diaphragm Cover
2. Choke Valve 41. Pivot (Throttle Rod) 80. Diaphragm Spring
3. Valve Screw 42.Throttle Valve Screw 81. Pump Cover and Screw
4. Choke Shaft 43.Throttle Shaft 82. Diaphragm
5. Operating Rod 44.Throttle Valves 83. Diaphragm Housing
6. Seal 45. Insulator 84. Seal (Bowl Screw)
7. Choke Control Lever 46.Adjusting Screw (Solenoid) 85. Bowl Screw
8. “E” Clip 47. Nut (Adjusting Screw) 86. Main Body (Front or Rear)
9. Fast Idle Cam 48.Cam, Pump 87. Gasket
10. Link 49. Pump Cam Screw 88. Throttle Body
11. Link Pin 50. Power Valve 89. Lever
12. Screw, Diaphragm Bracket 51. Power Valve Gasket 90. Screw
13. Choke Diaphragm 52. Gasket 91. “E” Clip
14. Vacuum Tube 53. Idle Mixture Screw 92. Screw, Throttle Body
15. Screw 54. Idle Mixture Screw Gasket 93. Throttle Valves
16. Fast Idle Cam Lever 55. Metering Body 94. Valve Screw
17. Throttle Body (Center Carb.) 56. Limiter Cap (Plastic) 95. Throttle Shaft
18. Plastic “T” 57. Metering Jet 96. Gasket
19. Tube and Clamp 58. Metering Jet 97. Plate
20. Screw, Throttle Body 59. Float 98. Gasket
21. Lever 60. Float Hinge Bracket 99. Metering Body
22. Spring 61. Fulcrum Pin 100. Float
23. Nut, Adjusting 62. Float Spring 101. Float Hinge Bracket
24. Spacer 63. Gasket 102. Float Spring
25. Curb Idle Screw and Spring 64. Sight Plug 103. Fulcrum Pin
26. Gasket 65. Sight Plug Gasket 104. Fuel Bowl
27. Screw Accelerator Pump Adj. 66. Fuel Inlet Fitting 105. Lock Screw
28. Main Body (Center Carb.) 67. Fuel Inlet Fitting Gasket 106. Gasket
29. Discharge Check Needle 68. Lock Screw 107. Adjusting Nut
30. Gasket 69. Gasket 108. Gasket
31. Cluster, Discharge 70. Bowl Vent Rod 109. Inlet Needle Seat
32. Gasket 71. Bowl Vent Valve 110. Seat “O” Ring
33. Cluster Screw 72. Adjusting Nut 111. Sight Plug
34. Nut 73. Gasket, Nut 112. Gasket
35. Sleeve (Rear) 74. Fuel Inlet Needle Seat 113. Seal (Bowl Screw)
36. Sleeve (Front) 75. Seat “O” Ring 114. Bowl Screw
37. Washer, Throttle Rod Sleeve 76. Fuel Bowl 115. Gasket
38. Spacer, Throttle Rod Sleeve 77. Spring, Pump 116. Fuel Inlet Fitting
39. Washer, Throttle Rod Sleeve 78. Diaphragm, Pump 117. Clutch Head Screw (Metering Body)
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HOLLEY
2300— FUEL SYSTEM
14-77
Fig. 32—Tri-Carburetor Assem blies (Exploded V ie w )
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the diaphragm will extend as an internal spring is touches stop on carburetor throttle body. Now, back
compressed. This spring must be fully compressed off 1 full turn to obtain the slow curb idle speed
for proper measurement of the vacuum kick adjust setting. (Approximately 650 to 700 r.p.m.)
ment.
(4) An adjustment will be necessary if a slight Idle Speed Adjustment (Curb Idle)
drag is not obtained as the drill is being removed. To make the idle speed adjustment on carburetors,
Shorten or lengthen the diaphragm link to obtain the secure an accurate ignition tachometer and a Sun
correct choke opening. Length changes should be Electric Combustion-Vacuum Unit, Model 80, Ex
made by carefully opening or closing the bend pro haust Condenser, Model EC, and Hose 669-14 or
vided in the diaphragm link. CAUTION: DO NOT equivalent. (The above analyzer is recommended;
APPLY TWISTING OR BENDING FORCE TO DIA however, other reliable makes of analyzers in good
PHRAGM. condition may be used). Proceed as follows:
(5) Reinstall the vacuum hose on the correct car (1) Engine running at normal operating tempera
buretor fitting. ture, and timing checked (refer to Distributor Spec
(6) Make the following check. With no vacuum ifications).
applied to the diaphragm, the CHOKE VALVE (2) Air cleaner installed.
SHOULD MOVE FREELY between the open and (3) Automatic Transmission in neutral position
closed positions. If movement is not free, examine (Not in park position).
the linkage for misalignment or interferences caused (4) On air conditioned vehicles, turn air condi
by the bending operation. Repeat the adjustment if tioning off.
necessary to provide proper link operation. (5) Connect ignition tachometer.
(6) Insert probe of exhaust analyzer in tail pipe
O u tb o ard C arburetor Throttle Rod as far as possible (2 ft. minimum distance).
Adjustment It is very important that probe and connecting
To synchronize the outboard throttle valves with tubing be free of leaks to prevent erroneous readings.
the center, or control carburetor, proceed as follows: If a garage exhaust system is used, to conduct ex
(1) Remove air cleaner (if not previously done), haust gases away, a plenum chamber or other means
then remove outboard throttle connector rod clips must be used to reduce vacuum of exhaust system to
and disengage front and rear rods from throttle levers 1/2 inch water or less.
(Fig. 30). (7) Connect exhaust gas analyzer, warm up and
(2) If this adjustment is to be done on vehicle, be calibrate according to manufacturer’s instructions.
sure ignition switch is OFF. (This de-energizes fast (8) Disconnect hose between distributor vacuum
curb idle solenoid so that clearance is obtained be control valve, (if so equipped) and intake manifold.
tween plunger and fast curb idle adjusting screw.) (9) Set idle speed to specified valve for specific
(3) Close throttle valves on the two outboard car engine-transmission combination.
buretors and the center carburetor. Hold in closed (10) IMPORTANT: When adjusting mixture screws
position. to obtain air-fuel ration specified, do not turn the
(4) Shorten or lengthen the front and rear con mixture screws more than 1/16 turn at a time. The
nector rods by turning rod in or out in threaded combustion analyzer is so sensitive that the ratio
sleeve, until rod end can enter hole in throttle lever must be changed by very small increments, if ac
evenly (Fig. 30). curate readings are to be obtained. The meters read
(5) Install throttle connector rod in lever and se in air-fuel ratio so that a higher reading indicates a
cure with clip. leaner mixture and vice-versa.
(a) Adjust each screw 1/16 turn richer (counter
Id le Speed Solenoid Adjustm ent clockwise) and wait 10 seconds before reading meter.
To set the idle speed solenoid for correct engine (b) If necessary, repeat step “a” until meter in
r.p.m., proceed as follows: dicates a definite increase in richness (lower read
(1) Warm up engine to normal operating tempera ing). This step is very important since meter reverses
ture, then attach a tachometer. its readings and indicates a richer mixture as car
(2) With engine running, turn idle speed solenoid buretor is leaned out, if carburetor is set too lean
adjusting screw in or out to obtain 900 r.p.m. for (c) When it has been established that meter is
both manual and automatic transmissions equipped indicating a lower reading (richer mixture) when
vehicles. idle mixture screws are turned in richer direction,
(3) After specified r.p.m. has been obtained and proceed to adjust carburetor to give 14.2 air/fuel
with engine still running (to energize solenoid), ad ratio; turning screws counterclockwise (richer) to
just curb idle speed screw until end of screw just lower meter reading and clockwise (leaner) to in-
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crease meter reading. Do not remove plastic cap (if so
equipped) in order to obtain an over-rich mixture. FLOAT LEVEL LOCK SCREW
ADJUSTING NUT ^
(d) If idle speed changes as idle screws are turned, NUT 7 FUEL,BOWL METERING BODY
adjust speed to specified valve and readjust mixture
as required so that a 14.2 air/fuel ratio is obtained at \ / i ■ & *
specified idle speed.
M AIN
BODY
Cheeking W e t Fuel Level fOn Vehicle) % GASKET
Before checking wet fuel level, check the fuel
pump pressure to be certain 5 pound reading is
obtained.
(1) To check fuel level in bowl, start engine and FLOAT
then remove sight plug from fuel bowl (Fig. 31).
CWK.H HEAD SCREWS (6)
(2) Using a wrench and screwdriver, turn adjust
ing nut either up or down until fuel just dribbles out
of sight hole (Fig. 31). NU994
(3) Reinstall sight plug and gasket and tighten fig* 2—Removing or in s ta llin g Fuel Bowl
securely. Check other fuel bowls in the same manner.
CAUTION: It is suggested that a suitable precaution
METERiNG^BODY
be taken by placing a shop towel or a container under
the bowl, to catch any fuel that might be liberated
due to a high or improper previous setting. ^ J? "
-GASKET
DISASSEMBLING AND ASSEMBLING CLUTCH HEAD o .>
CARBURETOR (OUTBOARD— Front or Rear) SCREWDRIVER /■*,
.. ? ■
The disassembly and assembly procedure covering
the two outboard carburetors are similar to the cen
ter or control carburetor. In as much as the outboard GASKET
/ to
carburetors are not equipped with automatic choke, CLUTCH HEAD
power enrichment, accelerating pump, idle or spark SCREW
advance, the servicing of these two carburetors are
relatively simple. NU.995.
The following disassembly and assembly proce
dures will be covered by pictures, step by step, with Fig. 3 —Rem owing o r In s ta llin g Metering B o d y
no text reference. Should written instructions be re Screws
quired, refer to disassembly and assembly procedures
as written for the center unit.
VACUUM
DIAPHRAGM
j . PUELJBOWL GASKET %'
PLATE
I
ir j
PLUNGER
STEM -
ME" CLIP
/ SCREW SEAL (4) / \
GASKET
n r I
DIAPHRAGM
IRAGM
/ER
LEVER « “ W
/
ATTAi
/
ATTACHING ! METERING BODY PLATE /
'THROTTLE LEVER,
SCREWS (4)
NU996
NU993
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^MAIN
BODY
METERING
BODY v
S.
THROTTLE BODY
DIAPHRAGM BODY*
VACUUM DIAPHRAG M -
COVER
/ SCREW (6)
i f
r
* n H i
NU998
Fig. 6—Metering Body '“DIAPHRAGM VA C U U M PORT
COVER
NUlOOf
Fig, 9—'Vacuum Diaphragm (Exploded View)
VA C U U M DIAPHRAGM
M A IN BODY
'E" CLIP
NU999
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AFB SERIES CARTER CARBURETOR
INDEX
Page Page
Automatic Choke (well ty p e ) .................................... 2 Secondary Throttle L e v e r................. ................... 88
Carburetor A djustm ents............................................ 87 Secondary Throttle L ockout................................. 89
Accelerator Pump .................................................. 88 Cleaning Carburetor P a r t s ........................................ 2
Bowl Vent V alv e...................................................... 90 Closed Crankcase Vent System (Group 9—Engine)
Choke Piston In d e x ................................................ 87 Disassembling Carburetor ......................................... 82
Choke Unloader (Wide Open K ick)..................... 88 General Information ........................................ ......... 81
Fast Idle Speed Cam P o sitio n ............................. 87 Inspection and R eassem bly..................................... 85
Fast Idle Speed (On V ehicle)............................... 89 Specifications.............................................................. 127
Idle S p e e d ............................................................... 90
GENERAL INFORMATION
The twin four barrel carburetors (Fig. 1) are used various disassembly procedures will not always show
on the 426 cu. in. Hemi engine. Carburetor Models any one specific carburetor.
AFB-4742S (front) are used on the 426 cu. in. engine The throttle valves of the secondary half of the
(Street Hemi), when the vehicles are equipped with carburetor are mechanically connected to the primary
the manual or automatic transmissions. valves and open with the primary after an approxi
Carburetor Models AFB-4745S (rear) and AFB- mate 60° lag; and continue to open until both primary
4746S (rear) are used on the 426 cu. in. engine (Street and secondary throttle valves reach the wide open
Hemi), when the vehicles are equipped with the man position simultaneously. As engine speed increases,
ual or automatic transmissions respectively. the forces exerted by the velocity of intake air down
These carburetors are equipped with a hot idle through the venturis of the carburetor increases and
compensator valve. (Fig. 2.) This valve is a thermo tends to overcome the counterweight attached to the
statically operated air bleed, to relieve an overrich velocity shaft, permitting the offset velocity valves to
condition at idle. This condition is the result of ex position themselves according to engine require
cessive heat and resultant overrich mixtures. ments.
These carburetors also work in conjunction with an The AFB (aluminum four barrel) carburetor con
idle speed solenoid, which is used to maintain a higher tains many features, some of which are the locations
idle speed when the vehicle is running and allows for the step-up rods and pistons. The step-up rods,
the throttle to close to a low idle speed throttle posi pistons and springs are accessible for service without
tion when the ignition key is turned off, to prevent removing the air horn or the carburetor from the
“after running”. engine. The venturi assemblies (primary and second
The idle solenoid is mounted between the two ary) are replaceable and contain many of the calibra
carburetors, on a bracket held by the carburetor tion points for both the high and low speed system.
mounting studs and nuts. (Fig. 23.) One fuel bowl feeds both the primary and secondary
Since the service procedures are identical on all nozzles on the right side while the other fuel bowl
Carter AFB carburetors, the illustrations showing the takes care of the primary and secondary nozzles on
LEFT HAND VIEW . . .
.RIGHT HAND VIEW
•J
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the left side. This provides improved performance in
cornering, quick stops and acceleration.
All the major castings of the carburetor are alumi
num, with the throttle body cast integral with the
main body. This allows an overall height reduction in
the carburetor. The section containing the accelerator
pump is termed the primary side of the carburetor.
The rear section is the secondary. The five conven
tional systems used in previous four barrel carbure
tors are also used in this unit. The five conventional
systems are, two float systems, two low speed systems,
(primary side only on front carburetors only) two
high speed systems, one accelerator pump system
and one automatic choke control system.
HOT IDLE The carburetors are equipped with a pair of veloc
COMPENSATO R VALVE ATTACHING SCREWS PY799 ity valves, which control the secondary valve opera
Fig. 2—Hot Idle Compensator Valve tion.
SERVICE PROCEDURES
DISASSEMBLES CARBURETOR (Fig. 1) nector rod to choke lever. Disengage rod from lever,
then swing rod at an arc until it can be disengaged
(1) Place- carburetor assembly on repair stand Tool from fast idle cam.
€-3400 or T-JL09-2878 elevating legs. These tools are (3) Remove retainer that holds throttle connector
used to protect throttle valves from damage and to rod in center hole of accelerator pump arm. Remove
provide a suitable base for working. hairpin clip that attaches lower end of rod in prim ary
(2) Remove hairpin clip th at attaches fast idle con throttle shaft lever. Disengage rod from arm and lev-
1;
ACCELERATOR PUMP O PE N IN G PLUG STEP-UP I ACCELERATOR
CHOKE VALVE.
ROCKER ARM \ PISTON 1 PUMP
\ COVER PLUNGER
BOWL VENT VALVE
V IN T TUBE
AIR HORN
CLOSED CRANKCASE
VENT TUBE FITTING
FUEL INLET
FITTING
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er, then remove from carburetor. clean gasoline or kerosene, to prevent leather from
(4) Remove screws attaching step-up piston and rod drying out.
cover plates. Hold cover down with a finger to prevent (5) Remove fuel inlet fitting and filter screen from
piston and rods from flying out. Lift off plates and air horn.
slide step-up pistons and rods out of air horn, (Fig. (6) Remove screws and retainer holding thermo
2). Remove step-up piston springs. Step-up rods are static coil housing to choke housing. Remove housing,
not interchangeable. gasket and baffle plate. To remove choke piston, re
(5) Remove ten screws that attach air horn to main move nut and washer, then slide piston off shaft and
body. (1 screw in hole in air horn.) Lift air horn work out of well.
straight up and away from main body. When remov
ing air horn, use care so as not to bend or damage M a in Body Disassembly
(1) Remove screws that attach accelerator pump jet
floats. Remove accelerator pump, plunger, lower
housing to main body. Lift out jet housing and gasket
spring from pump cylinder. Remove dashpot (if so
(Fig. 3). Discard gasket. Now, invert main body and
equipped).
drop out discharge check needle from discharge pas
sage.
Disassembling the Air Horn (2) Using Tool T-109-58, remove main metering jets
Place air horn in an inverted position on bench (to (primary side), (Fig. 4). The primary and secondary
protect the floats) then proceed to disassemble as fol main metering jets are not interchangeable. It is very
lows: important that these jets be installed in their respec
(1) Using a suitable Tool, remove float fulcrum tive locations in the main body at reassembly.
pins, (left and right) then lift float up and out of (3) Again using Tool T-109-58, remove main meter
bosses on air horn. It is suggested that the float on the ing jets (secondary side), (Fig. 4).
pump side be marked so that floats can be reinstalled (4) Remove screws that attach primary venturi
in their respective positions. (choke and pump side) to main body. Lift venturi
(2) Remove two needle valves from their respective straight up and away from main body, (Fig. 5). Dis
seats, after marking one on pump side for identifica card gaskets. The venturi assemblies are not inter
tion. Using a wide blade screw driver, remove needle changeable, side for side and must be reinstalled in
valve seats. Be sure each needle valve is returned to their original locations at reassembly.
its original seat at reassembly. (5) Remove screws that attach secondary venturi
(3) Remove spring clip that holds throttle con (choke and pump side) to main body. Lift secondary
nector rod in center hole of pump arm. Remove pump venturi assemblies straight up and away from body,
(Fig. 6). Remove velocity valves (Fig. 7).
arm pivot screw and lift off pump arm, at same time,
(6) Using Tool T-109-59, screw driver bit, remove
disengage link from arm and pump stem. Slide ac
accelerator pump intake check valve located inside
celerator pump plunger and spring out of air horn.
fuel bowl, adjacent to accelerator pump cylinder.
Remove gasket.
(7) Remove screws that attach hot idle compensa
(4) Place accelerator pump plunger in a jar of tor valve to main body boss. Remove valve and
gasket.
STEP-UP PISTON
n ,*™ AND METERING ROD V
COVER PLATE \5 0 -v. , .' ' ^ • V i f ■"■O b $ f N G
AND SCREW
GASKET
ACCELERATOR PUMP
. ‘...SC-IAtfo? P4SSAG0
s r ■ « . a?
•-‘-S C R E W
PY801 .\’/402
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SECONDARY VEivUR:
SPECIAL TOOl
VElCC.i'Y VaYviS
□
MAIN METERING JET},**;, %
PRIMARY C2)‘
H P
PRIMARY VENTURI
(PUMP SIDE)
m - W j s >\*>
1$^
\K b i
\ *
NK404
IDLE TRANSFER PORTSf PY802
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lowed. The screws that attach the throttle valves are primary and secondary venturi.
staked on the opposite side and care should be used in (5) Place new primary venturi gaskets in position,
removal so as not to break the screws in the throttle then install the primary venturi (pump and choke
shaft. Remove the staked portion of the screws with a side) by lowering straight down on gaskets. (Fig. 5).
file. Install attaching screws and tighten securely.
Remove the screws that attach the primary throttle (6) Install primary and secondary main metering
valves to the throttle shaft and slide valve (or valves) jets, using Tool T-109-58. (Fig. 4). Tighten jets se
out of bores. curely.
Remove the screws that attach the secondary throt (7) Install accelerator pump intake check ball using
tle valves to the throttle shaft and slide valve (or Tool T-109-59.
valves) out of bores.
The primary valves and secondary valves are not Accelerator Pump Test
interchangeable and should be kept separate in order (1) Pour clean gasoline into carburetor bowl (ap
that each may be returned to its respective bore. proximately 1/2 inch deep). Remove accelerator pump
(Fig. 9). plunger from jar of gasoline. Flex leather several
times, then slide into pump cylinder.
INSPECTION AND REASSEMBLY (2) Install accelerator pump discharge check needle
(1) Slide primary throttle valve (or valves) into in discharge passage. Raise pump plunger and press
their respective bores, install new screws, but do not lightly on plunger shaft to expel air from pump pas
tighten. Be sure idle speed adjusting screw is backed sages. Using a small clean brass rod, hold discharge
out. Hold valves in place with fingers. (Fingers press check needle firmly on its seat. Again raise plunger
ing on high side of valves.) and press downward. No fuel should be emitted from
(2) Tap valves lightly in this position, tighten either the intake or discharge passage.
screws securely. Stake screws by squeezing with (3) If fuel does emit from intake passage, remove
pliers. intake check ball and reclean the passage. Fuel leak
(3) Install idle mixture screws and springs in throt age at discharge check needle indicates presence of
tle body. (The tapered portion must be straight and dirt or a damaged check needle. Clean again and
smooth. If tapered portion is grooved or ridged, a then install a new check needle. Retest for leakage.
new idle mixture screw should be installed to insure (4) If either intake check assembly or discharge
having correct idle mixture control.) DO NOT USE A check needle leaks after above test and service fix,
SCREW DRIVER. Turn screws lightly against their attempt to reseat as follows:
seats with fingers. Back off the number of turns
counted at disassembly. Install new plastic caps with In ta k e Check Ball
tab against stops. This screw has a left hand thread. Remove the intake check assembly from the throt
Turn counterclockwise (Richer) and clockwise (Lean tle body. Install a new check assembly, then retest as
er). described previously.
Install velocity valves in position in body.
(4) Place new secondary venturi gaskets in posi Discharge Check N eedle
tion, then install secondary venturi (pump and choke (1) With discharge check needle installed, insert a
side) by lowering straight down on gaskets. Install piece of drill rod down on needle. Lightly tap drill
attaching screws and tighten securely. Be sure all the rod with a hammer to form a new seat. Remove and
metering holes and vent tubes are clean, in both the
discard old needle and install a new one. Retest as
described previously. If service fix does not correct
the condition, a new carburetor will have to be in
stalled.
(2) Install accelerator pump discharge check nee
dle, jet housing and gasket. Install housing and at
taching screws. Tighten screws securely.
(3) Press down on accelerator pump plunger shaft,
and as plunger is being depressed, a clear straight
stream should emit from each jet. If streams are not
PRIMARY identical, (if either one is diverted or restricted) a
VALVE
new accelerator pump jet housing should be installed.
KF946C After test, pour gasoline from carburetor bowl and
remove pump plunger.
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Assembling Air Horn ■THESE SURFACES-
(1) Slide fuel inlet screen into fuel line fitting, then MUST BE PARALLEL
install in air horn. Tighten securely. WITH EDGE OF CASTING
(2) Check to see if leather on accelerator pump jt— MINIM UM CLEARANCE-----%
plunger is hard, cracked or worn. If any sign of wear j\ WITHOUT BINDING /\
or deterioration is evident, install a new plunger as GASKET I \
sembly.
(3) Slide the accelerator plunger into air horn,
then install the accelerator pump link. When reas BOWL VENT
sembling, make sure the large diameter of pivot FLOAT- VALVE
OPERATING
screw enters hole in pump arm and that shoulder on LEVER-'
screw has not pinched pump arm.
The carburetors are equipped with synthetic rub ' ■ M < ' '
ber tipped fuel inlet needles. The needle tip is a rub •v ' i! S r
BOWL \
a w i VENT VALVE
ber material which is not affected by gasoline and is _\
VALVE SPRING PY727
stable over a wide range of temperatures. The tip is
flexible enough to make a good seal on the needle Fig. 10—Cheeking Float Alignment
seat, and to give increased resistance to flooding. (2) Check other float in same manner. If an ad
The use of new inlet needles require that care be justment is necessary, bend float arm using Tool
used when making float adjustments. Avoid applying T-109-22, until correct clearance has been obtained.
any pressure on the floats which might compress the After bending arm, recheck the float alignment.
tip of the fuel inlet needles. The tip can be com
pressed sufficiently to cause a false setting which will
Float Drop Setting
affect correct level of fuel in the bowl. (1) Holding air horn in an upright position, meas
(4) Place a new air horn to main body gasket in ure distance from the top of floats (outer end) to the
position on air horn, then install float needle valve air horn gasket, (Fig. 12). This measurement should
seats. (Be sure each needle seat and needle is rein be 3/4 inch. If an adjustment is necessary, bend stop
stalled in its original position.) tabs on float levers until correct drop setting has
(5) Slide right and left floats into position in air been obtained. Bend tab toward needle seat to lessen
horn, then install float fulcrum pins. (Be sure marked drop, or away from seat to increase drop.
float is installed on pump side of the air horn.) See (2) After floats have been checked and adjusted,
disassembly procedures. continue to assemble carburetor as follows:
(6) After floats have been installed, check float (3) Place accelerator pump plunger lower spring in
alignment, level and drop settings as follows: pump cylinder, then lower air horn carefully down
on main body. Care must be taken to center small
Float Alignm ent Setting brass main bleed tubes so that they will pass through
(1) Sight down side of each float shell to determine
holes in air horn without being damaged. Be sure
if side of the float is parallel to outer cage of air horn
the fuel baffles on the air horn, slide down in front,
casting, (Fig. 10).
(bowl side) of the float chamber baffles, or the air
(2) If sides of float are not in alignment with edge
horn will not index correctly with the main body and
of casting, bend float lever by applying pressure to
can cause the floats to hang up. Be sure the leather
end of float shell with thumb. To avoid damage to
on the plunger does not curl or wrinkle. Accelerator
the float, apply only enough pressure to bend the
pump operation will be affected if this precaution is
float lever.
(3) After aligning floats, remove as much clearance not observed. Install dashpot (if so equipped.)
as possible between arms of float lever and lugs of air (4) Install 10 air horn attaching screws and tighten
horn. To do this, bend float lever. The arms of float
lever should be as parallel as possible to inner sur ( ASKi i i;< liAC! H f A\ i iOA'f GA UGF
faces of lugs of casting.
i i l l
- / ' :::W L
// I .
.. . . - '
Float Level Setting
(1) With air horn inverted, air horn gasket in place
and float needle seated, slide float gauge (refer to
i . - ...... G A U G E OUTER
specifications for carburetor being worked on) be 1 r N D OF FLOAT
tween top of the float (at outer end) and air horn
gasket, (Fig. 11). Float should just touch gauge (T-109- m sm
106).
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y GASKET IN PLACE 2 STEPS
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(2) Remove throttle return spring so throttle can
liGHT CLCS.NG OR OAJGE
be set to a mid position. PRESSURE =VGA;NST
(3) Let choke blade go wide open. C H C < E V A -v c I'?
(4) Insert an .026 inch wire gauge* into choke pis aw
ton slot so that hook on the end goes into slot in
cylinder (Fig. 15).
*This gauge can be made by bending a piece of .026 x _JP>'
2 (inches long) wire bent at a right angle (1/8") as
shown. If this size wire is not readily available, .026
3:E>!0 TANG
inch step-up wire used in BBD Carburetors can be LN'.OAD'E? " W O SHOULD
bent to shape and used for this purpose. CONTACT TH'Z :A-r IDLE CAM
(5) Push on choke piston lever thermostat tang /
trapping the wire gauge between piston and cylinder
slots with linkage hanging free.
(6) Adjust the link connecting the choke shaft to
the choke piston lever by bending the link at an angle
IN WIDE
to give correct opening between choke valve and wall NK593A C?:N POSITION
of air horn. (Refer to Specifications). Remove wire
gauge before bending link. Fig. 16—Checking Choke Unloader (wide open kick)
(7) Reassemble choke, setting the coil two notches 109-41, until correct opening has been obtained (Fig.
rich and install the throttle return spring. 16).
.Choke Unloader Adjustm ent (W id e O pen
Accelerator Pump Adjustment
Kick) Move the choke valve to wide open position, to re
The choke unloader is a mechanical device to par
tially open the choke at wide open throttle. It is lease the fast idle cam. Back off the idle speed adjust
used to eliminate choke enrichment during cranking ment screw (curb idle) until the throttle valves are
of an engine. Engines which have been flooded or seated in the bores.
stalled by excessive choke enrichment can be cleared Measure the distance from the top of the air horn
by use of the unloader. Adjust the system as follows: to the top of the plunger shaft, using a “T” scale,
(1) Hold throttle valves in wide open position. In (Fig. 17). This distance should be 7/16 inch.
sert specified drill (refer to Specifications), between If an adjustment is necessary, bend the throttle
upper edge of choke valve and inner wall of air horn connector rod at the lower angle, using Tool T-109-
213, until correct travel has been obtained.
(Fig. 16).
(2) With a finger lightly pressing against choke Secondary Throttle Lever Adjustment
valve lever, a slight drag should be felt as drill is To check the secondary throttle lever adjustment,
being withdrawn. If an adjustment is necessary, bend block the choke valve in the wide open position and
unloader tang on throttle shaft lever, using Tool T-
SCALE
,026" GAUGE J
± ~7% W
7 -----
BEND
THROTTLE
CONMEC TOF-
ROD AT
THIS / • * " * ’ *.
ANGLE /
\ v*.' \ '.Vo
CURB IDLE
SPEED
SCREW
BACKED
„A
KU2Q3 OFF
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BEND ROB AT THIS ANGLE
\
<F . S' ‘
‘C<£,
'If I -->;VcS
.... , ■ •• '•••
ScCONCA?f THROrTLi .AV/rS ■ " I \ S \ '
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J 11
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, sue::
\
■f SECONDARY SHQE„>
(BEND TO ADJUSi!
I <1./ES
'DRILL OR GAUGE PY804
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distributor control valve are correctly adjusted as SCALE BOWL VENT
outlined under Idle Speed Adjustment (Curb Idle). VALVE
CHECKING
r; I MOUNTING
BRACKET--.
OPERATING
LEVER
I 0 CURB ID
r# I ; SPEED
ADjUST NO
.\ • f jf 3 ,9 SCREW - d.'c :-~
-SCvi9V
'/'* \ OPERATING
/ \ ROD
/ BOWL VENT VALVE
SPRING
PY806
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adjusting screw in or out to obtain 900 r.p.m. on with engine still running (to energize solenoid), adjust
automatic transmission equipped vehicles and 1000 curb idle speed screw until end of screw just touches
r.p.m. on standard transmission equipped vehicles. stop on carburetor throttle body. Now, back off 1 full
(Fig. 23). turn to obtain slow curb idle speed setting. (Approxi
(3) After specified r.p.m. has been obtained and mately 650 to 700 r.p.m.)
GENERAL INFORMATION
383 Cubic Inch Engine at idle. This condition is the result of excessive heat
The Holley four barrel carburetor models C.A.S. and resultant overrich mixtures. The distributor
(Cleaner Air System) E-4367A, R-4368A and R-4369A ground switch retards the distributor when the car
are used on the 383 cu. in. engines when the vehicles buretor is at curb idle, for better emission control.
are equipped with manual or automatic transmissions Since the service procedures are identical on all
respectively. Model R-4369A is used with vehicles Holley four barrel carburetors, the illustrations show
equipped with air conditioning only and has a hot idle ing the various disassembly procedures will not always
compensator valve. This valve is a thermostatically show any one specific carburetor.
operated air bleed, to relieve an overrich condition The Holley 4160 Series Carburetor (Figs. 1, 2 and 3)
at idle. This condition is the result of excessive heat can be considered as two dual downdraft carburetors
and resultant overrich mixtures. (Fig. 1). mounted side by side, each having its own fuel bowl
The Holley four barrel carburetor models E.C.S. and float system. The two fuel bowls insure a constant
(Evaporation Control System) R-4217A and R-4218A supply of fuel for all the fuel metering systems. Fuel
are also used on the 383 cu. in. engines when the ve from the bowls flow into the primary and the second
hicles are equipped with a manual or automatic ary metering bodies where the fuel is mixed with
transmission respectively. These two carburetors are air for all phases of engine operation. This type of
also equipped with a hot idle compensator valve as is metering provides for adequate diagnosis and easier
R-4369A above. (Fig. 2). servicing.
All of these carburetors are equipped with a dis The two primary bores have one choke valve, con
tributor ground switch, which retards the distributor nected to a well type automatic choke. Each bore has
when the carburetor is at curb idle, for better emis its own venturi, booster venturi, main fuel discharge
sion control. nozzle and throttle valve.
Additional fuel for acceleration is supplied by a
4 4 0 Cubic Inch Engine diaphragm type, mechanically operated pump which
The Holley four barrel carburetor model C.A.S. is located on the primary fuel bowl. The pump is
(Cleaner Air System) R-4366A is used on the 440 cu. in. actuated from a cam on the primary throttle. An over
engine when the vehicle is equipped with an automatic ride spring on the pump operating lever prolongs the
transmission. (Fig. 1). discharge of fuel for smoother acceleration.
The Holley four barrel carburetor model E.C.S. A power valve, mounted on the primary metering
(Evaporation Control System) R-4360A is also used on body, which is actuated by manifold vacuum, delivers
the 440 cu. in. engine when the vehicle is equipped the additional fuel necessary for full power and high
with an automatic transmission. (Fig. 2). speed operation.
Both of these carburetors are equipped with a hot The larger volume of fuel, in two separate bowls
idle compensator valve. This valve is a thermostatical exposed to the cooling air stream, is an effective
ly operated air bleed, to relieve an overrich condition means of reducing percolation and hard starting
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s e c o n d a ry FUEL BOWL . CHOKE LINK -CHOKE valve;
\
\
SECONDARY VACUUM
DIAPHRAGM \
-BOWL VENT VALVE
METERING BLOCK
- |T
CHOKE DIAPHRAGM LINK *
ACCELERATOR PUMP
ADJUSTING NUT HOT IDLE
COMPENSATOR
VALVE COVER
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HOT IDLE BOWL VENT VALVE
COMPENSATOR OPERATING ROD
.VALVE COVER
CHOKE VALVE
FUEL CHOKE ■IDLE MIXTURE BOWL VENT
TRANSFER TUBE VACUUM ADJUSTING VALVE
CHOKE VALVE DIAPHRAGM ; SCREW PLUNGER
SECONDARY \
VACUUM
BOWL VENT DIAPHRAGM DISTRIBUTOR
VALVE SECONDAR'' GROUND
\ VACUUM
/ FUEL SWITCH
BOWL \
? „ BOWL
DIAPHRAGM CONNECTOR
VENT VALVE ^ V - &
OPERATING ROD \ f
IDLE MIXTURE
ADJUSTING-*. /
SCREW 7
*4-
v BOWL VENT
CARBURETOR X VALVE VENT
7 0 AIR CLEANER /
ACCELERATOR SECONDARY TUBE
VENT TUBE
PUMP STOP LEVER j VACUUM HOSE
- FITTING rASV iDLE
ADJUSTING
CHOKE CAM
NUT SECONDARY
ACCELERATOR CONTROL
THROTTLE DISTRIBUTOR VACUUM
PUMP LEVER LEVER ■
SHAFT ADVANCE TUBE
CHOKE
CONNECTION
SECONDARY ■DIAPHRAGM
THROTTLE LINK
CURB IDLE SPEED
CONNECTOR
ADJUSTING •• LINK ■ ! CHOKE ■
SCREW UNLOADER LEVER FY872
»BOOSTER VENTURIS
CHOKE DIAPHRAGM. w
•CURB IDLE AIR BLEEDS
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when the engine is hot. An external vent on the
primary bowl, vents the primary fuel bowl when the
throttle is closed.
The primary and/or secondary bowls can be quickly
removed to adjust the fuel level or change the fuel
inlet valve without removing the carburetor from the
engine.
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supplied through two idle air bleed restrictions and
by a curb idle air bleed adjusting screw.
This is the only screw used to adjust curb idle mix
ture.
The screw is located near the primary bowl vent on
the choke air horn.
Turning the screw clockwise leans the curb idle
mixture; counter-clockwise enrichens the mixture.
P rim a ry Id le Transfer System (Fig. 5)
A separate off-idle system is used in the carbureto1-
to provide fuel air mixture from idle operation until
the main system is in full operation.
Fuel for the idle transfer system enters the main
well through the main jet and travels up through the
idle transfer tube and crosses over a passage into a
vertical channel where air is added from the idle air Fig. 6—Main Metering System
bleeds. The fuel air mixture is then discharged
through the primary transfer slots. into the booster venturi and then in the air stream of
As the throttle valve is opened still wider and en the carburetor venturi.
gine speed increases, the air flow through the car The throttle valve controls the amount of fuel-air
buretor is also increased. This creates an increased mixture admitted to the intake manifold, regulating
vacuum in the venturi to bring the main metering the speed and power output of the engine in accord
system into operation. The flow from the idle transfer ance with accelerator pedal movement.
system tapers off as the main metering systems begin P ow er Enrichment System
discharging fuel. The two systems are engineered to During high power operation, the carburetor must
provide smooth gradual transition from idle to cruis provide a mixture richer than is needed when the
ing speeds. engine is running at cruising speed under no great
power requirements. The added fuel for power opera
M a in M e te rin g System tion is supplied by the power enrichment system
As the engine is running, the intake stroke of each
(Fig. 7).
piston draws the air through the carburetor venturi This system is controlled by manifold vacuum
and booster venturi. The air, passing through the re which gives an accurate indication of the power de
striction of the venturi, creates a low pressure com mands placed upon the engine. Manifold vacuum is
monly called a vacuum. The strength of this low pres strongest at idle and decreases as the load on the
sure is determined primarily by the velocity of the air engine increases. As the load on the engine is in
flowing through the venturi. This, in turn, is regulated creased, the throttle valve must be opened wider to
by the speed and power output of the engine. The maintain a given speed. Manifold vacuum is thus re
difference, between the pressure in the booster ven duced because the opened throttle valve offers less
turi and the normal air pressure in the float chamber, restriction to air entering the intake manifold.
causes fuel to flow through the main metering sys A vacuum passage in the throttle body transmits
tem (Fig. 6).
At cruising speed, the fuel flows from the float
chamber through the main jet, which measures or
meters the fuel flow, into the bottom of the main well.
The fuel moves up the main well past the main well
air bleed hole in the side of the well. Filtered air,
enters through the high speed air bleed in the main
body and then into the main metering body by inter
connecting passages. This mixture of fuel and air,
being lighter than raw fuel, responds faster to any
change in venturi vacuum and vaporizes more readily
when discharged into the air stream of the venturi.
The mixture of fuel and air moves up the main well
and passes into the short horizontal passage leading
to the main body, then through the horizontal chan
nel of the discharge nozzle. This fuel is discharged
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manifold vacuum to the power valve chamber in the check ball on its seat preventing fuel from flowing
main body. The power valve which is located in the back into the float chamber. The fuel flows from the
main metering body is effected by this manifold short passage in the fuel bowl into the long diagonal
vacuum. The manifold vacuum, acting on the dia passage in the primary metering body. The fuel passes
phragm at idle or normal load conditions, is strong into the main body and then in the pump discharge
enough to hold the diaphragm closed, and overcomes chamber. The pressure of the fuel causes the dis
the tension of the power valve spring. When high charge needle valve to raise and fuel is discharged
power demands place a greater load on the engine into the venturi.
and manifold vacuum drops below a predetermined As the throttle is moved toward the closed position,
point, the power valve spring overcomes the reduced the linkage returns to its original position and the
vacuum opening the power valve. Fuel flows from the diaphragm spring forces the diaphragm down. As the
float chamber, through the valve and out the small diaphragm returns to its original position the pump
holes in the side of the valve through the diagonal inlet check ball is moved off its seat and the dia
restrictions in the main metering body and then into phragm chamber is filled with fuel from the float
the main well. In the main well, the fuel joins the fuel bowl.
flow in the main metering system, enriching the mix
ture. Secondary Throttle O p eratin g System
As engine power demands are reduced, manifold At lower speeds, the secondary throttle valves re
vacuum increases. The increased vacuum acts on the main nearly closed, allowing the engine to maintain
diaphragm, overcoming the tension of the power valve satisfactory fuel air velocities and distribution. When
spring. This closes the power valve and shuts off the engine speed increases to a point where additional
added supply of fuel which is no longer required. breathing capacity is needed, the vacuum controlled
secondary throttle valves open automatically.
Accelerating Pump System Vacuum taken from one of the primary barrels and
Upon acceleration, the air flow through the car one of the secondary barrels acts upon a diaphragm
buretor responds almost immediately to the increased which controls the secondary throttle valves. At high
throttle opening. speeds when engine requirements approach the ca
Therefore during the brief interval before the fuel, pacity of the two primary bores, the increased pri
which is heavier than air, can gain speed and main mary venturi vacuum moves the diaphragm, com
tain the desired balance of fuel and air, the acceler pressing the diaphragm spring. The diaphragm, acting
ating pump supplies fuel until the other systems can through the diaphragm link and lever, will commence
once again provide the proper mixture (Fig. 8). to open the secondary throttle valves (Fig. 9).
The accelerating pump is located in the bottom of The position of the secondary throttle valves de
the primary fuel bowl. The pump begins to function pends on the strength of the vacuum. This in turn, is
when the pump operating lever is actuated by throttle determined by the air-flow through the bores to the
movement. When the throttle is opened, the pump engine. As the air-flow increases, a greater secondary
linkage, actuated by a cam on the primary throttle throttle valve opening will result and the secondary
shaft, forces the pump diaphragm up. As the dia barrels will supply a greater portion of the engine’s
phragm moves up, the pressure forces the pump inlet requirements. As top speed is reached, the secondary
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throttle valves will approach wide open. ing a smoother idle.
As the secondary throttle valves begin to open, a When the secondary throttle valves are opened
vacuum is created in the secondary barrels, first at further the pressure differential causes the secondary
the throttle valves and then, as air flow increases, at main metering system to begin functioning.
the throat of the secondary venturi. This vacuum
assists the secondary metering system to operate. A u tom atic Choke
When engine speed is reduced, venturi vacuum in The automatic choke supplies enriched fuel-air mix
the bores become weaker. As the vacuum acting on ture for starting and operating a cold engine (Fig. 11).
the diaphragm is lessened, the load on the diaphragm Most of the fuel from the carburetor of a cold engine
spring will commence closing the secondary valves. is liquid. This fuel in liquid form burns slowly and
The diaphragm spring is assisted by the design of the incompletely. Power loss and stalls result. The choke
secondary valves. Each secondary valve is slightly valve supplies the extra fuel by restricting air flow
offset. When the valves are closing, the combined during cranking and warm-up. Vacuum created by the
force of manifold vacuum and the air stream has restriction causes this fuel flow from both the main
greater effect on the larger, upstream area of the metering and idle systems.
valves forcing the valves to a closed position. The The thermostat spring of a cold engine pushes the
secondary valves are retained in the closed position choke valve toward the closed position. When the
when the primary valves are fully closed by the sec engine is started, manifold vacuum acts on both the
ondary throttle connecting rod. This rod, which is choke valve and a vacuum diaphragm attached to the
fastened to the primary throttle lever, rides in a slot carburetor body. This vacuum acts to oppose the ther
in the secondary throttle lever. mostat spring and partially opens the choke valve to
prevent stalls from richness. The choke shaft does
Secondary Fuel M etering Systems not pass through the center of a choke valve. Instead,
The secondary system is supplied with fuel from it is offset to expose a large area at one side to mani
the secondary fuel bowl, which receives its fuel fold vacuum. During idle or low temperature crank
through a connecting tube, from the primary fuel ing, manifold vacuum is not sufficiently strong to
inlet. open the choke valve. But air impact against the valve
The secondary fuel bowl is equipped with a fuel causes partial opening. These two factors, vacuum
inlet assembly which regulates the flow of fuel into and air impact allow ample air to run the engine. Con
the bowl, the same as the primary fuel bowl. The sec tinued running of the engine develops heat and
ondary fuel inlet system must maintain a specified causes the thermostat assembly to move to the open
level of fuel as the two secondary fuel systems are choke position.
calibrated to deliver the proper mixture only when During the warm-up period, air flow past the par
the fuel is at this level. tially open offset choke valve acts to open the valve.
As the valves begin to open the fuel flows through Just as in the start cycle, vacuum and air impact com
bine to control the choke valve. The engine required
the secondary metering restrictions into the idle well
less choking at high speeds. The offset choke valve,
(Fig. 10).
vacuum diaphragm and thermostat spring are engi-
A secondary fixed curb idle discharge passage sup
plies fuel directly to the intake manifold, thus allow-
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Fig. Carburetor Assembly (Exploded View)
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1—Lever, Pump Operating 47—Gasket, Power Valve
2—Locknut 48—Primary Jets
3—Spring, override 49—Needle, Idle Adjusting Mixture
4—Screw, Pump Adjusting 50—Gasket, Idle Mixture Needle
5—Screw, Fuel Bowl (Primary) 51—Screws, Choke Valve
6—Gasket, Bowl Screw 52—Choke Valve
7—Fuel Bowl (Primary) 53—Choke Shaft & Lever Assembly
8—Gasket, Fuel Bowl 54—Discharge Nozzle Screw, Pump
9—Metering Body (Primary Side) 55—Gasket, Nozzle Screw
10—Gasket, Metering Body 56—Nozzle, Pump Discharge
11—Fuel Tube (Float Bowl Connecting) 57—Needle, Pump Discharge Jet
12—“0 ” Rings, Fuel Tube 58—Cotter Pins, Connecting Rods
13—Screw, Fuel Bowl (Secondary) 59—Rod, Secondary Connecting
14—Gasket, Bowl Screw 60—Screw and Lockwasher, Fast Idle Cam Lever
15—Fuel Bowl (Secondary) 61—Lever, Fast Idle Cam
16—Screw, Metering Body (Secondary) 62—Screws, Primary Throttle Valve
17—Metering Body (Secondary) 63—Throttle Valves, Primary
18—Gasket, Metering Body (Secondary) 64—Screw, Pump Cam
19—Plate, Metering Body (Secondary) 65—Pump Cam
20—Gasket, Metering Body Plate 66—Screw and Lockwasher, Secondary Stop Lever
21—Balance Tube 67—Lever, Secondary Stop
22—Washers, Balance Tube 68—Screws, Secondary Throttle Valves
23—“0" Rings, Balance Tube 69—Throttle Valves, Secondary
24— Choke Link 70—Fast Idle Cam Lever
25—Seal, Choke Rod 71—Fast Idle Cam
26—Throttle Body Screws 72—Retainer (E-Clip)
27—Main Body 73—Choke Diaphragm Link
28—Throttle Body 74—Choke Diaphragm Assembly
29—Gasket, Main to Throttle Body 75—Choke Vacuum Hose
30—Screw, Bowl Vent Valve Rod Clamp 76—Choke Diaphragm Bracket Screw
31—Clamp, Valve Rod 77—Secondary Diaphragm Cover Screw
32—Rod, Bowl Vent Valve 78—Diaphragm Cover (Machine)
33—Spring Vent Valve Rod 79—Secondary Diaphragm Return Spring
34—Valve, Bowl Vent 80—Secondary Diaphragm Assembly
35— Retainer, Clip, Float 81—Secondary Diaphragm Housing (Machine)
36—Float 82—Secondary Diaphragm Housing Gasket
37—Spring, Float 83—Secondary Diaphragm Assembly Screw
38—Baffle, Float 84—Throttle Connecting Rod Retainer Washer
39—Needle Valve and Seat 85—Pump Operating Lever (E-Clip)
40—Screws, Fuel Pump Cover 86—Secondary Stop Screw
41—Cover Assembly, Fuel Pump 87—Throttle Stop Screw
42—Diaphragm, Fuel Pump 88—Throttle Stop Screw Spring
43—Spring, Fuel 'Pump Diaphragm 89— Baffle
44— Fitting, Fuel Inlet 90—Limiter Cap
45—Gasket, Fuel Inlet, Fitting 91—Bowl Vent Valve Assy. (E.C.S.)
46—Valve Assembly, Power
neered to provide satisfactory choking for most condi within the carburetor to control spark timing to
tions of engine speed, output and temperature. satisfy all engine speed and load conditions.
In order to obtain a vacuum to operate the spark
F a s t Id le
advance as dictated by the engine speed and load
The choke control lever at the carburetor actuates
conditions, a port is located in the throttle bore just
a fast idle cam during choking. A cam has a series of
above the full closed position of the throttle valves,
steps designed to increase carburetor air flow to main
as the throttle is opened, this port is subject to mani
tain satisfactory cold engine speed levels. The prop
fold vacuum, which varies with changes in engine
er cam step is moved into position as the choke rod
load. This port in the throttle body is connected to the
is moved from closed to open conditions. Each step
main body by a short vertical passage, and then to a
permits a slower idle rpm as engine temperature
rises and choking is reduced. passage in the main metering body. This passage
leads to an outlet on the side of the main metering
S p a rk M dw anee body which connects to a single flexible tube to the
The distributor utilizes changes in air pressure distributor.
SERVICE PROCEDURES
Servicing Carburetor (1) All parts should be carefully cleaned in a suit
Dirt, dust, water and gummy deposits are some of able solvent, then inspected for damage or wear.
the main causes for poor carburetor operation. How (2) Use air pressure only to clear the various ori
ever, proper cleaning and the installation of new fices and channels.
parts, where required, will return the carburetor to (3) Replace questionable parts with New Ones.
its originally designed performance. When checking parts removed from the carburetor.
When overhauling the carburetor, several items of it is at times rather difficult to be sure they are satis
importance should be observed to assure a good job: factory for further service. It is, therefore, recom
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mended that in such cases, New Parts be installed. O" RING
BALANCE TUBE
(4) Always use a complete repair kit when over
hauling the carburetor. Using the code number METERING BODY
stamped on the airhorn, adjacent to the fuel inlet,
refer to the parts catalog and order the correct repair
kit for the carburetor being worked on.
DISASSEMBLING CARBURETOR
CARBURETOR
GASKET
MAIN BODY
PLATE
GASKET
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DISTRIBUTOR 'GROUND CURB IDLE SPEED
SWITCH l.EAO /A D J U S T IN G SCREW
GASKET
VALVE
w
VALVE
COVER\
I fflH P
/ sJ INSULATING
4 GROUND BUSHING
SWITCH POWER VALVE,
^ :MSULATING TOOL NY41B
TERMINAL
WASHER ■
SCREWS PY903 Fig. 7—Removing or Installing Power Valve
Fig. 5—Removing or Installing Hot Idle fuel bowl baffles are of a different design and should
Compensator Valve be installed in the correct bowl at reassembly.
(2) Remove float retainer “E” clip, then slide float Disassembling M a in M ete rin g Body
and spring out of float chamber. (As float is being
removed, the fuel inlet needle may drop out of seat P rim a ry
assembly.) Remove float baffle. (1) Using Tool C-3747, remove power valve assem
(3) Remove fuel inlet needle valve seat. Discard bly from primary metering body (Fig. 7).
the gasket. (2) Using Tool C-3748, remove main metering jets.
(4) Remove screws attaching accelerator pump (Fig. 8).
cover. Remove cover, then carefully remove dia (3) Remove idle adjusting needles and gaskets.
phragm and spring. (4) Turn idle limiter caps to stops. Remove caps by
(5) Remove fuel inlet fitting and discard gasket. prying off ends of screws, using a suitable tool. (Be
(6) Remove screws attaching bowl vent valve cover careful not to bend screws.) Be sure and count num
to fuel bowl. Lift off cover and remove vent valve, ber of turns to seat the screws, as the same number
spring and seal. (Fig. 1). Remove seal from bottom of of turns (from the seat) must be maintained at installa
valve. tion. Remove screws and springs from metering body.
Secondary Secondary
(1) Remove float retainer “E” clip, then slide float No disassembly required, but it is very important
and spring out of float chamber. (As float is being re that the well bleed parts, main metering restrictions
moved, the fuel inlet needle may drop out of seat as and idle feed restrictions are clean (Fig. 9).
sembly.) Remove float baffle.
(2) Remove fuel inlet needle valve seat. Discard
(1) Remove the diaphragm cover screws and sepa-
gasket.
It should be noted that the Primary and Secondary MAIN METERING
BODY (PRIMARY)-------
BOWL VENT BAFFLE PLATE
VALVE FLOAT POWER
VALVE .
TOOL
FLOAT PIVOT-..- .
PIN
INLET ;■1 i
ACCELERATC NEEDLE MAIN METERING
PUMP COVL AND SEAT JETS
AND LEVER ASSEMBLY NP759 NY43C
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M AIN W E.'. Never clean jets with a wire, drill or other mechanical
FUEL AND A!” IDLE FEED means because the orifices may become enlarged,
RESTRICTION
I making the fuel mixture too rich for proper perform
ance.
DO NOT clean any rubber diaphragms or plastic
parts in cleaning solvent because of possible damage.
INSPECTION AND REASSEMBLY
DOWL Throttle Body
V WELL BLEED if the throttle valves were removed because of
damage, install new valves as follows:
(1) Slide new primary throttle valves in position on
NP761A
throttle shaft, with the valve number on the bottom
(flange side) and toward idle transfer and spark ad
Fig. 9 —Secondary Metering Body vance control ports.
(2) Install new attaching screws but do not tighten.
rate diaphragm cover from housing. (3) Hold valves in place with fingers. (Fingers press
(2) Remove diaphragm return spring from cover, ing on high side of valves.)
then slide diaphragm out of housing. (4) Tap valves lightly with screwdriver in this posi
Disassembling Throttle Body tion to center in bores. Tighten securely. Operate the
CAUTION: In normal routine cleaning and overhaul throttle shafts. From closed to open position, they
of the carburetor, do not remove the throttle valves must operate smoothly without drag or sticking. Hold
unless they are nicked or damaged. If necessary to throttle body up to a strong light. The light which is
remove, proceed as follows: visible around the outer diameter of the valves and
(1) Remove screws that hold throttle valves to the bores should be uniform.
throttle shafts. These screws are staked to prevent (5) Install secondary throttle valves in the same
loosening and care is necessary to avoid breaking off manner as described previously. The numbers
in shaft. Remove staking with a file. stamped on the valves must be toward idle transfer
(2) Slide damaged throttle valves out of bores. It and spark advance ports in primary bores. For adjust
should be noted at this time, that the secondary ment (See Secondary Throttle Adjustment).
throttle valves are thicker than the primary valves.
Assembling M a in M e te rin g Body
Do not install secondary valves in primary bores or
(Prim ary)
visa versa as the relationship of the primary valves to
(1) Install idle mixture screws and springs in meter
the idle transfer port and spark advance control ports
ing body. (The tapered portion must be straight and
is carefully established for one particular assembly.
smooth. If tapered portion is grooved or ridged, a new
CLEANING CARBURETOR PARTS idle mixture screw should be installed to insure hav
ing correct idle mixture control.) DO NOT USE A
The recommended solvent for gum deposits is de SCREW DRIVER. Turn screws lightly against their
natured alcohol which is easily obtainable. However, seats with fingers. Back off the number of turns
there are other commercial solvents, (such as Metal- counted at disassembly. Install new plastic caps with
clene) which may be used with satisfactory results. tabs against stop.
The choke diaphragm can be damaged by solvents. (2) Slide a new gasket over power valve and install,
Avoid placing the diaphragm assembly in ANY liquid. using Tool C-3747. Tighten securely (Fig. 7).
Clean the external surfaces with a clean cloth or soft (3) Install main metering jets (Fig. 8), using Tool
wire brush. Shake dirt or other foreign material from C-3748. Tighten securely.
the stem side of the diaphragm. Depressing the dia
phragm stem to the retracted position, will provide an Assembling Fuel Bowls
additional hole for the removal of dirt. Compressed P rim a ry
air can be used to remove loose dirt, but should not (1) Install accelerator pump spring in position in
be connected to the vacuum inlet fitting. fuel bowl, followed by diaphragm and pump cover.
IMPORTANT: If the commercial solvent or cleaner (When installing diaphragm, be sure contact button is
recommends the use of water as a rinse, it should be toward pump lever in cover.) (Fig. 10).
"HOT". After rinsing, all trace of water must be (2) Place cover over diaphragm (with lever on fuel
blown from the passages with air pressure. It is fur inlet fitting side) (Fig. 10). Install attaching screws and
ther advisable to rinse all parts in clean gasoline or tighten securely.
kerosene to be certain no trace of moisture remains. (3) Install new gasket on fuel inlet needle seat (Fig.
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11) then install in fuel bowl. Tighten securely. Slide PRIMARY
fuel inlet needle into seat. FUEL I N i E T ^
i-'JEL BOWL
(4) Install float baffle in position, then slide float SEAT /
hinge over pivot and secure with “E” clip. Install FUEL INLET *
float spring. NEEDLE •
(5) Install new gasket over fuel inlet fitting, then FLOAT
install fitting in primary fuel bowl. Tighten securely. RETAIN HP
9
(NOT REMOVABLE) bowl. Press in on tube end until seated.
(10) Carefully slide secondary fuel bowl over bal
PUMP LEVER r PUMP ance tube and fuel tube and seat against gasket. In
NP762 COVER SCREWS
stall secondary fuel bowl attaching screws after in
stalling new gaskets. Tighten securely.
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BAFFLE ' FLOAT
FUEL
BOWL-
T
SECONDARY
FUEL BOWL
‘ NEEDLE
AND SEAT
ACCELERATOR ASSEMBLY
PUMP COVER
AND LEVER
PRIMARY
FUEL BOWL
' r
15/64" DRILL
17'64" DRILL OR GAUGE TOE OF
FLOAT NP764A
v\
■ 1 INCH
SPARK VACUUM ._
PASSAGE \ WASHER 'Jl»
Mai
IE
y
"O" :VS(s '
SECONDARY IDLE
FUEL PASSAGE
Ij^vSI
K g
SECONDARY
washer / METERING BODY
CURB IDLE ,D L t KtAN'jI'-ER' NP765 "O'" r<n-:G
Fig. 13—Main Body Identification (Bottom View)
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and discard old needle and install a new one. Retest (7) Turn screw into boss, at the same time, keep
as described previously. If the service fix does not insulating washer aligned.
correct the condition, a new carburetor will have to
be installed. Assembling Secondary D ia p h ra g m
(12) Install pump discharge nozzle gasket, nozzle (1) Slide diaphragm into housing (Fig. 15).
and mounting screw and gasket. Tighten screw se (2) Position diaphragm so that the vacuum hole in
curely. Test nozzle operation. Press pump lever down. housing is aligned with vacuum hole in diaphragm.
The two streams from the nozzle should be identical (3) Install diaphragm return spring with coiled end
and should strike the two venturi in the same spot. snapped over button in cover.
(13) Slide the bowl vent valve shaft down between (4) Support diaphragm stem in order to keep dia
fuel tube and carburetor body. Hold in position, then phragm flat as spring and cover are installed.
install clamp, after engaging stub end of spring in (5) Align vacuum port in cover with port in housing
clamp. Install retaining screw and tighten securely. then carefully lower cover. Install attaching screws
(14) Loosen choke valve attaching screws slightly. and tighten securely.
(15) Tap lightly on choke valve to center valve in (6) Check diaphragm by pressing in on stem and
air horn. Holding choke valve with the fingers, tighten placing finger over port. Diaphragm should stay in
attaching screws securely. Stake by squeezing with retracted position.
pliers. (7) Install a new gasket in vacuum passage recess
(16) Engage fast idle cam with fast idle cam lever, in diaphragm housing, then install secondary dia
then slide assembly onto stub shaft positioning fast phragm on main body of carburetor and at the same
idle cam behind fast idle cam lever. At the same time time engage stem with secondary stop lever. Install
engage fast idle cam lever with choke rod. Install “E” screws and tighten securely.
clip to secure. (8) Install pump lever on stub shaft and secure
with “E” clip. Slide spring and locknut between fuel
Choke Vacuum D iap h ra g m pump lever and pump operating lever. Open throttle
Inspect the diaphragm vacuum fitting to be sure valve and install adjusting screw. Tighten 2 or 3
that the passage is not plugged with foreign material. threads to hold. The correct setting of the adjusting
Leak check the diaphragm to determine if it has in screw will be covered under adjustments.
ternal leaks. To do this, first depress the diaphragm
stem, then place a finger over the fitting to seal the CARBURETOR ADJUSTMENTS
opening. Release the stem. If the stem moves more
than 1/16 inch in ten (10) seconds, the leakage is It is very important that the following adjustments
excessive and the assembly must be replaced. be made on a reconditioned carburetor:
Install the diaphragm assembly on the carburetor Qualifying the Choke Control Lever
Choke Unloader Adjustment (wide open kick)
as follows: Fast Idle Cam Position Adjustment
(1) Engage choke link in slot in choke lever. Vacuum Kick Adjustment (On or off vehicle)
(2) Place the diaphragm on the mounting surface. Fast Idle Speed Adjustment (On the vehicle)
Install and tighten the attaching screws securely. Checking the Bowl Vent Valve Clearance.
(3) Inspect the rubber hose for cracks before plac Checking the Pump Lever Clearance
ing it on the correct carburetor fitting. Do not connect Idle Speed Adjustment (Curb idle)
the vacuum hose to the diaphragm fitting until after Adjusting the Float
the vacuum kick adjustment has been made. Secondary Throttle Adjustment
(4) Install hot idle compensator valve gasket in
position in recess in main body, followed by valve. (Be
sure valve is positioned with legs toward outside of
main body.) (Fig. 5). Place cover over opening and
install attaching screws. Tighten securely. (If so
equipped.)
(5) Slide a new distributor ground switch insulated
bushing into stop on main body, with the notch aligned
with raised portion of boss. Force into position against
stop.
(6) Place insulating washer over tangs on lead wire VACUUM HOLE NP767
terminal, then install curb idle speed screw with
spring through terminal and washer.
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Idle Mixture Adjustment T109-213, until correct clearance has been obtained.
Checking Wet Fuel Level
Checking Accelerator Pump Lever Clearance
To check accelerator pump lever clearance (Fig.
Cheeking Bowl Vent V a lve Clearance
17), proceed as follows:
(C.A.S.)
To check the bowl vent valve clearance (Fig. 16), (1) With throttle valves wide open, and the pump
proceed as follows: lever held down, it should be possible to insert a .015
(1) With throttle valves at curb idle, it should be inch gauge between adjusting nut and lever.
possible to insert a 1/16 inch drill shank between (2) If an adjustment is necessary, adjust pump over
bowl vent valve and top of primary fuel bowl, with ride screw until correct clearance has been obtained.
the idle speed properly set. (3) There must be no free movement of pump
(2) If an adjustment is necessary, bend rod to leverage when throttle is at curb idle.
change arc of contact with throttle lever, using Tool Q u a lify in g Choke Control Lever
T109-213 until correct clearance has been obtained. Adjustment of the choke control lever is necessary
to provide correct relationship between choke valve,
Checking Bowl Vent V a lve Clearance (E.C.S.) thermostatic coil spring and the fast idle cam. It
To check the bowl vent valve clearance adjustment, should be checked and adjusted (if necessary) after
proceed as follows:
carburetor assembly or as preparation of the choke
(1) With the throttle valves at curb idle, it should
system linkage before making the Vacuum Kick, Cam
be possible to insert a number 72 drill shank (.005 to Position or Unloader Adjustment. These three adjust
.025 inch) between bowl vent valve plunger stem and ments must and should be made after qualification of
operating rod, (Fig. 16).
the choke control lever.
(2) If an adjustment is necessary, bend rod to
(1) Open the throttle to mid-position.
change arc of contact with throttle lever, using Tool (2) Close the choke valve by slight pressure on
choke control lever.
DRILL OR ADJUST VENT
GAUGc VALVE ROD HERE (3) The top of choke rod hole in control lever
\ should be 1-11/16 ± 1/64 inch above choke assembly
(carburetor on engine) or 1-23/32 ± 1/64 inch above
carburetor base (Carburetor on bench) (Fig. 18).
l—■ --- jf-'j - / " (4) Adjust if necessary by bending choke shaft rod
at point indicated.
CAUTION: Improper bending will cause binding of
rod. Test for free movement between open and closed
choke positions and rebend if necessary to eliminate
any interferences.
4. \ r . ; ; '
GAUG i ik r 7f t •
,« h p >
E.C.S. -" w
THROTTLE VALVES AT
CARBURETOR PUMP OVERRIDE
CLOSED CURB IDLE PY873 PUMP LEVER
HELD DOWN ADJUSTING SCREW NP769B
Fig. 16—Checking Bowl Vent Valve Clearance
(C.A.S. a n d E.C.S.)
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TO ADJUST, BEND TOP EDGE OF CHOKE
• FAST IDLE CAM
AT THIS POINT CONTROL ROD HOLE
/
2ND '
r "SPEED
'Tj>w
1-11/16 + 1/64 INCH
j *
ABOVE CHOKE / , |TU SCREWDRIVER
FAST IDLE SPEED-
ASSEMBLY (CARBURETOR ADJUSTING TANG FOR ADJUSTMENT
ON ENGINE) U3BBM &9
4 p w a f
•*
t 1-23/32 t 1/64'INCH
(CARBURETOR ON BENCH) NR452A
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FAST DRILL OR
GAUGE . DRILL OR
-IDLE
GAUGE .
CAM
9
/ “ ■4FAST IDLE CAM
:llw . LIGHTLY PRESS
JiM%! UP O N CHOKE
I'l \ CONTROL LEVER
\ 2 N D HIGHEST
SPEED STEP rc vacuum r
I CHOKE CONTROL
SUPPLY il NP773B
I LEVER (LIGHT
t CLOSING PRESSURE) NR454A Fig. 22—Vacuum Kick Adjustment
Fig. 21—Fast Idle Cam Position Adjustment minimum choke valve opening without distortion of
the diaphragm link. Note that the cylindrical stem of
pressure on choke control lever.
the diaphragm will extend as an internal spring is
(3) Insert specified drill between the choke valve
compressed. This spring must be fully compressed for
and wall of the air horn (see specifications).
proper measurement of the vacuum kick adjustment.
An adjustment will be necessary if a slight drag is
(4) An adjustment will be necessary if a slight drag
not obtained as the drill is being removed.
(4) To adjust, bend the indicated tang (Fig. 21) un is not obtained as the drill is being removed. Shorten
til the correct choke valve opening has been obtained. or lengthen the diaphragm link to obtain the correct
choke opening. Length changes should be made by
Vacuum K i c k Adjustm ent carefully opening or closing the bend provided in the
(O Nor O F F Vehicle) diaphragm link. CAUTION: DO NOT APPLY TWIST-
The choke diaphragm adjustment controls the fuel ING OR BENDING FORCE TO DIAPHRAGM.
delivery while the engine is running. It positions the (5) Reinstall the vacuum hose on the correct car
choke valve within the air horn by use of linkage be buretor fitting.
tween the choke shaft and the diaphragm. The dia (6) Make the following check. With no vacuum ap
phragm must be energized to measure the vacuum plied to the diaphragm, the CHOKE VALVE SHOULD
kick adjustment. Vacuum can be supplied by a dis MOVE FREELY between the open and closed posi
tributor test machine, another vehicle or vehicle to tions. If movement is not free, examine the linkage
be adjusted. for misalignment or interferences caused by the bend
(1) If the adjustment is to be made with the engine ing operation. Repeat the adjustment if necessary to
running, position the fast idle tang (Fig. 21) (Cam provide proper link operation.
position adjustment) to allow choke closure to kick
position. If auxiliary vacuum source is to be used,
open throttle valves, (engine not running) and move PRIMARY FUEL i •' SECONDARY
BOWL 1 rUEL BOWL
choke to closed position. Release throttle first, then
release choke. \ r s M
WET LEVEL
GAUGE
(2) When using an auxiliary vacuum source, discon ' I w _ .
nect the vacuum hose from the carburetor and con
nect it to the hose from the vacuum supply with a m t ' V i f e f c a fcr. 9 ; i
small length of tube to act as a fitting. Removal of
the hose from the diaphragm may require forces •9 I'* *•.
which damage the system. Apply a vacuum of 10 or
more inches of hose.
(3) Insert the specified drill (see specifications) be TAKE READING
O N GRADUATED
tween the choke valve and the wall of the air horn.
NP788B SCALE
(Fig. 22). Apply sufficient closing pressure on the
lever to which the choke rod attaches to provide a
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Secondary Throttle Adjustm ent from fuel supply (Primary and Secondary) and install
This adjustment no longer required as valves are C-4051 wet fuel level gauge (Fig. 23). As screw is be
pre-adjusted and need no further adjustment. ing removed, fuel will be lost. Start or crank engine
and allow fuel bowls to fill. The reading on level gauge
Idle Speed Adjustm ent (Curb Idle) should be 9/16 for Primary and 13/16 inch for Sec
Refer to General Information at front of Group. ondary, with 5 pounds fuel pump pressure.*
If an adjustment is necessary remove fuel bowl and
Checking W e t Fuel Level (On Vehicle) bend tang on float until correct specifications are ob
Before checking wet fuel level, check the fuel pump tained.
pressure to be certain 5 pound reading is obtained. *Fuel level will vary 1/32 inch for every pound of fuel pump
To check wet fuel level, remove lower bolt furthest pressure under or over specifications.
FUEL PUMP
INDEX
Page Page
Assembling Fuel Pump (RD-267A) ......................... 112 Service D iagnosis...................................................... 109
Disassembling Fuel Pump (RD-267A) ................... 112 Specifications .............................................................. 129
Fuel Vapor S e p a ra to r................................................ 113 Testing Fuel Pump (On V ehicle)............................ 110
General Information ............................... ................... 109
GENERAL INFORMATION
Fuel pump Model MS-4588SA and MS-4844S (E.C.S.) down on the pump rocker arm. (On the 383, 426
(Fig. 1), are used exclusively on the 198/225 cubic and 440 cubic inch engine, a push rod operates be
inch 6 cylinder engine. Model MS-4587SA (Fig. 2) is tween the camshaft and the fuel pump rocker arm.)
used on the 318 and the 340 cu. in. engine. This action lifts the pull rod and diaphragm up
Model MS-4589SA (Fig. 3) and Model RD-267A, (Fig. wards against the fuel pump main spring, thus creat
6) (optional) is used on the 383 and 440 cubic inch ing a vacuum in the valve housing and opens the inlet
engine. Model MS-4024S is used on the 426 cu. in. en valve and fuel is drawn into the valve housing cham
gine (Fig. 5). Model MS-4845S is used on the 440 cu. ber. On the return stroke the main spring forces the
in. H.P. engine (Fig. 3). diaphragm to the down position, which closes the in
The fuel pumps are driven by an eccentric cam let valve and expels the fuel in the valve housing
that is cast on the camshaft in the 198-225, 383 and chamber through the outlet valve, to the fuel filter
426, 440 cubic inch engines, or by a pressed steel ec and the carburetor.
centric cam mounted on the gear end of the camshaft The fuel filter should be changed every 24,000
in the 318 and 340 cubic inch engine. miles, to insure having an unrestricted flow of fuel at
As the camshaft rotates, the eccentric cam presses all times. Do not attempt to clean.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
FUEL PUMP LEAKS- (a) Worn, ruptured or torn diaphragm. (a) Install new pump.
FUEL (b) Loose diaphragm mounting plates. (b) Install new pump.
(c) Loose inlet or outlet line fittings. (c) Tighten line fittings.
FUEL PUMP LEAKS- (a) Cracked or deteriorated pull rod oil (a) Install new pump
OIL seal.
(b) Loose rocker arm pivot pin. (b) Install new pump.
(c) Loose pump mounting bolts. (c) Tighten mounting bolts securely.
(d) Defective pump to block gasket. (d) Install new gasket.
INSUFFICIENT FUEL (a) Vent in tank restricted. (This will also (a) Unplug vent and inspect tank for
DELIVERY cause collapsed fuel tank.) leaks.
(b) Leaks in fuel line or fittings. (b) Tighten line fittings.
(c) Dirt or restriction in fuel tank. (c) Install new fuel filter and clean out
tank.
(d) Worn, ruptured, or torn diaphragm. (d) Install new pump.
(e) Frozen gas lines. (e) Thaw lines and drain tank.
(f) Improperly seating vaIves. (f) Install new fuel pump.
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(g) Vapor lock. (g) Install heat shield where lines or
pump are near exhaust.
(h) Low pressure. (h) Install new fuel pump.
(i) Incorrect fuel pump. (i) Install correct fuel pump.
(j) Restricted fuel filter. (j) Install new filter.
FUEL PUMP NOISE (a) Loose mounting bolts. (a) Tighten mounting bolts.
(b) Scored or worn rocker arm. (b) Install new fuel pump.
(c) Weak or broken rocker arm spring. (c) Install new spring.
SERVICE PROCEDURES
TESTING FUEL PUMP (On Vehicle) Vacuum Test
If the fuel pump fails to supply fuel properly to the The vacuum test should be made with the fuel line
carburetor, the following tests should be made be disconnected from the carburetor. (This will allow the
fore removing the fuel pump from the vehicle. pump to operate at full capacity, which it must do to
prime a dry carburetor.) The minimum reading should
be at least 10 inches of vacuum at 500 r.p.m. with the
Pressure Test
(1) Insert a “T” fitting in fuel line at carburetor, fuel line disconnected at the carburetor.
(Fig. 4).
(2) Connect a 6 inch piece of hose between “T” Volum e Test
fitting and gauge C-3411. (The hose should not exceed The fuel pump should supply 1 quart of fuel in 1
6 inches. A longer hose may collect fuel and addi minute or less at 500 r.p.m.
tional weight of fuel would be added to pressure of
pump and result in an inaccurate reading.)
(3) Vent pump for a few seconds (this relieves air
trapped in fuel chamber). If this is not done, pump
will not operate at full capacity and low pressure
reading will result.
(4) Connect a tachometer, then start engine and
run at 500 r.p.m. The reading should be as shown in
specifications (depending on pump) and remain con
stant or return to zero very, very slowly when engine
is stopped. An instant drop to zero indicates a leaky
outlet valve. If pressure is too low a weak diaphragm
main spring, or improper assembly of diaphragm may NH414A
be cause. If pressure is too high, main spring is too Fig. 2—Fuel Pump Assembly (318 and 340
strong. Cu. In. Engine)
NH415B
NH413B
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Inlet V a lv e Test
To test the inlet valve, connect a vacuum gauge on
the inlet fitting while the line is disconnected.
(1) Start engine or turn over with starting motor.
(2) There should be a noticeable vacuum present,
not alternated by blowback.
(3) If blowback is present, inlet valve is not seat
ing properly and a new pump should be installed.
If fuel pump does not perform to above test re
quirements, fuel pump should be removed from
vehicle.
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TO REAR TO FRONT
CARBURETOR^ CARBURETOR
FUEL SUPPLY
ALTERNATOR TUBE
HOSE
VAPOR SEPARATOR
ASSEMBLY
FUEL PUMP
% 6-Fuel Pump Assembly (RD-267A) Fig. 8—Fuel Vapor Separator (426 Cu. In. Engine)
383 and 440 Cm. In * Engines DISASSEMBLING FUEL PUMP (RD-267A)
rocker arm housing. Place the valve body in position Before disassembly, mark housings in such manner
on the diaphragm with the scribe marks aligned. that the mark "Inlet" will be facing inlet fuel line
(Be sure the holes in the diaphragm, rocker arm when reassembled. This is important!
housing and valve bodies are aligned). Compress the (1) Grind or file off peened end of pivot pin, then,
unit together, then install the attaching screws, but drive out pivot pin. Remove washer.
do not tighten. Never use shellac or any other ad (2) Remove rocker arm follower spring.
hesive on the diaphragm. (3) Remove screws holding rocker arm housing to
(4) Slide the rocker arm into the housing and en valve body. Separate body and housing.
gage the diaphragm pull rod. Align the pivot pin (4) Press in on diaphragm and disengage rocker
holes in the arm with those in the housing, then in arm from diaphragm pull rod. Remove rocker arm
stall pivot pin. Install new plug and drive in securely. and spacer washers.
(5) Install the rocker arm follower spring over (5) Slide diaphragm and spring out of rocker arm
the tab on the rocker arm and over dimple in the housing.
housing. (6) Remove sleeve from two piece rocker arm, then
(6) Place the pump in a vise (with protector separate rocker arm pull lever from eccentric arm.
jaws) then push on the rocker arm until full travel
is reached. Hold in this position, while tightening Cleaning Fuel Pump Parts
the attaching screws. This will prevent tearing of Clean all fuel pump parts (except diaphragm) in a
the diaphragm when the pump is in operation with suitable solvent, then blow dry with compressed
the pump arm in its full stroke. air. Check the condition of the valve seats and parts
(7) Test the fuel pump as described previously. for gum deposits. If gum deposits are found, remove
with denatured alcohol. If the valves are badly worn
ALTERNATOR
FUEL LINE TO or damaged, install a complete new valve body as
CARBURETOR
ALTERNATOR
sembly. The valves are not serviced individually. Ex
BRACKET amine the diaphragm for cracks, torn screw holes or
CLAMP ruptures. Check the rubber oil seal (diaphragm pull
HOSE rod) in housing for deterioration. If unfit for further
VAPOR SEPARATOR service, install a new rocker arm housing. Check the
DRIVE BELT ASSEMBLY rocker arm for scoring or galling on the camshaft
FUEL PUMP push rod bearing surface.
ASSEMBLING FUEL PUMP
FUEL SUPPLY (1) Assemble rocker arm by sliding the pull arm
TUBE
VAPOR SEPARATOR into eccentric cam and install sleeve. (Be sure the
TO FUEL TANK hook on the arm is facing up).
FITTING (RETURN) NR44
(2) Grease spacer washers and slide over each side
of sleeve shoulder.
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(3) Install diaphragm and spring in rocker arm
housing.
(4) Slide rocker arm in position and engage hook
of arm with slot in pull rod. (Compress diaphragm
and spring to engage arm with pull rod.)
(5) Using suitable drift, align rocker arm and wash
ers then install pivot pin. Install retaining washer,
then peen pivot pin to retain.
(6) Place valve body on diaphragm. Align, then in
stall attaching screws. Draw down evenly.
(7) With pump held in vise, compress rocker arm
to its full travel. Hold in this position, then tighten
screws securely. (This will prevent tearing diaphragm
when pump is operated at full stroke.) Fig. 9—Fuel Vapor Separator
(8) Install pump arm follower spring between (Sectional View)
rocker arm and housing. (Be sure spring is seated.) by excessive heat) that has gathered in the indrawn
(9) Test pump as described previously. fuel rises to the top of the separator unit and is forced
out of the metered fitting into the return line to the
FUEL VAPOR SEPARATOR tank for condensation to liquid fuel.
As previously mentioned, the vapor separator unit
The fuel vapor separator (Figs. 7, 8 and 9), is used is serviced only as an assembly. Check to see if the
on the 440 cu. in. High Performance engine and the unit is installed correctly (with the inlet fitting and
426 Hemi engine to prevent vapor lock. return fitting at the bottom, and the outlet fitting at
The vapor separator is located between the fuel the top.
pump and carburetor, depending on model (Figs. 7 To check the unit for a restricted or plugged
or 8) on the right side (front) of the engine. The screen, disconnect fuel line at carburetor, then with
separator is serviced as an assembly only and con a container placed under end of line, turn engine over
sists of a sealed can, a filter screen, an inlet and out with starting motor. Check the quantity of fuel
let fitting and a metered orifice outlet fitting for the pumped through the unit. This should be 1 quart of
return line to the fuel tank (Fig. 9). fuel in 1 minute, at 550 r.p.m.
Fuel is drawn from the fuel tank by the fuel pump, If vapor lock is evident, remove the return hose
through the supply line, into the pump and thence to and check to see if the metered orifice is open. If
the vapor separator unit, until the unit is filled with clogged, bend a paper clip and insert through re
fuel. The outlet tube picks up fuel from the bottom stricted orifice to clear. If necessary, use air pressure
of the separator unit and flows into the carburetor to clear return line to fuel tank, after removing filler
for distribution to the engine. Any fuel vapor (caused cap.
FUEL TANK
C.A.S. (CLEANER AIR SYSTEM)
INDEX
Page Page
General Information .............................................. 113 Removing Fuel Tank ................................................ 115
Installing Fuel T a n k ............................................... 116
GENERAL INFORMATION
The fuel tank conventional models (111" wheel located in the rear quarter panel.
base) is located at the rear of the body, under the If a car is to be stored for any appreciable length of
trunk compartment floor, (Figs. 1 or 2). The filler tube time, the gasoline should be drained from the entire
is located in the left rear quarter panel. system in order to prevent gum formation. If the ve
The fuel tank on the 110 inch wheel base models, is hicle has been undercoated, be sure the tank vent
located at the rear of the body under the trunk com tube is open. If this vent is plugged, a collapsed fuel
partment floor. (Fig. 3). The removal and installation tank will result.
procedures are the same as the 111 inch wheel base The fuel tank on all 110 and 111" wheelbase models
models, with the exception of the filler tube, which is has an 18 gallon capacity (Imperial 15). The fuel tank
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ROOF SIDE RAIL SUPPORT
HOSE-STA. WAGON
HOSE-SEDAN
SCREW-(3)
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PY904
it
•FUEL
y/ /// d
CLIP-FUEL GAUGE
GROUNDING
STUD-FUEL GAUGE STUD-FUEL GAUGE UNIT
TUBE-FUEL GAUGE TANK UNIT NR11
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INSTALLING FUEL TANK (HOand 111" W/B
Vehicles) (Figs. 1,2 or 3)
Before installing the fuel gauge, check the condi
tion of the filter on the end of the suction tube. If the
filter is plugged, install a new filter.
\ \ (1) Install a new rubber grommet in tank. Insert a
M ''
if* ' /
\ ' new gasket in fuel gauge opening recess then slide
gauge into tank. Align positioning tangs on gauge
with those in tank. Install lockring, then tighten se
curely, using Tool C-3582. (If tank insulator was torn
or damaged during removal of tank, be sure and in
stall a new insulator at reassembly.)
f r
(2) Locate insulation pad on top of tank. Slide
\ / tank under car and up in position. Hold in position,
PHILLIPS HEAD OR
THEFT PROOF SCREWS NP1006A then raise retaining straps and thread onto “J ” bolts.
Fig. 6 —Fuel Tank Filler Cap Install nuts, and tighten. (Not over 50 inch-pounds.)
(3) Lubricate rubber grommet using a suitable
tube seal to floor pan, then remove end of vent tube rubber lubricant, then slide filler tube down through
from seal. dust seal and into tank, far enough to clear quarter
(5) Grasp filler tube with both hands, twist tube, panel. Twist (or rotate) filler tube 180 degrees and
and at same time, force downward into tank, until align with opening in quarter panel. Install a new
end of tube clears quarter panel. Remove gasket. (If gasket over end of tube, then slowly withdraw tube
tube is frozen in tank, use a rubber lubricant from tank and into position against quarter panel.
around joint and work into grommet, after sliding Align attaching screw holes; install screws and tight
dust shield out of way.) en securely. Slide vent tube through seal.
(6) Twist (or rotate) filler tube approximately 180 (4) If dust seal was disturbed during removal oper
degrees, then work tube carefully out of tank and ation, realign and tighten attaching screws securely.
dust shield seal. Remove tube from inside of trunk (5) Reconnect vent tube to filler tube connector.
compartment. (6) Reconnect fuel supply line, ground strap and
(7) Remove nuts that hold tank retaining straps to wire lead to gauge (Fig. 5).
“J ” bolts. Allow straps to drop or hang, then lower (7) Refill tank and check for leaks.
tank and remove from under car.
(8) Remove tank gauge unit, using spanner wrench Fuel Tank Filler Cap (If so Equipped)
C-3582. Slide gauge assembly out of fuel tank. Discard The fuel tank filler cap (Fig. 6) is attached to the
gasket. filler pipe by theft proof or Phillips head screws.
(9) If necessary check operation of fuel gauge, as Should it become necessary to remove cap, use
described in Electrical Section of Manual. special Tool C-4058.
FUEL T A N K
E.C.S. (E V A P O R A T IO N CONTROL SYSTEM)
GENERAL INFORMATION
Certain Chrysler Corporation Vehicles are equipped is an existing part of the Cleaner Air System (CAS)
with an Evaporation Control System (ECS) to reduce into the base of the carburetor to be burnt by engine
the loss of fuel from the fuel system to the atmo combustion.
sphere by evaporation. This is a closed system which The possible expansion of fuel in a full fuel tank,
controls fuel expansion and feeds fuel evaporation due to a rise in temperature, is allowed for by a 1.4
emissions from the carburetor or fuel tank. The gallon over-fill limiter tank inside the main fuel tank
vapors pass through vent lines to the crankcase by which fills much slower than the main tank. When the
way of the crankcase inlet air cleaner. Since fuel main tank is filled, it remains essentially empty to
vapors are two to four times heavier than air, they allow for thermal expansion. (Fig. 1).
settle to the bottom of the crankcase. With the engine The loss of any fuel or vapor out of the filler neck
running the fuel vapors are purged from the crank is prevented by the use of a filler cap which will re
case and together with the normal crankcase vapor lease only under significant pressure (1/2 to 1 psi) or
are drawn via the crankcase ventilation system, which vacuum (1/4 to 1/2 psi). This cap is identified by the
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CRANKCASE
AIR CLEANER
VAPOR-LIQUID
SEPARATOR
VENT-LIQUID
RETURN LINE
THERMAL -
EXPANSION
VOLUME TANK
PY940
SERVICE DIAGNOSIS
The ECS system should not require any mainte by placing against the mouth and blowing into the
nance in normal service. Any loss of fuel or vapor hole in the release valve housing. An immediate leak
from the fuel filler cap would indicate one or more of with light blowing or lack of release with hard blow
the following: ing indicates a defective or incorrect unit.)
(1) An unsatisfactory seal between cap and filler (3) All ECS lines plugged between fuel tank and
neck. vapor separator.
(2) A malfunction of ECS cap release valve. (4) Plugged ECS line between the vapor separator
(A quick check of the ECS fuel cap may be made and the crankcase air inlet filter.
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FLOOR PAN
CROSSMEMBER
VAPOR
FUEL TANK
SEPARATOR
SCREW
CLAMP
FILLER
TUBE
QUARTER
QUARTER PANEL
SCREW
GASKET
PY953
VAPOR TUBE TO
FRONT OF VEHICLE
SCREW
HOSE I HOSE tu b e
FLOOR PAN PLUG SHIELD SHIELD PY954
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FUEL SUPPLY TUBE
CLIP-FUEL GAUGE <TUBE—FUEL LINE
GROUNDING ■ WIRING—FUEL GAUGE TANK UNIT
/ / // P
CLIP-FUEL GAUGE
GROUNDING
STUD-FUEL GAUGE STUD-FUEL, GAUGE UNIT
TUBE-FUEL GAUGE TANK UNIT NR11
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1 RACKET'
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clamp in direction away from carburetor lever. and pocket (21) at rear end of throttle cable.
(4) Back off ferrule (2) 1/4". This provides 1/4" (2) Block choke valve in full open position. Open
cable slack at idle. Tighten cable clamp nut (1) to throttle slightly to release fast idle cam, then return
45 inch-pounds. carburetor to curb idle.
(5) Connect choke rod or remove blocking fixture. (3) Loosen cable clamp nut (12), adjust position of
cable housing ferrule (13) in the clamp (14) so that all
M a n u a l Transmission (Fig. 2)
slack is removed from cable with rear carburetor at
(6 C ylinder Engines)
(1) Apply a thin film of multi-purpose grease on curb idle. To remove slack from cable, move ferrule
accelerator shaft where it turns in bracket, anti-rattle (13) in the clamp (14) in direction away from carbu
retor lever.
spring where it contacts shaft, ball end and pocket at
(4) Back off ferrule (13) 1/4". This provides 1/4"
rear end of throttle cable.
free play. Tighten clamp (12) to 45 inch-pounds.
(2) Disconnect choke at carburetor or block choke
(5) Attach carburetor rod (4) assembly between
valve in full open position. Open throttle slightly to
the carburetors with slotted rod end (16) attached to
release fast idle cam, then return carburetor to curb
idle. outboard side of inboard lever on rear carburetor.
With rear carburetor at wide open throttle, adjust
(3) Loosen cable clamp nut (1), adjust position of
length of connector rod (4) so that front carburetor
cable housing ferrule (2) in the clamp so that all slack
is removed from cable with carburetor at curb idle. is also at wide open throttle. To lengthen this rod (4),
turn adjusting stud (17) clockwise as viewed from
To remove slack from cable, move ferrule (2) in the
clamp in direction away from carburetor lever. front of engine. Tighten lock nut (18).
(4) Back off ferrule (2) 1/4 inch to provide 1/4 (6) Remove choke valve blocking fixture.
inch cable slack at idle. Tighten cable clamp nut to HOOD FRESH AIR INTAKE SYSTEM (Fig. 1)
45 inch-pounds. (If so Equipped)
(5) Connect choke rod or remove blocking fixture.
GENERAL INFORMATION
M a n u a l Transmission (Fig. 3)
(W ith H e m i Engine) Functional hood fresh air intake scoops allow fresh
(1) Apply a thin film of multi-purpose grease on air to flow directly from the outside of the engine
accelerator shaft (5) where it turns in bracket ball end compartment to the air cleaner. This device increases
:,v
BEZEL
A IR SCOOP
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engine performance. Cable operated doors, enables Fiberglass-reinforced thermosetting plastic pas
the driver to close the hood openings during rainy sages, attached to the hood inner panel, extend out
weather or during engine warm-up period. When the board from the air cleaner to openings on the top of
fresh air intake doors are closed, warm air is admitted the hood. A rubber gasket forms an airtight seal be
to the air cleaner (from the intake area) through a tween the passages and the air cleaner base.
series of holes in the housing, (in the engine compart Methods of attachment of the fresh air intake sys
ment). tem will be found in the Body Section of this Manual.'
SPECIFICATIONS
BALL AND BALL SINGLE THROAT CARBURETOR
C.A.S. C.A.S. E.C.S. E.C.S.
Manual Trans. Auto. Trans. Manual Trans. Auto. Trans.
Model BBS-4715S BBS-4716S BBS-4717S BBS-4718S
Engine Displacement (Cu. In.) 198 198 198 198
Bore ....................................... ........... 1-11/16" 1-11/16" 1-11/16" 1-11/16"
Venturi ............................................... 1-11/32" 1-11/32" 1-11/32" 1-11/32"
Main Metering Jet
Standard ....................................... #120-429S #120-429S #120-429S #120-429S
Step-Up Wire (Standard ............... 75-1842 75-1880 75-1842 75-1880
Diameter ...................................... .038" x .034" .041" x .037" .038" x .034" .041" x .037"
ADJUSTMENTS
Float Setting ................................... 1/4" 1/4" 1/4" 1/4"
Choke Unloader ............................. 3/16" 3/16" 3/16" 3/16"
Fast Idle Cam Position ................ #48 #48 #48 #48
Vacuum Kick (drill s iz e )................ #35 #48 #35 #48
Bowl Vent Valve Setting (from
under side of valve to air horn) 1/32" 1/32" 9/32" 9/32"
Idle Speed R.P.M. (curb id l e ) ___ 750* 750* 750* 750*
Fast Idle Speed (r.ppm.) .............. 1800 1800 1800 1800
CHOKE
Type .............................................. Well
Control ......................................... Thermostatic Coil Spring
Setting ......................................... 2 Notches Rich
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Fast Idle Speed (Engine Hot and
Screw on 2nd Highest Step of
Cam rpm)
Manual Trans. .................. 1700 1600 1600
Automatic Trans............... 1700 1800 1800
CHOKE
Type ............................................ Well Well
Control ....................................... Thermostatic Coil Spring
Setting ........................................ 2 Notches Rich 2 Notches Rich
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Fast Idle Speed R P M ........................... 1700* 1700* 1700* 1700* 1700*
CHOKE
Type ........................................................ Well Well
C ontrol.................................................... Thermostatic Coil SpringThermostatic Coil Spring
S e ttin g .................................................... 2 Notches Rich 2 Notches Rich
*After Approx. 500 Miles (If Necessary) ***W ith Air Conditioning **Without Air Conditioning
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Float Setting ......................................... 7/32" 7/32" 7/32" 7/32" 7/32"
Float Drop ............................................ 1/2" 1/2" 1/2" 1/2" 1/2"
Air Valve Spring Tension— (from Ver-
tical-Turns) ........................................ 2 2 2 2 2
CHOKE
Type ........................................................ Well Well Well Well Well
C ontrol.................................................... Thermostatic Coil Spring Thermostatic Coil Spring
S e ttin g .................................................... On Index On Index On Index On Index On Index
CARTERA V S SE R IE S CARBURETORS
C.A.S. C.A.S.E.C.S. C.A.S.
Type ........................................................ Carter 4 Barrel Downdraft
M o d e l...................................................... **AVS-4736S ***AVS-4732S AVS-4734SAVS-4737S
Transmission T y p e ............................... Automatic Automatic Automatic Manual
Engine Displacement (Cu. I n . ) ............ 383 383 383 440
THROTTLE BORE
Primary ................................................... 1-7/16" 1-7/16" 1-7/16" 1-11/16"
Secondary.............................................. 1-11/16" 1-11/16" 1-11/16" 1-11/16"
MAIN VENTURI
Primary .................................................. 1-3/16" 1-3/16" 1-3/16" 1-3/16"
MAIN JET
Primary .................................................. .089" .089" .089" .089"
Secondary................... ........................... .098" .098" .098" .095"
LOW SPEED JET
Primary .................................................. #68-.031" #68-.031" #68-.031" #65-.035"
STEP-UP ROD (2 Stage)
Standard ................................................ 16-546 16-546 16-546 16-617
ADJUSTMENTS
Accelerator Pump (top of plunger
to air hor n) . . . . . . . . . . . . ............ 7/16" 7/16" 7/16" 7/16"
Fast Idle Cam Position (drill size) . . . #50 #50 #50 #50
Choke Unloader ................................... 1/4" 1/4" 1/4" 1/4
Vacuum Kick (drill s iz e )..................... #44 #44 #44
Bowl Vent Valve S e ttin g ..................... 3/64" 3/64" 3/64" 3/64
Fast Idle Speed (r.p.m.) ..................... 1700* 1700* 1700* 2000*
Idle Speed (r.p.m.) ............................... 700 700 700 900
Secondary Throttle Lever Adj............. 19/64" 19/64" 19/64" 23/64"
Secondary Throttle Lockout Adj......... .020" .020" .020" -020
Float Setting ........................................ 5/16" 5/16" 5/16" 7/32"
Float Drop .......................................... 1/2" 1/2" 1/2" 1/2"
Air Valve Spring Tension—
(from Vertical-Turns) ......................
CHOKE 2 2 2 2
Type ............... .............. Well Well
Control’ 9 9 9 ............................................... Coil Spring Coil Spring
S e ttin g .................................................... ....2 Notches Rich 2 Notches Rich
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STEP-UP ROD (2 Stage)
Standard ................................................ 16-575 16-575 16-617 16-575
ADJUSTMENTS
Accelerator Pump (top of plunger to
air horn) ....................... ..................... 7/16" 7/16" 7/16" 7/16"
Fast Idle Cam Position (drill size) . . . #50 #50 #50 #50
Choke U nloader................................. 1/4" 1/4" 1/4" 1/4"
Vacuum Kick (drill s iz e )..................... #20 #20 #20 #20
Bowl Vent Valve S e ttin g ..................... 3/64" 3/64" 3/4" 3/4"
Fast Idle Speed (r.p .m .)....................... 1800* 1800* 2000* 1800*
Idle Speed (r.p .m .)............................... 800 800 900 800
Secondary Throttle Lever Adj............... 23/64" 23/64" 23/64" 23/64"
Secondary Throttle Lockout Adj......... .020" .020" .020" .020"
Float S ettin g .......................................... 7/32" 7/32" 7/32" 7/32"
Float Drop ............................................ 1/2" 1/2" 1/2" 1/2"
Air Valve Spring Tension— (from
Vertical-Turns) ................................. 2 2 2 2
CHOKE
Type ........................................................ Well Well
C ontrol.................................................... Coil Spring Coil Spring
Setting .................................................... On Index On Index
SPECIAL TOOLS
T109-287 .............. Elevating Legs C-3748 ................. Main Metering Jet Remover-lnstaller
C-3886 ................. Stand C-4051 ................. Wet Fuel Gauge
C-3747 ................. Power Valve Remover-lnstaller CL-13 .................... Clutch Head Screwdriver
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HOLLEY 2 3 0 0 SERIES CARBURETORS
Center Outboard Center Outboard
C.A.S. C.A.S. Front Rear E.C.S. E.C.S. Front Rear
Type ................................................................ Holley Dual Downdraft
Engine Displacement (cu. in.) ...... ......... .. 440 440
440 440 440 440
Manual Transmission . . . . . . . ..................... R-4375A —
R-4382AF R-4374A — R-4175AF
Automatic Transmission............................... — R- 4376A
R-4383AR — R-4144A R-4365AR
Bore ............................................................... 1-1/2" 1-1/2"
1-3/4" 1-1/2" 1-1/2" 1-3/4"
Main V e n tu ri............... ................................... 1-3/16" 1-3/16"
1-9/16" 1-3/16" 1-3/16" 1-9/16"
Main Metering Jet
Standard ............................................ . 64 63 — 64 63 —
1 Size L e a n ................................................ 63 62 — 63 62 —
2 Size Lean (5,000-10,000 f t . ) ................... 62 61 — 62 61 —
Adjustments
Curb Idle Speed ....................................... 900 900 — 900 900 —
Fast Idle Speed (No. 2 S te p )................. 2200* 1800* — 2200* 1800* —
Bowl Vent Valve ...................................... #38 #38 — #38 #38 —
Unloader Adjustment
(wide open th ro ttle)......................... . 5/32" 5/32" — 5/32" 5/32" —
Vacuum Kick Adjustm ent....................... #28 #50 — #28 #50 —
Fast Idle Cam Position ........................... #53 #53 — #53 #53 —
Float Setting (D ry )................... ................. Center float in bowl with fuel bowl inverted.
Accelerator Pump Override
Adjustment (wide open th ro ttle )...............015" min. .015" min. — .015" min. .015" min.
Fuel Level (Wet) ....................................... With bowl sight plugs removed, fuel level should be at
bottom edge of sight plug hole but not over-flowing.
Note that floats are externally adjustable.
Choke
Type ............... ............................................ Well None Well None
Control ........................................................ Coil Spring None Coil Spring None
Setting ........................................................ 2-Notches Rich None 2-Notches Rich None
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Float Drop .......................................... 3/4" 3/4" 3/4"
Idle Mixture Screw (turns open) 1-2 1-2
Air Valve Spring Tension— (from
Vertical-Turns) ..............................
CHOKE
Type .................................................... Well Well
Control ................................................ Thermostatic Coil Spring
Setting ................................................ 2 Notches Rich 2 Notches Rich
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PROPELLER SHAFT AND UNIVERSAL JOINTS
CONTENTS
Page Page
CROSS AND ROLLER UNIVERSAL JOINT. . 5 SERVICE DIAGNOSIS ................................ 1
GENERAL INFORMATION . 1 SPECIFICATIONS........................................ 7
PROPELLER SHAFT ANGULARITY . 1 TIGHTENING REFERENCE......................... 8
GENERAL INFORMATION
The propeller shaft and universal joint applications relubricated unless seal leakage is evident. If the
on the Dart and Challenger model vehicles incorporate cross and roller universal joints are repacked with
an internally splined yoke at the front universal the recommended lubricant, see “Lubrication”, Group
joint. The sliding splined yoke slides fore and aft on 0 of this manual.
the transmission output shaft to compensate for the Two types of propeller shafts are used on the Dart
movement of the rear axle. A bellows type rubber and Challenger vehicle models, dependent upon en
seal on the transmission extension, with a nylon ring gine, transmission and axle ratio combinations. Cer
which fits over the sliding yoke is used to exclude tain applications will require the usage of propeller
road splash and other foreign material (Fig. 1). shafts having solid tubes in some models.
The universal joints and sliding spline yoke are The other propeller shafts will incorporate an in
permanently lubricated. The joints should be in ternal vibration absorber inside the shaft in the loca
spected every time the vehicle is serviced, for external tion of the front universal joint. Servicing of both
seal leakage. The joints need not be disassembled or propeller shafts is the same in all respects. (Fig. 2).
SERVICE DIAGNOSIS
Condition Possible Cause Correction
PROPELLER SHAFT (a) Undercoating or other foreign matter (a) Clean exterior shaft and wash with
VIBRATION on shaft. solvent.
(b) Loose universal joint flange bolts. (b) Tighten bolt nuts to specified torque.
(c) Loose or bent universal joint flange (c) Install new flange. Tighten to specifi
or high runout. cations.
(d) Improper drive line angularity. (d) Correct angularity. See “Propeller
Shaft Angularity."
(e) Rear spring center bolt not in seat. (e) Loosen spring U-bolts, reseat center
bolts and tighten U-bolts to specifica
tions.
(f) Worn universal joint bearings or miss (f) Recondition universal joint.
ing rollers.
(g) Propeller shaft damaged (bent tube) (g) Install new propeller shaft.
or out of balance.
(h) Broken rear spring. (h) Replace rear spring.
(i) Excessive runout or unbalanced con (i) Reindex propeller shaft 180°, reride
dition. and correct as necessary.
UNIVERSAL JOINT (a) Propeller shaft flange bolt nuts loose. (a) Tighten nuts to specifications.
NOISE (b) Lack of lubrication. (b) Recondition universal joint.
SERVICE PROCEDURES
PROPELLER SHAFT ANGULARITY All joint angle measurements on the vehicle should
be made with the car supported by the tires if pos
The increased emphasis on the need for a quiet, sible; such as, on an alignment pit or a platform hoist.
smooth operating drive line in all cars require that A two post hoist may be used where other means are
the universal joint angles be maintained within ac not available. The vehicle should be approximately
ceptable tolerances. Propeller shaft and rear axle level when taking angle measurements with any
housing angularity may be measured by using the heavy items removed from the luggage compartment
Propeller Shaft Angularity Tool C-3976A (Fig. 4). This or passenger compartment. The fuel tank should be
tool makes it possible to check the angularity at the full or the equivalent weight simulated.
engine and differential and carrier. When using a twin post hoist, the vehicle must be
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OUTPUT SHAFT (5) With gauge SP-5060 adjusted for the correct
engine angle reference, position gauge SP-5060
squarely and firmly along underside of the propeller
shaft (Fig. 6). Make sure Veeway is in alignment and
that both adapter pins are contacting propeller shaft.
Be sure arrow on gauge is pointing toward the front
of car.
(6) Observe position of bubble in spirit level and
compare the position with that shown on Chart (Fig.
13) for front joint angle. A normal joint angle will
cause bubble to position itself within the acceptable
Fig. 1—Front Universal Joint Sliding Yoke range. If bubble is found to be slightly forward of the
acceptable tolerance range, this means that the angle
supported by the lower control arms and rear axle is actually smaller than that specified and does not
housing. DO NOT USE A FRAME CONTACT HOIST need correcting. If bubble in spirit level is found to be
WHEN MEASURING PROPELLER SHAFT ANGU rearward of the acceptable range, the angle is too
LARITY. large, and must be corrected. To reduce front uni
versal joint angle, install a flat shim between the
FRONT UNIVERSAL JOINT ANGLE transmission extension housing and rear engine
(1) Attach engine adapter SP-5046 to gauge SP- mount (Fig. 7). Flat shims 1/8 inch in thickness are
5060. required to move the bubble in spirit level one gradu
(2) Position gauge on left side of engine so that ation.
adapter pins contact fiat surface of engine oil pan (7) To install shim, loosen bolts in rear mount to
flange adjacent to the vertical wall of the oil pan (Fig. transmission extension housing.
5). On models equipped with six cylinder engines, use (8) Raise transmission sufficiently using a floor
right side of the engine. The gauge must be held stand and block of wood beneath transmission oil
vertical as shown with arrow on gauge SP-5060 point pan.
ing toward the front of car. (9) Install 1/8" shim, lower transmission, remove
(3) Adjust position of bubble in spirit level in ac floor stand and tighten bolts in rear mount to
cordance with the listing for appropriate car model as transmission extension housing to specifications.
shown in Chart (Fig. 13). (10) Recheck front joint angle, starting with step
(4) Remove engine adapter SP-5046 and gauge SP- (1) of “Procedure.”
5060 from flange adjacent to the vertical wall of oil CAUTION: If a great amount of shimming is required
pan and separate the gauge from engine adapter. at the transmission extension rear mount, make sure
SHAFT
RETAINER
I BUSHING
AND ROLLERS
- r
SLIDING
YOKE
RETAINER
RETAINER
SEAL
BUSHING
A N D ROLLERS
BUSHING
A N D ROLLERS
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BUSHING^ RETAINER . BUSHING SHAFT
RETAINER , SEAL /
j/ RETAINER
RETAINER
SEAL
B U SH IN G -
RITAINER
RETAINER
NF571B
f '
ADAPTER (DIFFERENTIAL)
(SP-5038)
T / \A
\ / ■
ADAPTrR PINS
ADAPTER (SP-5053)
f
r
ADAPTER (DIFFERENTIAL) (C-4050) NR295
Fig. 5—Adjusting Gauge on Engine (Front Joint
Fig. 4—Propeller Shaft Angularity Tool C-3976A Angle References)
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I
m m rn *
W w l ADAPTER^
ADAP1
co sn
SP-5Q38J™
ip ?
GAUGE
.&
NN215
NN214
% . 9—Adjusting Gauge on Differential (Models with
Fig. 6—Measuring Front Universal Joint Angle 7 -1 /4 " Axle) (Rear Joint Angle Reference)
y'&
GAUGE
-1NN242
:1 ■I
, GAUGE ^
1 M i -
1) ♦'
\ V -/
A D JU S T IN G SC REW *
;: ”• r--
.. # 4 ; _ .
;r.v ND4/A
Fig. 8—Adjusting Gauge on Differential (Rear Joint
Angle Reference)
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member this rule. If bubble is too far forward, insert CAUTION: Do not allow propeller shaft to drop or
shim with thick end toward front of car. If bubble is hang loose from either joint during removal. Wire up
too far to rear, the nose of differential is too high, so or otherwise support the loose end of shaft to prevent
thick end of shim goes toward rear of car (Fig. 12). A damage to joint.
1° shim will move bubble in spirit level about 3 grad
uations forward or rearward, depending on which Front Joint (All M odels)
way the thick end is installed. (1) Slide propeller shaft with the front yoke from
Presently, there are a number of makes of wedge the transmission output shaft (Fig. 2). Be careful not
type shims available commercially. Always make sure to damage splines on output shaft or yoke. Examine
shims you use are made of steel and are the same sliding yoke seal for evidence of leakage. If no leak
width as the springs on the car. Chrysler Parts Divi age is evident, do not disturb the seal. If necessary to
sion has made available steel shims in varying angles replace the seal, see Transmission, Group 21.
of 1/2°, 1°, 2°, and 3° making it possible with these CAUTION: It is important to protect the machined
combinations to set the rear universal joint angle surface of the sliding yoke from damage after propel
within 1/2° of a perfect angle. ler shaft has been removed.
(6) To install shims, loosen spring “U” bolt nuts
and install shims between rear springs and axle hous Installation
ing spring pads. Front Joint (All Models)
(7) Tighten spring “U” bolt nuts to proper specifi (1) Before installing propeller shaft, wipe sliding
cations. yoke clean and inspect machined surface for
(8) Recheck rear universal joint angle after instal scratches, nicks, burrs and correct as necessary.
lation of wedge type shim, to make sure position of (2) Engage the yoke splines on end of output shaft,
bubble in spirit level is within the acceptable range. being careful not to burr the splines (Fig. 2).
(9) Reinstall rebound bumper and plate assembly
on differential carrier, tighten screws to 200 inch- Rear Joint (All M odels)
pounds. (1) Install rear universal joint cross and roller
CAUTI ON : Under no circumstances should a shim bushings in the seats of drive pinion flange. Install
pack be used that is over 1/4 inch thick at the center. bushing clamps and attaching screws (Fig. 3). Tighten
If that much shimming is required, look for a possible clamp screws to 170 inch-pounds on all models.
broken rear spring, mislocated spring seat, etc.
Cleaning an d Inspection
(1) Clean all parts in a suitable solvent and dry
with compressed air. Examine bearing surfaces of
cross. They should be smooth and free from ripples
and pits. If bearing surfaces or seal retainers are
damaged, replace cross assembly.
Fig. 12—Tapered Wedge Location (Rear Universal
(2) Examine rollers in bushings. Rollers that have
Joint Angle Correction) operated on a worn cross should be replaced. Rollers
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ANGULARITY MEASUREMENT AND CORRECTION CHART
UNIVERSAL JOINT FRONT JOINT ANGLE REAR JOINT ANGLE
~V i i i i w i i i i / |J X HTWru t t T
CHALLENGER
ALL MODELS
HX. K M - 1 ■ KI H
FINAL READING O N PROPELLER SHAFT J L p . T
(ALL MODELS)
~V IWWTOH T
<2>
FRONT OF CAR FRONT OF CAR
ADD SHIMS AT ENGINE REAR MOUNT ADD SHIMS AT REAR AXLE HOUSING
(V i" FOR EACH GAUGE DIVISION) SPRING SEATS. 1° WEDGE SHIM MOVES
CORRECTION PROCEDURE TO REDUCE FRONT JOINT ANGLE. BUBBLE 3 TO 4 GAUGE DIVISIONS. TO
CORRECT LOW ANGLES ONLY IF FLOOR REDUCE ANGLE, INSTALL THICK END OF
PAN INTERFERENCE IS ENCOUNTERED. WEDGE TO FRONT OF CAR.
PY266
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CHALLENGER
SPECIFICATIONS
— Rear .................................................................... Cross and Roller
*From centerline of front yoke bearing bores to centerline of rear bearing bores.
16-7
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SPECIFICATIONS
DART
Model Application
PROPELLER SHAFT *Length-lnches
Type ...................................................................................Tubular
MANUAL TRANSMISSION 3-SPEED
198, 225, C. I. Engine 7-1/4" A x le ........................... ..54.36
198, 225, 318 C. I. Engine 8-3/4" A x le ..................... ..52.27
MANUAL TRANSMISSION 4-SPEED
318, 340 C. I. Engine 8-3/4" A x le ..................... ........ 51.53
AUTOMATIC TRANSMISSION (904)
198, 225, 318 C. I. Engine 7-1/4" A x le ..................... ..54.36
318, 340 C. I. Engine 8-3/4" A x le ............................. ..52.27 Diameter-lnches
AXLE RATIO 2.76 2.93 3.23 3.55 3.91
MANUAL TRANSMISSION 3-SPEED
198 C. I. Engine 7-1/4" A x le ................................. _ — 3.00 3.00
225 C. I. Engine 7-1/4" A x le ........................... . 3.00 (IVA) - 3.00 (IVA) 3.00 3.00
198, 225 C. I. Engine 8-3/4" A x le ......................... — - 3.00 _ — .
318 C. I. Engine 8-3/4" A x le ................................. — -- 3.00 (IVA) — —
MANUAL TRANSMISSION 4-SPEED
318, 340 C. I. Engine 8-3/4" Axle ........... ............. — — 3.00 3.00 3.00
AUTOMATIC TRANSMISSION
3.00 (IVA) _ 3.00 (IVA) 3.00 3.00
3.00 (IVA) -• 3.00 (IVA) 3.00 —_
3.00 (IVA) - 3.00 (IVA) — —.
318 C. I. Engine 8-3/4" A x le ................................. — - 3.00 (IVA) — —
340, C. I. Engine 8-3/4" A x le ................... ................. — — — —
UNIVERSAL JOINTS
Type— Front ............................................ ...................... Sliding Spline Cross and Roller
— Rear ..................................................................... Cross and Roller
TIGHTENING REFERENCE
Pounds
Foot Inch
Pinion Flange Clamp Screw
(7-1/4", 8-3/4" Axle) ............................... 170
Pinion Flange Clamp Screw
(9-3/4" A x le ).................... ....................... 170
Rear Spring "U” Bolt Nut (7-1/4" Axle) .. 40
Rear Spring “U” Bolt Nut
(8-3/4", 9-3/4" Axle) ...... ............. ........... 45
Pinion Bumper Plate Screw (7-1/4" Axle) 150
Pinion Bumper Plate Screw
(8-3/4", 9-3/4" Axle) ............................... 200
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SHOCK ABSORBERS AND REAR SPRINGS
CONTENTS
Page Page
REAR SPRINGS ............................................ 3 SPECIFICATIONS.............. 6
SHOCK ABSORBERS................................ 1 TIGHTENING REFERENCE 6
GENERAL INFORMATION
The rear springs are of the semi-elliptical type on some heavy-duty packages and is optional on
and are designed to have little or no camber under others.
very light loads. When the load on the rear suspen Zinc interleaves are used between the leaves of
sion is increased, a small amount of reverse spring all springs to reduce corrosion and improve spring
camber is normal. A relatively flat rear spring gives life.
better lateral stability and reduces side sway which The double acting shock absorbers do not help
provides a well controlled ride and superior hand support the load, but are a means used to control
ling and stability characteristics. ride motion. The shock absorbers are matched to the
Rubber bushings inserted into the “eye” of each particular suspension of the vehicle. It is not usually
end of the main leaf are the means by which the necessary to replace shock absorbers in pairs. Their
springs are attached to the mounting brackets bolted action does NOT change with use. Slight fluid seepage
to the body at the front and to spring shackles at the during cold weather operation, resulting in a damp
rear. The rubber bushings serve as isolators and re appearance, is normal and does not affect the perform
duce noise being transmitted to the body. ance or life of the shock absorber. Replace a shock
Heavy duty rear springs offered as part of the absorber only if it is broken or leaking badly (not
heavy duty suspension option have a higher rate for just damp) or has lost resistance in one or both
greater stability under loaded conditions. (Trailer directions, due to internal damage. Resistance in the
Towing). They are part of a complete, engineered rebound direction is usually greater than in the
option which includes heavy-duty torsion bars, and jounce direction. Be sure to use the same replace
heavy-duty shock absorbers, a sway bar is included ment part as the original equipment.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
SPRINGS SAG (a) Springs sagged or taken a set. (a) Replace spring.
OR BOTTOM (b) Broken, bent or weak spring leaves. (b) Replace spring.
SPRING NOISE (a) Loose “U” bolts. (a) Tighten “U” bolt nuts to specifica
tions.
(b) Loose or worn eye bushings. (b) Replace bushings and tighten shackle
bolt nuts to specifications.
(c) Worn or missing interliners. (c) Install new interliners.
SPRING BREAKAGE (a) Loose “U” bolts. (a) Replace spring. Inspect “U" bolts for
damage. Tighten “U" bolt nuts to
specifications.
(b) Shock absorber inoperative. (b) Replace spring and shock absorber.
SHOCK ABSORBER (a) Bushing excessively worn. (a) Replace bushing.
NOISY (b) Undercoating on shock absorber res (b) Clean undercoating off shock ab
ervoir. sorber.
(c) Loose bolt or stud. (c) Tighten to specifications.
(d) Air trapped in system. (d) Purge shock absorber.
SHOCK ABSORBER (a) Worn seal. (a) Replace shock absorber.
DRIPPING OIL (b) Damaged crimp or reservoir. (b) Replace shock absorber.
SERVICE PROCEDURES
SHOCK ABSORBERS end of shock absorber piston rod.
(2)
I a n d 2)
F r o n t R e m o v a l (F ig s . loosen and remove lower attachment bolt nut. Remove
(1) Loosen and remove nut and washer from upper this bolt from lower shock absorber eye and lower
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mounting bushing and if it appears worn, damaged,
or deteriorated, remove bushing by first pressing
out inner sleeve with a suitable tool then prying out
or cutting out the rubber bushing. (This bushing will
take some set after it has been in service and should
be replaced once it has been removed.)
(5) If lower bushing requires replacement, remove
it from shock absorber using Tool C-3553 by press
ing on the outer sleeve of bushing (Fig. 3).
Pressing on inner sleeve of lower bushing will not
remove outer sleeve from the shock absorber. New
shock absorbers are furnished with the lower bushing
installed; however, bushings are furnished separately
for service installation. Test and expel air from shock
absorber before installation.
Testing a n d Expelling A ir
(1) With shock absorber removed, extend fully in
an upright position.
(2) Inspect for evidence of fluid running from up
Fig. I —Front Shock Absorber (Dart) per end of reservoir. (Actual leakage will be a stream
of fluid running down side and dripping off lower
control arm mounting bracket. end of unit. A slight amount of seepage is not unusu
(3) Compress shock absorber by pushing upward al and does not affect performance).
and remove from vehicle by pulling down and out of (3) Test for low fluid level or air trapped in cyl
upper shock absorber mounting bushing. inder, by holding shock absorber in its normal verti
(4) Check appearance of upper shock absorber cal position and alternately extending and compress
ing unit. There should be no lost motion in either
NUT direction.
-RETAINER (4) Should lost motion be evident hold shock ab
— BUSHING sorber in its normal vertical position and fully extend
it.
(5) Invert unit and compress it. Do not extend unit
while inverted.
(6) Repeat steps 4 and 5 several times to expel any
air trapped in cylinder.
(7) Should lost motion persist, replace shock ab-
TOOl ■
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sorber. Repeat operation 4 and 5 prior to installation
of a new shock absorber. (New shock absorbers may
have a greater resistance than an old one due to
friction of new seal).
Installation
(1) To install;upper rubber bushing,, remove inner
steel sleeve and immerse bushing in water (DO NOT
use oil or soap) and with a twisting motion, start
bushing into hole of upper mounting bracket, then
tap into position with a hammer. Reinstall steel
inner sleeve in bushing.
(2) Install lower mounting bushing in eye of shock
absorber using Tool C-3553 (Fig. 3).
(3) Test and expel air from shock absorber, then,
compress to its shortest length. Position washer on
upper rod of shock absorber and insert rod through
upper bushing and install upper compression wash
er and nut and tighten to 25 foot-pounds.
(4) Position and align lower eye of shock absorber
with that of lower control arm mounting holes. In
stall bolt (from rear side only on Dart) and nut and
tighten to 50 foot-pounds with the full weight of ve
hicle on the wheels.
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(2) Using floor stands under axle assembly, raise
axle assembly to relieve weight on rear spring.
(3) Disconnect rear shock absorber at spring plate
lower mounting stud. Lower axle assembly, permit
ting rear springs to hang free.
(4) Loosen and remove “U” bolt nuts and remove
“U” bolts and spring plate.
(5) Loosen and remove the nuts holding front
spring hanger to body mounting bracket (Figs. 6
and 7).
(6) Loosen and remove rear spring hanger bolts
and let spring drop far enough to pull front spring
hanger bolts out of body mounting bracket holes.
(Challenger models, loosen and remove rear shackle
nuts, plate and remove shackle, which will let spring
be easily removed.
Fig. 6 —R e a r S prin g (D a rt) (7) Loosen and remove front pivot bolt from front
suspension height on both sides, correct tire pres spring hanger.
sures, no passenger or luggage compartment load (8) Loosen and remove shackle nuts and remove
and a full tank of fuel. shackle from rear spring.
(1) Jounce car several times (front bumper first).
Release bumpers at same point in each cycle. Installation
(2) Measure shortest distance from highest point Inspect rear spring front pivot bolt bushing and if
on underside of rear axle bumper strap (at rear of necessary, replace bushing, see “Pivot Bushing Re
bumper) to top of axle housing. placement” procedure.
(3) Measure both right and left sides. (1) Assemble shackle and bushings in rear of
If these measurements vary by more than 3/4 inch spring and rear spring hanger. (Do not lubricate rub
(side to side), it is an indication that one of the rear ber bushings.) Start shackle bolt nut. Do not tighten.
springs may need replacing. (Challenger models position bushing into spring eye
It is normal for rear springs to show some reverse followed by lower shackle bolt and raise spring into
arch, even with no load, so appearance alone should position. Insert upper bushings into hanger and install
not be reason for spring replacement. shackle bolt. Install plate and nuts. Do not Tighten.
(2) Assemble front spring hanger to front spring
REPLACEMENT eye and install pivot bolt and nut. Do not tighten.
(3) Position rear spring hanger to body bracket
Rem oval and install bolts and tighten bolts to 30 foot-pounds.
(1) Raise vehicle on hoist to a comfortable work (4) Raise the spring and start the spring hanger
ing position. bolts in mounting bracket holes (light leverage such
as mechanics shoulder under spring might be neces
sary to position spring hanger studs in mounting
bracket holes. Install nuts and tighten to 30 foot
pounds).
(5) Lower axle assembly into correct position with
axle centered over spring center bolt.
(6) Correctly position the lower spring plate and
install “U” bolts and nuts and tighten nuts 40 foot
pounds (Dart and Challenger with 7-1/4" axle) and 45
foot-pounds (all other axles). Do not over tighten
"U" bolt nuts.
(7) Install shock absorber on stud and tighten nut
50 foot-pounds.
(8) Lower vehicle to floor and with full weight of
vehicle on the wheels, tighten pivot bolts and/or nuts
85 foot-pounds on (Dart), and 125 foot-pounds on all
other models. Tighten shackle nuts 30 foot-pounds
(Dart), 40 foot-pounds (Challenger).
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SP-92 SP 3179 SP-3180 SP-3242
I
w _I
NH171A
/ SP-332 BUSHING SP-3178
SPRING NY204A Fig. 9 —Zinc Interleaf
Fig. 8—Pivot Bushing Replacement other models. Tighten shackle nuts 40 foot-pounds
(Challenger), 30 foot-pounds (Dart).
(9) It is recommended that after a rear spring has (12) Reinstall shock absorber on spring plate stud
been replaced, that the vehicle be driven and the and tighten to 50 foot-pounds.
front suspension heights be remeasured and cor
rected if necessary.
Spring In te rlin er Replacement
R em oval
Pivot Bushing Replacement (1) Raise vehicle on hoist to a comfortable working
The removal of old bushings and installation of position.
new bushings is performed in one operation, using (2) Using floor stands under axle assembly, raise
Tool C-3709 or Tool C-3729 on Dart models (Fig. 8). axle assembly to relieve weight on rear spring.
(1) Raise vehicle on hoist to a comfortable work (3) Disconnect rear shock absorber at spring plate
ing position. lower mounting stud. Lower axle assembly, permit
(2) Using floor stands under axle assembly, raise ting rear springs to hang free.
axle assembly to relieve weight on rear wheels. (4) Remove spring alignment clips and discard.
(3) Disconnect rear shock absorber at spring plate (5) Using a tapered pry bar or screwdriver, sepa
lower mounting stud. Lower axle assembly, permit rate spring leaves and remove interliners.
ting rear springs to hang free. (6) Keeping spring leaves separated, clean mating
(4) To replace front pivot bushing, remove rear area of both spring leaves thoroughly. If rust or
spring front hanger from body bracket. Remove pivot corrosion is evident, wrap fine sandpaper around a
bolt and hanger from spring. flat file or putty knife and sand until area^ is smooth
(5) Place new bushings on Tool C-3709 or Tool C- and clean.
3729 (Dart models) (Fig. 8). Arrange tool in spring eye, (7) With spring leaves still separated, insert new
then press out old bushing while pressing new bushing interliner with retaining buttons in alignment with
in one operation. locating holes.
(6) Assemble front hanger to spring but do not (8) Press retaining buttons into retainer holes
tighten pivot bolt nut until full weight of vehicle is and remove pry bar or screwdriver from spring
on wheels.
leaves.
(7) Attach spring hanger to body bracket and tight
en mounting bolts to 30 foot-pounds. (9) Repeat above procedure for balance of inter
(8) To replace rear spring shackle bushings re liners. (Do not lubricate interliners.)
move rear spring hanger from body bracket. Remove (10) Install new alignment clips.
shackle, then slide bushings out of spring and hanger. (11) Reinstall shock absorber on spring plate stud
(9) Insert new bushings in spring and hanger then and install washer and nut, tighten to 50 foot-pounds.
assemble shackle and hanger on spring. Start shackle (12) Lower vehicle onto its wheels.
bolt nuts.
(10) Attach hanger to body bracket and tighten Zinc In te rle a f
mounting bolt to 30 foot-pound. To remove or install zinc interleaves (Fig. 9) be
(11) Lower vehicle to floor and with full weight of tween spring leaves, it will be necesssary to remove
vehicle on the wheels, tighten pivot bolts and/or nuts center bolt and disassemble spring leaves. Tighten
85 foot-pounds on (Dart), and 125 foot-pounds on all spring center bolt nut 10 foot-pounds.
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SPECIFICATIONS
Dart Challenger
REAR SPRINGS
Type ................................................................................................................. Semi-Elliptical
NUMBER OF LEAVES
Standard (198 C. I. Engine) ....................................................................... 4 —
(225 C. I. E n g in e)....................... ................................................. 5 4 1 /2
(318, 340 C. I. Engine) ...................................................... . 6 4- 1/2
(383 C. I. Engine) W /4 BBI........................................................... 6 4-1/2
(426 Hemi or 440 C. I. E n g in e )**................................................ — 5-1/2
Heavy D u ty .................................................................................................. 6 4-1/2
Taxi ................................................................................................................... 6 —
Police ............................................................................................................... 6 —
LENGTH (Inches) ...................................................................................... 55 57
WIDTH (Inches) ................................................................................................ 2.50 2.50
MOUNTING
F ro n t................................................................................................................. Pivot Rubber Bushing
Rear ................................................................................................................. Shackle Rubber Bushing
SHOCK ABSORBERS
Type .................................................................................................................. Double Acting
Mounting ......................................................................................................... Rubber Bushing
**Models equipped with 426 Hemi or 440 C. I. engine use 6 full spring leaves on left side and 5 leaves plus
two 1/2 leaves forward of axle on right side.
TIGHTENING REFERENCE
Foot Pounds Foot Pounds
REAR SPRINGS “U” Bolt Nut— Challenger and Dart
Center Bolt N u t ........................................... 10 7 1/4" axle ........................................ ... 40
Front Hanger N u t ......................................... 30 8- 1/4"—8-3/4"—9-3/4" Axle ............... 45
Pivot Bolt or N u t .......................................... 125 SHOCK ABSORBERS
D a r t.............................................................. 85 Front Lower Bolt N u t ................................... 50
Rear Hanger B o lt........................................ . 30 — Upper Shaft N u t ................................. 25
Shackle Nut— Challenger ........................... 40 Rear Lower Stud Nut ............................ . 50
D a r t.............................................................. 30 — Upper Bolt Nut—Challenger .............. 70
Stud Nut— Dart ................................... 50
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STEERING
CONTENTS
Page Page
MANUAL GEAR ............................................ 1 PUMPS .......................................................... 19
POWER GEAR . . . .......................................... 7 STEERING COLUMNS.................................. 32
GENERAL INFORMATION
The manual steering gear (Fig. 1) is designed to pressed into the gear housing, and the upper bearing
provide easy steering with minimum friction in the cup is pressed into the wormshaft bearing adjuster.
steering gear. A ball nut travels up or down on the The cross shaft is integral with the sector gear. The
wormshaft, riding on recirculating balls acting as a sector gear meshes with the rackteeth on the re
screw thread. circulating ball nut. Adjustment at this point is con
The wormshaft and ball nut assembly is supported trolled by the cross shaft adjusting screw which ex
in the gear housing by an adjustable ball thrust type tends through the housing cover.
upper and lower bearing. The lower bearing cup is
SERVICE DIAGNOSIS
Condition Possible Cause Correction
HARD STEERING (a) Low or uneven tire pressure. (a) Inflate tires to recommended pres
sures.
(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 Sus
pension."
(e) Steering column misaligned. (e) See “Steering Column— Manual
Transmission."
PULL TO ONE SIDE (a) Incorrect tire pressure. (a) Inflate tires to recommended pres
(Tendency of the Vehicle sures.
to veer in one direction (b) Wheel bearings improperly adjusted. (b) See “Front Wheel Bearing Adjust
only) ment."
(c) Dragging brakes. (c) Inspect for weak, or broken brake
shoe spring, binding pedal.
(d) Improper caster and camber. (d) See “Front Wheel Alignment.”
(e) Incorrect toe-in. (e) See “Front Wheel Alignment"
(f) Grease, dirt oil or brake fluid on (f) Inspect, replace and adjust as nec
brake linings. essary.
(g) Front and rear wheels out of align (g) Align the front wheels. See “Front
ment. Suspension."
(h) Broken or sagging rear springs. (h) Replace rear springs.
(i) Bent suspension parts. (i) Replace parts necessary.
WHEEL TRAMP (a) Incorrect tire pressure. (a) Inflate tires to recommended pres
(Excessive Vertical sures.
Motion of Wheels) (b) Improper balance of wheels, tires (b) Balance as necessary. See "Wheels
and brake drums. and Tires.”
(c) Loose tie rod ends or steering con (c) Inspect and repair as necessary.
nections.
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(d) Worn or inoperative shock absorbers, (d) Replace shock absorbers as neces
sary.
EXCESSIVE PLAY OR (a) Steering gear shaft adjusted too loose (a) Replace worn parts and adjust ac-
LOOSENESS IN THE or badly worn. cording to instructions.
STEERING WHEEL (b) Steering linkage loose or worn. (b) Replace worn parts. See "Front
Wheel Alignment.”
(c) Front wheel bearings improperly (c) Adjust according to instructions,
adjusted.
(d) Steering arm loose on steering gear (d) Inspect for damage to the gear shaft
shaft. and steering arm, replace parts as
necessary.
(e) Steering gear housing attaching bolts (e) Tighten attaching bolts to speci-
loose. fications.
(f) Steering arms loose at steering (f) Tighten according to specifications,
knuckles.
(g) Worn ball joints. (g) Replace the ball joints as necessary.
See “Front Suspension."
SERVICE PROCEDURES
Adjustments back out adjusting screw approximately two turns.
Two adjustments are provided in the steering gear This will relieve any friction load which may be
(Fig. 2). The worm-bearing pre-load adjustment, and present at closely meshed ball nut rack and sector
the ball nut rack sector gear mesh adjustment. gear teeth.
Before correct adjustment can be made at ball nut (4) Turn steering wheel two complete turns from
rack and sector gear, it must be determined that straight ahead position, and place torque wrench Tool
worm bearing pre-load is properly adjusted. C-3380 on steering shaft nut.
The worm-bearing pre-load adjustment is controlled (5) Rotate steering shaft at least one turn toward
by the worm thrust bearing adjuster which threads straight ahead position, while testing rotating torque
into the housing at the upper end of the wormshaft. with torque wrench.
W o rm Bearing Pre-Load
The torque required to keep wheel moving should
(1) Remove steering gear arm retaining nut and be between 1-1/2 and 4-1/2 inch-pounds. If reading is
lock washer. Remove arm with Tool C-3646 (Fig. 3). not within these limits, adjustment can be made in
(2) Remove horn button or horn ring. or out of vehicle as follows:
(3) Loosen cross shaft adjusting screw lock nut, and (a) Loosen adjuster lock nut.
FILLER PLUG CROSS SHAFT
ND 459
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column, it is recommended that the steering column
be completely detached from floor and instrument
STEERING
-GEAR panel before steering gear is removed. See Steering
Column Section of this manual for proper removal,
■ alignment and installation procedure.
STEERING .■;* (1) Remove steering column.
Am ,
(2) From under vehicle, remove steering arm re
\ taining nut and lock washer. Remove steering arm
with Tool C-3646 (Fig. 3).
TOOL (3) Remove gear to frame retaining bolts and re
move gear.
Installation
(1) Position gear on frame and install gear to frame
y NY 1218 retaining bolts and lock washers. Tighten to specifi
cations.
Fig. 3—Removing Steering Gear Arm (2) Rotate worm shaft by hand and center cross
(b) Use adjuster wrench from Tool C-3884 set and shaft to mid point of its travel. Align master serration
turn adjuster clockwise to increase pre-load, or coun on cross shaft with splines in steering arm. Install
terclockwise to decrease pre-load. steering arm with lock washer and nut. Tighten to
(c) While holding adjuster from turning, tighten specifications.
lock nut securely. Retest worm bearing pre-load. (3) Align and install steering column as outlined.
(See “Steering Columns”).
Ball N u t Rack and Sector Mesh
The cross shaft adjusting screw, located in housing W o rm Shaft Replacement
cover, raises or lowers the shaft to provide proper The master serration on the steering gear worm
mesh load between tapered teeth of sector gear and shaft spline, used for centering the steering shaft
tapered teeth of ball nut. This adjustment can be coupling, is machined after the steering gear is com
accurately made only after proper worm bearing pre pletely assembled.
load has been established. If it should become necessary to replace a steering
(1) Turn steering wheel gently from one stop gear worm shaft, it will be necessary to file a master
to the other, carefully counting number of turns. serration on the spline of the worm shaft, since the
Turn steering wheel back exactly half way, to center replacement part does not have a master serration
position. machined in the spline.
(2) Turn cross shaft adjusting screw clockwise to To file a master serration on a worm shaft spline,
remove all lash between ball nut rack and sector the steering gear must be completely assembled and
gear teeth, then tighten adjusting screw lock nut to the worm shaft centered in its travel, then with the
35 foot-pounds. steering gear in its normal upright position remove
(3) Turn steering wheel about 1/4 turn away from one tooth of the spline, at the 12 o’clock position,
center or “high spot” position. Using torque wrench with a suitable file.
Tool C-3380, at steering wheel nut, measure torque
required to rotate steering wheel through high spot at G ear Reconditioning
center position. The reading should be between 8 and Thoroughly clean entire outside surface of steering
11 inch-pounds. This represents total of worm shaft gear before disassembly to avoid contaminating
bearing pre-load and ball nut rack and sector gear wormshaft and ball nut assembly with dirt or grit.
mesh load. Readjust cross shaft adjustment screw if (1) Attach steering gear to holding fixture, Tool
necessary, to obtain proper torque reading. C-3323 and install holding fixture in a vise (Fig. 2).
(4) After adjustments have been completed, place (2) Loosen cross shaft adjusting screw lock nut, and
front wheels in a straight ahead position, and with back out screw about two turns to relieve load caused
steering gear and steering wheel centered, install by close mesh between ball nut rack and sector gear
steering arm on cross shaft. teeth. Remove cross shaft seal as outlined in "Cross
(5) Tighten steering arm retaining nut to 180 foot Shaft Oil Seal Replacement."
pounds. (3) Position steering wormshaft in straightahead
position.
STEERING GEAR (4) Remove bolts from the cross shaft cover, and
Removal slowly remove cross shaft while sliding arbor Tool
To avoid damage to the energy absorbing steering C-3875 into housing (Fig. 4).
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CROSS SHAFT CROSS SHAFT
BEARING /
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sembly, including a needle bearing or bushing, is shaft in housing bearings. Inspect fit of shaft pilot in
serviced as an assembly. cover bearing. Make sure wormshaft has not been
(11) Remove wormshaft oil seal from wormshaft bent or otherwise damaged.
bearing adjuster, by inserting a blunt punch behind (18) The cross shaft and wormshaft oil seals should
seal and tap alternately on each side of seal until seal be replaced when unit is reconditioned.
is driven out of adjuster. (19) Install cross shaft outer needle bearing by
(12) Remove wormshaft spacer and upper bearing placing bearing on end of Tool C-3875 with adapter
cup in same manner. However, this must be done ring. Press bearing into housing to 1/2 inch below end
carefully to avoid cocking bearing cup and distorting of bore to provide space for oil seal.
adjuster counterbore. (20) Install inner needle bearing by placing bearing
(13) Remove lower cup if replacement is necessary on Tool C-3875 (Fig. 9). Press bearing into inside end
by positioning locking head jaws of remover Tool of housing bore flush with inside end of bore surface.
C-3868 (Fig. 8) behind bearing cup and expanding re (21) To install wormshaft bearing cups, position
mover head by pressing down on center plunger of cups in housing and bearing adjuster nut. Then press
tool. Withdraw bearing cup by turning remover screw in place with Tool C-3865 (Figs. 10 and 11).
nut in a clockwise direction while holding center (22) Install wormshaft oil seal by positioning seal
screw. in wormshaft adjuster with seal metal retainer UP.
(14) Wash all parts in clean solvent and dry with Drive seal into place with a suitable sleeve so it is
compressed air. slightly below end of bore in adjuster.
(15) Test operation of ball nut assembly on worm (23) Apply a coating of steering gear lubricant to
shaft. If ball nut does not travel smoothly and freely all moving parts during assembly, also place lubricant
on wormshaft and there is roughness or binding, as on and around oil seal lips.
sembly must be replaced. (24) Clamp holding fixture and housing in a vise
(16) Extreme care is necessary when handling with bearing adjuster opening upward.
aluminum worm bearing adjuster to avoid damaging (25) Place a thrust bearing in lower cup in housing.
threads. It is equally important to avoid damaging (26) Hold ball nut from turning (Fig. 6), and insert
mating threads in gear housing. The wormshaft ad wormshaft and ball nut assembly into housing with
juster must never be screwed into housing without end of worm resting in thrust bearing.
lubrication, or when threads are dirty or damaged. (27) Place upper thrust bearing on wormshaft.
These precautions must be taken to avoid “picking Thoroughly lubricate threads on adjuster and
up” threads and ruining housing and/or wormshaft threads in housing.
bearing adjuster. (28) Place a protective sleeve of plastic tape over
(17) Inspect cross shaft for wear and check fit of wormshaft splines so splines do not damage seal. Slide
PULLER
WORMSHAFT
CROSS SHAFT
3EARIHG
k PRESS- RAM
TOOL
\
9
^— 1
M—
I
\ ND471
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juster lock nut, and retest to be sure preload remains
BEARING CU’I
I- PRESS
RAM
STEERING
GEAR-
between 1-1/8 and 4-1/2 inch-pounds.
(32) Before installing cross shaft, pack wormshaft
cavities in housing above and below ball nut with
steering gear lubricant. Use steering gear lubricant
whenever possible, but if not available, a good grade
of multi-purpose lubricant may be used. Do not u se,
INSTALLER HOUSING
gear oil. When gear is properly packed with steering
gear lubricant it will contain eleven fluid ounces of
lubricant, and level of lubricant will be at top of
worm.
(33) Slide cross shaft adjusting screw and shim into
slot in end of shaft.
(34) Test end clearance (Fig. 12). The screw must
be free to turn with zero to .004 inch end play. Three
different thickness shims are available to obtain
specified clearance.
(35) Start cross shaft and adjuster screw into bear
Hr ND 464
/ O , “.SHAFT
i 2.CONG
ADJUSTER
CROSS SHAFT
ADJUSTING SCREW
NY1231B
ND470
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HOUSING
HOUSING
TOOL C-3880 •
Hlvy’l
TOOL C-3880
•>
NK459 NK461
Fig. 13—Removing Cross Shaft Oil Seal fig . 14—Installing Cross Shaft O il Seal
check torque required to rotate shaft through high (2) Slide threaded adapter over end of cross shaft
spot at center position. The reading should be be and install nut portion of tool on shaft. (Fig. 13).
tween 8 and 11 inch-pounds. Readjust cross shaft Maintain pressure on adapter with tool nut while
adjusting screw as necessary to obtain proper torque screwing adapter into seal until it grips oil seal firmly.
reading. Tighten lock nut to 35 foot-pounds and re Place two half rings and retainer over both portions
check cross shaft torque. of tool. Turn tool nut counterclockwise to withdraw
seal from housing.
Cross Shaft O il Seal Replacement (3) Place seal onto splines on cross shaft with lip
The cross shaft oil seal may be replaced by the of seal facing gear housing.
following procedure either on the bench, or without (4) Place installing adapter SP-3052 from Tool C-
removing steering gear from vehicle. 3880 against seal. Press seal in until a gap of 1/4 inch
CAUTION: When replacing oil seal in vehicle, clean exists between adapter and housings (Fig. 14).
the exposed portion of cross shaft to help prolong oil (5) Place nut from Tool Set C-3880 on cross shaft,
seal life. and turn it down against adapter, pressing seal into
(1) Remove steering gear arm retaining nut and housing until step on adapter contacts end of hous
lock washer. Remove arm with Tool C-3646 (Fig. 3). ing.
Use Tool C-3880 to service cross shaft seal. The tool (6) Remove tool, install steering arm, lock washer
consists of adapter SP-3056; half rings SP-1932 and and retaining nut and tighten nut to 180 foot-pounds.
nutSP-3610.
GENERAL INFORMATION
The power steering gear (Figs. 1 and 2) consists of a recirculating ball contact. The steering valve,
gear housing containing a cross shaft with sector gear, mounted on top of the steering gear, directs the flow
a power piston with gear teeth broached into the side of fluid in the system.
of the piston which is in constant mesh with the cross Fluid is supplied to the steering gear, by an engine
shaft sector, and a wormshaft connecting the steering driven constant displacement type pump through a
wheel to the power piston through a pot type cou pressure hose. Oil is returned to the pump reservoir
pling. The wormshaft is geared to the piston through from the steering gear through a return hose.
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SERVICE DIAGNOSIS
Condition Possible Cause
HARD STEERING (a) Tires not properly inflated. (a) Inflate tires to recommended pres
sures.
(b) Low oil level in pump reservoir (usu (b) See “Fluid Level,” Power Steering
ally accompanied by pump noise). Pump.
(c) Loose pump belt. (c) See “Group 7—Cooling."
(d) Improper caster and camber. (d) See “Front Wheel Alignment" Front
Suspension Group 2.
(e) Power steering output low. (e) Pressure test pump.
(f) Steering linkage binding. (f) Repair and lubricate as necessary.
(g) Steering gear malfunctions. (g) Adjust or repair as follows:
1. Cross shaft adjustment too tight. 1. See “Cross Shaft Adjustment."
2. Faulty or damaged valve lever. 2. Repair as necessary.
3. External leakage. 3. Inspect for leakage at the lower
cross shaft oil seal; the cross
shaft cover “0 ” ring.
4. Excessive internal leakage. 4. Recondition steering gear.
POOR RECOVERY (a) Tires not properly inflated. (a) Inflate tires to recommended pres
FROM TURNS sures.
(b) Steering linkage binding. (b) Repair and lubricate as necessary.
(c) Improper wheel alignment. (c) See “Front Wheel Alignment,” Front
Suspension Group 2.
(d) Damaged steering tube bearing. (d) Remove jacket tube and replace bear
ings.
(e) Steering wheel column jacket and (e) See “Gear Installation.”
steering gear improperly aligned.
(f) Steering gear malfunctions. (f) Adjust or repair as follows:
1. Improper cross shaft adjustment. 1. See “Cross Shaft Adjustment.”
2. Column support spanner nut loose. 2. Repair as necessary.
3. Damaged valve lever. 3. Repair as necessary.
4. Improper worm thrust bearing ad 4. Recondition steering gear.
justment.
5. Worn or damaged cylinder head 5. Recondition steering gear.
worm seal ring or faulty worm
piston ring.
6. Burrs or nicks in the reaction ring 6. Repair as necessary.
grooves in the cylinder head or col
umn support.
7. Dirt or chips in the steering gear 7. Recondition steering gear.
unit.
8. Rough worm in the piston as 8. Recondition steering gear.
sembly.
9. Valve binding. 9. Replace valve assembly.
CAR LEADS TO EITHER (a) Tires not properly inflated. (a) Inflate tires to recommended pres
SIDE sures; See “Wheels and Tires."
(b) Improper wheel alignment. (b) See “Front Suspension, Front Wheel
Alignment." Group 2.
(c) Valve body out of adjustment. (c) If vehicle leads to the left, move the
steering valve housing up on the
steering housing. If vehicle leads to
the right, move the steering valve
housing down on the steering housing.
(d) Valve lever damaged. (d) Repair as necessary.
(e) Column support spanner nut loose. (e) Repair as necessary.
(f) Coupling not centered. (f) Center coupling. Refer to “Gear In
stallation.”
(g) Internal leakage in the steering gear (g) Replace the steering gear valve body
valve body. assembly.
TEMPORARY (a) Oil level low in pump reservoir. (a) See “Fluid Level.”
INCREASES IN EFFORT (b) Loose pump belts. (b) See “Group 7— Cooling.”
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.
TO THE RIGHT OR LEFT (e) Engine idle too slow. (e) See “Fuel Specifications." Group 14.
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(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" cor
rection (e).
(h) Gear malfunction. (h) Adjust and repair as outlined under
"Hard Steering”— condition and cor
rection (g).
NOISES (a) Buzzing noise in neutral and stops (a) Noisy pump, make pressure test and
when the steering wheel is turned. repair as necessary. Damaged hydrau
lic lines or interference of the hoses
with components attached to the fen
der shield. Air in system; work steer
ing wheel from right to left until the
air is expelled.
(b) Chucking noise. Cause as follows: (b) Correct as follows:
1. Improper cross shaft adjustment. 1. See “Cross Shaft Adjustment.”
2. Improper worm shaft thrust bear 2. Recondition steering gear.
ing adjustment.
3. Coupling loose on the worm shaft. 3. Inspect worm shaft splines for
wear. Inspect coupling bolt for
tightness, if loose, replace bolt and
inspect wormshaft and coupling.
4. Worn worm and piston assembly. 4. Replace worm and piston assem
bly.
(c) Metallic clatter or hissing noise. (c) Replace back pressure valve cushion.
(d) Knocking condition at the bracket (d) Rubber stop worn or missing from
stop when the engine is running. pump bracket.
(e) Loose pump belt. (e) See Group 7 Cooling.
EXCESSIVE STEERING (a) Improper cross shaft adjustment. (a) See “Cross Shaft Adjustment."
WHEEL FREE-PLAY (b) Column support spanner nut loose. (b) Repair as necessary.
(c) Improper worm thrust bearing ad (c) Repair as necessary.
justment.
(d) Coupling loose on the worm shaft. (d) Inspect wormshaft splines for wear.
(e) Excessive worm-piston side play. (e) Install new worm-piston assembly.
LACK OF ASSIST (a) Oil leaking past worm shaft oil seal (a) Recondititon steering gear.
(One Direction) ring.
(b) Broken or worn ring on worm piston. (b) Recondition steering gear.
(c) Piston end plug loose. (c) Replace the worm and piston assem
bly.
(d) Reaction seal missing. (d) Remove the steering gear and repair
as necessary.
LACK OF ASSIST (a) Pump belt slipping. (a) See Group 7.
(Both Directions) (b) Pump output low. (b) Pressure test pump.
(c) Broken or worn ring on worm piston. (c) Recondition steering gear.
(d) Piston end plug loose. (d) Replace the worm and piston assem
bly.
(e) Valve binding. (e) Install new valve assembly.
SERVICE PROCEDURES
SERVICE IN VEHICLE a light grip. Tighten adjusting screw until backlash
just disappears.
Cross Shaft Adjustm ent Continue to tighten to 3/8 to 1/2 turn from this
(1) Disconnect center link from steering gear arm. position and tighten lock nut to 50 foot-pounds to
(2) Start engine and run at idle speed. maintain this setting.
(3) Turn steering wheel gently from one stop to the
other, counting number of turns. Then turn wheel
back exactly half way, to center position. Valve Body Recondition
(4) Loosen adjusting screw until backlash is evident (1) Disconnect high pressure and return hoses at
in steering gear arm. Feel backlash by holding end of the valve body and tie the ends above the reservoir
steering gear arm between thumb and forefinger with fluid level.
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OIL OUTLET OIL INLET
RIGHT TURN POWER CHAMBER SPOOL VALVE
PIVOT LEVER
RECIRCULATING BALL GUIDE
REACTION SPRINGS
STEERING COLUMN
CONNECTION
WORM SHAFT
NH717A
(2) Remove two screws attaching valve body to edges of valve. The sharp edge is vitally important to
main gear housing. operation of this valve.
(3) Lift valve body upward to disengage from valve (7) Clean valve bodies and valve piston thoroughly
lever (Fig. 8). in clean solvent. Blow out all passages with com
(4) Remove the two screws attaching control valve pressed air. Lubricate pistons and bores with power
body to steering valve body and separate two bodies steering fluid.
(Fig. 3). (8) Install steering spool valve in valve body so
(5) Remove outlet fitting, washer, spring, valve pis valve lever hole is aligned with lever opening in valve
ton and cushion spring. body. Valve must be perfectly free in valve body
(6) Carefully shake out spool valve and inspect for FITTING
nicks, burrs and scores. Do not remove valve body end
plug unless inspection indicates a leak at gasket.
If spool valve or valve body is damaged, replace / ■ CONTROL VALVE BODY
GASKET , ,
valve and body assembly.
Small burrs and nicks may be removed with crocus SPRING
cloth if extreme care is used not to round off sharp PISTON
/ A STEERING VALVE BODY
SPRING
CROSS SHAFT SCREW / "O' RINGS
SECTOR GEAR
FITTING'—* ' ( .
#
„ •?*. •
AJ *
/ -« S . ^ " \ ° 0
GASKET^ " ; - '9
0
GASKET-*^
NY 1248 POWER PISTON NR189
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without sticking or binding (Fig. 3).
(9) Install a new gasket on end plug (if removed).
STEERING
Tighten plug to 25 foot-pounds. GEAR
(10) Install piston cushion spring in control valve
body being sure it seats in counterbore at bottom of
housing. Lubricate piston and insert nose end of pis STEERING
ARM
ton into body bore. Test for smooth operation. Be sure
cushion spring is not cocked.
(11) Install spring on top of piston, and install
copper washer and fitting, tighten to 20 foot-pounds. TOOL
(12) Position two new “O” rings on control valve
body and attach to steering valve body. Tighten the
two attaching screws to 95 inch-pounds.
(13) If pressure inlet fitting has been removed,
NY 1218
tighten fitting to 30 foot-pounds.
(14) Align lever hole in valve spool with lever open
ing in valve body. Fig. 4 —Removing Steering Gear Arm
(15) Install on gear housing making sure the valve (3) Slide threaded adapter SP-3609 of Tool C-3880
lever enters hole in valve spool and key section on over end of cross shaft and thread tool nut SP-3610 on
bottom of valve body nests with the keyway in gear shaft. Maintain pressure on threaded adapter
housing. with tool nut while screwing adapter far enough to
CAUTION: These parts should go together with rela engage metal portion of grease retainer. Place the two
tive ease. Use of force may damage the lever. If they half rings SP-1932, and Tool retainer ring over both
do not go together easily, lift off valve assembly, re portions of the Tool (Fig. 5). Turn the tool nut
align valve spool hole with lever opening in valve counter-clockwise to withdraw grease retainer from
body and install valve body. housing.
(16) Install two screws and tighten to 7 foot-pounds (4) Remove oil seal snap ring with pliers and re
to prohibit leakage during valve centering operation. move seal back-up washer.
(17) Connect high pressure and return hoses to (5) Use Tool C-3880 in same manner as outlined in
valve body. step (3) to remove inner seal.
(18) Start engine. If unit is self-steering tap valve (6) Place tool adapter SP-3828 with long step of
up or down to correct. When tapping valve "down," adapter against new seal and slide it over shaft with
hit valve body on end plug. When tapping valve "up," seal lip toward housing (Fig. 6). Install tool nut on
tap on head of screw attaching the valve body to gear shaft and tighten tool nut until shoulder of tool
main valve body. Do not hit control valve body. adapter contacts gear housing.
(19) Turn steering wheel from stop to stop several (7) Remove tool nut and adapter and install seal
times to expel air from system. Refill reservoir as back-up washer and oil seal snap ring with sharp edge
required. out.
CAUTION: Do not turn hard against ends of travel. (8) Position grease retainer in housing bore. Place
This will generate high pressure and may blow out
the "O" rings since the valve body screws have not
been finally tightened.
(20) With steering wheel in straight ahead center
position, start and stop the engine several times, tap
ping the valve body up or down as required until
there is no movement of the steering wheel when the
engine is started or stopped.
(21) The valve is now centered. Tighten the two SEAL
screws attaching valve body to housing to 200 inch-
pounds.
Cross Shaft O il Seal Replace
The cross shaft oil seal may be replaced without
removing the steering gear from the vehicle.
(1) Remove steering arm nut.
(2) Disconnect steering gear arm from sector shaft
with Tool C-3646 (Fig. 4).
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19-12 S T I i i i i i — POWER' JO
TOOL
. TOOL
- JF
j , .> * :«
SEAL
itf?-
SEAL
NH633 NH631
Fig. 6—Installing Cross Shaft Inner Oil Seal Fig. 8—Removing Worm Shaft Oil Seal
tool adapter SP-3828 with short step of lip against seal worm shaft spline, used for centering the steering
(Fig. 7). Install tool nut on gear shaft and tighten tool shaft coupling, is machined after the steering gear is
nut until shoulder of tool adapter contacts gear completely assembled.
housing. If it should become necessary to replace a power
(9) Place steering gear and front wheels in straight steering gear worm shaft and piston assembly, it will
ahead position and install steering gear arm and nut. be necessary to file a master serration on the spline
(10) Tighten steering gear arm nut to 180 foot of the worm shaft, since the replacement part does
pounds. not have a master serration machined in the spline.
To file a master serration on a worm shaft spline,
W o rm Shaft O il Seal Replacement the power steering gear must be completely assem
The worm shaft oil seal may be replaced without bled and the worm shaft centered in its travel, then
removing gear from vehicle. Remove steering column with the steering gear in its normal upright position
as outlined under “Steering Columns” and remove oil remove one tooth of the spline at the 12 o’clock posi
seal with Tool C-3638 (Fig. 8). Drive new oil seal in tion, with a suitable file.
place (lip of seal toward housing) with Tool C-3650
(Fig. 9). Install and align steering column as described G ear Removal
in “Steering Columns”. To avoid damage to the energy absorbing steering
column, it is recommended that the steering column
SERVICE OUT OF VEHICLE be completely detached from floor and instrument
panel before steering gear is removed. See Steering
W o rm Shaft a n d Piston Replacement Column Section of this Manual for proper removal,
The master serration on the power steering gear alignment and installation procedure.
TOOL
TOOL
NH632 N H 630
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(1) Remove steering column. PIVOT LEVER
(2) Disconnect power steering pressure and return
hoses at centering valve on gear. Tie free ends of \
hoses above pump level to avoid loss of fluid.
(3) From under vehicle, remove steering arm re
taining nut and lock washer. Remove steering arm
with Tool C-3646.
(4) Remove three gear to frame retaining bolts
(use 1/2 inch twelve point socket) remove gear.
G ear Reconditioning
Clean the gear assembly thoroughly in a suitable
solvent and install unit in holding fixture Tool C-3323.
(1) Drain steering gear through the pressure and
return connections by turning steering wormshaft NH628
from one extreme of travel to the other.
(2) Remove valve body attaching screws, and re Fig. I 1—Removing Pivot Lever
move valve body and three “O” rings (Fig. 10). (9) While holding power train firmly compressed,
(3) Remove pivot lever and spring. Pry under pry on piston teeth with a screw driver using cross
spherical head with a screw driver (Fig. 11). shaft as a fulcrum and remove complete power train
CAUTION: Use care not to collapse slotted end of the (Fig. 12).
valve lever as this will destroy the bearing tolerances It is important that cylinder head, center race and
of the spherical head. spacer assembly and housing head be maintained in
(4) Remove cross shaft grease retainer and oil seal close contact with each other. This will eliminate the
as outlined in “Cross Shaft Oil Seal Replacement.” possibility of reaction rings becoming disengaged
(5) Loosen cross shaft adjusting screw locknut and from their grooves in the cylinder head and housing
remove cross shaft cover spanner nut with Tool C-3988 head. It will prohibit center spacer from becoming
(Fig. 10). separated from center race and becoming "cocked" in
(6) Rotate wormshaft to position cross shaft sector housing which may make it impossible to remove
teeth at center of piston travel. Loosen steering power power train without damaging the spacer, the housing,
train retaining nut with Tool C-3989. or both.
(7) Position holding Tool C-3323 so cross shaft is (10) Place power train vertically in a vise equipped
in a horizontal position. Place Tool C-3875 on thread with soft jaws to avoid damaging piston assembly. See
ed end of cross shaft and slide tool into housing until Fig. 13 for parts identification.
both tool and shaft are engaged with bearings. The 33 worm bearing needle rollers will fall out
(8) Turn wormshaft to full left turn position to when housing head is removed from wormshaft. Use
compress power train parts. Remove power train re arbor Tool C-3929 (Fig. 14) to hold rollers in posi
taining nut with C-3989. Remove housing head tang tion when housing head is removed.
washer. (11) Raise housing head until wormshaft oil seal
VALVE ASSEMBLY A!'?BOR
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19-14
STEERING— POWER
SNAP RING
RETAINER GREASE RETAINER
SEAL
BEARING WORM AND PISTON ASSEMBLY
HOUSING
“ O ” RING
PISTON RING
“ O ” RING
“O” RING
SHAFT
SCREW
00^ CIT’
COVER
SEAL
NUT
VALVE ASSEMBLY
NY1214F
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Wire brush the knurled sections to remove the
chips, then blow out the nut and wormshaft to remove
any metal particles.
(17) Remove upper thrust bearing race (thin) and
upper thrust bearing.
(18) Remove center bearing race.
>OWES TRAIN (19) Remove lower thrust bearing and lower thrust
bearing race (thick).
(20) Remove lower reaction ring and reaction
SUPPORT spring.
(21) Remove cylinder head assembly.
TOOL (22) Remove two “0 ” rings in two outer grooves in
NH624 cylinder head.
(23) Remove reaction “O” ring from groove in face
Fig. 14—Retaining Bearing Rollers with Arbor Tool of cylinder head with air pressure directed into oil
just clears top of wormshaft and position arbor tool hole located between two “O” ring grooves (Fig. 16).
C-3929 on top of wormshaft and into oil seal. With (24) Remove snap ring, sleeve and rectangular oil
arbor in position pull up on housing head until arbor seal ring from cylinder head counterbore (Fig. 17).
is positioned in bearing. Remove housing head and (25) Test operation of wormshaft. The torque re
arbor. quired to rotate wormshaft throughout its travel in or
To reinstall rollers, if they should become dis out of piston must not exceed 2 inch-pounds with a 15
lodged, retain rollers in the cage with wheel bearing pound side load. The worm should run in and out of
lubricant.
piston under its own weight.
CAUTION: If the wormshaft oi l seal is to be replaced,
The worm and piston is serviced as a complete as
perform the operation with the housing head assem
sembly and should not be disassembled.
bled in the steering gear housing.
(12) Remove large “O” ring from groove in hous (26) Test for excessive side play with the piston
ing head. held firmly in a vise with the rack teeth up, and the
(13) Remove reaction seal from groove in face of worm in its approximate center of travel. The vertical
housing head with air pressure directed into ferrule side play measured at a point 2-5/16 from the piston
chamber (Fig. 15). flange should not exceed .008 inch when the end of
(14) Inspect all grooves for burrs. Make sure pas the worm is lifted with a force of 1 pound (Fig. 18).
sage from ferrule chamber to upper reaction chamber (27) Inspect condition of rubber sealing ring lo
is unobstructed. cated under cast iron ring and replace if necessary.
(15) Remove reaction spring, reaction ring, worm Install cast iron piston ring as follows:
balancing ring and spacer. (a) Slide a new piston ring into place in piston
(16) Hold wormshaft from turning, then turn nut groove, then place piston and ring assembly in Tool
with sufficient force to release staked portions from
knurled section and remove nut. “ O" R!NGS INDER HEAD
/ ' .
-
/
AIR N O Z /i'
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PISTON RING
PISTON
W O RM SHAFT
/
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\ ‘*1/'',
I iiv 1
\ "IpU.
P'
I
Fig. 17—Removing Cylinder Head Oil Seal Fig. 19—Installing Piston Ring
C-3676 with lower part of piston and ring resting on stall parts in the following order:
land of tool (Fig. 19). (a) Lower thrust bearing race (thick).
(b) Press down on piston to seat ring in piston (b) Lower thrust bearing.
groove, forcing open ends of ring out for ease of lock (c) Lower reaction spring (with the small hole over
ing the ring. the ferrule).
(28) Place piston assembly in a vertical position (d) Lower reaction ring (flange up so ring pro
(wormshaft up) in a vise equipped with soft jaws. trudes through reaction spring and contacts the reac
(29) Inspect cylinder head ferrule oil passage for tion “O” ring in the cylinder head).
obstructions and the lands for burrs, then lubricate (e) Center bearing race.
the two large “0 ” rings and install them in the cylin (f) Upper thrust bearing.
der head grooves (Fig. 13). (g) Upper thrust bearing race (thin).
(30) Install worm sleeve seal, sleeve and snap ring (h) Start wormshaft thrust bearing adjusting nut
(if removed). Make sure snap ring is seated in groove. (do not tighten).
(31) Install lower reaction seal (O-ring) in cylinder (34) Turn wormshaft clockwise one-half turn. Hold
head groove. wormshaft in this position with splined nut, Tool C-
(32) Slide cylinder head assembly (ferrule up) on 3637 and socket wrench, and hold in this position
wormshaft. Check wormshaft seal ring making sure through items 35 and 36, then tighten nut to 50 foot
gap is closed to avoid damaging the ring as the cylin pounds to prestretch wormshaft threads.
der head moves against piston flange. (35) Loosen adjusting nut. Place several rounds of
(33) Lubricate with power steering fluid, and in- cord around center bearing race (Fig. 20). Make a loop
in one end of cord and hook loop of a distributor
breaker arm spring scale Tool MTU-36 in cord loop.
Pulling cord will cause bearing race to rotate. Re-
1 POUND PULL*
tighten worm bearing adjusting nut while pulling on
cord with scale. When adjusting nut is tightened
properly, reading on the scale should be 16 to 24
ounces (20 ounces preferred while the race is turn
ing).
(36) Stake upper part of wormshaft adjusting nut
into knurled area of shaft.
(a) Hold a 1/4 inch flat end punch on center line of
wormshaft end at a slight angle to nut flange (Fig.
21).
' ^ 'V§Pra« < I *vv., (b) Strike punch a sharp blow with a hammer and
test preload.
-- - M y If adjusting nut moved during staking operation, it
* 42-5/16- NN634
can be corrected by striking the nut a glancing blow
in the direction required to regain proper preload.
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spacer with flange down against spacer.
(39) Install upper reaction spring over reaction ring
WO.?M GHA.T
with cylinder head ferrule through hole in reaction
ADJUSTING NUT ... spring.
(40) Install worm balancing ring (without flange)
RACE - ' inside upper reaction ring.
CORD. (41) Lubricate ferrule “O” ring and install in
groove on cylinder head ferrule.
(42) If oil seal was removed from housing head, in
m stall a new seal with Tool C-3650 (Fig. 7). See
SCALE (TOOL) “Wormshaft Oil Seal Replacement.” With lip of seal
toward bearing, drive seal until tool bottoms on the
FERRULE support.
(43) Lubricate and install reaction seal in groove in
face of housing head with flat side of seal out (Fig. 22
and 23). Install “O” ring in groove on housing head.
KR65B
(44) Slide housing head and arbor, Tool C-3929
Pig. 20—Checking Center Bearing P reload
over the wormshaft carefully engaging cylinder head
ferrule and “O” ring and making sure reaction rings
(c) After retesting for proper preload, stake t i e nut enter circular groove in housing head. The power
at three more locations 90° apart around upper part train is now ready for installation in housing.
of the nut. (45) It is generally not necessary to remove sector
(d) To test total staking, apply 20 foot-pounds of shaft cover. However, this may be easily accomplished
torque in each direction. If nut does not move, stak by removing the adjusting screw. While holding the
ing operation is satisfactory. cover, turn adjusting screw clockwise until the shaft
Retest wormshaft preload to determine that adjust becomes disengaged from cover. The adjusting screw
ment remains constant after nut is securely locked. will now slide out of the “T” slot in end of shaft.
(37) Position spacer assembly over center race, en
gaging dowel pin of spacer in.slot of race, and slot of G ear Shaft Assembly
spacer entered over cylinder head ferrule. (46) To remove gear shaft needle bearings from
This will align the valve pivot lever hole in the housing, remove grease retainer, oil seal snap ring
center bearing race with the valve pivot lever hole in with pliers and remove seal back-up washer.
center bearing spacer assembly. The small uO " ring (47) Insert Tool C-3875 in steering housing; place
for the ferrule groove should not be installed until housing in a press and press out bearings and oil seal.
after upper reaction spring and spacer have been (48) To install gear shaft lower needle bearing
installed. place bearing on end of Tool C-3875. Press bearing
(38) Install upper reaction ring on center race and into steering gear housing 1/32 inch below end of
bearing bore to provide space for oil seal, back-up
W ORM
SHAFT washer and snap ring and cross shaft grease retainer.
PUNCH See “Cross Shaft Oil Seal Replacement.”
ADJUSTING NUT1 CAUTION: The arbor adapter ring must be used with
C-3875 Remover and Installer Arbor, otherwise the
OUTER RACE bearings may be crushed.
(49) To install upper needle bearing, place bearing
m
t
m RING
SPRING i
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REACTION SEAL WORM SHAFT
■I
REACTION
RING
BALANCING
RING
I — — TOOL
SPACER
REACTION
SPRING
Fig. 23—Reaction Rings Installed (Cut-away View) hole in steering housing so that slots in valve lever are
parallel to wormshaft in order to engage the anti
on end of Tool C-3875. Press bearing into housing rotation pin in center race. Install valve pivot lever
flush with end surface of bore. spring small end first.
(50) Insert gear shaft and adjusting screw into Turn worm until the piston bottoms in both direc
cover and using a screwdriver through the threaded tions and observe the action of the lever. It must be in
hole in cover, turn screw counterclockwise to pull the center of the hole and snap back to its center
shaft completely into the cover. Lubricate a new position when the worm torque is relieved.
square section seal ring and slide it over adjusting (58) Install valve body on housing making sure
screw into position on top of cover. Install adjusting valve pivot lever enters hole in valve spool (Fig. 1).
screw lock nut, but do not tighten at this time. Be sure “O” ring seals are in place. Tighten valve
(51) Lubricate cross shaft cover “O” ring with wheel mounting screws to 7 foot-pounds.
bearing grease and install on shelf of gear housing. (59) Install new gear shaft seal followed by seal
(52) Lubricate power train bore of the housing with back-up washer and snap ring and a new grease re
power steering fluid, and carefully install power train tainer as outlined under “Cross Shaft Oil Seal Re
assembly. To keep reaction rings from coming out of placement.”
their grooves keep worm turned fully counterclock
wise. The piston teeth must be facing to the right and Test and Adjustments
the valve lever hole in center race and spacer must be (1) Remove oil reservoir cover and fill reservoir
in the “up” position. with Power Steering Fluid, Part No. 2084329 or
CAUTION: Make sure the cylinder head is bottomed equivalent, to the level mark.
on the housing shoulder (Figs. 1 and 2). (2) Connect test hoses with proper adapters to hy
(53) Align valve lever hole in center bearing race draulic pump on the vehicle with pressure gauge C-
and spacer exactly with the valve lever hole in the 3309D installed between the pump and steering gear.
gear housing. Turn the housing head by tapping on a (3) Start the engine.
reinforcing rib with hammer and drift. Use Tool C-
3649 to maintain alignment (Fig. 24).
The aligning tool should not be removed until the
spanner nut is securely tightened.
(54) Install housing head tang washer to index with
groove in housing. Install spanner nut and tighten to
110 to 200 foot-pounds with Tool C-3989.
(55) Set the power piston at the center of travel
VALVE PIVOT LEVER
and install gear shaft and cover assembly so that
sector teeth index with piston rack teeth. Make sure
cover “0 ” ring is properly installed on shelf in
housing.
(56) Install cover spanner nut and tighten 110 to
200 foot-pounds with Tool C-3988.
(57) Install valve pivot lever (double bearing end
first) (Fig. 25) into center race and spacer through
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(4) Center valve until unit is not self-steering. Tap
on the head of valve body attaching screws to move
valve body up on steering housing, and tap on end
plug to move valve body down on housing. Expel all
air from the unit by turning wormshaft back and
forth through the travel several times. I m IM
(5) Refill reservoir before proceeding with follow
ing tests and adjustments on the bench.
(a) With steering gear on center, tighten gear shaft
adjusting screw until backlash in steering gear arm
just disappears. See “Cross Shaft Adjustment.”
If power train has been removed, tighten 1-1/4
turns from this position and while holding adjusting
screw in this position, tighten lock nut (Fig. 26).
This is a temporary adjustment to bring the piston NH621A
rack and sector teeth in full alignment.
(b) Operate unit through its full travel several Fig. 26—Adjusting Steering Gear Mesh
times to align piston rack and sector teeth.
G ear Installatio n
(c) With gear on center, readjust sector .shaft back (1) Position gear on frame and install three gear
lash. This will require loosening adjusting screw until to frame retaining bolts and lock washers. Tighten to
backlash is evident. Then retighten adjusting screw specifications.
u ntil backlash just disappears. Continue to tighten for (2) Rotate worm shaft by hand and center cross
3/8 to 1/2 turn from this position and tighten lock shaft to mid point of its travel. Align master serration
nut to 50 foot-pounds to maintain setting. on cross shaft with splines in steering arm. Install
(d) Starting from a point at least one full turn of steering arm with lock washer and nut. Tighten to
the wormshaft either side of center, torque at sector specifications.
shaft required to turn unit through center at 2 rpm (3) From engine compartment, connect pressure
in each direction shall not exceed 20 foot-pounds or and return hoses to centering valve on gear.
vary more than 5 foot-pounds from left to right. (4) Align and install steering column as outlined.
(e) Adjust torque to be equal in both directions by (See “Steering Columns”).
readjusting the valve. (5) Fill power steering pump with power steering
Tighten valve body adjusting screw to 200 inch- fluid Part No. 2084329 or equivalent.
pounds. (6) Start engine and turn steering wheel several
(f) With gear at or near full turn in either direc times from stop to stop to bleed the system of air.
tion, attempt to return unit to center by applying Stop engine check oil level and correct if necessary.
torque wrench at steering gear shaft. Hold wormshaft
until cross shaft torque builds up to 50 foot-pounds.
Release wormshaft and maintain a constant steady Hose Installatio n
When either hose is reinstalled or replaced, it is
pull at 2 rpm on the gear shaft. If cross shaft torque essential that the sponge sleeve hose protector be
does not drop to 20 foot-pounds maximum as the unit installed as follows:
passes through center, check for too much interior (1) Avoid sharp bends in large section of hose (about
drag; binding valve lever, binding spool valve, or 10 inch diameter is recommended).
tight cross shaft adjustment. (2) Hose must remain at least 1 inch away from all
(6) With unit under power, but with no load, torque pulleys, battery case and brake lines and 2 inches
required to rotate wormshaft through an included away from exhaust manifold.
angle of 180° (90° either side of center) at 6 rpm (or (3) Sponge sleeves must be installed where hose
one revolution every ten seconds) shall be 6-10 inch- contacts composition or metal.
pounds. Disconnect test equipment and mounting fix (4) Tighten pump end hose fitting to 24 foot-pounds
ture and install unit in vehicle. and gear end fitting to 160 inch-pounds.
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Page Page
Pump Rem oval___ . 23 Service Diagnosis .......................................... ......... 21
Pump Installation . . . . 23 Service Procedures ................................................. 22
Oil Seal Replacement . 23 Inspection ............................................................... 24
.94 M o d e l................ . 23 .94 M o d e l ............................................................... 24
1.06 M o d e l............. . 27 1.06 M o d e l ............................................................. 28
Reconditioning.......... . 23 Specifications ........................ ........ ......................... 44
.94 M o d e l............... . 23 Tightening References ............................................ 45
' 06 M o d e l............. . 28
GENERAL INFORMATION
Two different power steering pumps are used on and exhausted through the discharge ports as the
Dodge models. rollers are forced into vee shaped cavities of the rotor.
The .94 pump can be identified by the long oval
shape of the filler neck and a drive pulley secured to FLOW CONTROL VALVE
the drive shaft with a large nut. (Fig. 1). Rectangular
pumping vanes carried by a shaft driven rotor, move A flow control valve permits a regulated amount of
the fluid from the intake to the pressure cavities of the oil to return to the intake side of the pump when ex
cam ring. As the rotor begins to rotate, centrifugal cess output is generated during high speed operation.
force throws the vanes against the inside surface of This reduces the power requirements to drive the
the cam ring to pick up residual oil which is forced pump and minimizes temperature build-up.
into the high pressure area. As more oil is picked up The 1.06 pump incorporates a two-stage flow control
by the vanes, oil is forced into the cavities of the valve. High pressure oil passes through two orifices in
thrust plate, through two cross-over holes in the cam a metering insert. (The metering insert is located in an
ring and pressure plate which empty into the high oil passage sealed with a 1/8 inch pipe plug.) At low
pressure area between the pressure plate and the speed, approximately 2.7 gpm is passed to the gear.
housing end plate. As speed increases and the valve moves, excess oil is
Filling the high pressure area causes oil to flow by-passed to inlet and the valve acts to block flow
under the vanes in the slots of the rotor forcing the through one orifice. This drops flow to the gear to
vanes to follow the inside oval surface of the cam ring. approximately 1.6 gpm at high speeds. Two-stage flow
As the vanes rotate to the small area of the cam ring, control provides high flow at low speed for improved
oil is forced out from between the vanes. steering, while reducing the flow at high speed to re
The 1.06 pump can be identified by a 3/8 inch duce the power steering system oil temperature.
threaded hole in the pulley end of the drive shaft (Fig. When steering conditions exceed maximum pres
2). The operation of the 1.06 pump is similar to the sure requirements, such as turning the wheels against
vane type pump but differs in appearance and design. the stops, the pressure built up in the steering gear
The rotor is star shaped and upon rotation, pro- also exerts pressure on the spring end of the flow con
pells 12 steel rollers against the inside surface of trol valve. This end of the valve houses the pressure
the cam ring. As the rollers follow the eccentric pat relief valve on both the .94 and 1.06 models. High
tern of the cam ring, oil is drawn into the inlet ports pressure lifts the relief valve ball from its seat and al-
OVAL SHAPED
FILLER TUBE
^ S'
W m
NN1002
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lows oil to flow through a trigger orifice located in the put of the pump to a safe level.
outlet fitting of the .94 pump and in the front land of Under normal operating conditions, the pressure
the flow control valve of the 1.06 pump. This reduces requirements of the pump are below maximum, caus
pressure on the spring end of the valve which then ing the pressure relief ball and the flow control valve
opens and allows the oil to return to the intake side of to remain closed.
the pump. This action limits maximum pressure out
SERVICE DIAGNOSIS
Condition Possible Cause Correction
INTERMITTANT OR (a) Loose belt. Tighten belt.
(a)
NO ASSIST (b) Low fluid level. Inspect and correct fluid level.
(b)
(c) Low pump efficiency. Service as necessary.
(c)
*(d) Pump seizure. Replace pump.
(d)
(e) Flow control bore plug ring not in Replace snap ring. Inspect groove for
(e)
place. depth.
(f) Flow control valve sticking. (f) Service flow control valve as neces
sary.
(g) Wrong pressure-relief valve setting. (g) Replace flow control valve— .94 pump.
Replace pump partial assembly.—
1.06 pump.
(h) Damaged “0 ” ring on flow control (h) Replace “0 ” ring.
bore plug.
(i) Loose plug in end of flow control (i) Tighten plug. See “Tightening Refer
valve. ence”.
(j) Distorted pressure plate. (j) Replace pressure plate— .94 pump.
*(k) Cam ring badly worn. (k) Replace cam ring— .94 pump.
(I) Vanes improperly installed. (I) Install vanes properly— .94 pump.
(m) Plugged metering orifice(s) or trigger (m) Disassemble pump and clean.
orifice.
(n) Damaged or leaky pressure relief (n) Replace seat and ball— 1.06 pump;
valve seat (plug) or ball. replace flow control valve— .94 pump.
(o) Damaged housing bore “0 ” ring(s) or (o) Replace “0 ” rings.
pressure plate " 0 ” ring.
*(p) Scored pressure plate, thrust plate, (p) Replace rotating group package— 1.06
cam, rotor or rollers. pump.
NOISY PUMP (a) Low fluid level. (a) Inspect and correct fluid level.
(b) Belt noise. (b) Inspect for pulley alignment, paint or
grease on pulley and correct.
(c) Belt loose (causing pump rattling (c) Adjust belt. See “Cooling System”
noise). Group 7— 1.06 pump.
(d) Foreign material blocking pump hous- (d) Remove reservoir, visually check inlet
ing oil inlet hole. oil hole and service as necessary.
(e) Vanes improperly installed. (e) Install properly or replace if neces
sary— .94 pump.
(f) Vanes sticking in rotor. (f) Recondition pump and correct cause
— .94 pump.
(g) Faulty flow control valve. (g) Replace flow control valve— .94 pump.
*(h) Pressure plate, thrust oJate or rotor (h) Replace badly scored part or lap in if
scored. lightly scored— .94 pump.
*(i) Pressure plate, thrust plate, cam, ro- (i) Replace rotating group package— 1.06
tor or rollers scored. pump.
(j) Pump hose interference with sheet (j) Reroute hoses.
metal or brake lines.
(k) Pulley loose. (k) Retorque pulley retaining nut- ,94
pump.
PUMP VIBRATION (a) Pump hose interference with sheet (a) Reroute hoses.
metal or brake lines.
(b) Faulty or loose belt. (b) Replace or adjust belt as necessary.
See "Cooling System," Group 7.
(c) Pulley loose or out of round. (c) Replace pulley.
(d) Crankshaft pulley loose or damaged. (d) Replace crankshaft pulley.
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________ Condition Possible Cause Correction
PUMP LEAKS (a) Cap or filler neck leaks. (a) Correct fluid level. (Fluid Level Too
High).
(b) Reservoir solder joints leak. (b) Resolder or replace reservoir as nec
essary.
(c) Reservoir “0 ” ring leaking. (c) Inspect sealing area of reservoir. Re
place “O” ring or reservoir as neces
sary.
(d) Shaft seal leaking. (d) Replace seal.
(e) Loose rear bracket bolts. (e) Tighten bolts. See “Tightening Refer
ence”.
(f) Loose or faulty pressure hose ferrule. (f) Tighten fitting to 24 foot-pounds, 1.06
pump— 20 foot-pounds, .94 pump or
replace as necessary.
(g) Damaged pressure hose “O” ring. (g) Replace “0 ” ring— 1.06 pump.
(h) Housing ball plug leaking. (h) Replace pump partial assembly.—
1.06 pump.
(i) Rear bolt holes stripped or casting (i) Repair, if possible, or replace pump.
cracked.
SERVICE PROCEDURES
Checking Fluid Level engine and warm up fluid to a temperature between
150 and 170 degrees Fahrenheit.
1.06 M o d el Turning the wheels from stop to stop will aid in
(1) Start engine, turn steering wheel from stop to warming the fluid. Do not hold wheels against stop
stop several times to expel air from system, then shut for extended period as undue internal pump over
off engine. heating will result.
(2) Wipe reservoir filler cap free of dirt, remove (5) With engine idling at 600 RPM, and gauge valve
cap and visually inspect oil level in reservoir. open, note pressure while turning steering wheel
Engine at room temperature— Oil should just cover from one extreme position to the other. Turn the
filler neck/reservoir joint (1-3/4 inches to 2 inches wheels all the way to one or the other stop momen
from top of filler neck). tarily and note the maximum pressure. A pressure of
Engine Hot-—Oil level should be one-half way up in at least the minimum pressure shown for the partic
filler neck. ular pump in “Specifications” should be read.
(6) If pressure is under the specified rating, the
.94 M o d e l steering system is not functioning properly. To deter
The oil level in the .94 pump should be checked mine which unit is faulty, momentarily close the
only after pump has reached normal operating tem pressure gauge valve and note maximum pressure
perature. A dip stick, built into the reservoir cap, registered on gauge. If the pressure reads less than
indicates “FULL” or “ADD”. Fluid level should be the maximum pressure shown for the particular pump
at the “FULL” mark when hot. in “Specifications” the pump is faulty and should be
Replenish the fluid, if necessary, in all pumps with
Power Steering Fluid, Part No. 2084329 or equiva #1
VALVE ON OUTLET I
%■ SIDE OF GAUGE
lent.
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reconditioned. Should pressure reading in step 5 read
low but not in step 6, the steering gear is faulty.
When removing test equipment, be sure to reinstall
hoses in original position to avoid interference with
engine or sheet metal.
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NN1005 NN1007
END
COVER HNN1006
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DRIVE THRUST
SHAFT * "PLATE
m am
NU413 LOCAT.-NG
HOLES
Fig. 10—Removing Full Diameter Lock Ring
loose vanes require replacement of rotor and/or
vanes. Binding can be relieved by cleaning or removal ?ORT*:D
SIDE U.»
of burrs with a thin fine file.
(4) Inspect flat surfaces of pressure and thrust Fig. 12 —Installing Thrust Plate
plates for wear or scoring. Light scoring can be re
in grooves in pump cavity. These rings are the same
moved by lapping on a flat surface. Remove all lap
size. Lubricate with power steering fluid.
ping compound thoroughly before reassembly.
(4) With drive shaft clamped splined end up in soft
(5) Inspect inner surface of cam ring for heavy
jawed vise, install thrust plate on drive shaft (smooth,
scuff or chatter marks. Replace if necessary. Light
ported side up) (Fig. 12).
score or scuff marks can be removed by polishing
(5) Slide rotor over splines with the counterbore
with a small, flat oil stone.
of rotor facing down. Install rotor lock ring making
(6) Inspect end cover for nicks or burrs on sur
sure ring is seated in groove (Fig. 13).
face contacting “O” ring and remove with a fine (6) Install two dowel pins in holes in pump cavity.
stone. Carefully insert drive shaft, rotor and thrust plate
(7) Inspect pump body drive shaft bushing for ex assembly in pump cavity indexing locating holes with
cessive wear. Replace pump body and bushing as an dowel pins (Fig. 14).
assembly if badly worn or scored. (7) Slide cam ring over rotor on dowel pins with
arrow on ring facing “UP” (Fig. 15).
Assembly (8) Install ten vanes in rotor slots with radius edge
(1) Place pump body on flat surface and drive new facing out towards cam ring inner surface (Fig. 16).
drive shaft seal into bore with a 7/8 or 15/16 inch CAUTION: Vanes installed with flat edge out will
socket till seal bottoms on shoulder (Fig. 11). result in noisy pump operation.
CAUTION: Excessive force will distort the seal. (9) Position pressure plate on dowel pins. Place
(2) Lubricate seal with power steering fluid and a 1-1/4 inch socket in groove of pressure plate and
clamp pump body in vise, (shaft end down). seat entire assembly on “O” ring in pump cavity by
(3) Install end cover and pressure plate “O” rings pressing down on socket with both thumbs (Fig. 17).
SEAL*
I NN1010
* 4 1 'in ra iiliiM a lP l' litlF I ii i
Fig. 13 —Installing Rotor Lock Ring
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PRESSURE
D OWEL "O” RINGS PLATE
PINS (2) (2 )
\H R ^
r/ft-
*r-
N N 1013 NN 1016
Fig. 14—Rotor and Thrust Plate Installed Fig. 17—Seating Pressure Plate
DOWEL CAM This operation can be performed in an arbor press
PIN RING if available. Care should be exerted to prevent cock
LOCATING ing the end cover in the bore or distorting the as
HOLES ARROW
(2) UP sembly.
(12) Using a punch, tap retainer ring ends around
in the groove until opening is opposite flow control
valve bore. This is important for maximum retention
of the retainer ring (Fig. 18).
(13) Replace reservoir “0 ” ring seal, two mounting
stud “O” ring seals and flow control valve “O” ring
seal on pump body, lubricate with power steering fluid
and carefully position reservoir on pump body.
Visually align the mounting stud holes till studs can
be started in threads.
(14) Using a plastic hammer, tap reservoir down on
pump and insert flow control valve spring and valve
Fig. 15—Installing Cam Ring (slotted end up).
(10) Place spring in groove in pressure plate and (15) Replace “O” ring on pressure hose fitting and
position end cover lip edge UP over spring. lubricate with power steering fluid (Fig. 19).
(11) Press end cover down below retaining ring CAUTION: Be sure "O" ring is installed on upper
groove with thumb and install ring making sure it is groove. It is possible to install "O" ring in lower
seated in groove (Fig. 18).
rEND COVER RETAINER
W RING ENDS
FLOW
CONTROL
VALVE
BORE
DOWEL
PIN
RADIUS
EDGE
CAM NN1017
RING N N 1015
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Assembly
(1) Insert spring, guide and pressure relief ball in
end of flow control valve (Fig, 20).
(2) Install he x head plug using the same number
of shims as were removed. Altering shim thickness
will change relief pressure.
(3) Install hex head plug and tighten to 50 inch-
pounds.
(4) Insert flow valve spring and valve in bore. In
stall new “O” ring on pressure hose fitting and lubri
cate with power steering fluid.
(5) Thread fitting into pump body and tighten to
20 foot-pounds.
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around until one end of ring lines up with hole in
"K pump body. Insert punch in hole far enough to dis
engage ring from groove in pump bore. Remove ring
from body (Fig. 25).
(8) Tap end cover with plastic hammer to jar it
loose. Spring under cover should push cover up.
■ :* (9) Remove pump body from vise, place in inverted
T O O L ' €-4068 * position on clean flat surface and tap end of drive
shaft to loosen rotating group. Lift pump body off
rotating group.
(10) Remove and discard brass seal plate and fibre
1 gasket. (Some pumps may be assembled with brass
plates only). The fibre gasket may be found stuck
to housing floor; it can easily be lifted or pulled away.
Insure that all portions of gasket are removed and
that housing floor is not scratched or damaged.
NR313 (11) Discard pressure plate and end cover “O”
rings.
Fig. 21—Removing Drive Pulley (1.06 Pump)
(12) Remove snap ring, bore plug, flow control
end plates when pump is in operation. valve and spring from housing. Discard “O” ring.
(10) Install pump and adjust belt as outlined under (13) If necessary to disassemble flow control valve
“Cooling” Group 7. for cleaning, see “Flow Control Valve Disassembly”.
■ TOOL
*ADAPTER
TOOL
m
n
**
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OIL SEAL
:PUMP BODY
SEAL PLATE
" O " RINGS
DRIVE PULLEY
MOUNTING
FIBRE GASKET BRACKETS
FLOW CONTROL
VALVE ASSEMBLY
END COVER
K MOUNTING'
RETAINER RING SCREW NR254C
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CORE POCKET
- FIBRE GASKET
ROTOR
SSsiSf I *
A
s'
NOTCH
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■ IN10 F./ \ h \ i ) \ H *■“ ■
J D O V 'T i. PIH
' ■ 99/9'"
warn
(3 FOOL C-4063
NU277
1NR321A
Fig. 3 3 —Pulley Installation—6 Cylinder Engines
Fig. 31—Installing Pressure Plate
shaft, securely thread installer Tool C-4063, without
(14) Replace reservoir mounting bolt seal.
adapter, into 3/8 inch threaded hole in end of shaft.
(15) Lubricate flow control valve with power steer
(Fig. 33).
ing fluid and insert valve spring and valve into bore
Pumps installed on eight cylinder engines have
(spring first then hex plug end of valve). Install new
drive pulleys pressed flush with the end of the pump
“O” ring on bore plug, lubricate with power steering
shaft. With drive pulley placed on end of shaft, se
fluid and carefully install into bore. Install snap ring,
curely thread installer Tool C-4063, with adapter SP-
with sharp edge UP.
5399, into 3/8 inch threaded hole in end of shaft
CAUTION: Do not depress the bore plug more than
(Fig. 34).
1/16 inch beyond snap ring groove.
(19) With installer shaft clamped securely in vise,
(16) Place reservoir on pump body and visually
tighten drive nut against thrust bearing and press
align mounting bolt hole. Tap reservoir down on pump
with plastic hammer. pulley onto shaft.
(17) Remove pump from vise and install mounting CAUTION: Do not attempt to press pulley on to shaft
brackets with three mounting bolts, tighten to 18 foot without the use of special tool as serious damage will
pounds. result to interior of pump.
(18) Install drive pulley. See “Pulley Installation” A small amount of drive shaft end play will be ob
(Figs. 33 and 34). served when pulley is installed. This movement is
Power steering pump drive pulleys installed on six necessary and will be minimized by a thin cushion of
cylinder engines are not pressed flush with the end of oil between the rotor and end plates when pump is in
the pump shaft. With drive pulley placed on end of operation.
PRESSURE PLATE
OIL PASSAGE SLOT
NU81 NU278
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(20) Install pump assembly on engine, connect PRESSURE RELIEF
hoses (using new pressure hose “O” ring), and tighten SPRING
drive belt see “Cooling System”. Group 7. Fill reser FLOW CONTROL
VALVE BODY
voir with power steering fluid, test and inspect for
leaks. / . /
PLUG . ■" * * *
Disassembly—1.06 M o d el
(1) Remove pump from engine and reservoir from *
PRESSURE
pump. RELIEF BALL NR 327
(2) Remove snap ring and plug from flow bore. Dis
card “O” ring from plug. Fig. 35—Flow Control Valve Disassembled View
(3) Depress control valve against spring pressure pressure. (Fig. 35).
and allow to spring back. The valve should pop out of (6) Remove valve from vise and remove pressure
bore far enough to be lifted out. Light tapping on
relief ball, guide and spring.
rear face of pump body may be necessary to remove
(7) Clean all parts thoroughly. Dirt Particles On
a stuck valve. Ball or Ball Seat Will Cause Improper Pump Opera
If dirt of foreign particles are found on valve or
tion.
within valve bore, entire pump should be disassem
bled, cleaned and rebuilt. The high pressure and re
turn hoses must also be flushed and the steering gear Assembly
(1) Insert spring, guide and pressure relief ball in
valve body reconditioned see “Power Steering Gear”.
If valve bore is badly scored, replace pump body and end of flow control valve (Fig. 35).
flow control valve. (2) Install hex head ball seat using the same num
(4) Remove nicks or burrs that might cause the ber and thickness shims as were removed. Tighten to
valve to stick by rubbing valve over a flat surface 50 inch-pounds.
covered with crocus cloth. (3) Lubricate valve with power steering fluid and in
(5) Clamp land of valve in a soft jawed vise and sert flow valve spring and valve in bore. Install new
remove hex head ball seat and shim(s). Note number “O” ring on bore plug, lubricate with power steering
and gauge of shims on ball seat. Same number and fluid and carefully install into bore. Install snap ring.
gauge of shims must be installed on assembly of CAUTION: Do not depress the bore plug more than
valve. Altering shim thickness will change relief 1/16 inch beyond snap ring groove.
STEERING COLUMN
INDEX
Page Page
A ssem bly................................................................... 38 Installation .............................................................. 43
Disassembly ............................................................. 35 Rem oval.................................................................... 34
Inspection ......................................................... ....... 38
GENERAL INFORMATION
The steering column under head-on collision con 3. A two-piece telescoping steering shaft with upper
ditions is designed to telescope at a controlled rate. and lower sections connected by plastic friction col
The telescoping action reduces the likelihood of the lars and shear pins.
steering wheel being driven rearward toward the 4. A mounting bracket connecting steering column
driver. If the driver is thrown forward into the wheel, to the instrument panel, which allows the column to
the column can telescope further at the same con slide forward but blocks its rearward movement to
ward the driver.
trolled rate, thereby reducing force of the impact.
The center section of the column jacket has dia
The Dart assembly (Fig. 1) has four principal mond-shaped perforations and is formed with accor
components: dion pleats. These pleats allow it to compress like a
1. A column jacket with a mesh section designed bellows from impact forces.
to shorten in “accordion” fashion. The gearshift tube is made up of two sections de
2. A two-piece telescoping transmission gearshift signed to telescope together. These sections are inter
tube interconnected by plastic inserts and shear pins. connected and held together by injections of plastic
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that form the interconnecting inserts and shear pins. susceptible to damage through ordinary usage than
Under impact, the pins shear first, followed by a previous columns; however, when it is removed,
gradual paring away of the inserts by the knife-like special care must be taken in handling this assembly.
edge in the adjoining tube section. When the column is removed from the car such
The steering shaft is a two-piece assembly. The actions as a sharp blow on the end of the steering
upper piece is solid and has a double-flatted lower shaft or shift levers, leaning on the column assembly,
section. The lower piece is hollow and formed to or dropping of the assembly could shear or loosen
fit over the double-flatted section of the upper piece. the plastic shear joints that maintain column
The purpose of the flatted section is to provide rigidity. It is, therefore, suggested that the removal
continued steering action even though completely and installation, and the disassembly and reassembly
telescoped. Plastic is injected through two small procedures be carefully followed when servicing
holes in the hollow piece into a pair of annular this assembly.
grooves on the solid portion of the shaft. The four IMPORTANT: Bumping, jolting and hammering on the
small holes filled with plastic form the shear pins. steering shaft and gearshift tube must be avoided
Upon impact, the shear pins break off and the shaft during all servicing operations. If the shear pins are
gradually telescopes against a resistance provided broken, the controlled rate of the impact-absorbing
by the plastic collars in the annular grooves. features will be destroyed making these parts unfit
The mounting bracket is designed to restrain the for further use. The Special Tools required and their
column from being shifted toward the driver during usage are covered in the following service procedures.
impact. It incorporates three “break-away capsules” The Challenger column (Fig. 2) has a telescoping
that allow the mounting bracket to slip off the at steering shaft, but all other components are conven
taching points, permitting the steering column to tional. A corrugated cylinder is added between steer
compress or yield in a forward direction under a ing wheel and steering column for energy absorption
severe impact from the driver side. on impact.
When the column is installed in a car it is no more
COLUMN BRACKET-
CLINCH NUT
WASHER
BOLT
AUTO. TRANS.
SHIFT LEVER STEERING GEAR
WASHERS C
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'NUT (3)
SHIFT HOUSING
"O" RING
RETAINER
"O" RING
F1OOR PLATE
STEERING
SHAFT COUPLING
STEERING
GEAR
SCREW A N D ,
WASHER ASSY (4)
NUT AND
WASHER ASSY (2)
SCREW A N D SCREW A N D
WASHER ASSY (2) WASHER ASSY (4) PY869
SERVICE PROCEDURES
COLUMN REMOVAL (F ig s .la n d 2) umn bracket to instrument panel support. If so
(1) Disconnect negative (ground) cable from bat equipped, save shim pack from between bracket for
tery. ward leg and support for reuse during installation.
(2) Disconnect linkage from lower end of steering (11) Carefully pry lower coupling from steering
column. gear wormshaft, then remove column assembly out
(3) Remove steering shaft lower coupling to worm through passenger compartment being careful not to
shaft roll pin. damage paint or trim.
(4) Disconnect wiring connectors at steering col
umn jacket.
(5) Remove horn ring ornament assembly.
(6) Disconnect wire at horn switch. Remove TURN SIGNAL LEVER
screws attaching horn ring and switch to steering
wheel, then remove horn ring and switch.
(7) Dart models: remove steering wheel retaining
nut and washer. Remove steering wheel with Tool
C-3428A. Do not bump or hammer on steering shaft
to remove wheel. Challenger models: remove three
nuts fastening steering wheel to corrugated cylinder,
remove nut and washer from steering shaft and in
$
stall tool C-3428A to pull cylinder from shaft splines. t.j’
(8) Remove turn signal lever (Fig. 3).
(9) Remove floor plate to floor pan attaching -
screws. Remove finish plate from under instrum ent x
panel to expose steering column bracket.
(10) Remove nuts or bolts attaching steering col
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RETAINING
PLATE ^
BEARING HOUSING
I TO LOCK HOUSING
TURN STEERING SHAFT BEARING SCREW (3)
SIGNAL
"•s..
UPPER SNAP RING
SWITCH ■
PY882
PY884
Fig. 4—Retainer and Turn Signal Switch
COLUMN DISASSEMBLY Fig. 6—Steering Shaft Bearing Upper Snap Ring
(2) Install steering shaft remover C-4044 and press
(1) Remove four bolts attaching bracket assembly shaft out of bearing and remove bearing housing
to column jacket. from shaft (Fig. 7).
(2) Remove two screws and lift off wiring trough. (3) Remove bearing lower snap ring from shaft.
(3) Attach Column Holding Fixture C-4132 to col (4) Pry sleeve off steering shaft lock plate hub to
umn jacket and clamp the assembly in a vise. expose pin.
(4) Drive out gearshift lever pivot pin, then remove (5) Install Tool C-4113 on steering shaft lock plate
lever and spring from housing. hub to press pin out of shaft, DO NOT HAMMER
(5) Remove turn signal switch and upper bearing
(Fig. 8).
retainer screws. Remove retainer and lift switch up (6) Remove tool and lock plate from shaft.
ward out of the way (Fig. 4). (7) Remove shaft through lower end of column.
(6) Remove two retaining screws and lift the igni
tion key lamp assembly out of the way (Fig. 5).
(7) Remove snap ring from upper end of steering Lock Homing
(1) If equipped with shift indicator quadrant, re
shaft (Fig. 6). move pointer attached to shift housing with one
screw.
Steering Shaft (2) Remove two screws and lift out buzzer switch
(1) Remove three screws which hold bearing hous
(Fig. 9).
ing to lock housing.
(3) Remove two retaining screws and the lock lever
CAUTIO N: These screws must be removed before
steering shaft removal.
T IG NITIO N KEY
LAMP ASSEMBLY
/I
A STEERING SHAFT
REMOVING TOOL
all
l !
■i 4.
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.
LOCK LEVER
, 9 : 9 GUIDE PLATE
STEERING SHAFT
TO LOCK PLATE
PIN TOOL
IG NITIO N SWITCH
'm - RETAINING SCREWS PY888
IG NITIO N KEY
BUZZER SWITCH J ■TA B
IN CASTING
FOR SPRING
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SHIFT TUBE SUPPORT
RETAINING CUP
V
\\
Fig. 16—Shift Tube Support Retaining C lip
,-X ,,
\
\
on!.-T iu'-L
PY892 D’j S f SiAL
ual models, remove the three bearing support screws Fig • 17'—S h ift Tmbm Assembly—
at lower end of jacket and the two adjustable bush Rem oval o r Installation
ing screws from cam slots in jacket. Pull the tube FLOOR PLATE, 1 ^ BUSHING SUPPORT AND BEARING
ASSEMBLY
SPACER
■ K
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SELECTO R SPRING ■ SHIFT TUBE A N D NLGI Grade 2 E.P. or Multi-Mileage Lubricant, Part
LEVER ASSEMBLY
Num ber 2525035. Apply a thin coating to all friction
surfaces.
(1) Install column holding tool C-4132 and clamp
column in a vise with both ends of column accessible.
(2) Install the O -ring retainer, O-ring, and floor
plate on lower end of column jacket. This must be
done before installing shift tube.
(3) Coat spring washer with grease and install on
COLUMN JACKET lower hub of gearshift housing. Position gearshift
NYLON BUSHING housing on the jacket (Fig. 21 or 22).
(4) Column Shift Automatics and Floor Shift Mod
els
- ND530B (a) With dust seal and shift tube support installed
on shift tube, slide the assembly into jacket. Guide
Fig. 19—Shift Tube Assembly Removal o r Installation key on upper end of tube into slot in gearshift hous
ing. Hold firmly together and tighten lock screw in
and lever assembly out of jacket lower end (Figs. 18 shift housing (Fig. 15).
& 19).
(b) Bend corners of shift tube slot out against shift
housing casting (Fig. 14).
Steering Shaft Coupling (Fig. 20) (c) Insert wire retainer in slots in lower end of
(1) Pry cover tangs out from coupling body and jacket and into groove in shift tube support (Fig. 16).
pull seal and cover from body. (d) Column Shift Automatics only. Position the shift
(2) Drive the small short dowel pin at edge of
lever and crossover load spring in the gearshift hous
coupling body, down into coupling and discard.
ing and tap in the pivot pin (Fig. 23).
(3) Pull body off the shaft and shoe assembly.
Install the shift lever gate on the lock housing (Fig.
(4) Separate and clean all parts.
24).
Feed gear selector indicator lamp assembly wire
Inspection
through hole behind the indicator quadrant on the
A fter cleaning, inspect all parts for wear or damage.
lock housing and route wire down through the space
Note condition of shift lever gate and inner end of
shift lever. Inspect tu rn signal switch for distortion, between the housing and jacket and insert wire te r
broken or damaged parts. Inspect wiring insulation minal into ignition switch connector. Secure lamp as
for worn or bare spots. sembly to rear of indicator quadrant with 2 screws
Inspect steering shaft bearing for smooth operation, (Fig. 25).
and lubricate with Multi-Purpose Chassis Lubricant or Secure gear selector indicator lens assembly to
sim ilar lubricant. If bearing has any signs of rough front of lock housing gear selector quadrant with 2
ness or wear, it should be replaced. screws.
(5) Seat the lock housing on top of the jacket, in
COLUMN ASSEMBLY (Fig. 21 or 22) dexing the key in the housing with the slot in the
jacket. Insert all four screws and tighten them al
The grease recom mended for use during reassem ternately in steps to insure proper seating of the
bly procedures is Automotive Multi-Purpose Grease housing on the jacket. Tighten to 80 inch pounds
MASTER SPLINE MARK
(Fig. 13).
SHOES COVER (6) Column Shift Manual Transmission Only
I SHOE SPRING
SEAL
I DOWEL PIN HOLE (a) Turn bushing on shift tube (Fig. 19) so the two
1 , \ holes in bushing are aligned with centerline of 2nd
and direct shift lever. Slide shift tube and lever as
sembly through jacket and into gearshift housing.
m Start the two bushing retaining screws through slots
COUPLING BODY
\
STEERING SHAFT
in jacket but do not tighten.
(b) Install spacer (Fig. 18) over crossover blade
ROLL PIN HOLE STEERING SHAFT TO SHOE PIN PY22
so it rests against the 2nd and direct shift lever.
Install low and reverse lever, then install support
Fig. 2 0 —Steering Shaft " P o t" Coupling Disassembled and bearing assembly. Install and tighten the three
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SPRING IN
RETAINER PLATE-SWITCH SCREW (2) ASSEMBLED POSITION
BEARING
AN D BEARING
INSULATOR
LOCK HOUSING
REFERENCE
COLUMN—STEERING
STEERING SHAFT
VIEW IN CIRCLE A
19-39
PY831
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19-40
STEERING—COLUMN
SCREW (2) SPRING IN
RETAINER PLATE-SWJTCH
AND BEARING
SHIFT HOUSING
COLUMN JACKET
PY830
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CRO SS-OVER BLADE IN NEUTRAL
SHIFT LEVER SPRING SHIFT SHIFT
LEVER TUBE
GATE SET
SCREW
CROSS-SECTION
W ITH LEVER A N D
SPRING IN ASSEMBLED
P O SITION PY896
PY897
(d) Place a screwdriver blade between 2nd and Fig. 2 7 —Install Shift Lever—M an u al
direct shift lever and crossover blade, so it will be
held in neutral position half-way between the two
shift levers (Fig. 26).
STEP I V IE W A
STEP HI
STEP II
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Make sure that the lock lever spring leg is firmly in column and shift tube assembly.
place in lock casting notch (Fig. 12). (2) Install the lock plate on the steering shaft and
(9) Install the lock lever guide plate and retaining press the pin into place. DO NOT HAMMER use tool
screws (Fig. 10). C-4113 (Fig. 8). Make sure pin is centered.
(10) Position ignition switch to center detent (OFF) (3) Install steering column shaft lock plate sleeve
position. Feed wires down through the space between over shaft lock plate pin and against lock plate.
housing and jacket. Position switch in housing and (4) Install the bearing lower snap ring on the
tighten three mounting screws (Fig. 11). steering shaft.
(11) Feed buzzer switch wires behind wiring post
and down through space between housing and jacket. Bearing Housing Assembly (Fig. 21 or 22)
Position switch in housing and tighten two m ounting (1) Place rubber insulator with ground staple, over
screws (Fig. 9). column upper bearing and install assembly into bear
(12) With the ignition key cylinder in the LOCK ing housing bore. Use a soap solution or rubber lu
position, and with the key removed, insert the key bricant to ease installation.
cylinder into the lock housing. Press the cylinder (2) Install the turn signal switch in the bearing
into place until contact is made with the pin on the housing, feeding the wires through the opening in
ignition switch cam. Insert the key into the lock and the housing. Feed the ignition key lamp assembly
rotate the lock until the slot in the cylinder plate wires through the opening in the housing at this
lines up with the pin. Press the key cylinder the time.
rem aining way into the lock housing, making sure (3) Install the retaining plate over the switch and
the retainer bar snaps into its slot in the lock hous tighten 3 screws to 27 in. lbs. (Fig. 4).
ing. (4) Install the turn signal lever or turn signal/
speed control lever on the turn signal switch. If
Steering Shaft Coupling Assembly (Fig. 20) speed control, feed the wires through the opening
(1) Fill coupling body with grease to approximately provided in the bearing housing (Fig. 3).
1/2 inch from top. (5) Position the bearing housing assembly on the
(2) Place cover and seal on shaft. column jacket assembly, feeding the wires through
(3) Press shoe pin into steering shaft so that it the space between the lower housings and the jacket.
projects an equal distance on each side of shaft. (6) When installing this housing, the steering shaft
(4) Place spring on side of shaft, straddling the m ust be drawn, not pushed, through the bearing,
shoe pin. using the bearing inner race as a reaction member,
(5) Place shoes on pin ends with flat side toward or damage to the shaft plastic shear pins, lock hous
spring engaging tangs. ing components, or bearing could result. DO NOT
(6) Squeeze shoes together, compressing spring, DRIVE THE SHAFT INTO THE BEARING.
and push assembly into coupling body (Fig. 29) with (7) Install on steering shaft, Tool C-3879, with
gauge hole in shaft aligned with m aster spline in washer and steering wheel nut (Fig. 30). Turn nut to
coupling. pull shaft through bearing. Remove tool and install
(7) Drive in a new dowel pin flush to outer surface upper snap ring on shaft.
of coupling body.
(8) Position seal and cover on body and crimp
cover tangs over the projections on body securely.
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(8) Install and tighten to 35 in.-lbs. the 3 bearing instrum ent panel support. Install but do not tighten
housing to lock housing screws. the two upper bracket nuts.
(9) Carefully install the ignition key lamp as (5) Center steering shaft coupling at midpoint of
sembly in the bearing housing (2 screws). its travel. This is accomplished by moving column
(10) On column shift automatic only, position and bracket assembly fore and aft in the instrum ent
pointer under indicator quadrant and tighten at panel support so dimension between top of coupling
taching screw to shift housing (Fig. 22). and center of gauge hole is 13/16 inch (Fig. 32).
(11) Install the wiring trough in place over the Tighten the two upper bracket nuts to 110 inch-
wires, being careful to not pinch wires between pounds. Attach electrical ground wire to one of the
trough and jacket. rear m ounting studs.
(6) Position floor plate over floor pan opening,
COLUMN IDENTIFICATION (Fig. 1 or2) centering it around the column, then install and
tighten retaining bolts. Slide “O” ring down the
(1) Tool C-4134 must be used to hold the steering jacket and into recess in floor plate, position re
shaft in the center of the shift tube while installing taining plate over “O” ring and secure w ith.the two
and aligning the column in the vehicle. bolts. Do not pry to align plates and attaching bolts
(This operation is not necessary on Column shift or column misalignment will occur.
manual transmission columns.) (7) If so equipped, place shim pack between col
(a) Remove thumbscrew and open tool to straddle umn bracket forward leg and instrum ent panel sup
shift tube lever and steering shaft (Fig. 31). port. Maximum shim pack thickness error must not
(b) Close tool and tighten thumbscrew. exceed .060 inch before tightening the bolt. Add.
(c) If hole in tool is too large to grip steering shims, if necessary, then tighten bolt to 110 inch-
shaft, add the split insert to adapt tool to smaller pounds.
shaft diam eter. (8) Attach finish plate to bottom of instrum ent
(2) Position bracket assembly on steering column panel.
(Fig. 1), install ground wire and tighten the four (9) Install tu rn signal lever.
short retaining screws to 120 inch-pounds. Plastic (10) Place steering wheel (or corrugated cylinder
capsules should be pre-assembled in bracket slots, on Challenger) on steering shaft with m aster splines
except Challenger. Insert column assembly through aligned. Install retaining nut and washer, tighten
floor pan opening, being careful not to damage paint nut to 27 foot-pounds. Do not drive wheel on shaft,
or trim. draw wheel down with retaining nut.
(3) With front wheels in straight ahead position (11) Install horn switch parts previously removed
and m aster splines on wormshaft and coupling from steering wheel. Connect horn switch wire.
aligned, engage coupling with wormshaft and install (12) Connect wiring connectors at steering column
the roll pin. CAUTION: Do not apply end loads to jacket. Connect battery ground cable, test operation
steering shaft. of lights and horns.
(4) Hold column assembly with bracket against the (13) Connect and adjust gearshift linkage, refer
THUMB SCREW-*.
to “Transmission Group.”
FLOOR PLATE ASSEMBLY ■---------
SHIFT LEVERS*
9 ' ^ t '
MASTER
SPLINE
INDICATOR
SHIFT
LEVER
TO O L
LEVER END-PLAY
HINGE
ADJUSTMENT
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SPECIFICATIONS
MANUAL STEERING
Type .. — ............................................................................. ................................... Recirculating Ball Nut
Ratio ..................................................................... ....................................................... 24 to 1
Cross Shaft B earings.................................................................................................. 3-Needle Bearings
Dart 6 cyl........................................................................................................................ Bronze Bushings
Worm Shaft B earings.................................................................................................. 2-Caged Ball Bearings
Cross Shaft Adjusting Screw End P l a y .............................................. ......................000-.004 Inch
Worm Bearing Pre-Load ................................................................................... ....... 1 to 4 in. lbs. to Keep Wheel
Moving
Sector Mesh Adjustment Pre-Load Torque—
Includes worm bearing Pre-Load ......................................................................8 to 11 in. lbs. Pull through high
spot
PUMPS
Type ............. .............. .................................................................. .............................. Constant Displacement—.94
Cu. In. per revolution
Constant Displacement—1.06
Cu. In. per revolution
Maximum Pressure
Dart (All Engines)
1.06 pump ................................................................................................................750 to 850 psi
Challenger
1.06 pump (225 C.I.D. Engine) ............................................................................. 750 to 850 psi
1.06 pump (318, 340 or 426 C.I.D. E ngine)..........................................................950 to 1050 psi
.94 pump (318, 340, 383 or 440 C.I.D. Engine) ................................................ 950 to 1075 psi
Pump Output
.94 p u m p ............................................................................................................ . 2 .1 to 2 .6 g p m
1.06 pump
High level ................... .................................................................................................. 2.5 to 3.0 gpm
Low le v e l...................................................... ..................................... ......................... 1.4 to 1.8 gpm
Type of F l u id ......................... ..................................................................................... Power Steering Fluid—Part
No. 2084329 or equivalent—
Do Not use Type “A”
Transmission Fluid
TIGHTENING REFERENCE
MANUAL STEERING
Foot Foot
Pounds Pounds
Cross Shaft Adjusting Screw Lock N u t ............ 35 Steering Arm N u t ................................................... 175
Cross Shaft Cover B o l t ....................................... 25 Steering Wheel N u t ....................................... ....... 27
Gear Assembly to Frame B o l t ........................... 80
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POWER STEERING GEAR
Foot I nch Foot Inch
Pounds Pounds
Gear Housing to Frame B o lt................ 80 Steering Column Support N u t ............. ...............140
Gear Shaft Adjusting Screw Lock Nut. 50 . Steering Shaft Coupling B o lts ............. ...............200
Gear Shaft Cover N u t ......................... 20 Valve Body Attaching B o lts ..................................200
Pump Inlet F ittin g ................................. 30 Valve Body End P lu g .......................— 25
Steering Arm N u t ................................. 120 Steering Wheel N u t ................................ 27
PUMPS
Location Foot-Pounds Location Foot-Pounds
High Pressure Hose Fittings Flow Control Valve Plug
Gear End .94 p u m p ................................................ 4
All Models ....................... 12-14 1.06 p u m p ................................................ 7
Pump End Pulley Retaining Nut (.94 p u m p ).............. 45-55
All M odels......................... 21-27 Bracket Mounting B o lts............................. 25-35
Bracket Bolts 1.06 pump
.94 p u m p ......................... 30-40 1/8 inch pipe clean out p l u g ................ 7
1.06 p u m p ......................... 18
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TRANSMISSIONS
CONTENTS
Page Page
MANUAL TRANSMISSION—4 SPEED . . . . 68 SPECIFICATIONS . .................................... 112
MANUAL TRANSMISSION—3 SPEED...................... TIGHTENING REFERENCE......................... 115
MODEL A-903 ......................................... 84 TORQUEFLITE TRANSMISSION ............... 1
MODEL A-230 .................................. . . . 95
TORQUEFLITE TRANSMISSIONS
(A-904 and A-727)
INDEX
Page Page
General Information .................................................. 1 Fluid Leakage .......................................................... 66
Hydraulic Control S y s te m ........................................ 2 Recondition Sub-Assemblies ............................... 34
Operating Instructions.............................................. 13 Accumulator Piston and S p rin g ....................... 38
Service Diagnosis ...................................................... 14 Extension Housing Bushing and Oil Seal — 38
Service in Vehicle Front Clutch—A-904 .......................................... 42
Air Pressure Tests ................................................ 25 Front Clutch—A-727 .......................................... 44
Aluminum Thread R e p a ir ..................................... 20 Governor and S u p p o r t...................................... 38
Band Adjustm ents................. ................................ 22 Kickdown Servo and Band ............................... 54
Console G e a rsh ift.................................................. 59 Low-Reverse Servo and Band ......................... 54
Extension Housing and Output Shaft Bearing .. 26 Oil Pump and Reaction Shaft Support
Extension Housing Yoke S e a l ............................... 26 —A-904 .............................................................. 39
Gearshift Linkage A djustm ent............................. 59 Oil Pump and Reaction Shaft Support
Governor ................................................................. 27 —A-727 .............................................................. 41
Hydraulic Control Pressure A djustm ents.......... 23 Overrunning C lu tc h ........................................ .. 52
Hydraulic Control Pressure T e s t s ....................... 22 Parking Lock S p r a g ............................................ 38
Lubrication ................. ............................................ 20 Planetary Gear Train—A-904 ........................... 49
Neutral Starting Switch ....................................... 21 Planetary Gear Train—A-727 ........................... 51
Parking Lock Com ponents............................. ....... 28 Rear Clutch—A-904 ............................................ 46
Speedometer Pinion ............................................ 25 Rear Clutch—A-727 ............................................ 48
Throttle Rod Adjustment ..................................... 61 Valve Body A ssem bly........................................ 34
Valve Body and Accumulator P i s to n ................. 28 Removal—Transmission and Converter................. 29
Service Out of Vehicle Pump Oil Seal ................. ...................................... 31
Assembly—Sub-Assembly Installation .............. 54 Starter Ring G e a r .................................................... 30
Disassembly—Sub-Assembly Removal .............. 32 Torque Converter Flushing................................... 31
Installation—Transmission, Converter and Specifications............................................................. 113
Drive Plate .......................................................... 57 Tightening R e feren ce..................... .......................... 115
GENERAL INFORMATION
The TorqueFlite Transmission model identification some internal parts will be different to provide for
m arking shown in the following application chart, is this. Therefore, when replacing parts, refer to the
cast in raised letters about 3 /8 inch high on the lower seven digit part number stamped on left side of the
left side of the bell housing. Transmission usage is de transmission oil pan flange.
term ined by the type of engine with which it is in The transmission combines a torque converter and
stalled. a fully-automatic 3-speed gear system (Figs. 1 and 2).
The A-727-RG is available for heavy duty police The converter housing and transmission case are an
and taxi service with the .6 Cyl., 225 Cu. In. engine. integral aluminum casting. The transmission consists
Because of the similarity in design and in servicing of two m ultiple disc clutches, an over-running clutch,
the transmissions, the procedures have been com two servos and bands, and two planetary gear sets to
bined in this Manual. W here variations in procedures provide three forward ratios and a reverse ratio. The
occur, application is indicated. common sun gear of the planetary gear sets is con
CAUTIO N: Transmission operation requirements are nected to the front clutch by a driving shell which is
different for each vehicle and engine combination and splined to the sun gear and to the front clutch re-
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CLUTCH ENGAGEMENT AND BAND APPLICATION CHART
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REAR CLUTCH f REAR PLANETARY GEAR SET
OUTPUT SHAFT
OVERRUNNING CLUTCH
GOVERNOR
SEARING SEAL.
TORQUEFLITE
fp ' ^
„
.V. SPEEDOMETER PINION
-wmpz BUSHING
TRANSMISSIONS
PARKING LOCK ASSEMBLY
21-3
Fig. Y—TonyueFlife Transm ission e n d Torque C o n v e rte r (A -9 0 4 )
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21-4
TURBINE;
TRANSMISSIONS—TORQUEFLITE
IMPELLED REAR CLUTCH REAR PLANETARY GEAR. SET
FRONT CLUTCH
LOW AND REVERSE BAND
O VERRUNNING CLUTCH
GOVERNOR
BUSHING
lI P
\ EXTENSION HOUSING
\ ■ X. PARKING LOCK ASSEMBLY
VALVE BODY
ENGINE CRANKSHAFT
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TO LUB.
CONTROL SYSTEM IN
PARK
C L .„ z n z = r T r z : ___ ______ j
ENGINE RU NN IN G
NN34C
P ark H yd ra u lic Circuits
LINE....................... 55 psi I
PUMP SUCTION □
CONVERTER............. 30 -5 5 psi
T O LUB.
CONTROL SYSTEM IN
NEUTRAL
ENGINE R U N N IN G
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SERVO
THROTTLE................... 40 psi
CONTROL SYSTEM IN
T O LUB,
DRIVE (BREAKAWAY)
HALF THROTTLE
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KD n SERVO
O I L PRESSURES
LINE........................... 75 psi
THROTTLE......... .. 40 psi
DRIVE CSICOND1
HALF THROTTLE
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KD _ SERVO
TO LUB.
CONTROL SYSTEM IN
DRIVE (DIRECT)
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LINE.
PUMP SUCTION.
THROTTLE................... 9 0 psi
LUBRICATION............5-30 psi c m
CONTROL SYSTEM IN
TO LUB.
DRIVE CfCiCiCDOWNl
AT 50 M .P.H.
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OIL PRE SSURES
LINE.......................... 55 psi
CONTROL SYSTEM IN
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PU iP SUCTION.
GOVERNOR............... 0 -3 0 psi
LUBRICATION.. . . . . . 5 - 3 0 psi □
CONTROL SYSTEM IN
MANUAL LOW
T O LUB,
CLOSED THROTTLE
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OIL PRESSURES
LINE 2 3 0 -2 6 0 psi
1 1
PUMP SUCTION
CONTROL SYSTEM IN
TO LUB.
REVERSE
OIL FILTER
1 ewmme H y d m u l k C ircuits
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The throttle valve transm its regulated pressure to
the transm ission (in conjunction with governor
pressure) to control upshift and downshift speeds.
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SHIFT PATTERN SUMMARY CHART
(Eight Cylinder Vehicles)
Vehicle Speed To Axle Ratios
318
Cu. In. Eng. 340 & 383 Cu. In. Eng. High Performance
426 440
Condition 2.76:1 3.23:1 2.76:1 3.23:1 3.55:1 3.23:1 3.23:1
Closed Throttle 1-2 Upshift 7-13 6-11 8-14 6-13 6-10 8-15 7-12
Closed Throttle 2-3 Upshift 12-18 10-15 13-18 11-17 10-14 13-19 11-16
Wide Open Throttle 1-2 Upshift 30-47 25-40 31-49 31-50 28-42 41-58 33-48
Wide Open Throttle 2-3 Upshift 70-82 59-71 72-85 62-81 57-67 80-93 68-78
3-2 Kickdown Limit ..................... 60-73 51-63 63-76 55-73 50-60 70-84 60-70
3-1 Kickdown Limit ..................... 27-31 23-27 28-32 23-36 22-35 30-45 25-36
Closed Throttle Dow nshift.......... 5-12 5-10 6-13 5-12 4-9 6-13 5-11
S tarting the Engine require heavy throttle for 1/2 mile or more. This
The engine will start with the selector lever in reduces possibility of overheating the transmission
either the P (park) or N (neutral) positions. and converter under these conditions.
(1) As a safety precaution when starting in the N
(neutral) position, apply the parking or foot brake. Towing Vehicle
(2) Depress the accelerator pedal one-third of Transmission Inoperative: Tow the vehicle with a
travel to insure proper choke operation. rear end pickup or remove the propeller shaft.
(3) T urn the ignition key all the way to the right to Transmission Operating Properly: The vehicle may
START position. W hen the engine starts, release the be towed safely in N (neutral) with rear wheels on the
key and it will retu rn to the ON position. ground at a speed not to exceed 30 mph. If the vehicle
NOTE: The TorqueFlite transmission will not permit is to be towed for extended distances, it should be
starting the engine by pushing or towing. done with a rear end pickup or the propeller shaft
removed. Because the transmission receives lubrica
M o u n tain Driving tion only when the engine is running, it is good prac
W hen driving in the m ountains with either heavy tice to always tow a disabled vehicle with a rear end
loads or when pulling trailers, the 2 (second) or 1 pickup or remove the propeller shaft.
(low) position should be selected on upgrades which
SERVICE DIAGNOSIS
The transmission should not be removed nor disassembled until a careful diagnosis is made, the definite
cause determined and all possible external corrections performed. In diagnosing any abnormal shift condi
tion, always make the hydraulic pressure tests before disassembly or replacement of parts.
Condition Possible Cause Correction
HARSH ENGAGEMENT (a) Engine idle speed too high. (a) Adjust engine idle speed to specifica
IN D, 1, 2 AND R tions. Readjust throttle linkage.
(b) Hydraulic pressures too high or low. (b) Inspect fluid level, then perform hy
draulic pressure tests and adjust to
specifications.
(c) Low-reverse band out of adjustment. (c) Adjust low-reverse band.
(d) Valve body malfunction or leakage. (d) Perform pressure tests to determine
cause and correct as required.
(e) Accumulator sticking, broken rings or (e) Inspect accumulator for sticking, bro
spring. ken rings or spring. Repair as re
quired.
(f) Low-reverse servo, band or linkage (f) Inspect servo for damaged seals,
malfunction. binding linkage or faulty band lining.
Repair as required.
(g) Worn or faulty front and/or rear (g) Disassemble and inspect clutch. Re
clutch. pair or replace as required.
DELAYED ENGAGEMENT (a) Refill to correct level with Automatic
IN D, 1 ,2 AND R Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
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(b) Incorrect gearshift control linkage (b) Adjust control linkage.
adjustment.
(c) Hydraulic pressures too high or low. (c) Perform hydraulic pressure tests and
adjust to specifications.
(d) Oil filter clogged. (d) Replace oil filter.
(e) Valve body malfunction or leakage. (e) Perform pressure tests to determine
cause and correct as required.
(f) Accumulator sticking, broken rings or (f) Inspect accumulator for sticking, bro
spring. ken rings or spring. Repair as re
quired.
(g) Clutches or servos sticking or not (g) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(h) Faulty oil pump. (h) Perform hydraulic pressure tests. Ad
just or repair as required.
(i) Worn or faulty front and/or rear (i) Disassemble and inspect clutch. Re
clutch. pair or replace as required.
(j) Worn or broken input shaft and/or (j) Inspect and replace seal rings as
reaction shaft support seal rings. required, also inspect respective
bores for wear. Replace parts as re
quired.
(k) Aerated fluid. (k) Inspect for air leakage into pump suc
tion passages.
RUNAWAY OR HARSH (a) Low fluid level. (a) Refill to correct level with Automatic
UPSHIFT AND 3-2 Transmission Fluid, AQ-ATF, Suffix A.
KICKDOWN or (Dexron).
(b) Incorrect throttle linkage adjustment. (b) Adjust throttle linkage.
(c) Hydraulic pressures too high or low. (c) Perform hydraulic pressure tests and
adjust to specifications.
(d) Kickdown band out of adjustment. (d) Adjust kickdown band.
(e) Valve body malfunction or leakage. (e) Perform pressure tests to determine
cause and correct as required.
(f) Governor malfunction. (f) Inspect governor and repair as re
quired.
(g) Accumulator sticking, broken rings or (g) Inspect accumulator for sticking, bro
spring. ken rings or spring. Repair as re
quired.
(h) Clutches or servos sticking or not (h) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(i) Kickdown servo, band or linkage (i) Inspect servo for sticking, broken seal
malfunctions. rings, binding linkage or faulty band
lining. Repair as required.
(j) Worn or faulty front clutch. (j) Disassemble and inspect clutch. Re
pair as required.
(k) Worn or broken input shaft and/or (k) Inspect and replace seal rings as re
reaction shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
NO UPSHIFT (a) Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid AQ-ATF, Suffix A.
or (Dexron).
(b) Incorrect throttle linkage adjustment. (b) Adjust throttle linkage.
(c) Kickdown band out of adjustment. (c) Adjust kickdown band.
(d) Hydraulic pressures too high or low. (d) Perform hydraulic pressure tests and
adjust to specifications.
(e) Governor sticking or leaking. (e) Remove and clean governor. Replace
parts if necessary.
(f) Valve body malfunction or leakage. (f) Perform pressure tests to determine
cause and correct as required.
(g) Clutches or servos sticking or not (g) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
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(h) Faulty oil pump. (h) Perform hydraulic pressure tests, ad
just or repair as required.
(i) Kickdown servo, band or linkage mal (i) Inspect servo for sticking, broken seal
function. rings, binding linkage or faulty band
lining. Repair as required.
(j) Worn or faulty front clutch. (j) Disassemble and inspect clutch. Re
pair or replace as required.
(k) Worn or broken input shaft and/or (k) Inspect and replace seal rings as re
reaction shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
NO KICKDOWN OR (a) Incorrect throttle linkage adjustment. (a) Adjust throttle linkage.
NORMAL DOWNSHIFT (b) Incorrect gearshift control linkage ad (b) Adjust control linkage.
justment.
(c) Kickdown band out of adjustment. (c) Adjust kickdown band.
(d) Hydraulic pressures too high or low. (d) Peform hydraulic pressure tests and
adjust to specifications.
(e) Governor sticking or leaking. (e) Remove and clean governor. Replace
parts if necessary.
(f) Valve body malfunction or leakage. (f) Perform pressure tests to determine
cause and correct as required.
(g) Clutches or servos sticking or not (g) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(h) Kickdown servo, band or linkage (h) Inspect servo for sticking, broken seal
malfunction. rings, binding linkage or faulty band
lining. Repair as required.
(i) Overrunning clutch not holding. (i) Disassemble transmission and repair
overrunning clutch as required.
SHIFTS ERRATIC (a) Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Aerated fluid. (b) Inspect for air leakage into pump suc
tion passages.
(c) Incorrect throttle linkage adjustment. (c) Adjust throttle linkage.
(d) Incorrect gearshift control linkage (d) Adjust control linkage.
adjustment.
(e) Hydraulic pressures too high or low. (e) Perform hydraulic pressure tests and
adjust to specifications.
(f) Governor sticking or leaking. (f) Remove and clean governor. Replace
parts if necessary.
(g) Oil filter clogged. (g) Replace oil filter.
(h) Valve body malfunction or leakage. (h) Perform pressure tests to determine
cause and correct as required.
(i) Clutches or servos sticking or not (i) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(j) Faulty oil pump. (j) Perform hydraulic pressure tests, ad
just or repair as required.
(k) Worn or broken input shaft and/or (k) Inspect and replace seal rings as re
reaction shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
SLIPS IN FORWARD (a) Low fluid level. (a) Refill to correct level with Automatic
DRIVE POSITIONS Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Aerated fluid. (b) Inspect for air leakage into oil pump
suction passages.
(c) Incorrect throttle linkage adjustment. (c) Adjust throttle linkage.
(d) Incorrect gearshift control linkage ad (d) Adjust control linkage.
justment.
(e) Hydraulic pressures too low. (e) Perform hydraulic pressure tests and
adjust to specifications.
(f) Valve body malfunction or leakage. (f) Perform pressure tests to determine
cause and correct as required.
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. Condition Possible Cause Correction
(g) Accumulator sticking, broken rings or (g) Inspect accumulator for sticking,
spring. broken rings or spring. Repair as re
quired.
(h) Clutches or servos sticking or not (h) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(i) Worn or faulty front and/or rear (i) Disassemble and inspect clutch. Re
clutch. pair or replace as required.
(j) Overrunning clutch not holding. (j) Disassemble transmission and repair
overrunning clutch as required.
(k) Worn or broken input shaft and/or re (k) Inspect and replace seal rings as re
action shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
SLIPS IN REVERSE ONLY (a) Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Aerated fluid. (b) Inspect for air leakage into pump suc
tion passages.
(c) Incorrect gearshift control linkage (c) Adjust control linkage.
adjustment.
(d) Hydraulic pressures too high or low. (d) Perform hydraulic pressure tests and
adjust to specifications.
(e) Low-reverse band out of adjustment. (e) Adjust low-reverse band.
(f) Valve body malfunction or leakage. (f) Perform pressure tests to determine
cause and correct as required.
(g) Front clutch or rear servo, sticking or (g) Remove valve body assembly and per
not operating. form air pressure tests. Repair as re
quired.
(h) Low-reverse servo, band or linkage (h) Inspect servo for damaged seals,
malfunction. binding linkage or faulty band lining.
Repair as required.
(i) Faulty oil pump. (i) Perform hydraulic pressure tests, ad
just or repair as required.
SLIPS IN ALL POSITIONS (a) Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid AQ-ATF, Suffix A.
or (Dexron).
(b) Hydraulic pressures too low. (b) Perform hydraulic pressure tests and
adjust to specifications.
(c) Valve body malfunction or leakage. (c) Perform pressure tests to determine
cause and correct as required.
(d) Faulty oil pump. (d) Perform hydraulic pressure tests, ad
just or repair as required.
(e) Clutches or servos sticking or not (e) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(f) Worn or broken input shaft and/or (f) Inspect and replace seal rings as re
reaction shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
NO DRIVE IN ANY (a) Low fluid level. (a) Refill to correct level with Automatic
POSITION Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Hydraulic pressures too low. (b) Perform hydraulic pressure tests and
adjust to specifications.
(c) Oil filter clogged. (c) Replace oil filter.
(d) Valve body malfunction or leakage. (d) Perform pressure tests to determine
cause and correct as required.
(e) Faulty oil pump. (e) Perform hydraulic pressure tests, ad
just or repair as required.
(f) Clutches or servos sticking or not (f) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(g) Torque converter failure. (g) Replace torque converter.
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________ Condition Possible Cause Correction
NO DRIVE IN (a) Hydraulic pressures too low. (a) Perform hydraulic pressure tests and
FORWARD DRIVE adjust to specifications.
POSITIONS (b) Valve body malfunction or leakage. (b) Perform pressure tests to determine
cause and correct as required.
(c) Clutches or servos, sticking or not (c) Remove valve body assembly and per
operating. form air pressure tests. Repair as re
quired.
(d) Worn or faulty rear clutch. (d) Disassemble and inspect clutch. Re
pair or replace as required.
(e) Overrunning clutch not holding. (e) Disassemble transmission and repair
overrunning clutch as required.
(f) Worn or broken input shaft and/or (f) Inspect and replace seal rings as re
reaction shaft support seal rings. quired, also inspect respective bores
for wear. Replace parts as required.
NO DRIVE IN (a) Incorrect gearshift control linkage ad (a) Adjust control linkage.
REVERSE justment.
(b) Hydraulic pressures too low. (b) Perform hydraulic pressure tests and
adjust to specifications.
(c) Low-reverse band out of adjustment. (c) Adjust low-reverse band.
(d) Valve body malfunction or leakage. (d) Perform pressure tests to determine
cause and correct as required.
(e) Front clutch or rear servo, sticking or (e) Remove valve body assembly and per
not operating. form air pressure tests. Repair as re
quired.
(f) Low-reverse servo, band or linkage (f) Inspect servo for damaged seals,
malfunction. binding linkage or faulty band lining.
Repair as required.
(g) Worn or faulty front clutch. (g) Disassemble and inspect clutch. Re
pair or replace as required.
DRIVES IN NEUTRAL (a) Incorrect gearshift control linkage ad (a) Adjust control linkage.
justment.
(b) Valve body malfunction or leakage. (b) Perform pressure tests to determine
cause and correct as required.
(c) Rear clutch inoperative. (c) Inspect clutch and repair as required.
DRAGS OR LOCKS (a) Kickdown band out of adjustment. (a) Adjust kickdown band.
(b) Low-reverse band out of adjustment. (b) Adjust low-reverse band.
(c) Kickdown and/or low-reverse servo, (c) Inspect servo for sticking, broken seal
band, linkage malfunction. rings, binding linkage or faulty band
lining. Repair as required.
(d) Front and/or rear clutch faulty. (d) Disassemble and inspect clutch. Re
pair or replace as required.
(e) Planetary gear sets broken or seized. (e) Inspect condition of planetary gear
sets and replaced as required.
(f) Overrunning clutch worn, broken or (f) Inspect condition of overrunning
seized. clutch and replace parts as required.
GRATING, SCRAPING (a) Kickdown band out of adjustment. (a) Adjust kickdown band.
GROWLING NOISE (b) Low-reverse band out of adjustment. (b) Adjust low-reverse band.
(c) Output shaft bearing and/or bushing (c) Remove extension housing and re
damaged. place bearing and/or bushing.
(d) Governor support binding or broken (d) Inspect condition of governor sup
seal rings. port and repair as required.
(e) Oil pump scored or binding. (e) Inspect condition of pump and repair
as required.
(f) Front and/or rear clutch faulty. (f) Disassemble and inspect clutch. Re
pair or replace as required.
(g) Planetary gear sets broken or seized. (g) Inspect condition of planetary gear
sets and replace as required.
(h) Overrunning clutch worn, broken or (h) Inspect condition of overrunning
seized. clutch and replace parts as required.
OIL LEAKAGE (a) Speedometer adaptor. (a) Replace rubber “0 ” ring seal. Inspect
for bore porosity.
(b) Speedometer drive pinion seal. (b) Replace rubber seal.
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(c) Oil pan gasket. (c) Can often be stopped by tightening
the attaching bolts to proper torque
(150 in. lbs.). If necessary, replace gas
ket. Inspect oil pan gasket mounting
face for flatness. Caution: Do not over
torque pan bolts.
(d) Fluid filler tube. (d) Replace “0" ring seal. Inspect for
tube damage, and bore porosity.
(e) Fluid lines and fittings. (e) If leakage cannot be stopped by tight
ening a fitting, replace the defective
part.
(f) Manual control lever. (f) Replace either or both the manual
lever or throttle lever shaft seal.
(g) Pipe plugs. (g) Torque to specified torque. If leak per
sists, replace plug.
(h) Rear extension seal. (h) Check for O.D. Bore damage and re
place seal.
(i) Rear bearing access plate, (i) Replace gasket.
(j) Extension bolts. (j) Replace bolt.
(k) Extension gasket. (k) Replace gasket and check for sealing
surface damage on case and exten
sion.
(I) Kickdown band adjusting screw. (I) Apply sealer.
(m) Neutral switch. (m) Replace switch and/or gasket.
(n) Fluid leakage in converter housing (n) See section on fluid leakage.
area.
BUZZING NOISE (a) Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Pump sucking air. (b) Inspect pump for nicks or burrs on
mating surfaces, porous casting, and/
or excessive rotor clearance. Replace
the parts as required.
(c) Valve body malfunction. (c) Remove and recondition valve body
assembly.
(d) Overrunning clutch inner race dam (d) Inspect and repair clutch as required.
aged.
HARD TO FILL, OIL (a) High fluid level. (a) Drain fluid to correct level.
FLOWS OUT FILLER (b) Breather clogged. (b) Inspect and clean breather vent open
TUBE ing in pump housing.
(c) Oil filter clogged. (c) Replace oil filter.
(d) Aerated fluid. (d) Inspect for air leakage into oil pump
suction passages.
TRANSMISSION (a) Low fluid level. (a) Refill to correct level with Automatic
OVERHEATS Transmission Fluid, AQ-ATF, Suffix A.
or (Dexron).
(b) Kickdown band adjustment too tight. (b) Adjust kickdown band.
(c) Low-reverse band adjustment too (c) Adjust low-reverse band.
tight.
(d) Faulty cooling system. (d) Inspect the transmission cooling
system, clean and repair as required.
(e) Cracked or restricted oil cooler line (e) Inspect, repair or replace as required.
or fitting.
(f) Faulty oil pump. (f) Inspect pump for incorrect clearance,
repair as required.
(g) Insufficient clutch plate clearance (g) Measure clutch plate clearance and
in front and/or rear clutches. correct with proper size snap ring.
STARTER WILL NOT (a) Incorrect gearshift control linkage (a) Adjust control linkage.
ENERGIZE IN NEUTRAL adjustment.
OR PARK (b) Faulty or incorrectly adjusted neutral (b) Test operation of switch with a test
starting switch. lamp. Adjust or replace as required.
(c) Broken lead to neutral switch. (c) Inspect lead and test with a test lamp.
Repair broken lead.
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STALL TEST If stall speeds are 250-350 rpm below specifications,
and the vehicle operates properly at highway speeds,
WARNING: DURI NG TEST LET NO ONE STAND IN but has poor through-gear acceleration, the stator
FRONT OF VEHICLE. overrunning clutch is slipping.
The stall test consists of determ ining the engine If stall speed and acceleration are normal, but ab
speed obtained at full throttle in D position. This test normally high throttle opening is required to main
checks the torque converter stator clutch operation, tain highway speeds, the stator clutch has seized.
and the holding ability of the transmission clutches. Both of these stator defects require replacem ent of
The transmission oil level should be checked and the the torque converter.
engine brought to normal operating tem perature be
fore stall operation. Both the parking and service NOISE
brakes must be fully applied and front wheels blocked
while making this test. A whining or siren-like noise due to fluid flow is
Do not hold the throttle open any longer than is normal during stall operation with some converters;
necessary to obtain a maximum engine speed reading, however, loud metallic noises from loose parts or in
and never longer than five seconds at a time. If more terference within the assembly indicate a defective
than one stall check is required, operate the engine torque converter. To confirm that the noise originates
at approxim ately 1,000 rpm in neutral for 20 seconds within the converter, operate the vehicle at light
to cool the transmission fluid between runs. If engine throttle in D and N on a hoist and listen under the
speed exceeds the maximum limits shown, release the transmission bell housing.
accelerator immediately since transmission clutch
slippage is indicated. STALL SPEED
SPECIFICATION CHART
STALL SPEED ABOVE SPECIFICATION
Engine Engine
If stall speed exceeds the maximum specified in Model Transmission Speed
chart by more than 200 rpm, transmission clutch slip (C.I.D.) Type (RPM)
page is indicated. Follow the transmission oil pressure 198 A904-G 1500-1700
and air pressure checks outlined in the Service in 225 A904-G 1800-2000
Vehicle section to determ ine the cause of slippage. 225 A727-RG 1450-1650
318 A904-LA 2100-2320
318 A727-A 1750-1950
STALL SPEED BELOW SPECIFICATION 340-4 BBL. A727-A 2250-2450
383-2 BBL. A727-B 1850-2100
Low stall speeds with a properly tuned engine indi 383-4 BBL. A727-B 2350-2650
cate torque converter stator clutch problems. A road 440-4 BBL. A727-B 2000-2300
test will be necessary to identify the exact problem. 426-2, 4 BBL. A727-B 2650-2850
SERVICE PROCEDURES
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HELI-COIL CHART
Heli-Coil Insert Drill Tap Inserting Extracting
Tool Tool
Thread Part Insert Part Part Part
Size No. Length Size No. No. No.
10-24 1185-3 .285" 13/64" (.203") 3 CPB 528-3N 1227-6
1/4-20 1185-4 3/8" 17/64" (.265") 4 CPB 528-4N 1227-6
5/16-18 1185-5 15/16" Q (.332") 5 CPB 528-5N 1227-6
3/8-16 1185-6 9/16" X (.397") 6 CPB 528-6N 1227-6
7/16-14 1185-7 21/32" 29/32" (.453") 7 CPB 528-7N 1227-16
matic transm ission and no change is recommended in and tighten retaining screws to 35 inch-pounds.
vehicles used in norm al service. Regularly scheduled (6) Clean the oil pan, and reinstall using a new
fluid and filter changes, therefore will not be re gasket. Tighten oil pan bolts to 150 inch-pounds.
quired, except when the operation of the vehicle is (7) Pour six quarts of Automatic Transmission Fluid
classified as severe. AQ-ATF Suffix “A ” or (Dexron) through the filler
If, for any reason, the factory fill fluid is replaced tube.
with another fluid, the fluid m ust be changed every (8) Start engine and allow to idle for at least two
three years or 36,000 miles in norm al service. minutes. Then, with parking brake on, move selector
Hemi Engine Vehicles: The factory fill fluid should lever m om entarily to each position, ending in the
be changed after the first 24,000 miles or 24 months, neutral position.
whichever occurs first, and periodically thereafter (9) Add sufficient fluid to bring level to the "ADD
every 12,000 miles or 12 months. The filter should ONE PINT" mark.
be changed with each fluid change. If for any reason, Recheck fluid level after transm ission is at norm al
the factory fill fluid is replaced with another fluid operating tem perature. The level should be between
prior to the 24,000 mile or 24 m onth interval, the the "Full" m ark and "ADD ONE PINT" m ark (Fig.
fluid m ust be changed every 12,000 miles or 12 5).
months. CAUTIO N: To prevent dirt from entering transmis
sion, make certain that dip stick cap is fully seated
Fluid Level onto the filler tube.
Inspect fluid level every six months with engine
and transm ission at norm al operating tem perature. BACK-UP LIGHT AND NEUTRAL
Refer to “Lubrication and M aintenance,” Group 0. STARTING SWITCH (Figs. 6 and 7)
The transm ission should not be idled in gear for
long periods. Replacement and Test
The NEUTRAL STARTING SWITCH is the center
T railer Tow ing Service an d H a rd Usage term inal of the 3 term inal switch. It provides ground
If vehicle is used for trailer towing or is used in for the starter solenoid circuit through the selector
hard or severe service, m ore frequent servicing is re lever cam in only Park and Neutral positions.
quired as outlined. (1) To test switch, remove wiring connector from
Drain and refill transm ission and replace filter switch and test for continuity between center pin of
initially at 36,000 miles or 3 years and every 12,000 switch and transmission case. Continuity should exist
miles or 12 months thereafter. only when transmission is in Park or Neutral.
Drain a n d Refill
(1) Raise vehicle on a hoist. Place a drain container
with a large opening, under transm ission oil pan.
(2) Loosen pan bolts at one com er, tap the pan to
break it loose allowing fluid to drain, then remove the
oil pan. ' DRA’K PLUG
(3) Remove access plate from in front of converter,
remove drain plug allowing fluid to drain (Fig. 4).
Install and tighten converter drain plug to 110 inch-
pounds, and install the access plate.
(4) If necessary, adjust the reverse band.
(5) Install a new filter on bottom of the valve body, Fig. 4 —C o n v e r t e r Drain Plug
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LOW A N D
REVERSE BANC
ADJUSTING
SCREW
FILTER—S . f
FLUID I
BACK-UP LIGHT
AN D NEUTRAL
ND167A START SW ITCH-----► / \ \ PAPK----- SWITCH
/ \ rA riK OPERATING
NEUTRAL
REVERSE CAM NU451
Fig. 5 —D ip Stick M arkings
(2) Check gearshift linkage adjustm ent before re Fig. 7 —Bottom V iew of Transmission (Pan Removed)
placing a switch which tests bad. turns. Test adjusting screw for free turning in the
(3) Unscrew switch from transmission case allow transmission case.
ing fluid to drain into a container. Move selector lever (2) Using wrench, Tool C-3380 with adapter C-3705,
to Park and then to Neutral positions, and inspect to tighten band adjusting screw 47 to 50 inch-pounds. If
see that the switch operating lever fingers are cen adapter C-3705 is not used, tighten adjusting screw to
tered in switch opening in the case. 72 inch-pounds which is the true torque.
(4) Screw switch and new seal into transmission (3) A-904: Back off adjusting screw 2 turns (198,
case and tighten to 24 foot- pounds. Retest switch with 225, and 318 cu. in. engines). Hold adjusting screw in
the test lamp. this position and tighten lock nut to 29 foot-pounds.
(5) Add fluid to transmission to bring up to proper A-727: Back off adjusting screw 2 turns (1-1/2 turns
level. for 426 cu. in. engine). Hold adjusting screw in this
(6) The Back-Up Light Switch Circuit is through the position and tighten lock nut to 29 foot-pounds.
two outside term inals of the 3 term inal switch.
(7) To test switch, remove wiring connector from Low a n d Reverse Band
switch and test for continuity between the two outside (1) Raise vehicle, drain transmission fluid and re
pins. move the oil pan.
(8) Continuity should exist only with transmission (2) Loosen adjusting screw lock n u t and back off
in Reverse position. nut approximately five turns (Fig. 7). Test adjusting
(9) No continuity should exist from either pin to screw for free turning in the lever.
the case. (3) Using wrench, Tool C-3380 with adapter C-3705,
tighten band adjusting screw 47 to 50 inch-pounds. If
BAND ADJUSTMENTS adapter C-3705 is not used, tighten adjusting screw to
Kickdown Band 72 inch-pounds which is the true torque.
The kickdown band adjusting screw is located on (4) A-904: Back off adjusting screw 3-1/4 turns (4
left side of the transm ission case. turns for 318 cu. in. engine). Hold adjusting screw in
(1) Loosen lock n u t and back off approximately five this position and tighten lock nut to 35 foot-pounds.
A-727: Back off adjusting screw 2 turns. Hold ad
CONTACT justing screw in this position and tighten lock nut to
SEAL 35 foot-pounds.
(5) Reinstall oil pan using a new gasket. Tighten oil
pan bolts to 150 inch-pounds.
(6) Fill transmission with Automatic Transmission
Fluid AQ-ATF, Suffix “A” or (Dexron).
W IRING
CONNECTOR HYDRAULIC CONTROL PRESSURE TESTS
SWITCH
Line Pressure a nd Front Servo
Fig. 6 -N e u t r a l-P a r k Starting Switch a n d Back-Up Release Pressure
Light Switch Line pressure and front servo release pressure tests
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m ust be made in D (drive) position with rear wheels psi pressure gauge, Tool C-3292 to the “tee” fitting.
free to turn. The transm ission fluid m ust be at operat (2) At 1,000 engine rpm , with throttle closed and
ing tem perature (150 to 200°F). transm ission in direct, lubrication pressure should be
(1) Install an engine tachom eter, raise vehicle on a 5-15 psi. Lubrication pressure will be approxim ately
hoist and position tachom eter so it can be read under doubled as the throttle is opened to maximum line
the vehicle. pressure.
(2) Connect two 0-100 psi pressure gauges, Tool C-
3292 to pressure take-off-points at side of accumu Rear Servo A p p ly Pressure
lator and at front servo release (Fig. 8). (1) Connect a 0-300 psi pressure gauge, Tool C-3293
(3) W ith control in D (drive) position, speed up en to apply pressure take-off point at rea r servo (Fig. 9).
gine slightly until transmission shifts into direct. (2) W ith transmission control in R (reverse) posi
(Front servo release will be pressurized in direct.) Re tion and engine speed set at 1600 rpm , reverse servo
duce engine speed slowly to 1,000 rpm. Line pressure apply pressure should be 230 to 300 psi.
at this tim e (1,000 rpm) m ust be 54-60 psi, and front
servo release pressure m ust not be more than 3 psi G overnor Pressure
below the line pressure. (1) Connect a 0-100 psi pressure gauge, Tool C-3292
(4) Disconnect throttle linkage from transmission to governor pressure take-off point, located at lower
throttle lever and move throttle lever gradually to the left side of extension near the m ounting flange (Fig.
full throttle position. Line pressure m ust rise to a 9).
maximum of 90-96 psi ju st before or at kickdown into (2) Governor pressures should fall within the limits
low gear. Front servo release pressure m ust follow given in the “Governor Pressure Chart.”
line pressure up to kickdown point and should not be If governor pressures are incorrect at the given
more than 3 psi below line pressure. vehicle speeds, the governor valve an d /o r weights are
If pressure is not 54-60 psi at 1,000 rpm, adjust probably sticking. The governor pressure should re
the pressure as outlined on Page 25. spond smoothly to changes in mph and should return
If front servo release pressures are less than pres to 0 to 1-1/2 psi when vehicle is stopped. High pres
sures specified and line pressures are within limits, sure at stand still (above 2 psi) will prevent the
there is excessive leakage in the front clutch an d /o r transmission from downshifting.
front servo circuits. Always inspect e x ternal transmis-
tion throttle lever for looseness on the valve body Throttle Pressure
shaft when making the pressure tests. No provisions are made to test the throttle pres
sure. Incorrect throttle pressure should only be sus
Lubrication Pressures pected if part throttle shift speeds are either very
The lubrication pressure test should be made at delayed or occur too early in relation to vehicle
same time that line pressure and front servo release speeds. In which case, the throttle linkage should be
pressure are tested. adjusted before throttle pressure setting is adjusted.
(1) Install a “tee” fitting between cooler retu rn line
fitting and fitting hole in transmission case at rear HYDRAULIC CONTROL PRESSURE
left side of the transmission (Fig. 9). Connect a 0-100 ADJUSTMENTS
u Line Pressure
An incorrect throttle pressure setting will cause in
.. FILLER TUBE correct line pressure readings even though line pres
KICK DO W N SERVO RELEASE v \ sure adjustm ent is correct. Always inspect and cor
LINE PRESSURE. \ \ rect throttle pressure adjustm ent before adjusting the
IOW-REVERSE St'I?VO ^ line pressure. Before adjusting line pressure, meas
/ \ \ ure distance between manual valve (valve in 1-low
position) and line pressure adjusting screw (Fig. 10).
I syM This measurement must be 1-7/8 inches; correct by
fe te 9
\ n a B loosening spring retainer screws and repositioning
the spring retainer. The regulator valve may cock
and hang up in its bore if spring retainer is out of
position.
If line pressure is not correct, it will be necessary
N R I6 8 A
to remove valve body assembly to perform the ad
justm ent.
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GOVERNOR PRESSURE CHART
(Six Cylinder Engines)
* '
m m
9 %
S 9 9 i
X
■ : '
, -w - , / ■
NN72A
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CAUTION: Compressed air supply must be free of all
^TO O L dirt or moisture. Use a pressure of 30 to 100 psi.
KICKDOWN
VALVE Front Clutch
Apply air pressure to front clutch “apply” passage
and listen for a dull “thud” which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
^ •L O C K
NUT
Rear Clutch
Apply air pressure to rea r clutch “apply” passage
. THROTTLE
LEVER and listen for a dull “thud” which indicates that rear
clutch is operating. Also inspect for excessive oil
'— STOP
! SCREW leaks.
N N73A
NOTE: If a dull "thud" cannot be heard in the clutch,
place finger tips on clutch housing and again apply
Fig. 12—1Throttle Pressure Adjustment air pressure. Movement of piston can be felt as the
clutch is applied.
ment is made with spring fully compressed and valve
bottomed in the valve body. Kickdown Servo
(6) Remove tool and tighten stop screw lock nut Direct air pressure into front servo “apply” pas
securely. sage. Operation of servo is indicated by a tightening
AIR PRESSURE TESTS of front band. Spring tension on servo piston should
release the band.
A "NO DRIVE" condition might exist even with
correct fluid pressure, because of inoperative clutches Low and Reverse Servo
or bands. The inoperative units, clutches, bands and Direct air pressure into rea r servo “apply” passage.
servos can be located through a series of tests by sub Operation of servo is indicated by a tightening of rear
stituting air pressure for fluid pressure (Fig. 13). The band. Spring tension on servo piston should release
front and rear clutches, kickdown servo, and low- the band.
reverse servo may be tested by applying air pressure If clutches and servos operate properly, no up-shift
to their respective passages after the valve body as or erratic shift conditions indicate that malfunctions
j
sembly has been removed. To make air pressure tests, exist in the valve body.
proceed as follows:
G overnor
UN* Pl'r'-JJZ1; r o AtV:;JMULA>0*> FRONT SFRVO APPLY,
Governor operating failures can generally be diag
W0m .... nosed by a road test or hydraulic pressure test. Refer
r'RONT SERVO RELEASE
m
to “Hydraulic Control Pressure Tests”.
SPEEDOMETER PINION
REAK
SERVO i PUMP
i
AP Plv ‘ S U C IiO N Rem oval an d Installation
Rear axle gear ratio and tire size determ ines pinion
hr PUMP gear size requirem ents. Refer to “Speedometer Pinion
PPb’SSUPE C hart” in Specifications for pinion usage.
(1) Remove bolt and retainer securing speedom eter
FRONT CLUTQi
pinion adapter in the extension housing (Fig. 14).
- 4A PPL/
(2) W ith cable housing connected, carefully work
PPAR riUTCH adapter and pinion out of the extension housing.
APPLY (3) If transmission fluid is found in cable housing,
• ,;«£5* i BsHj replace seal in the adapter (Fig. 15). Start seal and
■ ro .‘opqijc
(,ONV»:l< ff:R retainer ring in the adapter, then push them into
•o o v :<vi U.^" adapter with Tool C-4004 until tool bottoms (Fig. 16).
% FROM rODOUK CAUTION: Before installing pinion and adapter as
ro oovk:,»«o;-:
NDfcA
COi IVFRiLR
i’u coon r
Fig. 13—A ir Pressure Tests
m sembly make sure adapter flange and its mating
area on extension housing are perfectly clean. Dirt
or sand will cause misalignment resulting in speed
ometer pinion gear noise.
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TOOL
\
SEAL
ADA?'T; k
X
N N 74A
I NN361
— 6 O ’CLOCK POSITION
Fig. 14—Speedometer Pinion and A d ap ter—Installed Fig. I 7 —Removing Extension Housing Yoke Seal
(Retainer Remowed fo r View)
(2) Remove the extension housing yoke seal (Fig.
RETAINER 17) with Tool C-3994 or C-3985.
ADAPTER
(3) To install a new seal, position seal in opening of
, / »0 « R1No . extension housing and drive it into the housing with
PINION Tool C-3995 or C-3972 (Fig. 18).
(4) Carefully guide front universal joint yoke into
extension housing and on the m ainshaft splines. Align
.WASHER J .OIL SEAL
m arks made at removal and connect propeller shaft
RETAINEi to rea r axle pinion shaft yoke.
RING
NN362
EXTENSION HOUSING AND OUTPUT
Fig. 15—Speedometer Drive
SHAFT BEARING
(4) Note num ber of gear teeth and install speed
om eter pinion gear into adapter (Fig. 15). R em oval
(5) Rotate the speedom eter pinion gear and adapter (1) Mark parts for reassembly then disconnect pro
assembly so th at the num ber on the adapter, cor peller shaft at rear universal joint. Carefully pull shaft
responding to the num ber of teeth on the gear, is in assembly out of the extension housing.
the 6 o’clock position as the assembly is installed (2) Remove speedom eter pinion and adapter as
(Fig. 14). sembly (Fig. 14). Drain approximately two quarts of
(6) Install retainer and bolt, with retainer tangs in fluid from the transmission.
adapter positioning slots. Tap adapter firmly into the (3) Remove bolts securing extension housing to the
extension housing and tighten retainer bolt to 100 crossmember. Raise transm ission slightly with service
inch-pounds. jack Tool C-3203A, then remove center crossmember
and support assembly.
EXTENSION HOUSING YOKE SEAL (4) Remove extension housing to transm ission
bolts.
Replacement
(1) Mark parts for reassembly then disconnect pro Console Shift: Remove two bolts securing gearshift
peller shaft at rear universal joint. Carefully pull shaft torque shaft lower bracket to extension housing.
yoke out of the transmission extension housing. Swing bracket out of way for extension housing
CAUTION: Be careful not to scratch or nick ground removal.
surface on sliding spline yoke during removal and IMPORTANT: In removing or installing extension
installation of the shaft assembly. housing (step 5), the gearshift lever must be in "I"
ADAPTER LOCK RING (low) position. This positions parking lock control rod
TOOL
NN125
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rearward so it can be disengaged or engaged with the BEARING SNAP RING FRONT SNAP
parking lock sprag. GRO O VE RING
-g f a - r
t.
? .'4
•>
SNAP RING
'S N A P RING m
j NN76 LOCK STRAPS NN77
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Fig. 22—Governor Assembly Fig. 2 3 —P arking Lock Components
(5) Remove snap ring from behind governor body, the parking sprag and spring (Fig. 23). Remove snap
then slide governor and support assembly off the out ring and slide the reaction plug and pin assembly
put shaft. If necessary remove the four bolts and out of the housing.
separate governor body from the support. (4) To replace the parking lock control rod, refer to
“Valve Body—Removal and Installation.”
Cleaning a n d Inspection
The prim ary cause of governor operating failure is Installatio n
due to a sticking governor valve or weights. Rough (1) Position sprag and spring in the housing and
surfaces may be removed with crocus cloth. Thor insert the shaft (Fig. 23). Make sure square lug on
oughly clean all parts in clean solvent and inspect for sprag is toward parking gear, and spring is positioned
free movement before assembly. so it moves sprag away from the gear.
(2) Install reaction plug and pin assembly in the
Installation housing and secure with snap ring.
(1) Assemble governor body to the support (if dis (3) Install extension housing.
assembled) and tighten bolts finger tight. Make sure
oil passage of governor body aligns with passage in
VALVE BODY ASSEMBLY AND
the support.
ACCUMULATOR PISTON
(2) Position support and governor assembly on the
output shaft. Align assembly so valve shaft hole in
R em oval
governor body aligns with hole in the output shaft, (1) Raise vehicle on a hoist.
then slide assembly into place. Install snap ring be (2) Loosen oil pan bolts, tap the pan to break it
hind governor body (Fig. 21). Tighten the body to loose allowing fluid to drain, then remove oil pan.
support bolts to 100 inch-pounds. Bend ends of lock (3) Disconnect throttle and gearshift linkage from
straps over bolt heads. levers on the transmission. Loosen clamp bolts and re
(3) Assemble governor weights and spring, and move the levers.
secure with snap ring inside of large governor weight. (4) Remove E-clip (Fig. 24), securing parking lock
Place ,weight assembly in governor body and install rod to the valve body manual lever.
snap ring. (5) Remove Back-Up Light and N eutral Start Switch.
(4) Place governor valve on the valve shaft, insert (6) Place a drain pan under transmission, then re
assembly into the body and through governor weights. move the ten hex-head valve body to transmission
Install valve shaft retaining snap ring. Inspect valve case bolts. Hold valve body in position while removing
and weight assembly for free movement after installa the bolts.
tion. (7) While lowering valve body down out of trans
(5) Install output shaft bearing and extension hous mission case, disconnect parking lock rod from the
ing. lever.
To remove parking lock rod, pull it forw ard out of
PARKING LOCK COMPONENTS
the case. If necessary, rotate propeller shaft to align
Rem oval parking gear and sprag to perm it knob on end of
(1) Remove extension housing. control rod to pass the sprag.
(2) To replace the governor support and parking (8) W ithdraw accumulator piston from the trans
gear, refer to “Governor and Support”. mission case. Inspect piston for scoring, and rings for
(3) Slide shaft out of extension housing to remove wear or breakage. Replace as required.
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parking lock rod to m anual lever and secure with
E-clip. Position valve body in the case, install retain
ing bolts finger tight.
(5) W ith neutral starting switch installed, place
m anual lever in the n eu tral position. Shift valve body
if necessary to center neutral finger over the n eu tral
switch plunger. Snug bolts down evenly, then tighten
' t to 100 inch-pounds.
E-CUP-.. (6) Install gearshift lever and tighten clamp bolt.
Check lever shaft for binding in the case by moving
lever through all detent positions. If binding exists,
loosen valve body bolts and re-align.
(7) Make sure throttle shaft seal is in place, then
install flat washer, lever and tighten the clamp bolt.
Connect throttle and gearshift linkage and adjust as
required.
PARKING ;G C V (8) Install oil pan, using a new gasket. Add trans
CONTROL ?.OD /'
3 a C ;<-IP l ig h t a n d mission fluid to bring it up to proper level.
N U 452 H-JTKAL STARTING SWITCH
Fig. 2 4 —Parking Lock Control Rod Retaining E-Clip SERVICE OUT OF VEHICLE
(9) If valve body m anual lever shaft seal requires
replacem ent, drive if out of the case with a punch. TRANSMISSION AND CONVERTER REMOVAL
(10) Drive a new seal in the case with a 15/16 inch The transmission and converter must be removed
socket and ham m er (Fig. 25). as an assembly; otherwise, the converter drive plate,
Servicing the valve body assembly is outlined under pump bushing, and oil seal will be damaged. The
"Recondition— Sub-assemblies". drive plate will not support a load; therefore, none of
the weight of the transmission should be allowed to
installation rest on the plate during removal.
(1) Make sure Back-Up Light and N eutral Start
(1) Connect a rem ote control starter switch, Tool
Switch has been removed. If parking lock rod was re
C-763 to starter solenoid and position switch so engine
moved, insert it through opening in re a r of case with
can be rotated from under the vehicle.
knob positioned against the plug and sprag. Move
(2) Disconnect high tension wire from the distribu
front end of rod toward center of transmission while
tor cap.
exerting rearw ard pressure on the rod to force it past
(3) Remove cover plate from in front of converter
the sprag. (Rotate propeller shaft if necessary).
to provide access to the converter drain plug and
(2) Install accum ulator piston in the transm ission
mounting bolts.
case.
(4) Rotate engine with rem ote control switch to
(3) Position accum ulator spring on the valve body.
bring the drain plug to “6 o’clock” position. Drain
(4) Place valve body m anual lever in LOW position.
torque converter and transmission.
Lift valve body into its approxim ate position, connect
(5) Mark converter and drive plate to aid in reas
sembly. The crankshaft flange bolt circle, inner and
outer circle of holes in drive plate, and four tapped
holes in front face of converter all have one hole
J5/'6“ SOCX5T offset so these parts will be installed in original posi
tion. This m aintains the balance of engine and con
verter.
(6) Rotate engine with rem ote control switch to lo
cate two converter to drive plate bolts at “5 and 7
o’clock” positions. Remove the two bolts, rotate en
gine with switch and remove the other two bolts. Do
not rotate converter or drive plate by prying with a
screw driver or similar tool as the drive plate might
become distorted. Also, starter should never be en
gaged if drive plate is not attached to converter with
at least one bolt or if transmission case to engine bolts
have been loosened.
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(7) Disconnect negative (ground) cable from the assembly out of the transmission.
battery.
(8) Remove the starting m otor assembly. STARTER RING GEAR REPLACEMENT
(9) Disconnect wire from the neutral starting
switch. The starter ring gear is mounted directly on outer
(10) Disconnect gearshift rod from the transm is diam eter of the torque converter front cover. With
sion lever. Remove the gearshift torque shaft from torque converter removed from vehicle, replacem ent
transmission housing and left side rail. of the gear is as follows:
Console Shift: Remove two bolts securing gearshift
torque shaft lower bracket to the extension housing. Rem oval
Swing bracket out of way for transm ission removal. (1) Cut through weld m aterial at re a r side of ring
Disconnect gearshift rod from the transm ission lever. gear with a hack saw or grinding wheel (Fig. 27). Be
(11) Disconnect throttle rod from throttle lever on careful not to cut or grind into front cover stamping.
the transmission. (2) Scribe a heavy line on front cover next to front
(12) Disconnect oil cooler lines at transm ission and face of ring gear to aid in locating the new gear.
remove oil filler tube. Disconnect the speedom eter (3) Support converter with the four lug faces rest
cable. ing on block of wood. The converter must not rest on
(13) Mark parts for reassembly then disconnect pro the front cover hub during this operation. Using a
peller shaft at rear universal joint. Carefully pull shaft blunt chisel or drift and hammer, tap downward on
assembly out of the extension housing. ring gear near welded areas to break any rem aining
(14) Remove rea r m ount to extension housing bolts. weld m aterial (Fig. 27). Tap around ring gear until it
(15) Install engine support fixture, Tool C-3487-A comes off the converter.
and raise the engine slightly (Fig. 26). (4) Smooth off weld areas on the cover with a file.
(16) Some models have exhaust systems which will
have to be partially removed for clearance. See Ex Installation
haust Systems, Section 11. Any of the following m ethods may be used to heat
(17) Remove crossmember attaching bolts and re and expand starter ring gear for installation on the
move the crossmember. converter:
(18) Place a transmission service jack under Oven: Place ring gear in Oven and set tem perature
transmission to support the assembly. at 200 degrees F. Allow ring gear to rem ain in oven
(19) Attach a small “C” clamp to edge of bell hous for 15 to 20 minutes.
ing to hold converter in place during rem oval of the Boiling Water: Place ring gear in a shallow con
transmission. tainer, add water, and heat for approximately eight
(20) Remove the bell housing retaining bolts. Care minutes after w ater has come to a boil.
fully work transm ission rearw ard off engine block Steam: Place ring gear on a flat surface and direct
dowels and disengage converter hub from end of the a steam flow around gear for approximately two
crankshaft. minutes.
(21) Lower transmission jack and remove trans Flame: Place ring gear squarely on a flat surface.
mission and converter assembly.
(22) To remove converter assembly, remove “C”
clamp from edge of bell housing, then carefully slide
- sr«.
.* r,
k m
>*• WOOD
.-Jft b lo c k s
TRANSMISSIO N
JACK
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Using a medium size tip, direct a slow flame evenly This tool adapts a drill motor to an input shaft to
around inner rim of the gear. Do not apply flame to spin the turbine and includes a draw ing for a simple
the gear teeth. Place a few drops of w ater on face of wooden fixture to hold the converter. This fixture
gear at intervals during heating process. W hen gear is will hold the converter upright fo r the spinning and
hot enough to just boil the water, installation of gear draining operations.
on the torque converter can be made. (4) Repeat flushing operation a t least once, or as
(1) A fter ring gear is expanded by heating, place many times as required until solvent or kerosene
the gear in position on converter front cover. Tap drained out is clear.
gear on the cover evenly with a plastic or rawhide (5) A fter flushing, shake and rotate converter sev
mallet until face of gear is even with scribed line eral times with drain plug out to rem ove any residual
(made during removal) on the front cover. Make sure solvent and dirt. Flush any remaining solvent from
gear is even with scribed line around full circum converter with two quarts of new transmission fluid.
ference of the front cover. This will prevent any adverse effect the solvent may
(2) Reweld ring gear to torque converter front have on the transmission seals. Reinstall drain plug
cover, being careful to place, as nearly as possible, and tighten to 110 inch-pounds.
same amount of weld m aterial in exactly same loca (6) Flush and blow out the oil cooler and its lines.
tion as was used in original weld. This is necessary in
order to m aintain proper balance of the unit. Place MACHINE FLUSHING
welds alternately on opposite sides of converter to
minimize distortion. Machine cleaning is recommended; using the type
(3) The following suggestions are offered as an aid which rotates the converter while pumping cleaning
in making the weld: fluid through it. The machine automatically adds
a. Do not gas weld. timed blasts of compressed air to the cleaning fluid
b. Use a D.C. welder that is set at straight polarity as it enters the converter, providing more thorough
or an A.C. welder if the proper electrode is available. cleaning than the hand flushing operation.
c. Use a 1/8 inch diam eter welding rod, and a weld
ing current of 80 to 125 amps. PUMP OIL SEAL
d. Direct the arc at intersection of the gear and
front cover from an angle of 45 degrees from rear Replacement
face of the gear. The pump oil seal can be replaced without remov
(4) Inspect gear teeth and remove all nicks where ing pump and reaction shaft support assembly from
m etal is raised, weld m etal splatter, etc., in order to the transmission case. The vent shield shown in (Figs.
ensure quiet starter operation. 28 and 29) is not used or required on the A-904
pumps.
TORQUE CONVERTER FLUSHING (1) A-904: Screw seal rem over Tool C-3981 into
seal (Fig. 28), then tighten screw portion of tool to
When a transmission failure has contam inated the withdraw the seal.
fluid, the torque converter should be flushed to insure A-727: Using Tool C-3861, remove seal in the same
that metal particles or sludged oil are not later trans m anner.
ferred back into the reconditioned transmission.
V 0
HAND FLUSHING
(1) Place converter in horizontal position and pour
two quarts of new clean solvent or kerosene into con
verter through the impeller hub.
(2) Turn and shake converter so as to swirl solvent
through the internal parts. Turn the turbine and stator
with transmission input and reaction shafts to dis
lodge foreign material.
IQ IP
(3) Position converter in its normal operating posi
TOOL
tion with drain plug at the lowest point. Remove drain
plug and drain solvent. Rotate turbine and stator, and
shake converter while draining to prevent d irt par
ticles from settling. Tool C-3963-A is available to do
this job faster and more effectively.
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(2) A-904: To install a new seal, place seal in open
✓ TRANSMISSIO N
ing of the pump housing (lip side facing inward).
Using Tool C-3757, drive seal into housing until tool
bottoms (Fig. 29).
A-727: Using Tool C-3860, install new seal in the
same manner.
O il Pan
(1) Place transmission assembly in repair stand,
Tool C-3750-A, for 6 cyl. engines.
P* • ‘ MD184A
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(2) Remove extension housing to transm ission
bolts.
(3) Remove two screws, plate and gasket from bot
tom of extension housing m ounting pad. Spread large
2 -3 /4 " snap ring from output shaft bearing with Tool C-
DRILL 7 /1 6 " HOLES
(5 PLACES) 3301A (Fig. 19). W ith snap ring spread as far as pos
sible, carefully tap extension housing off the output
shaft and bearing.
(4) Using heavy duty snap ring pliers C-4020, re
move output shaft bearing re a r snap ring. Remove
bearing from shaft, then remove front snap ring.
Fig. 32—Repair Stand B rack et Dimensions O il Pump and Reaction Shaft Support
(1) Tighten front band adjusting screw until band
(3) Remove the ten hex-head valve body to trans
is tight on front clutch retainer. This prevents clutch
mission bolts. Remove E-clip securing parking lock
retainer from coming out with pump which might
rod to the valve body manual lever (Fig. 24).
cause unnecessary damage to the clutches.
(4) While lifting valve body upward out of trans
(2) Remove oil pump housing retaining bolts.
mission case, disconnect parking lock rod from the
(3) Attach Tool C-3752 to pum p housing flange,
lever.
(Fig. 34), in threaded holes in the flange.
Accumulator Piston a n d Spring (4) Bump outward evenly on the two “knocker
(1) Lift spring off accum ulator piston and withdraw weights” to withdraw pump and reaction shaft sup
piston from the case. port assembly from the case.
Extension Housing
Before removing extension housing, pull parking Front Band and Front Clutch
lock rod forw ard out of the case. Rotate output (1) Loosen front band adjuster, remove band stru t
shaft if necessary to align parking gear and sprag and slide band out of the case.
to perm it knob on end of control rod to pass the TRANSMISSION VENT
sprag.
(1) Remove speedom eter pinion and adapter assem
bly.
w B m W H I
TOOL
ND19
r
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(2) Slide front clutch assembly out of the case.
ing screw then remove band and low-reverse drum. Fig. 3 5 —Compressing Kickdown Servo Spring
placem ent for most all bushings in the TorqueFlite
O verrunning Clutch
(1) Note position of overrunning clutch rollers and transmission. The two bushings in sun gear are not
spring before disassembly to assist in reassembly. serviced because of the low cost of sun gear assembly.
(2) Carefully slide out clutch hub and remove If bushings are found worn or scored, they should be
rollers and springs, if the overrunning clutch cam replaced as outlined in the following reconditioning
and/or roller spring retainer are found damaged or procedures.
worn, refer to INDEX for replacement procedures. The bushing replacement tools listed by "SP"
numbers are part of Tool Kit C-3887-A.
Kickdown Servo The use of crocus cloth is permissible where neces
(1) Compress kickdown servo spring by using en sary, providing it is used carefully. When used on
gine valve spring compressor, Tool C-3422, then re valves, use extrem e care to avoid rounding off the
move snap ring (Fig. 35). sharp edges. The sharp edge is vitally im portant to
(2) Remove rod guide, springs and piston rod from this type of valve. Sharp edges prevent dirt and
the case. Be careful not to damage piston rod or guide foreign m atter from getting between the valve and
during removal. body, thus reducing possibility of sticking. When
(3) W ithdraw piston from the transmission case. it becomes necessary to recondition transmission, and
vehicle has accumulated considerable mileage, install
Low and Reverse Servo new seal rings on parts requiring their usage. Coat
(1) Compress low and reverse servo piston spring each part with Automatic Transmission Fluid AQ-
by using engine valve spring compressor, Tool C-3422, ATF Suffix "A" or (Dexron) during assembly.
then rem ove the snap ring.
(2) Remove spring retainer, spring, and servo pis VALVE BODY ASSEMBLY
ton and plug assembly from the case.
CAUTION: Never clamp any portion of valve body or
RECONDITION SUB-ASSEMBLIES transfer plate in a vise. Any slight distortion of the
aluminum body or transfer plate will result in stick
The following procedures cover disassembly, in ing valves, excessive leakage or both. When removing
spection, repair, and assembly of each sub-assembly or installing valves or plugs, slide them in or out care
as rem oved from the transmission. fully. Do not use force.
Heli-Coil inserts are recom mended for repairing Rework valve body repair stand, Tool C-3749 by
damaged, stripped or worn threads in alum inum drilling the 5/16 inch diam eter hole to 7/8, and 3 /4
parts. inch deep (Fig. 36). The stand can then be used with
Pre-sized service bushings are available for re- either the old or new type valve bodies.
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SPRING RETAINER
• 7 /8 " DIA.
SCREWS
REGULATOR
VALVE
SPRING
T.C
CONTROL
VALVE
SPRING
V ' ONE
PRESSURE
NN79 THROTTLE
ADJUSTMENT
LEVER A .S ?
S K A -7 ^ MANUAL
Fig. 3 6 —R e w o r k Valve Body Repair Stand
LEVER ASSY.
THROTTLE i t r S
STOP SCREW REPAIR STANO N N 80A
Disassembly
(1) Place valve body assembly on repair stand, Tool Fig. 3 7 —V a l v e Body and Control Assembly
C-3749, (Fig. 37). Remove three screws from fluid separator plate to tran sfer plate, and carefully lift off
filter and lift off the filter.
separator plate (Fig. 38).
(2) While holding spring retainer firmly against the (7) Remove and note location of 7 steel balls and 1
spring force, remove the three bracket retaining spring in valve body (Fig. 39). CAUTION: Do Not mix
screws (Fig. 37).
up the two larger balls. The 3 /8 inch diam eter ball
(3) Remove spring retainer, torque converter con goes on the spring in the corner and is the high pres
trol valve spring, and regulator valve spring with line
sure relief valve. The 5/16 diam eter ball in the large
pressure adjusting screw assembly. Do not alter
chamber is the front clutch ball check.
setting of line pressure adjusting screw and nut. The
(8) Invert valve body and lay it on a clean cloth or
nut has an interference thread and does not turn
easily on the screw. paper. Remove E-clip and washer from throttle lever
(4) Slide regulator valve out of valve body. Slide shaft (Fig. 40). Remove any burrs from shaft, then
torque converter control valve out of valve body. while holding m anual lever detent ball and spring in
(5) Remove the transfer plate retaining screws. their bore with Tool C-3765 or sim ilar tool, slide
Carefully lift tran sfer plate and steel separator plate manual lever off the throttle shaft. Remove the detent
assembly off the valve body. ball and spring.
(6) Invert transfer plate assembly and remove the (9) Remove m anual valve, carefully slide it out of
stiflener plate. Remove rem aining screws securing valve body with a rotating motion.
TRANSFER .STIFFENER
PLATE PLATE
SEPARATOR
iiH ► PLATE
■ip
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5 /1 6" DIA. BALL' **
(5) SMALLER^ STEEL BALLS
P m
N U 367,
TORQUE CONVERTER
CONTROL VALVE
SHUTTLE VALVE
E-CLIP
THROTTLE VALVE
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REGULATOR VALVE REGULATOR VALVE THROTTLE
lato r valve line pressure plug, sleeve, and regulator END PLATE PRESSURE PLUG
SLEEVE
valve throttle pressure plug out of valve body.
/
42). Install shift valve end plate and tighten the three
retaining screws to 28 inch-pounds.
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(11) Place six steel balls in valve body chambers TOOL INSTALLING
BUSHING
with large ball in the large chamber (Fig. 39). Install
spring and high pressure relief valve ball (3/8" Dia.).
(12) Position transfer plate assembly on valve body.
\
Install 14 retaining screws, starting at center and
working outward, tighten screws to 35 inch-pounds. u \ ' mov|NG
(13) Install torque converter valve and regulator
valve (Fig. 41). END
(14) Position torque converter valve spring and INSTALLIN cT e ND NU43
regulator valve spring over ends of th eir respective
valves. Place line pressure adjusting screw assembly Fig. 44—Replacing Extension Housing Bushing
on end of regulator valve spring with long dimension PARKING LOCK SPRAG
of nut at right angles to valve body (Fig. 37).
(15) Install spring retainer, making sure converter Disassembly
valve spring is engaged on the tang and position (1) Slide shaft out of extension housing to remove
squarely in retainer. Tighten the three retaining parking sprag and spring (Fig. 23). Remove snap ring
screws to 28 inch-pounds (Fig. 37). and slide reaction plug and pin assembly out of the
Measure and if necessary, align spring retainer as housing.
shown in Fig. 10.
(16) Install oil filter and tighten the three retaining Inspection
screws to 35 inch-pounds. Inspect sprag shaft for scores and free movement
After valve body has been serviced and completely in the housing and sprag. Inspect sprag and control
assembled, adjust throttle and line pressures (Fig. rod springs for distortion and tension. Inspect square
11 and 12). However, if pressures were satisfactory lug on sprag for broken edges, also lugs on parking
prior to disassembly, use original settings. gear for damage. Inspect knob on end of control rod
for nicks, burrs and free turning.
ACCUMULATOR PISTON AND SPRING To replace parking gear, refer to “Governor and
Support—Disassembly and Assembly.”
Inspection
Inspect seal rings for wear and make sure they tu rn Assembly
freely in piston grooves. It is not necessary to remove (1) Install reaction plug and pin assembly in the
rings unless conditions w arrant. Inspect piston for housing and secure with snap ring (Fig. 23).
nicks, burrs, scores and wear. Inspect piston bore in (2) Position sprag and spring in housing and insert
the case for scores or other damage. Inspect piston the shaft. Make sure square lug on sprag is toward
spring for distortion. Replace parts as required. parking gear, and spring is positioned so it moves
sprag away from the gear.
EXTENSION HOUSING BUSHING AND
GOVERNOR AND SUPPORT
OIL SEAL
Disassembly
Replacem ent (1) Remove large snap ring from weight end of
(1) Remove the extension housing yoke seal (Fig. governor body, lift out weight assembly.
17) with Tool C-3994 or C-3985. (2) Remove snap ring from inside governor weight,
(2) A-904: Press or drive out bushing with Tool remove inner weight and spring from outer weight.
C-3996 (Fig. 44). (3) If lugs on support gear are damaged, remove
A-727: Remove bushing in the same m anner with four bolts and separate support from governor body.
Tool C-3974.
(3) A-904: Slide a new bushing on installing end of
Cleaning and Inspection
Tool C-3996. Align oil hole in bushing with oil slot in Figure 22 shows a disassembled view of the gov
the housing, then press or drive bushing into place ernor assembly.
(Fig. 44). Inspect all parts for burrs and wear. Inspect inner
A-727: Using Tool C-3974, install a new bushing in weight for free movement in outer weight, and outer
same m anner. weight for free movement in governor body. Inspect
(4) A-904: Drive a new oil seal into housing with valve for free movement in governor body. The
Tool C-3995 (Fig. 18). weights and valve should fall freely in th e bores when
A-727: Using Tool C-3972, install a new oil seal in clean and dry. Rough surfaces may be removed with
same m anner. crocus cloth.
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REACTION SHAF
SUPPORT
INNER RO TOR
OUTER ROTOR
\
OIL PUMP BO DY
Inspect governor weight spring for distortion. In ance between straight edge and face of rotors. Clear
spect lugs on support gear for broken edges or other ance limits are from .0015 to .003 inch. Also, m easure
damage. Thoroughly clean all governor parts in clean rotor tip clearance between inner and outer rotor
solvent and test for free movement before assembly. teeth. Clearance limits are from .005 to .010 inch.
Clearance between outer rotor and its bore in oil
Assembly pump body should be .004 to .008 inch.
(1) If support was separated from governor body,
assemble and tighten bolts finger tight. Pump Bushing Replacement (A-904)
(2) Assemble governor weights and spring, and se (1) Place pump housing (seal face down) on a
cure with snap ring inside of large governor weight. smooth firm surface.
Place weight assembly in governor body and install (2) Place removing head, Tool SP-3551 in bushing
snap ring. and install handle, Tool SP-3549 in the removing head
(Fig. 46).
OIL PUMP AND REACTION SHAFT SUPPORT— (3) Drive bushing straight down and out of pump
A-904 housing bore. Be careful not to cock tool in the bore.
(4) Position new bushing on installing head, Tool
Disassembly SP-5117.
Figure 45 shows the oil pump and reaction shaft
support disassembled. TOOL HANDLE SP-3549 REMOVAL
(1) Remove bolts from rear side of reaction shaft
support and lift support off the pump. REMOVING HEAD
(2) Remove rubber seal ring from pump body SP-3551
flange. FRONT PUMP HOUSING
Inspection
Inspect interlocking seal rings (Fig. 45) on reaction
shaft support for wear or broken locks, make sure
they tu rn freely in the grooves. Do not remove rings TOOL HANDLE SP-3549
unless conditions w arrant. Inspect front clutch piston
retainer to reaction shaft support thrust washer for
wear. W asher thickness should be .043 to .045 inch, INSTALLATION
replace if necessary. Inspect machined surfaces on
pum p body and reaction shaft support for nicks and
burrs. Inspect pump body and reaction shaft support
bushings for wear or scores. Inspect pump rotors for
scoring or pitting. W ith rotors cleaned and installed in
pump body, place a straight edge across face of rotors
and pum p body. Use a feeler gauge to m easure clear
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(5) W ith pum p housing on a smooth clean surface, HEX N U T
TOOL HANDLE
SP-1191
start bushing and installing head in the bushing bore. SP-3549
Install handle, Tool SP-3549 in the installing head
(Fig. 46).
(6) Drive bushing into housing until tool bottoms in
the pum p cavity. Be careful not to cock tool during REMOVER
SP-5324
installation.
(7) Stake bushing in place by using a blunt punch INSTALLING
HEAD SP-5325
or similar tool (Fig. 47). A gentle tap at each stake slot
location will suffice.
(8) Using a narrow-bladed knife or sim ilar tool,
remove high points or burrs around staked area (Fig.
47). Do not use a file or sim ilar tool that will remove
more m etal than is necessary. ND 345A
Reaction S haft Bushing Replacement (A-904) Fig. 4 8 —Replacing Reaction Shaft Bushing (A-904)
In case of a reaction shaft bushing failure, always
installing head. Drive bushing into the shaft until tool
inspect the support for wear from the input shaft seal
bottoms.
ring lands. If worn or grooved, replace support
(8) Thoroughly clean reaction shaft support assem
assembly.
bly before installation.
(1) Assemble rem over Tool SP-5324, cup Tool SP-
3633, and hex nut Tool SP-1191 (Fig. 48).
CAUTION: Do not clamp any part of reaction shaft or Assembly
support in a vise. (1) Place reaction shaft support in assembling Tool
(2) W ith cup held firmly against reaction shaft, C-3759, with hub of support and tool resting on a
thread rem over into bushing as far as possible by smooth flat surface bench (Fig. 49). Screw two pilot
hand. studs, Tool C-3283 into threaded holes of reaction
(3) Using a wrench, screw rem over into bushing 3 shaft support flange.
to 4 additional turns to firmly engage threads in the (2) Assemble and place rotors in center of the sup
bushing. port (Fig. 49).
(4) Turn hex nut down against cup to pull bushing (3) Lower pump body over the pilot studs, insert
from reaction shaft. Thoroughly clean reaction shaft Tool C-3756 through pump body and engage pump
to remove chips made by rem over threads. inner rotor. Rotate the rotors with tool to enter rotors
(5) Lightly grip bushing in a vise or with pliers and in pump body, then with pump body firm against
back tool out of the bushing. Be careful not to damage reaction shaft support, tighten clamping tool securely.
threads on bushing remover. (4) Invert pump and reaction shaft support assem
(6) Slide a new bushing on installing head Tool bly with clamping tool intact. Install support to pump
SP-5325, and sta rt them in the bore of reaction shaft body bolts and tighten to 160 inch-pounds. Remove
(Fig. 48). clamping tool, pilot studs and rotor alignm ent tool.
(7) Support reaction shaft upright on a clean ALIG N IN G TOOL
smooth surface and install handle Tool SP-3549 in -a
m . - ... p»-
PUMP
BODY PILOT
STUDS(2)
REACTION
SHAFT
SUPPORT
* W > ’ « Z ^ n 5344A
Fig . 4 9 —Assembling Pump &nd Memtion Sh&ft
Support (A-904)
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(5) Place a new oil seal in opening of pump housing inch. Clearance between outer rotor and its bore in
(lip of seal facing inward). Using Tool C-3757, drive oil pum p body should be .004 to .008 inch.
seal into housing until tool bottoms.
Pump Bushing Replacem ent (A-727)
OIL PUMP AND REACTION SHAFT SUPPORT— (1) Place pump housing on a clean smooth surface
A-727 with rotor cavity down.
(2) Place rem oving head Tool SP-3550 in the bush
Disassembly ing, and install handle Tool SP-3549 in the removing
Figure 50 shows the oil pump and reaction shaft head (Fig. 51).
support disassembled. (3) Drive bushing straight down and out of the
(1) Remove bolts from rear side of reaction shaft bore. Be careful not to cock tool in the bore.
support, and remove vent baffle and lift support off (4) Position a new bushing on installing head Tool
the pump. SP-5118.
(2) Remove rubber seal ring from pump body (5) W ith pump housing on a smooth clean surface
flange. (hub end down), sta rt bushing and installing head in
(3) Drive out oil seal with a blunt punch. the bushing bore. Install handle Tool SP-3549 in in
stalling head (Fig. 51).
Inspection (6) Drive bushing into housing until tool bottoms in
Inspect interlocking seal rings (Fig. 50) on reaction the pump cavity. Be careful not to cock tool during
shaft support for wear or broken locks, make sure installation.
they turn freely in the grooves. Do not remove rings (7) Stake the bushing in place by using a blunt
unless conditions w arrant. Inspect machined surfaces punch or sim ilar tool (Fig. 52). A gentle tap at each
on pump body and reaction shaft support for nicks stake slot location will suffice.
and burrs. Inspect pump body and reaction shaft sup (8) Using a narrow-bladed knife or sim ilar tool, re
port bushings for w ear or scores. Inspect pump rotors move high points or burrs around staked area (Fig.
for scoring or pitting. W ith rotors cleaned and in 52). Do not use a file or similar tool that will remove
stalled in pump body, place a straight edge across more m etal than is necessary.
face of rotors and pump body. Use a feeler gauge to (9) Thoroughly clean pum p housing before installa
m easure clearance between straight edge and face of tion.
rotors. Clearance limits are from .0015 to .003 inch.
Also, m easure rotor tip clearance between inner and Reaction Shaft Bushing Replacement (A-727)
outer teeth. Clearance limits are from .005 to .010 (1) Assemble rem over Tool SP-5301, cup Tool SP-
GASKET
VENT BAFFLE"
‘V A
SEAL RINGS
REACTION
SHAFT SUPPO RT-*
* * * * ;;
OUTER ROTOR
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Fig. 5 3 —Replacing Reaction Shaft Bushing (A-727)
bore of reaction shaft (Fig. 53).
(7) Support reaction shaft upright on a clean
Fig. 5 1 —Replacing Pump Bushing (A-727) smooth surface and install handle Tool SP-3549 in
3633, and hex nut Tool SP-1191 (Fig. 53). installing head. Drive bushing into shaft until tool
CAUTION: Do not clamp any part of reaction shaft or bottoms.
support in a vise. (8) Thoroughly clean reaction shaft support assem
(2) W ith cup held firmly against reaction shaft, bly before installation.
thread rem over into bushing as fa r as possible by
hand. Assembly
(3) Use a wrench to screw rem over into bushing 3 (1) Assemble pump rotors in the pump housing
to 4 additional turns to firmly engage threads in the (Fig. 50).
bushing. (2) Install reaction shaft support and position vent
(4) Turn hex nut down against the cup to pull baffle over vent opening. Install retaining bolts and
bushing from reaction shaft. Thoroughly clean reac tighten to 160 inch-pounds.
(3) Place a new oil seal in opening of pump housing
tion shaft to remove chips made by removing threads.
(lip of seal facing inward) using Tool C-3860 drive seal
(5) Lightly grip bushing in a vise or with pliers and
into housing until tool bottoms.
back tool out of the bushing. Be careful not to damage
threads on bushing remover.
FRONT CLUTCH—A-904
(6) Slide a new bushing (chamfered end first) on
installing head Tool SP-5302, and start them in the Disassembly
K T iA R R O w 'B L A D E ^ Figure 54 shows a disassembled view of the front
clutch assembly.
(1) Remove large selective snap ring th at secures
pressure plate in the clutch piston retainer. Lift
pressure plate and clutch plates out of the retainer.
(2) Install compressor, Tool C-3575 over piston
spring retainer (Fig. 55). Compress spring and remove
snap ring, then slowly release tool until spring re
tainer is free of the hub. Remove tool, retainer and
spring.
(3) Invert clutch retainer assembly and bump it on
a wood block to remove the piston. Remove seal rings
from the piston and clutch retainer hub.
Inspection
Inspect facing m aterial on all driving discs. Replace
discs that are charred, glazed or heavily pitted. Discs
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PISTON SEAL RING (INNER)
DRIVING DISCS
SPRING
PRESSURE PLATE
SNAP RING
(SELECTIVE)
1
PISTON RETAINER
ASSEMBLY PISTON
CLUTCH PLATES
I
piston spring, retainer and snap ring for distortion.
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TO O L HANDLE SP-3549 TO OL HANDLE FEELER
SP-3549 - GAUGE
\ INSTALLING
HEAD
SP-3626
FRONT
CLUTCH
RETAINER
DRIVING DISCS
PRESSURE PLATE
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TOOL
ND350A
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NP144
Fig. 6 1 —Front Clutch Piston Return Spring Location Fig. 6 3 —Front Clutch Piston Return Spring Location
(12 Springs) (8 Springs)
ing of wax type lubricant or Door Ease to outer edge and are available in .060-.062, .074-.076 and .088-.090
of seals for easier installation of piston assembly. inch thickness.
Place piston assembly in retainer and carefully seat
piston in bottom of retainer. REAR CLUTCH— A-904
(3) Refer to “Front Clutch Chart” and install
springs on piston exactly as shown in Figures 61, 62, Disassembly
63 or 64. Position spring retainer and snap ring over Figure 65 shows a disassembled view of the rear
the springs. Compress springs with Tool C-3863 (Fig. clutch assembly.
59), and seat snap ring in hub groove. Remove com (1) Remove large selective snap ring that secures
pressure plate in clutch piston retainer. Lift pressure
pressor tool.
plate, clutch plates, and inner pressure plate out of
(4) Lubricate all clutch plates, install one steel
the retainer.
plate followed by a lined plate (disc) until the num (2) Carefully pry one end of wave spring out of its
ber given in the chart is installed. Install pressure groove in clutch retainer, then remove wave spring,
plate and snap ring. Make sure snap ring is properly spacer ring and clutch piston spring.
seated. (3) Invert clutch piston retainer assembly and
(5) W ith front clutch completely assembled, push bump it on a wood block to remove piston. Remove
downward on pressure plate and insert a feeler gauge seals from piston.
between pressure plate and snap ring (Fig. 57). The (4) If necessary, remove snap ring and press input
clearance should be within lim its given in the chart. shaft from piston retainer.
If not, install a snap ring of proper thickness to ob
tain specified clearance. Inspection
Snap rings are the same as those used in rear clutch Inspect facing m aterial on all driving discs. Replace
NU462
NP143
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PISTON SEAL RING DRIVING DISCS SNAP RING
(OUTER) (SELECTIVE)
WAVE SPRING
SPACER RING
LARGE
SEAL RING PISTON
SMALL
SEAL RING
\ \
I ■
INPUT Sr.ArT
/
THRUST WASHER SHAP RING
' ON
■ : |G PRESSURE PLATE
PRESSURE
PLATE
PISTON SEAL RING
(INNER) O/JTCH PLATES NN86A
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SELECTIVE clutch assembly.
SNAP RING (1) Remove large selective snap ring that secures
'I h * pressure plate in clutch retainer. Lift pressure plate,
clutch plates, and inner pressure plate out of the re
tainer.
(2) Carefully pry one end of wave spring out of its
groove in clutch retainer, then remove wave spring,
spacer ring and clutch piston spring.
(3) Invert clutch piston retainer assembly and
bump it on a wood block to remove piston. Remove
seals from the piston.
(4) If necessary, remove snap ring and press input
shaft from clutch piston retainer.
Inspection
Inspect facing m aterial on all driving discs. Replace
discs that are charred, glazed or heavily pitted. Discs
should also be replaced if they show evidence of ma
FEEIER terial flaking off or if facing m aterial can be scraped
GAUGE
off easily. Inspect driving disc splines for wear or
'W -" ' other damage. Inspect steel plate and pressure plate
ND3
surfaces for burning, scoring or damaged driving lugs.
Fig. 6 7 —M easuring Rear Clutch Plate Clearance Replace if necessary.
ance is very important in obtaining proper clutch Inspect steel plate lug grooves in clutch retainer for
operation. Clearance can be adjusted by the use of smooth surfaces, plates m ust travel freely in the
various thickness outer snap rings. Snap rings are grooves. Note ball check in the piston, make sure ball
available in .060-.062, .068-.070 and .076-.078 inch moves freely. Inspect seal surfaces in clutch retainer
thickness. for nicks or deep scratches, light scratches will not
interfere with sealing of neoprene seals. Inspect neo
REAR CLUTCH— A-727 prene seals for deterioration, wear, and hardness. In
Disassembly spect piston spring, wave spring, and spacer for
Figure 68 shows a disassembled view of the rear distortion or breakage.
SNAP RING
(SELECTIVE)
DRIVING
PRESSURE DISCS L
PISTON SPRING PLATE
PISTON RETAINER
CLUTCH RETAINER
PRESSURE
PLATE
SEAL RINGS i l l CLUTCH
PLATES
" ^ ,
f - . *& ■ , ? \ SPACER RING
* . y
WSm x - J k
PISTON SEAL
¥ SNAP RING
(OUTER)
THRUST
WASHER
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Inspect interlocking seal rings (Fig. 68) on input (2) Lubricate and install inner and outer seal rings
shaft for wear or broken locks, make sure they turn on clutch piston. Make sure lip of seals face toward
freely in the grooves. Do not remove rings unless head of clutch retainer, and are properly seated in
conditions w arrant. Inspect bushing in input shaft for piston grooves (Fig. 68).
wear or scores. Inspect re a r clutch to front clutch (3) Place piston assembly in retainer and, with a
thrust washer for wear. W asher thickness should be twisting motion, seat piston in bottom of the retainer.
.061 to .063 inch, replace if necessary. (4) Position clutch retainer over piston retainer
splines and support the assembly so clutch retainer
Input Shaft Bushing Replacement (A-727 rem ains in place.
only) (5) Place clutch piston spring and spacer ring on
(1) Clamp input shaft in a vise with soft jaws, being top of piston in clutch retainer, make sure spring and
careful not to clamp on seal ring lands or bearing spacer ring are positioned in the retainer recess. Start
journals. one end of wave spring in retainer groove (Fig. 66),
(2) Assemble rem over Tool SP-3630, cup Tool SP- then progressively push or tap spring into place mak
3633, and hex nut Tool SP-1191 (Fig. 69). ing sure it is fully seated in the groove.
(3) With cup held firmly against clutch piston re (6) Install inner pressure plate in clutch retainer
tainer, thread rem over into bushing as far as possible with raised portion of plate resting on the spring.
by hand. (7) Lubricate all clutch plates, install one lined
(4) Using a wrench, screw rem over into bushing 3 plate followed by a steel plate until all plates are
to 4 additional turns to firmly engage threads in the installed. Install outer pressure plate and selective
bushing. snap ring.
(5) Turn hex nut down against cup to pull bushing (8) Measure rear clutch plate clearance by having
from input shaft. an assistant press downward firmly on outer pressure
(6) Thoroughly clean input shaft to remove chips plate, then insert a feeler gauge between the plate
made by rem over threads. Make certain small lubrica and snap ring (Fig. 67). The clearance should be be
tion hole next to ball in end of shaft is not plugged tween .025 to .045 inch. If not, install a snap ring of
with chips. Be sure no chips are lodged next to the proper thickness to obtain specified clearance. Low
steel ball. lim it clearance is desirable. Rear clutch plate clear
(7) Slide a new bushing on installing head Tool ance is very important in obtaining proper clutch op
SP-3636, and start them in the bore of input shaft. eration. The clearance can be adjusted by the use of
(8) Stand input shaft upright on a clean smooth various thickness outer snap rings. Snap rings are
surface and install handle Tool SP-3549 in the install available in .060-.062, .074-.076, .088-.090 and .106-
ing head (Fig. 69). Drive bushing into shaft until tool .108 inch thickness.
bottoms.
(9) Thoroughtly clean input shaft and clutch piston PLANETARY GEAR TRAIN—A-904
retainer before assembly and installation.
Measure end play of planetary gear assemblies, sun
Assembly gear and driving shell before removing these parts
(1> If removed, press in p u t shaft into clutch piston from oritput shaft. W ith assembly in an upright posi
retainer and install snap ring. tion, push rear annulus gear support downward on
HEX NUT SP-1191
the output shaft. Insert a feeler gauge between rear
TOOL HANDLE
annulus gear support hub and shoulder on output
SP-3549
REMOVER
shaft. (Fig. 70). The clearance should be .006 to .033
SP-3630 REMOVAL inch. If clearance exceeds specifications, replace
INSTALLATION
thrust washers an d / or necessary parts.
■CUP SP-3633
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ring from rea r of annulus gear to separate support
N Y 176D
OUTPUT SHAFT
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(4) Install steel washer and snap ring on one end of output shaft (Fig. 72).
sun gear. Insert sun gear through front side of driv (2) Remove selective snap ring from forward end of
ing shell, install rear steel washer and snap ring. output shaft, then slide front planetary assembly off
(5) Carefully slide driving shell and sun gear as the shaft.
sembly on the output shaft, engaging sun gear teeth (3) Slide front annulus gear off planetary gear set
with rear planetary pinion teeth. (Fig. 72). Remove thrust washer from rear side of
(6) Place front annulus gear support in the annulus planetary gear set.
gear and install snap ring. (4) Slide sun gear, driving shell and rear planetary
(7) Position front planetary gear assembly in front assembly off output shaft.
annulus gear, place thrust washer over planetary gear (5) Lift sun gear and driving shell off rear plane
assembly hub and install snap ring. Position thrust tary gear assembly. Remove thrust washer from in
washer on rear side of planetary gear assembly. side the driving shell. Remove snap ring and steel
(8) Carefully work front planetary and annulus washer from sun gear (rear side of driving shell) and
gear assembly on output shaft, meshing planetary slide sun gear out of the shell. Remove front snap
pinions with sun gear teeth. ring from sun gear if necessary. Note that front end
(9) With all components properly positioned, install of sun gear is longer than rear.
selective snap ring on front end of output shaft. Re (6) Remove thrust washer from forward side of
measure end play of the assembly. The clearance can rear planetary gear assembly, remove planetary gear
be adjusted by the use of various thickness snap rings. set and thrust plate from rear annulus gear.
Snap rings are available in .040-.044, .048-.052 and
.059-.065 inch thickness. Inspection
Inspect bearing surfaces on output shaft for nicks,
PLANETARY GEAR TRAIN— burrs, scores or other damage. Light scratches, small
A -727 nicks or burrs can be removed with crocus cloth or a
fine stone. Inspect speedometer drive gear for any
Measure end play of planetary gear assemblies, sun nicks or burrs, and remove with a sharp edged stone.
gear and driving shell before removing these parts Make sure all oil passages in shaft are open and clean.
from output shaft. With assembly in an upright posi Inspect bushings in sun gear for wear or scores,
tion, push rear annulus gear support downward on replace sun gear assembly if bushings are damaged.
output shaft. Insert a feeler gauge between rear an Inspect all thrust washers for wear and scores, re
nulus gear support hub and shoulder on output shaft place if damaged or worn below specifications. In
(Fig. 70). The clearance should be .010 to .037 inch. spect thrust faces of planetary gear carriers for wear,
If clearance exceeds specifications, replace thrust
scores or other damage, replace as required. Inspect
washers and/or necessary parts.
planetary gear carrier for cracks and pinions for
Disassembly broken or worn gear teeth and for broken pinion
(1) Remove thrust washer from forward end of shaft lock pins. Inspect annulus gear and driving gear
FRO NT
S N A P R IN G A N N U L U S GEAR D R IV IN G SHELL
(SELECTIVE! ASSEMBLY
THRUST REAR
\ W ASHER
GEAR
THRUST W A S H E R
(STEEL)
PLANETARY GEAR
ASSEMBLY
REAR ANN ULU S
THRUST GEAR ASSEMBLY
W ASHER
2
PLA^ L GEAR TH R UST W A S H E R S N A P R IN G
ASSEMBLY
6
\
SNAP RING
THRUST PLATE
TH R UST W A S H E R
O U T P U T SHAFT
N K 144B LO W A N D REVERSE D R U M
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teeth for damage. Replace distorted lock rings.
Assembly
Refer to Figure 72 for parts reference.
(1) Install rear annulus gear on the output shaft. m
9
Apply a thin coat of grease on thrust plate, place it on
BOLT A N D
the shaft and in the annulus gear making sure teeth W A S H E R (7)
are over the shaft splines.
(2) Position rear planetary gear assembly in the
rear annulus gear. Place thrust washer on front side
of planetary gear assembly.
(3) Install snap ring in front groove of sun gear
SPRING
(long end of gear). Insert sun gear through front side CAM
RETAINER ND28B
of driving shell, install rear steel washer and snap
ring. Fig. 7 3 —Overrunning Clutch Service Replacement
(4) Carefully slide driving shell and sun gear as Cam (A-904)
sembly on output shaft, engaging sun gear teeth with (3) Drill through each rivet head with a 3/8 inch
rear planetary pinion teeth. Place thrust washer in drill. Be careful not to drill into the transmission case.
side the front driving shell. Chip off rivet heads with a small chisel, then drive
(5) Place thrust washer on rear hub of front plane rivets and cam from the case with a blunt punch of
tary gear set, then slide assembly into front annulus proper size.
gear. (4) Carefully enlarge rivet holes in the case with a
(6) Carefully work front planetary and annulus 17/64 inch drill. Remove all chips and foreign matter
gear assembly on output shaft, meshing planetary from the case, make sure cam area is free of chips
pinions with the sun gear teeth. and burrs.
(7) With all components properly positioned, install (5) To install, position cam and roller spring re
selective snap ring on front end of output shaft. Re tainer in the case. Align cam bolt holes with holes in
measure end play of the assembly. The clearance can the case, then thread all seven retaining bolt and
be adjusted by the use of various thickness snap washer assemblies into cam a few turns. The cone
rings. Snap rings are available in .048-.052, .055-.059
washers must be installed so inner diameter is coned
and .062-.066 inch thickness.
toward the bolt head (Fig. 75).
OVERRUNNING CLUTCH (6) Tap cam firmly into the case if necessary. Draw
retaining bolts down evenly, then tighten to 100
Inspection inch-pounds.
Inspect clutch rollers for smooth round surfaces, (7) Screw two pilot studs, Tool C-3288 into the case
they must be free of fiat spots and chipped edges. (Fig. 76). Chill the support with ice (preferably dry
Inspect roller contacting surfaces in the cam and ice). Quickly position support over the pilot studs,
race for brinelling. Inspect roller springs for dis
tortion, wear or other damage.
A-727: Inspect cam set screw for tightness. If loose,
tighten and restake the case around screw.
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£
OUTPUT
C A Vi SHAFT
i RETAINING SU P PO R T NN129 1
SOUS (7)
w a rn ,
. \iN88A Fig. 7 7 —Removing Overrunning Clutch Cam (A-727)
Fig. 75 —Cam Retaining Bolts Installed (A-904) To install, screw two C-3288 pilot studs into the
case (Fig. 78). Chill the support with ice (preferably
and drive it firmly into the case with a wood block
and hammer. dry ice). Quickly position support over the pilot studs,
and drive it firmly into the case with a wood block
Overrunning Clutch Cam Replacement— and hammer.
A-727 (3) Clean all burrs and chips from cam area in the
If overrunning clutch cam and/or roller spring re case.
tainer are found damaged, replace cam and spring (4) Place spring retainer on the cam, making sure
retainer in the following manner: retainer lugs snap firmly into notches on the cam.
(1) Remove set screw from the case below clutch (5) Position cam in the case with cam serrations
cam. aligned with those in the case. Tap cam evenly into
(2) Remove four bolts securing output shaft support the case as far as possible with a soft mallet.
to rear of transmission case. Insert a punch through (6) Install Tool C-3863 and Adapter SP-5124 as
bolt holes and drive cam from the case (Fig. 77). shown in Figure 79, tighten nut on tool to seat cam
Alternate punch from one bolt hole to another so cam into the case. Make sure cam is firmly bottomed, then
will be driven evenly from the case.
install cam retaining set screw. Stake the case around
IMPORTANT: The output shaft support must be in
set screw to prevent it coming loose.
the case to install the overrunning clutch cam.
(7) Remove cam installing tool. Install and tighten
If the support requires replacement, drive it rear
ward out of the case with a wood block and hammer. support retaining screws to 140 inch-pounds. Stake
the case around cam in twelve places with a blunt
chisel (Fig. 80).
PILOT STUDS (T O O L )
PILOT
STUDS
i
OUTPUT
SHAFT
Sf. , SUPPORT
O U T P U T SH AFT
SU P P O R T
N N 130
NN89 '' #
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SEAL RING SPRING
r : PISTON ROD
ADAPTER SEAL
R IN G S (2)
TO OL
SNAP
R IN G
P IS T O N R O D G U ID E P IS T O N ^ N D 168A
f -'Y
PLUG SPRING SPRING RETAINER SNAP RING
SNAP RING NP147
,N N 1 3 2 A
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A D J U S T IN G S C R E W A N D LOCKNUT
LEVER
SO LEVER (SHORT)
ROLLER
H m s ta g *
'i's.' S
LO W AND
iie/KRSf- UN*
BAND
LIN K A N D A N C H O R
ND21
iKACE)
N O 14
Fig. 8 4 —Low-Reverse Band and Linkage
Fig. 8 3 —Overrunning Clutch, Low and Reverse case and adjusting screw touching center lug on
Band Link band (Fig. 86).
insert clutch hub inside the cam. Install overrunning
Kickdown Servo
clutch rollers and springs exactly as shown in Figure (1) Carefully push servo piston into the case bore.
83. Install piston rod, two springs and guide (Fig. 81).
The A-904 transmissions use one small spring only.
Low Reverse Servo and Band Also, one small spring only is used in the maximum
(1) Carefully work servo piston assembly into the performance vehicles with A-727 transmissions.
case with a twisting motion. Place spring, retainer (2) Compress kickdown servo springs by using en
and snap ring over the piston (Fig. 82). gine valve spring compressor Tool C-3422, then install
(2) Compress low and reverse servo piston spring snap ring.
by using engine valve spring compressor Tool C-3422,
then install snap ring. P la n e ta ry G ear Assemblies, Sun G ear, and
(3) Position rear band in the case, install short D riving Shell
strut, then connect long link and anchor to the band (1) While supporting assembly in the case, insert
(Fig. 84). Screw in band adjuster just enough to hold
strut in place. Install low-reverse drum. A D J U S T IN G SCREW
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- A D J U S T IN G SCREW (5) Align rear clutch plate inner splines, grasp in
put shaft and lower the two clutch assemblies into the
— LO C K N U T
transmission case.
LEVER (6) Carefully work clutch assemblies in a circular
motion to engage rear clutch splines over splines of
front annulus gear. Make sure front clutch drive lugs
-B A N D »
are fully engaged in slots in the driviftg shell. *
P IV O T P IK
Front Band
Figure 87 shows a disassembled view of the kick-
down band assembly. Anchor not used on A-904.
(1) Slide band over front clutch assembly.
" O " R IN G ' (2) Install band strut, screw in adjuster just enough
to hold strut and anchor in place.
B A N D R E A C T IO N P I N '
NR170
O il Pump an d Reaction Shaft Support
Fig. 8 6 —Double W ra p Band and L in k a g e - If difficulty was encountered in removing pump as
Disassembled (A-904-LA Transmission Only) sembly due to an exceptionally tight fit in the case, it
output shaft through rear support. Carefully work as may be necessary to expand the case with heat during
sembly rearward engaging rear planetary carrier lugs pump installation. Using a suitable heat lamp, heat
into low-reverse drum slots. the case in area of pump for a few minutes prior to
CAUTION: Be very careful not to damage ground sur installing pump and reaction shaft support assembly.
faces on output shaft during installation. A-904: Install thrust washer on reaction shaft sup
port hub (Fig. 45).
Front a nd Rear Clutch Assemblies A-727: If drive train end play was not within speci
The front and rear clutches, front band, oil fications (.037-.084 inch) when measured before dis
pump and reaction shaft support are more easily in assembly, replace thrust washer on reaction shaft
stalled with transmission in an upright position. support hub with one of proper thickness (Fig. 50).
One method to support transmission, is outlined The following selective thrust washers are available
in Steps 1 and 2. for A-727 transmissions.
(1) Cut a 3-1/2 inch diameter hole in a bench, in Thickness i < Color
the end of a small oil drum or a large wooden box .061-.063 inch Green
strong enough to support transmission. Cut or file .084-.086 inch Red
notches at edge of the 3-1/2 inch hole so output shaft .102-104 inch Yellow
support will fit and lay flat in the hole. (1) Screw two pilot studs, Tool C-3288 in pump
(2) Carefully insert output shaft into hole to sup opening in the case (Fig. 88). Install a new gasket
port the transmission upright, with its weight resting over the pilot studs.
on flange of the output shaft support. (2) Place a new rubber seal ring in the groove on
(3) A-904: Apply a coat of grease to selective thrust outer flange of pump housing. Make sure seal ring is
washer (Fig. 71) and install washer on front end of not twisted. Coat seal ring with grease for easy instal
the output shaft. If drive train end play was not lation.
within specifications (.030 to .089 inch), when tested
before disassembly, replace thrust washer with one ANCHOR
of proper thickness.
The following selective washers are available for
A-904 transmissions.
Thickness Color
.052-.054 inch Natural
.068-.070 inch Red
.083-.085 inch Black A D J U S T IN G
A-727: Apply a coat of grease on the input to output SCREW A N D
LO CK N UT
shaft thrust washer (Fig. 72), and install washer on
front end of the output shaft.
(4) Align front clutch plate inner splines, and place BAND
assembly in position on the rear clutch. Make sure
5- * .1 N D I7
front clutch plate splines are fully engaged on rear
clutch splines. Fig. 8 7 —Kickdown Band and Linkage
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(3) Install and tighten extension housing bolts to 24
foot-pounds.
(4) Install gasket, plate and two screws on bottom
of extension housing mounting pad.
(5) Install speedometer pinion and adapter as
sembly.
IMPORTANT: Measure drive train end play as de-
cribed under "Disassembly—Sub-assembly Removal".
Correct if necessary.
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pump bushing, and oil seal will be damaged. The
drive pl ate will not support a load; therefore, none of
the weight of transmission should be allowed to rest
on the plate during installation.
(1) Rotate pump rotors with Tool C-3756 (A-904)
or Tool C-3881 (A-727) until the two small holes in
handle are verticle (Fig. 90).
(2) Carefully slide converter assembly over input ■m
shaft and reaction shaft. Make sure converter
impeller shaft slots are also vertical and fully engage
pump inner rotor lugs.
Test for full engagement by placing a straight edge
on face of the case (Fig. 91). The surface of con
verter front cover lug should be at least 1/2 inch to
rear of straight edge when converter is pushed all f
way into the transmission.
(3) Attach a small “C” clamp to edge of bell hous
ing to hold converter in place during transmission
installation. ND6
(4) Inspect converter drive plate for distortion or Fig. 9 I —Measuring Converter fo r Full Engagement
cracks and replace if necessary (Fig. 92). Torque Drive in Transmission
Plate to Crankshaft bolts to 55 foot-pounds. When (Fig. 92). Carefully work transmission assembly for
Drive Plate replacement has been necessary, make ward over engine block dowels with converter hub
sure transmission dowel pins are in engine block and entering the crankshaft opening.
protruding far enough to hold transmission in align (7) After transmission is in position, install bell
ment. housing bolts and tighten to 28 foot-pounds.
(5) Coat converter hub hole in crankshaft with (8) Install and tighten the two lower drive plate to
wheel bearing grease. Place transmission and con converter bolts to 270 inch-pounds.
verter assembly on a service jack and position assem (9) Install starting motor and connect battery
bly under vehicle for installation. Raise or tilt as nec ground cable.
essary until transmission is aligned with engine. (10) Rotate engine with remote control switch and
(6) Rotate converter so mark on converter (made install the other two drive plate to converter bolts.
during removal) will align with mark on drive plate. Tighten bolts to 270 inch-pounds.
The offset holes in plate are located next to 1/8 inch
hole in the inner circle of plate. A stamped V mark
identifies the offset hole in converter front cover
'fOOl
’ a l ig n m e n t
x <i-iO LES
VtSTICAL
ND169A
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TIGHTENING TORQUE
200 IN. LBS
V
40 FT. LBS.
V
30 FT. LBS.
NU45A
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T R A N S M IS S IO N E X T E N S IO N
H O U S IN G
TIGHTENING TORQUE
BOLT (2)
50 FT. LBS.
$
30 FT. LBS.
%
40 FT. LBS.
§
PY171
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T O COOLER K IC K D O W N B A N D A D J U S T IN G S C R E W
6 C ylinder M odels (Fig. 101)
(1) Follow detailed instructions in Lubrication Sec
tion for linkage lubrication of all models.
(2) Disconnect choke (4) at carburetor or block
choke valve in full open position. Open throttle slight
ly to release fast idle cam, then return carburetor to
curb idle.
(3) Hold transmission lever (9) firmly forward
against its stop while performing the next two steps.
It is important that the lever remain firmly against the
stop during these steps to insure a correct adjustment.
(4) To make transmission rod length adjustment,
^ __
G E A R S H IFT C O N T R O L LEVER ' « * NN68 loosen the slotted link lock bolt (12). Pull forward on
the slotted adjuster link (7) so that it contacts carbu
Fig. 9 7 —External Controls and Adjustments retor lever pin.
button, spring and knob assembly on the cable end (5) Tighten transmission rod adjustment lock bolt
until dimension from top of button to top of knob is (12) to 95 inch-pounds. To check transmission linkage
13/32" (Fig. 100). Secure knob with set screw. freedom of operation move slotted adjuster link to
(8) Connect battery ground cable. the full rearward position, then allow it to return
slowly, making sure it returns to the full forward
THROTTLE ROD ADJUSTMENT position.
(6) When carburetor throttle is opened, the trans
With engine at operating temperature and carbu mission lever (9) should begin its travel at the same
retor off fast idle cam, adjust idle speed of engine time.
using a tachometer. Refer to “Fuel System” Group 14, (7) Loosen cable clamp nut (5), adjust position of
for idle speed Specifications and carburetor linkage cable housing ferrule (6) in the clamp so that all slack
adjustment. is removed from the cable with carburetor at curb
STE ER IN G C O L U M N
SIDE RAIL
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STEE R IN G C O L U M N
UPPER R O D
C O L U M N LO C K
FR O N T RO D
PY230
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NP504C
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rearward on rod with a slight effort and turning the tion for linkage lubrication of all models.
threaded adjustment (1). The rear end of slot should (2) Disconnect choke at carburetor or block choke
contact carburetor lever pin without exerting any for valve in full open position. Open throttle slightly to
ward force on pin when slotted adjuster link (1) is in release fast idle cam, then return carburetor to curb
its normal operating position against lever pin nut. idle.
(7) Assemble slotted adjustment (1) to carburetor (3) Loosen the transmission throttle rod adjustment
lever pin and install washer and retainer clip. As lock screw.
semble transmission linkage return spring (13) in (4) Hold the transmission lever forward against its
place. stop while adjusting the transmission linkage. (On
(8) To check transmission linkage freedom of op engines with solenoid idle stops, the solenoid plunger
eration, move slotted adjuster link (1) to full rearward must also be in its fully extended position).
position, then allow it to return slowly, making sure it (5) Adjust the transmission rod by pulling forward
returns to full forward position. on the slotted link with a slight effort so that the rear
(9) Loosen cable clamp nut (4), adjust position of edge of the slot is against the carburetor lever pin.
cable housing ferrule (5) in the clamp so that all slack Tighten transmission rod adjusting locking screw.
is removed from cable with carburetor at curb idle. Note: The slotted link and transmission lever must
To remove slack from cable, move ferrule (5) in the be held forward while the locking screw is being
clamp in direction away from carburetor lever. tightened.
(10) Back off ferrule (5) 1/4". This provides 1/4" (6) To check transmission linkage freedom of oper
free play of cable, with carburetor at curb idle condi ation, move slotted link to the full rearward position,
tion. Tighten cable clamp nut (4) to 45 inch-pounds. then allow it to return slowly, making sure it returns
(11) Connect choke (8) rod or remove blocking fix to the full forward position.
ture. (7) Loosen carburetor cable clamp nut. Adjust posi
tion of cable housing ferrule in the clamp so that all
8 C y li n d e r M o d e ls w i t h S in g le S e ctio n slack is removed from cable with carburetor at curb
T h r o t t le R o d (Fig. 103) idle. To remove slack from cable, move ferrule in the
(1) Follow detailed instructions in Lubrication Sec clamp in direction away from carburetor lever.
CHOKE
T R A N S M IS S IO N THROTTLE
ROD A DJU STM EN T
LO C K SCREW
CARBURETOR ^
CABLE C L A M P NUT !L
TRANSMISSION
THROTTLE ROD
TRANSMISSION
THROTTLE LEVER
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(8) Back off ferrule 1/4". This provides 1/4" free slotted adjuster link is in its normal operating
play. Tighten cable clamp nut to 45 inch-pounds. position.
(9) Connect choke rod or remove blocking fixture. (7) Assemble slotted adjuster link (2) to carburetor
lever stud and install washer and retainer pin. As
Models W ith 4 2 6 Cu. In. Eng. (Fig. 104) semble transmission linkage return spring (11) in
(1) Follow detailed instructions in Lubrication Sec place.
tion for linkage lubrication of all models. (8) To check transmission linkage freedom of opera
(2) Block choke valve in full open position. Open tion, move slotted adjuster link (2) to full rearward
throttle slightly to release fast idle cam, then return position, then allow it to return slowly, making sure it
carburetor to curb idle. returns to the full forward position against the stud.
(3) Hold transmission lever (10) firmly forward (9) Loosen cable clamp nut (12), adjust position of
against its stop, while performing adjustments in the cable housing ferrule (13) in the clamp (14) so that
next four steps. It is important that the lever remains all slack is removed from cable with rear carburetor
against the stop during these steps to insure a correct at curb idle. (To remove slack from cable, move fer
adjustment. (On engines with solenoid idle stop, the rule (13) in clamp (14) in direction away from car
solenoid plunger must be in fully extended position). buretor lever.)
(4) With a 3/16" diameter rod (8) placed in the (10) Back off ferrule (13) 1/4". This provides 1/4"
holes provided in upper bellcrank and lever (15), ad free play of cable, with carburetor at curb idle condi
just length of intermediate transmission rod (9) by tion. Tighten clamp nut (12) to 45 inch-pounds.
means of threaded adjustment at upper end. The (11) Route cable so it does not interfere with car
ball socket must line up with the ball end with a buretor rod (20) or upper bellcrank (15) throughout
slight downward effort on rod. full throttle linkage travel.
(5). Assemble ball socket to ball end and remove (12) Attach carburetor rod assembly (4) between
3/16" rod (8) from upper bellcrank and lever (15). the carburetors with slotted rod end (16) attached
(6) Disconnect return spring (11), adjust length of to outboard side of inboard lever on rear carburetor.
rod (20) by pushing rearward on rod with a slight With rear carburetor at wide open throttle, adjust
effort and turning threaded adjuster link (2). The length of connector rod (4) so that front carburetor
rear end of slot should contact carburetor lever stud is also at wide open throttle. To lengthen this rod
without exerting any forward force on the stud when (4), turn adjusting stud (17) clockwise as viewed from
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front of engine. Tighten the lock nut (18).
(13) Remove choke valve blocking fixture.
B OLT 1 /3 2 " SHEET M E T A L PY300 RING GEAR CRANKSHAFT PILOT WELD PLUG PY16
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W ELD OR BREA K EDGE 1 /1 6 "
VEN T PLUG ^
B R A ZE M IN .
RETAINER . - ' nr RETAINER
\
SLID IN G YOKE
W IRED IN PLACE I
O U TS ID E O F O P E N
E N D FOR T H IS
M A T E R IA L : 1 - 7 /8 IN C H O .D .
D IS T A N C E O N TUBE
T H IN W A L L E D STEEL T U B IN G
AND 1 /8 IN C H STEEL DISC P Y 304
S P R IN G
CONVERTER Fig. 6 —A -7 2 7 —Converter Hub Seal Cup
H U B SEAL C U P
and vent shield (in A-727 transmission). Install vent
P LU G — M A D E F R O M plug (rubber stopper), and vent plug retainer (Fig. 4)
O L D FILLER TUBE P Y 302
preferably using longer bolts than those removed.
Fig. 4 —Transmission Prepared fo r Test (3) With rotary motion, install converter hub seal
cup (Fig. 4), over input shaft, and through the con
Possible sources of converter leakage shown in
verter hub seal until the cup bottoms against the
(Fig. 3) are:
pump rotor lugs. Secure with cup retainer strap (Fig.
(1) Torque converter weld leaks at the outside
diameter (peripheral) weld. 4), using converter housing to engine block retaining
(2) Front pump hub weld. bolts.
(3) Crankshaft pilot weld. (4) Attach and clamp hose from nozzle of Tool C-
(4) Fluid leakage from the converter drain plug. 3499 to pipe nipple, which is in rear cooler line fitting
These leaks appear at the outside diameter of the position in case (Fig. 5).
converter on the engine side. (5) Pressurize the transmission using Tool C-3499,
until the pressure gage reads 8 psi. Position transmis
AIR PRESSURE TEST OF TRANSMISSION sion so that pump housing and case front may be
covered with soapy solution or water. Leaks are some
The transmission should be prepared for pressure times caused by porosity in the case or pump housing.
test as follows after removal of the torque converter: CAUTION: Do not, under any circumstances, pres
(1) Install filler tube bore plug, propeller shaft yoke surize a transmission to more than 10 psi.
(tie in with cord or wire), flared tube fitting cap (on If a leak source is located, that part and all associ
front cooler line fittings), and pipe nipple (in case at ated seals and gaskets should be replaced with new
rear cooler line fitting) (Fig. 4 and 5). parts.
(2) Remove necessary front pump housing bolts,
Fabricate equipment needed for test as shown in
FLARE C A P
(Figs. 1, 6, 7, 8, 9 and 10).
W E LD BREA K EDGE 1 /1 6 " M IN .
O R B RA ZE
A IR P U M P
C -34 9 9
=1/8"
\
■SEAL THIS END A IR TIGHT
POLISH
OUTSIDE
lU r ’t \ 1":
md k - i - 3 /4 " - OF OPEN
O N TUBE
MATERIAL: 1 -1 /2 IN C H O .D . T H IN
WALLED STEEL T U B IN G A N D
H O SE C L A M P 1/8 IN C H STEEL DISC
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1 3 /3 2 " DRILL 2 HOLES
1 5 /3 2 " DRILL 4 HOLES
M A T E R IA L : 1 /4 " STEEL S TO C K
1 -1 /4 " W ID E P Y306
M ANUAL tlSSION—(A -8 3 3 )
FOUR SPEED
INDEX
Page Page
Cleaning and Inspection ........................................ ... 80 Service Out of Vehicle ............................................ 73
General Information .................................................. ... 68 Assembling Transmission ..................................... 81
Service Diagnosis...................................................... ... 69 Disassembling Transmission ............................... 74
Service In Vehicle .................................................... ... 70 Extension Housing Bushing Replacement.......... 82
Column Lock Linkage ..............................................70 Transmission Installation ..................... ............... 84
Extension Housing Yoke Seal ................................ 73 Transmission Removal ........... ............................ 73
Four Speed G earsh ift................................................ 70 Specifications.............................................................. 113
Gearshift Linkage A djustm ent............................. ... 70 Tightening Reference................................................ 115
Speedometer Pinion G e a r..................................... ...71
GENERAL INFORMATION
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NH735B
transmission for identification numbers. maintained by a tubular spacer in the center and four
SAMPLE NUMBER: PP 833 1861 0250. thrust washers (one being used between the rows of
The first two letters identify the manufacturing roller bearings and one at each end).
plant. The next three numbers are the transmission The reverse idler gear is supported on a bronze
model number. The following four numbers are a bushing, pressed into the gear.
date of manufacture code. The last four numbers are The gearshifting is manually operated through shift
a sequence number. control rods to the transmission. Any forward gear
The main drive pinion and input shaft is supported may be engaged while the vehicle is in motion
by a ball bearing in the transmission case and an olite through the use of synchronizing clutches.
bushing pressed in the end of the crankshaft. The transmission may be used as an aid to deceler
The mainshaft front end is supported by roller ation by downshifting in sequence without double
bearings in the end of the main drive pinion and a clutching or gear clashing, due to the fact that all
ball bearing in the front of the extension housing. forward speeds are synchronized. The service pro
The output end of the mainshaft is splined to the cedures covering the four speed transmission used on
sliding universal joint yoke, which is supported by a all vehicles so equipped is identical to the following
bushing in the extension housing. service procedures except where noted.
The countershaft gear is supported by a double row IMPO RTANT: Some internal transmission parts are
of needle type roller bearings at each end and the different from standard on vehicles with high per
thrust is taken on thrust washers between the ends of formance engines. These "special" parts are listed
the gear and the transmission case. The alignment of in applicable Parts Catalog; therefore, be sure they
the needle type roller bearings within the gear is are used when replacement is necessary.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
HARD SHIFTING (a) I ncorrect clutch adjustment. (a) Refer to Clutch Group for corrections.
(b) Improper cross-over adjustment. (b) Perform cross-over adjustment as out
lined in “Gearshift Linkage Adjust
ments.”
(c) Synchronizer clutch sleeve damaged. (c-d-e) Causes noted can only be correct
(d) Synchronizer spring improperly in ed by disassembling transmission
stalled. and replacing damaged or worn parts.
(e) Broken or worn synchronizer stop
rings.
TRANSMISSION SLIPS (a) Linkage interference. (a) Inspect and remove all linkage inter
OUT OF GEAR ferences.
(b) Gearshift rods out of adjustment. (b) Adjust gearshift rods as outlined in
“Gearshift Linkage Adjustments.”
(c) Second or direct speed gear synchro (c) Disassemble transmission and re
nizer clutch teeth worn. place parts as necessary.
(d) Clutch housing bore or face out of (d) Refer to Clutch Group for correction
alignment. procedures.
TRANSMISSION (a) Excessive end play in countershaft
NOISES gear.
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(b) Loose synchronizer hub spline fit on (b) Inspect mainshaft and synchronizer
mainshaft. hub and replace parts as necessary.
(c) Damaged, broken or excessively worn (c) Replace worn gears,
gear teeth.
(d) Rough or pitted bearing race or balls, (d) Replace worn bearing.
SERVICE PROCEDURES
FOUR SPEED GEARSHIFT (1) Install floor shift lever aligning Tool C-3951 (Fig.
9) to hold the levers in neutral-crossover position.
Rem oval (Figs. 3,4,5 an d 6) (2) With all rods removed from transmission shift
(1) Disconnect negative (ground) cable from bat levers, place levers in neutral detent position.
tery. (3) Rotate threaded shift rods to make length ex
(2) Remove console and wiring if so equipped (See actly right to enter transmission levers. Start with 1-2
Body Section 23). shift rod (it may be necessary to pull clip at shifter
(3) Remove retaining screws from floor pan boot end to rotate this rod).
and slide up and off shift lever. (4) Replace washers and clips.
(4) Remove shift lever using a .010" feeler gauge (5) Remove aligning tool and test shifting action.
as a tool to release the internal spring clip as shown
in (Fig. 8). COLUMN LOCK LINKAGE (Fig. 7)
(5) Remove retaining clips, washers and control
rods from shift unit levers. For removal or installation of these parts, follow
(6) Remove two bolts and washers which secure the arrangement of parts shown in (Fig. 7).
shift unit to mounting plate on extension housing and
remove unit. LINKAGE ADJUSTMENT
Installatio n (Figs. 3 , 4, 5 a n d 6) (1) Loosen the adjustable rod swivel clamp bolt.
(1) Fasten unit to extension housing mounting plate (2) Place transmission in reverse gear.
with two bolts and lock washers and tighten to 30 foot (3) At the steering column, line up locating slots at
pounds. bottom of shift housing and bearing housing. Install
(2) Install shift rods, washers and clips. suitable tool in slots to hold alignment.
(3) See next paragraph for adjustment procedure. (4) Tighten adjustable swivel clamp bolt to 125
(4) Push Shift lever down into shift unit far enough inch-pounds.
for spring to click and lock lever in place. Pull up on
lever to make sure it is locked in. G E A R SH IFT
SELECTOR LEVER
(5) Slide boot down over lever and fasten to floor B O O T ASSEMBLY A SS E M B L Y
pan. -F L O O R
(6) Install console and connect wiring if so S T E E R IN G . C O L U M N
equipped (See Body Section 23).
C O LU M N LO CK)
(7) Reconnect battery cable. FR O N T ROD / TO RQ UE
L U B R IC A T IO N
FILL P L U G T R A N S M IS S IO N
D R IV E P IN IO N
1m
If'
* FR A M E
3 SID E R A IL
AND
R ETA IN ER D R IV E
C O L U M N LO CK SECOND ROD
P IN IO N COLUM N
ADJU STM EN T LO C K REAR REVERSE R O D
« B E A R IN G A N D SEAL
ROD
PY166
ID E N T IF IC A T IO N P A D NU37
Fig. 3 —Gearshift Mechanism—Assembled
(Typical fo r D a rt)
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LEVER
A S S EM B L Y
FIRST A N D
SECO ND
ROD
T R A N S M IS S IO N
C ASE
TH IR D A N D
FO U R T H R O D
T R A N S M IS S IO N
E X T E N S IO N
BOLT WASHER
REVERSE R O D
WASHER PY167
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Fig. 6—G earshift Meeh.—Disassembled (Challenger)
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-RETAINER ADAPTER
FLOOR SHIFT
ASSEMBLY ‘O ” R IN G
X
PINION
X
v
HAND LEVER BOLT A N D
W ASHER
".01C," FEELER GAGE
■ R ETAINER
ORiVES'S SIDE R IN G
\ N N362
X
Fig. 1 1—Speedometer Pinion and A d a p t e r -
Disassembled
't ‘
J*
ADAPTER LOCK RING
NU39
TO OL
SEAL
" ■•A D A P T E R
6 O ’C L O C K P O S IT IO N
NN3I1
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flange.
(7) Raise engine slightly with support fixture.
Disconnect extension housing from removable center
-T O O L
crossmember (Fig. 15 or 16).
(8) Support transmission with a suitable jack and
remove center crossmember. Remove transmission to
clutch housing bolts.
(9) Slide transmission toward rear until drive pin
ion shaft clears clutch disc, before lowering trans
— N N125
mission.
(10) Lower transmission and remove from under
Fig. 14—Installing Extension Housing Yoke Seal vehicle. Thoroughly clean exterior of unit, preferably
ponents, refer to “FOUR SPEED GEARSHIFT.” by steam. Mount transmission in repair stand
(2) Drain fluid from transmission. (Fig. 17).
(3) Disconnect propeller shaft at rear universal
joint marking parts to reinstall in same position. Care DISASSEMBLING TRANSMISSION (Fig. 18)
fully pull shaft yoke out of transmission extension
housing. G earshift Housing a nd Mechanism
CAUTION: Be careful not to scratch or nick ground (1) Remove reverse shift lever from shaft. Remove
surface on sliding spline yoke during removal and bolts that attach gearshift housing to transmission
installation of the shaft assembly. case (Fig. 19). With levers in neutral detent position,
(4) Disconnect speedometer cable and back-up light pull housing out and away from the case. (The first
switch leads. and second, third and fourth shift fork may remain in
(5) Some models have exhaust systems which will engagement with synchronizer sleeves.) Work forks
have to be partially removed for clearance. See Ex out of sleeves and remove from the case.
haust Systems, Group 11. The following three steps need only be done, if oil
(6) Install engine support fixture C-3487-A, engag leakage is visible around gearshift lever shafts.
ing the hooks in holes in frame side member. Be sure (2) Remove nuts, lockwashers and flatwashers that
support ends are up against underside of oil pan attach first and second, third and fourth speed shift
T R A N S M IS S IO N EX T.
H O U S IN G
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PY171
M A IN DRIVE P IN IO N G E A R SHIFT H O U S IN G
P IN IO N B E A R IN G RETAINER
G ASKET
BREATHER
E X T E N S IO N H O U S IN G
SEAL
9 ^ ^ '*^9ilHi|||i|,| M br
REPAIR STAND
REVERSE OPERATING LEVER
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1. Bearing Retainer 26. Lockwasher 49. Needle Bearing Rollers 71. Lockwasher
2. Bearing Retai ner Gasket 27. B olt 50. Bearing Spacer 72. Nut
3. Beari ng Retainer Oil Seal 28. Extension Housing 51. Countershaft Gear (Cluster) 73. Gearshift Control Housing
4. Snap Ring, Bearing (Inner) 29. M ainshaft Yoke Bushing 52. Needle Bearing Rollers 74. 1st and 2nd Operating Lever
5. Snap Ring, Bearing (Outer) 30. O il Seal 53. Thrustwasher, Needle Roller 75. Flatwasher
6. Pinion Bearing 31. Main Drive Pinion Bearing 76. Lockwasher, Lever
7. Transmissi on Case 33. Needle Bearing Rollers 54. Thrustwasher, Gear (1) 77. Nut, Lever
8. Filler Plug 34. Snap Ring 55. Backup Light Switch 78. Lockwasher, Lever
9. Gear, 2nd Speed 35. Stop Ring 56. Backup Light Switch Gasket 79. Flatwasher, Lever
10. Stop Ring 36. Snap Ring 57. Plug 80. 3rd and 4th Operating Lever
11. Shift Strut Springs 37. Shift Strut Spring 58. Retainer, Reverse Detent 81. Detent Ball
12. Clutch Gear 38. Clutch Gear Ball Spring 82. Detent Ball Pin
13. Shift Struts (3) 39. Shift Strut Spring 59. Gasket 83. Detent Ball Sleeve
14. Shift Strut Spring 40. Clutch Sleeve 60. Spring, Reverse Detent Ball 84. Detent Ball Spring
15. Snap Ring 41. Stop Ring 61. Ball, Reverse Detent 85. Detent Ball
16. 1st and 2nd Clutch Sleeve 42. 3rd Speed Gear 62. Woodruff Key 86. Oil Seal (2)
Gear 43. Mainshaft (Output) 63. Reverse Idler Gear Shaft 87. 3rd and 4th Lever
17. Stop Ring 44. S h ift S truts (3) 64. Bushing, Reverse Idler Gear 88. 1st and 2nd Lever
18. 1st Speed Gear 45. Woodruff Key 65. Gear, Reverse Idler 89. 3rd and 4th Speed Fork
19. Bearing Retainer Ring 46. Countershaft 66. Fork, Reverse Shifter 90. 1st and 2nd Speed Fork
20. Rear Bearing 47. Thrustwasher, Gear (1) 67. Reverse Lever 91. Drain Plug
21. Snap Ring 48. Thrustwasher, Needle Roller 68. Oil Seal, Reverse Lever Shaft 92. Gasket, Shift Control
24. Baffle Bearing 69. Reverse Operating Lever Housing
25. Gasket, Case to Extension 70. Flatwasher
Housing
LEGEND FOR FIG. 18
pinion adapter in extension housing (Fig. 10). Care (Do not separate 3rd and 4th speed synchronizer
fully work adapter and pinion out of extension hous clutch gear, sleeve, shift struts or springs unless in
ing. spection reveals a replacement part is required.)
(2) Remove bolts that attach extension housing to (7) Using long nose pliers, compress snap ring that
transmission case. retains mainshaft ball bearing in extension housing
(3) Slide third and fourth synchronizer sleeve (Fig. 23).
slightly forward, slide reverse idler gear to center of (8) Holding snap ring compressed, pull mainshaft
its shaft, then using a soft hammer, tap on extension assembly and bearing out of extension housing (Fig.
housing (in a rearward direction). Slide housing and 24). HEAVY DUTY MODEL (Fig. 25) has snap ring in
mainshaft assembly out and away from the case outer race of bearing. Use snap ring pliers to expand
(Fig. 20). and hold this ring while removing mainshaft and bear
(4) Refer to (Fig. 21) for location of various gears, ing from extension housing.
synchronizer sleeves and clutches before disassem (9) Remove snap ring that retains mainshaft bear
bling mainshaft. ing on the shaft (Fig. 26). Remove bearing from main
(5) Remove snap ring (Fig. 22), that retains 3rd shaft by inserting steel plates on front side of 1st
and 4th synchronizer clutch gear and sleeve, slide speed gear, then press or drive rear bearing off main
3rd and 4th synchronizer assembly off end of main shaft. (Be careful not to damage gear teeth.)
shaft. (10) Remove bearing, bearing retainer ring, 1st
(6) Slide 3rd speed gear and stop ring off mainshaft. speed gear, and first speed stop ring from the shaft.
(11) Remove snap ring that retains 1st and 2nd
3RD A N D 4TH LEVER SHAFT 1ST A N D 2 N D LEVER SHAFT
A N D DETENT PLATE A N D DETENT PLATE clutch sleeve gear and clutch to mainshaft (Fig. 27).
DETENT EALL /
GASKET EXTENSION HOUSING
1ST A N D 2 N D
GEARSHIFT FORK
NH741
3RD A N D 4TH INTERLOCK SLEEVE
GEARSHIFT FORK
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1ST A ND 2N D CLUTCH 1ST SPEED GEAR SNAP RING G R O O V E
EXTENSION
SLEEVE GEAR H O U S IN G BEARING \ 4
MAINSHAF
r , ‘.
MAINSHAFT
STOP RING j
STOP RING N H 7^5 EXTENSION H O U S IN G
3RD AND 4TH
3RD SPEED GEAR
CLUTCH SLEEVE N H742A Fig. 2 4 —R em o v in g or Installing M ainshaft
SNAP RING *
GROOVE IN BEARING
SNAP RING NU40
/
SLEEVE
Fig. 2 5 —Removing o r Installing M ainshaft
(Heavy Duty Model)
N H 7 4 3B
to be used at reassembly.
Fig. 22 —Disassembling M ainshaft (12) Using a feeler gauge, measure end play of
Slide 1st and 2nd clutch sleeve gear and clutch countershaft gear, by inserting gauge between thrust
from mainshaft. (Do not separate clutch sleeve gear washer and gear (Fig. 29). This measurement should
and clutch, unless inspection reveals a replacement be .015 to .029 inch. If measurement is greater than
part is required.) Remove 2nd speed gear. that specified, new thrust washers must be installed
Figure 28 shows various mainshaft bearing surfaces at reassembly.
of the gears. Inspect these surfaces for signs of wear, Reverse G ear, Lever an d Fork
scoring, or any condition that would not allow shaft (1) Remove reverse gearshift lever detent spring
CLUTCH GEAR SHIFT STRUTS (3) 1ST SPEED GEAR
1ST AND 2ND CLUTCH \ STO P RING ^
SLEEVE GEAR
L PLIERS
BEARING
SNAP RING
2N D SPEED GEAR—^
X BEARING
1ST A N D 2N D SYNCHRONIZER SNAP RING
RETAINING RING
CLUTCH GEAR
N H 744B ■ EXTENSION H O U S IN G PLIERS NH746
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£9.9.9
-PLIERS RCV?!:SE SHIFTER
REV MAFT AND DETENT
SNAP RING
\ STOP R IN G -
1ST SPEED GEAR
/ l ig h t
RETAINING RING SWITCH
/ PLUG
2ND ^
GEAR / CLUTCH
REVERSE IDLER
GEAR SHAFT
SNAP RING
GROOVE NH748
9 ? 0 : INSTALLED
.-1 GAUGE
r WASHER
HAFT GEAR
90 . /■' ~ /V\ V i r . O t " ■■>.-< .
■JACK-UP
i\t/V \C )V l,l) A o o u M d i -Y
NH750A NU42 LIGHT SWITCH
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age the ease bore, then carefully push reverse gear S N A P R IN G S C O U N T E R S H A F T G E A R IN C ASE
shift lever shaft inward and remove it from case
(Fig. 33). Lift out detent ball from bottom of case.
Remove shift fork from shaft and detent plate.
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Inspect countershaft gear and all gear teeth for
THRUST W A S H « COUNTER SHAFT
chipped or broken teeth, or showing signs of excessive TANG GEAR
wear. Small nicks or burrs must be stoned off.
Inspect teeth on main drive pinion. If excessively
worn, broken or chipped, a new pinion should be in
stalled. If the oil seal contact area on drive pinion
shaft is pitted, rusted or scratched, a new pinion is
recommended for best seal life.
Test interlock sleeve and pin for free movement in X
bore of shift housing. Examine detent balls for
signs of brinelling. If lever detents show signs of ex
cessive wear to extent of not locking in gear, install a
new part. Inspect shift forks for wear on the shanks \ THRUST WASHER
and pads. TANG NH754
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shaft was removed because of oil leak. TOOL INSTALLING
(1) Install a new oil seal “O” ring on reverse gear BUSHING
shift lever shaft. Coat lever shaft with Multi-purpose
grease, then carefully install lever shaft into bore in \
the case (Fig. 33). BMBt
(2) Install reverse detent spring retainer and gas BUSHING TOOL
. REMOVING
ket. Torque to 50 foot-pounds. Insert ball and spring. j/ END
Install plug and gasket. Torque to 24 foot-pounds.
IN M H v ! * ’
(3) Place reverse Idler gearshaft in position in end
INSTALLING END NU43
of case and drive it in far enough to position reverse
Idler gear on protruding end of shaft with shift slot Fig. 3 9 —Replacing Bushing in Extension Housing
toward rear (Fig. 31). At same time, engage slot with (3) Slide first and second synchronizer assembly
reverse shift fork. (including stop ring with lugs indexed in hub slots,
(4) With reverse Idler gear correctly positioned, (Fig. 40) over mainshaft, down against second gear
drive reverse gear shaft into case far enough to install cone and secure with a new snap ring (Fig. 27). Slide
woodruff key. Drive in shaft, flush with end of next stop ring over shaft and index lugs into clutch
case (Fig. 31). hub slots.
(5) Install back-up light and gasket. Torque to 15 (4) Slide first speed gear (synchronizer cone toward
foot-pounds. clutch sleeve gear just installed) over mainshaft into
position against clutch sleeve gear.
Extension Housing Bushing Replacem ent (5) Install mainshaft bearing retaining ring, fol
(1) Remove extension housing yoke seal (Fig. 13) lowed by mainshaft rear bearing. Using an arbor
with Tool C-3985. and a suitable tool, drive or press bearing down into
(2) Drive the bushing out of housing (Fig. 39) with position. Install a new snap ring on shaft to secure
Tool C-3974. bearing (Fig. 26). This snap ring is a select fit for
(3) Slide a new bushing on installing end of Tool minimum end play.
C-3974. Align oil hole in bushing with oil slot in hous (6) Install partially assembled mainshaft into ex
ing, then drive bushing into place (Fig. 39). tension housing far enough to engage bearing retain
(4) To install a new seal, position seal in opening of ing ring in slot in extension housing (Fig. 24). Now
extension housing and drive it into housing with Tool compress ring with pliers so that mainshaft ball bear
C-3972 (Fig. 14). ing can move in to bottom against its thrust shoulder
in extension housing. Release ring and seat it all
MAINSHAFT around its groove in extension housing (Fig. 23).
(1) Sub assemble the synchronizer parts in the HEAVY DUTY MODEL (Fig. 25). Install mainshaft
order shown in (Figs. 40 and 41) as follows: Place a assembly into extension housing until bearing touches
stop ring flat on the bench followed by the clutch snap ring in housing groove. Then expand ring with
gear and sleeve. Drop the struts in their slots and pliers so that mainshaft ball bearing can slide in
snap in a strut spring placing the tang inside one against shoulder in extension housing. Release snap
strut. Turn the assembly over on the stop ring and ring and see that it seats in bearing groove.
install second strut spring tang in a different strut. (7) Slide third speed gear over mainshaft (with
(2) Slide second speed gear over mainshaft (syn SNAP RING
chronizer cone toward rear) and down against shoul CLUTCH GEAR
der on shaft (Fig. 27). (POSITION LONG
HUB FORWARD)
DRIVE PINION BEARING RETAINER
lit11
CLUTCH SLEEVE
-STRUTS .AND REVERSE GEAR
SEAL INSTALLING TOOL
ro STRUT SPRINGS (2)
NU 44
STOP RING FORWARD PY201
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CLUTCH GEAR SLEEVEs STOP RING^ G earshift Housing and Mechanism
STRUT SPRINGS (2)s The following 4 steps need only be done if gear
shift housing was disassembled previously because
of leaking seals.
STOP RING (1) Slide interlock sleeve into position in housing
(Fig. 19). Install a new oil seal on each lever shaft.
Coat one of the shafts with Multi-purpose grease, then
carefully install shaft in shift housing. Fill recess
CLUTCH GEAR around shaft with Multi-purpose grease, then install
operating lever (Fig. 18). Tighten nut to 18 foot
(POSITION LONG pounds.
FORWARD
HUB FORWARD) (2) Place a detent ball in the sleeve, followed by
LUG-STOP RING spring and interlock pin. Coat other lever shaft with
'SNAP RING TO CLUTCH GEAR PY202 Multi-purpose grease and start shaft into housing.
Fig. 4 1 - 3 r d - 4 t h Synchronizer—Disassembled
Place remaining detent ball on the spring and com
press ball and spring with a small screwdriver, then
synchronizer cone toward front) followed by third push shaft in until seated. Fill recess around shaft
gear stop ring (Fig. 22). with Multi-purpose grease, then install operating
(8) Install third and fourth speed synchronizer lever. Tighten nut to 18 foot-pounds.
clutch gear assembly (including sleeve, shift struts (3) Position lst-2nd and 3rd-4th clutch sleeve
and springs) on mainshaft (shift fork slot toward rear) gears in neutral. Install gearshift forks in grooves in
against third speed gear. (Fig. 22). Be sure and index clutch sleeve gears. Position gasket and as shift hous
rear stop ring with clutch gear shift struts. ing is installed, align shift fork shafts with holes in
(9) Install retaining snap ring (Fig. 22). Then, levers (Fig. 19). Install retaining bolts finger tight.
using heavy grease, position front stop ring over (4) Eight of the shift housing retaining bolts are
clutch gear, again indexing ring slots with shift struts. shoulder bolts for accurately locating the mechanism
CAUTION: It is very important that indexing of all on the transmission. One bolt shoulder is longer and
stop rings and positioning of gears and clutches acts as a dowel, passing through the cover and into
on mainshaft be correct, or mating of extension hous the transmission case at center of rear flange (Fig. 32).
ing to the case will not be possible without damage. Two bolts are standard, located at lower rear of cover.
(10) Coat a new extension housing to case gasket Tighten all bolts evenly to 15 foot-pounds.
with grease (both sides) then place in position on the The reverse shift lever and 1-2 shift lever have cam
case. surfaces which mate in reverse position (Fig. 42) to
(11) To provide clearance so that assembly will be lock the 1-2 lever, fork and synchronizer in neutral
possible, slide reverse idler gear to center of its position. Test for correct action by placing transmis
shaft and move the 3rd and 4th synchronizer sleeve sion in reverse. Then, while turning input shaft, move
as far forward as practical (do not lose struts).
(12) Move drive pinion as far forward as possible 1-2 SHIFT LEVER
to give maximum clearance for mainshaft pilot end. 1-2 SHIFT FORK MARKED "A" = MORE
NEUTRAL CLEARANCE
(13) Now slowly insert mainshaft assembly into POSITION MARKED "B" = LESS
case (Fig. 20) tilting it as required to clear idler and CLEARANCE
cluster gears and finally entering the pilot rollers in CAM CLEARANCE
the drive pinion gear. (REVERSE POSITION)
(14) Place 3rd and 4th synchronizer sleeve in REVERSE
LEVER
neutral position.
NEUTRAL REVERSE DETENT
(15) If everything is in proper position the exten POSITION
BALL-SPRING
sion housing will bottom to the case gasket without RETAINER
force. If not, check to see if a strut, pinion roller, or
stop ring is out of position.
(16) Install extension housing bolts and tighten to
50 foot-pounds.
(17) Using Tool C-3789 or C-3801 for heavy duty REVERSE IDLER GEAR DETENT
SHIFT FORK SPRING
model (Fig. 38), install a new oil seal in retainer bore.
PLUG
Install main drive pinion bearing retainer and gasket. NN200A
DETENT DETENT
BALL SPRING
Coat threads with sealing compound, then install at
taching bolts and tighten to 30 foot-pounds (Fig. 2).
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1-2 lever in each direction. If input shaft locks or be (5) Using a pointed drift, align crossmember bolt
comes harder to turn, the synchronizer is partly en holes, then install attaching bolts. Tighten to 30 foot
gaging caused by too much cam clearance. Select new pounds (Fig. 15 or 16).
1-2 shift lever, size “A” or “B” as required (Fig. 42). (6) Remove engine support fixture and disengage
If too little cam clearance exists it will be difficult or hooks from holes in the frame side rails. Install
impossible to shift to reverse. extension housing to rear engine mount bolts and
(5) Grease reverse shaft and install operating lever tighten to 40 foot-pounds. On Challenger (Fig. 16) the
and nut. Tighten to 18 foot-pounds (Fig. 17). engine mount to center crossmember bolt and nut,
(6) Install speedometer drive pinion gear and adap loose assembled to this point, should now be torqued
ter being sure range number, representing number of to 50 foot-pounds.
teeth on gear, is in 6 o’clock position (Fig. 10). (7) Fasten shift unit to extension housing mounting
plate with two bolts and lock washers and tighten to
TRANSMISSION INSTALLATION 30 foot-pounds. Referring to “Gearshift Linkage Ad
Place a small amount of Multi-Purpose lubricant justment”, connect shift control rods to transmission
around inner end of pinion shaft pilot bushing in fly levers and connect speedometer cable.
wheel and on pinion bearing retainer release bearing (8) Carefully guide front universal joint yoke into
sleeve area. Do not lubricate end of pinion shaft, extension housing and onto mainshaft splines. Con
clutch disc splines or clutch release levers. nect propeller shaft to rear axle pinion yoke aligning
(1) With transmission on a suitable jack, slide as marks made at removal.
sembly under vehicle. (9) Reconnect exhaust pipes (if removed).
(2) Raise transmission until drive pinion is centered (10) Fill transmission with Multi-Purpose Gear Oil
in clutch housing bore. SAE 140. If shift effort becomes extremely high dur
(3) Roll transmission slowly forward until pinion ing cold weather, Multi-Purpose Gear Oil SAE 80 or
shaft enters clutch disc. Turn pinion shaft until 90 should be used. Automatic Tranmission Fluid
splines are aligned, then work transmission forward AQ-ATF Suffix “A” (Dexron) may also be used in ex
until seated against clutch housing. Do not allow tremely cold climates.
transmission to "hang" after pinion shaft has entered (11) Lower vehicle, install gearshift lever and con
the clutch disc. sole, refer to “FOUR SPEED GEARSHIFT.”
(4) Install transmission to clutch housing bolts and (12) Road test vehicle to make sure transmisson
tighten to 50 foot-pounds. shifts smoothly and operates quietly.
MANUAL TRANSMISSION—3-SPEED (A -9 0 3 )
INDEX
Page Page
Cleaning and Inspection ............... ........... ............. 92 Speedometer Pinion G e a r .................................... 87
General Information .................................................. 84 Service Out of Vehicle ............................................ 89
Service Diagnosis ...................................................... 85 Assembling Transmission ................... ................. 93
Service In Vehicle .................................................... 85 Disassembling Transmission ............................... 89
Extension Housing and Bushing ......................... 87 Transmission I nstallation .................................... 95
Extension Housing Yoke Seal ............................. 89 Transmission Removal ............... ....................... 89
Gearshift Interlock ................................................ 87 Specifications ............................................ ............... 112
Gearshift Linkage Adjustm ent ............................. 85 Tightening R eference ................................................ 115
GENERAL INFORMATION
The A-903 transmission (Fig. 1) is used on models 1 to 1; Reverse—3.80 to 1.
with 198 or 225 cu. in. 6 cylinder engines. A synchronizing clutch is provided between second
A pad has been provided on the right side of the and third gears to prevent gear clash. The counter
transmission (Fig. 2) for identification numbers. shaft gear is in constant mesh and is supported by
Sample Number: PP903 3262 2220 roller bearings at each end.
The first two letters identify the manufacturing The mainshaft front end is piloted in roller bear
plant. The next three numbers are the transmission ings in the end of the main drive pinion, and is sup
model number. The following four numbers are a ported by a ball bearing in the rear of the case. The
date of manufacture code. The last four numbers are rear end of the mainshaft is supported by the sliding
a sequence number. yoke and bushing in the extension housing. The
This transmission has the following gear ratios: speedometer drive gear is integral with the mainshaft.
First—2.95 to 1; Second— 1.83 to 1; Third or High—
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SERVICE DIAGNOSIS
Condition Possible Cause Correction
HARD SHIFTING (a) Incorrect clutch adjustment. (a) Refer to Clutch Group for corrections.
(b) Improper cross-over adjustment. (b) Perform cross-over adjustment as
outlined in “Gearshift Linkage Adjust
ments.”
(c) Synchronizer clutch sleeve damaged. (c-d-e) Causes noted can only be correct
(d) Synchronizer spring improperly in ed by disassembling transmission and
stalled. replacing damaged or worn parts.
(e) Broken or worn synchronizer stop
rings.
TRANSMISSION SLIPS (a) Linkage interference. (a) Inspect and remove all linkage inter
OUT OF GEAR ferences.
(b) Gearshift rods out of adjustment. (b) Adjust gearshift rods as outlined in
“Gearshift Linkage Adjustments."
(c) Second or direct speed gear synchro (c) Disassemble transmission and re
nizer clutch teeth worn. place parts as necessary.
(d) Clutch housing bore or face out of (d) Refer to Clutch Group for correction
alignment. procedures.
TRANSMISSION NOISES (a) Excessive end play in countershaft (a) Replace thrust washers.
gear.
(b) Loose synchronizer hub spline fit on (b) Inspect mainshaft and synchronizer
mainshaft. hub and replace parts as necessary.
(c) Loose spline fit on low speed sliding (c) Inspect low speed sliding gear and
gear to mainshaft spline. mainshaft. Replace parts as neces
sary.
(d) Damaged, broken or excessively worn (d) Replace worn gears.
gear teeth.
(e) Drive pinion bearing worn. (e) Replace worn bearing.
SERVICE PROCEDURES
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VENT COVER
1ST-REVERSE
SLIDING YOKE
i \ /
^SPEEDOMETER
DRIVE ASSY.
CLUTCH
•INTERLOCK
PA W L
DRIVE P IN IO N BEARING A N D SEAL RETAINER
PY61 P Y60
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CROSS-OVER SLADE IN NEUTRAL
(6) Disengage clutch and shift halfway to first or
1 / reverse. Clutch should now be held down by interlock
to prevent clutch engagement.
R em oval a n d Installatio n
Rear axle gear ratio and tire size determines pinion
gear size requirements. Refer to “Speedometer Pinion
Chart” in Specifications for pinion usage.
(1) Place drain pan under adapter or drain trans
mission.
(2) Remove bolt and retainer securing speedometer
pinion adapter in extension housing (Fig. 7).
SC REWD SIV HR' NP556A (3) With cable housing connected, carefully work
adapter and pinion out of extension housing.
Fig. 5 —Holding Cross-Over Blade in N e u tra l Position (4) If transmission fluid is found in cable housing,
G earshift Interlock (Fig. 6) replace seal in the adapter (Fig. 8). Start seal and
(1) Disconnect clutch rod swivel from interlock retainer ring in adapter, then push them into adapter
pawl. with Tool C-4004 until tool bottoms (Fig. 9).
(2) Adjust clutch pedal free play as specified in (5) Note number of gear teeth and install speed
clutch section. ometer pinion gear into adapter (Fig. 8).
(3) When first-reverse lever on transmission is in CAUTION: Before installing pinion and adapter as
neutral (middle detent) position, the interlock pawl sembly, make sure adapter flange and its mating area
will enter the slot in first-reverse lever. on extension housing are perfectly clean and lubri
(4) Loosen swivel clamp bolt and slide swivel on cated. Dirt or sand will cause mis-aiignment resulting
rod to enter pawl. Install washers and clip. Hold inter in speedometer pinion gear noise.
lock pawl forward and tighten swivel clamp bolt to (6) Rotate the speedometer pinion gear and adapter
100 inch-pounds. Clutch pedal has to be in full re assembly so that the number on the adapter, corres
turned position during this adjustment. ponding to the number of teeth on the gear, is in the
CAUTION: Do not pull clutch rod rearward to en 6 o’clock position as the assembly is installed (Fig. 7).
gage swivel in the pawl. (7) Install retainer and bolt, with retainer tangs
(5) Shift transmission in normal manner from neu in adapter positioning slots. Tap adapter firmly into
tral to first, and from neutral to reverse (disengage extension housing and tighten retainer bolt to 100
clutch while shifting and engage clutch when in inch-pounds.
gear). Clutch action should be normal. (8) Fill transmission to level of fill plug (Fig. 2).
Removal
(1) Drain transmission fluid.
(2) Disconnect propeller shaft at rear universal
RETAINER
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RETAINER ADAPTER LO CK R IN G
A DA PTER
TO OL
SEAL
NP2
Fig. 8 —Speedometer Pinion and A d a p t o r - Fig. 9—Installing Speedometer Pinion Seal
Disassembled
C-3996. Align oil hole in bushing with oil slot in hous
joint. Carefully pull shaft yoke out of transmission ing, then drive bushing into place (Fig. 12).
extension housing. (4) Drive a new oil seal into housing with Tool C-
CAUTION: Be careful not to scratch or nick ground 3995 (Fig. 13).
surface on sliding spline yoke during removal and
installation of the shaft assembly.
Installation
(3) Remove the speedometer pinion and adapter. (1) Slide extension housing, with a new gasket,
(4) Remove bolts securing extension housing to
over mainshaft and down against the case. Install and
crossmember. Raise transmission slightly with service
tighten attaching bolts to 50 foot-pounds.
jack and remove center crossmember (Fig. 10).
(5) Remove extension housing to transmission bolts (2) Install center crossmember and tighten retain
and slide extension housing off the mainshaft. ing bolts to 30 foot-pounds. Lower transmission, in
stall extension housing to rear engine mount bolts and
Bushing Replacement tighten to 40 foot-pounds.
(1) Remove extension housing yoke seal (Fig. 11) (3) Install the speedometer pinion and adapter.
with Tool C-3994. (4) Carefully guide front universal joint yoke into
(2) Drive the bushing out of housing (Fig. 12) with extension housing and onto mainshaft splines. Con
Tool C-3996. nect propeller shaft to rear axle pinion yoke.
(3) Slide a new bushing on installing end of Tool (5) Fill transmission to level of fill plug (Fig. 2).
\
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/jL X j: H O U S IN G
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1 7
REAR MOUNT
SECTION A-A
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-TOOL
TO O L
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SEAL
~ NN125
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GEAR COVER
GEAR
RING
RING
SLEEVE
RING' SHAFT
BEARING'
SNAP RING
EXTENSION
BUSHING.
SPACER
ROLLERS
WASHER
BEARING
WASHER
SCREW
ROLLERS
PINION
OIL SLINGER
SEAL LOCKWASHER
GASKET
LOCKWASHER
RETAINER N K260C
retainer to ease, then slide retainer off the pinion. Pry case slightly, then slide synchronizer front inner stop
seal out of retainer, using a suitable tool. To avoid ring from the short splines on pinion as assembly is
leakage around the new seal, do not nick or scratch being removed from the case (Fig. 18).
the bore in which the seal is pressed, or the surface on (4) Remove snap ring (Fig. 17), which locks bear
which seal bottoms. ing on pinion shaft. Remove pinion bearing washer,
(2) Rotate drive pinion so that the omitted clutch then carefully press pinion shaft out of bearing,
tooth area (Fig. 17) is next to countershaft gear f o r using an arbor press. Remove oil slinger.
removal clearance. (5) Remove snap ring and bearing rollers from cav
(3) Grasp pinion shaft and pull assembly out of ity in end of drive pinion (Fig. 19).
1ST-REVERSE GEAR
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3 TEETH O M ITTE D TO CLEAR CLUSTER
BEARING A N D GEAR D U R IN G ASSEMBLY CLUTCH GEAR SNAP RING ON MAINSHAFT
S N A P R IN G '
WASHER
SN AP R IN G
(SELECT THICKNESS FOR
M IN IM U M END PLAY)
■sJH
.........A
’i | p , J V
S LIN G E R
(1) Remove clutch gear retaining snap ring from case while steadying gears as they drop free (Fig. 22).
mainshaft (Fig. 20). (4) Remove selective snap ring from shaft (Fig. 23)
(2) Remove mainshaft bearing retaining snap ring and press bearing off the mainshaft.
from case (Fig. 21). (5) Now remove the synchronizer parts (Fig. 24)
(3) Slide mainshaft and bearing rearward out of
i MAINSHAFT BEAR IN G TO
SYNCHRONIZER-OUTER STOP RINGS CASE SNAP R IN G
BACK UP LIGHT
SWITCH (SELECT THICKNESS FOR
M IN IM U M END PLAY)
SPEEDOMETER DRIVE
W ORM O N
M A IN S H A FT PY65
PY63
Fig. 2 1 —Removing M ainshaft to Case Snap Ring
Fig. 18—Remo1 ©rive Pinion
im
mvm
SK . ■ ^ mm
,/
MAINSHAFT PILOT
-S N A P R IN G V..
BEARING ROLLERS
PY70
MAINSHAFT BEARING PY66
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PROP SHAFT 1ST-REVERSE 2 N D -G E A R LOW AND REVERSE CAM
SLIDING S L ID IN G G E A R B E A R IN G C LU TC H
YOKE SPLINES SPLINES SURFAC E GEAR
SPLINES
...\
PILOT
BEARING 2ND AND DIRECT CAM
SURFACE
>» 2ND AND
MAINSHAFT DIRECT FORK
BEARING
SNAP RING 2ND AND LOW AND
(SELECT THICKNESS DIRECT LEVER REVERSE FORK
, FOR MINIMUM
END PLAY) \
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Fig. 2 3 —M ainshaft and Bearing Assembly
second gear, first-reverse gear, and shift forks from “LOW AND REVERSE
BALL
the case. LEVER
\
SLEEVE SPRING iC \&
G earshift Mechanism NY858A
(This operation need only be done if the seals are
leaking.) Fig. 25—A-903 Shift Forks and Levers
(1) Remove operating levers from their respective
shafts. of case until small key can be removed from counter
(2) Drive out tapered retaining pin from either of shaft.
the two lever shafts, then withdraw lever shaft from (3) Drive countershaft remaining way out of case,
inside transmission. (The detent balls are spring keeping arbor tight against end of countershaft to
loaded; as shaft is being withdrawn, the ball will drop prevent loss of bearing rollers.
(4) Remove countershaft gear and thrust washers
to bottom of the case.)
from the case.
(3) Remove interlock sleeve, spring, pin and both
(5) Remove bearing rollers, washers and center
balls from the case (Fig. 25). Drive out remaining spacer from countershaft gear.
tapered pin, then slide lever shaft out of trans
mission.
Reverse Id le r G ear
(4) Using a suitable drift, drive out lever shaft oil (1) Using a suitable drift, drive reverse idler gear
seals. shaft towards rear and out of the case. Remove wood
ruff key from end of shaft.
Countershaft G ear (2) Lift reverse idler gear and thrust washers
(1) Using a feeler gauge, measure end play of coun out of the case. Remove bearing rollers from gear.
tershaft gear (Fig. 26). The end play should be .005
to .022. (This measurement will determine if new CLEANING AND INSPECTION
thrust washers are to be installed at reassembly).
(2) Using countershaft bearing arbor, Tool C-578 Clean transmission case thoroughly, using a suit
for A-903 transmission drive countershaft toward rear able solvent, dry with compressed air. Inspect case for
cracks, stripped threads in various bolt holes and ma
CLUTCH GEAR SPRING
SLEEVE chined mating surfaces for burrs, nicks or any condi
tion that would render case unfit for further service.
CLUTCH GEAR The front mating surface should be smooth; if any
SNAP RING burrs are present, dress them off with a fine mill file.
If threads are stripped, install Helicoil inserts.
Ball Bearings
Wash ball bearings, using a clean solvent and blow
dry with compressed air.
CAUTION: Do not spin bearings with air pressure;
turn slowly by hand. Spinning unlubricated bearings
INNER STOP RINGS PY140
may cause damage to races and balls.
Fig. 24—A-903 Synchronizer—Disassembled Be sure ball bearings are clean, then lubricate
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o ------------------------- 3 SPEED— TRANSMISSIONS 21-93
BACK-UP LIGHT SWITCH
M ain sh aft
Inspect mainshaft gear and bearing mating sur
faces. If gear contact surfaces show signs of galling or
are excessively worn, a new mainshaft should be in
stalled (Fig. 23).
Inspect snap ring grooves for burred edges. If
rough or burred, remove condition using a fine file or
crocus cloth. Inspect synchronizer clutch gear teeth
on shaft for burrs.
Countershaft G ear
Fig. 26—Checking Countershaft Gear End Play (1) Slide countershaft gear bearing roller spacer
over arbor Tool C-578 for A-903 transmission. Coat
them with light grade engine oil. Inspect bearings for
bore of gear with lubricant and slide tool and spacer
roughness. This can best be determined by slowly
in gear bore.
turning outer race by hand. Measure fit of bearings
(2) Lubricate bearing rollers with heavy grease and
on their respective shafts.
install 22 rollers in each end of gear in area around
arbor. Coat with heavy grease and install bearing
N eedle Type Bearing Rollers and Spacers spacer rings in each end of gear.
Inspect all bearing rollers for flat spots or brinnel- (3) If countershaft gear end play was found to ex
ling. Inspect all bearing roller spacers for signs of ceed .022 during disassembly, install new thrust
wear or galling. Install new parts as required. washers. Coat with heavy grease and install thrust
washer at each end of countershaft gear and over
Gears arbor. Install gear and arbor in the case making sure
Inspect gear teeth on synchronizer clutch gears and tabs on thrust washers slide into grooves in the case.
stop rings. If there is evidence of chipping or exces (4) Using countershaft and a soft hammer, drive
sively worn teeth, install new parts at reassembly. Be
arbor forward out of countershaft gear and through
sure clutch sleeve slides easily on the clutch gear. bore in front of the case. Before driving countershaft
Inspect countershaft gear and all sliding gear teeth all way into case, be sure keyway is positioned in line
for chipped or broken teeth, or showing signs of ex
with key recess in rear of case. Insert shaft key and
cessive wear. Small nicks or burrs must be stoned off.
continue to drive countershaft forward in case until
Inspect teeth on main drive pinion. If excessively
key is bottomed in recess.
worn, broken or chipped, a new pinion should be in
stalled. If the oil seal contact area on drive pinion
shaft is pitted, rusted or scratched, a new pinion is Reverse Id le r G ear
recommended for best seal life. (1) Position arbor Tool C-464 in reverse idler gear
Test interlock sleeve and pin for free movement in and using heavy grease, install 22 roller bearings in
bore of shift housing. Examine detent balls for signs gear.
of brinelling. If lever detents show signs of exces (2) Place front and rear thrust washers at each end
sive wear to extent of not locking in gear, install a new of reverse idler gear, and position assembly in trans
part. Inspect shift forks for wear on the shanks and mission case with chamfered end of gear teeth toward
pads. front (Fig. 26).
(3) Insert reverse idler shaft into bore at rear of
Synchronizer Stop Rings case with keyway to rear, pushing arbor toward front
Inspect gear teeth and threads on synchronizer in of transmission.
ner stop rings for broken teeth or worn threads. In (4) With keyway aligned with recess in case, drive
spect pins on synchronizer outer stop ring assembly shaft forward, inserting key before keyway is ob
for being straight and attached securely. Replace scured. Continue driving shaft forward until key seats
parts as required. in recess.
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G earshift Mechanism (Fig. 25) SPREADER 2N D SPEED
(1) Place new shift lever shaft seals in their bores SPRING GEAR
S U P P O R T IN G GEA R SET FO R
M A IN S H A F T IN S T A L L A T IO N
\
.DETENT BALL-HOLDING TOOL
PY142 PY68
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groove away from gear end), then seat on shaft, using ' DRIVS PiNiON
an arbor press.
(3) Install keyed washer between bearing and re
taining snap ring groove.
(4) Secure bearing and washer with selected thick
ness snap ring. Four snap rings are available to elimi
nate end play. Be sure snap ring is properly seated.
If large snap ring around bearing was removed, install
at this time. NU44
(5) Place pinion shaft in a vise (with soft jaws),
then install 14 bearing rollers in cavity of shaft. Fig. 3 0 —Drive Pinion Seal Replacement
Coat bearing rollers with heavy grease, then install crankshaft and on pinion bearing retainer release
bearing retaining ring in its groove. bearing sleeve area. Do not lubricate end of the pin
(6) Rotate drive pinion so that the omitted clutch ion shaft, clutch disc splines or clutch release levers.
tooth area is next to countershaft gear for assembly (1) Place transmission on a suitable jack and slide
clearance (Fig. 17). Guide drive pinion through front assembly under vehicle.
of case and engage inner stop ring with clutch teeth, (2) Raise transmission until drive pinion shaft is
then seat pinion bearing. The pinion shaft bearing is centered in clutch housing bore.
fully seated when snap ring is in full contact with the (3) Roll transmission slowly forward until pinion
case. shaft enters clutch disc. Turn pinion shaft until
(7) Install a new seal in pinion bearing retainer, splines are aligned, then push transmission forward
using Tool C-3789 (Fig. 30). until seated against clutch housing. Do not allow
(8) Position retainer assembly and new gasket on transmission to "hang" after pinion has entered the
the case. Use thread sealing compound on bolts then clutch disc.
install and tighten to 30 foot-pounds. (4) Install transmission attaching bolts and tighten
to 50 foot-pounds. Remove the jack.
Extension Housing (5) Using a pointed drift, align crossmember bolt
(1) Slide extension housing and a new gasket holes, then install attaching bolts. Tighten to 30 foot
over mainshaft while guiding shaft through bushing pounds (Fig. 10).
and oil seal. Install and tighten attaching bolts to 50 (6) Remove engine support fixture and disengage
foot-pounds. Use sealing compound on bol t used in hooks from holes in frame side rails. Install extension
one hole tapped through transmission case. housing to rear engine mount bolts and tighten to 40
(2) Install transmission gasket and cover, install foot-pounds.
and tighten cover bolts to 12 foot-pounds. (7) Reconnect speedometer cable, gearshift rods
(3) Rotate the speedometer pinion gear and adapter and back-up light switch wires. Refer to “Gearshift
assembly so that the number on the adapter, corre Linkage Adjustment” and “Gearshift Interlock” in
sponding to the number of teeth on the gear, is in the this Group.
6 o’clock position as the assembly is installed. (8) Carefully guide front universal joint yoke into
(4) Install and tighten drain plug to 25 foot-pounds extension housing and onto mainshaft splines. Con
and back-up light switch to 15 foot-pounds. nect propeller shaft to rear axle pinion yoke,
(9) Fill transmission to level of fill plug (Refer to
TRANSMISSION INSTALLATION Lubrication Group).
(10) Road test vehicle, making sure transmission
Place a small amount of Multi-Purpose Grease shifts smoothly and operates quietly.
around inner end of pinion shaft pilot bushing in
MANUAL TRANSMISSION—(A -2 3 0 )
THREE SPEED
INDEX
Page Page
General Information .................................................. 96 Gearshift Linkage Adjustment . 109
Service Diagnosis ...................................................... 96 Speedometer Pinion G e a r----- . 108
Service in Vehicle Service Out of Vehicle
Extension Housing Yoke Seal ............................. 109 Assembling Transmission —
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Page Page
Cleaning and Inspection...................................... 101 Transmission Rem oval.......................................... .. 97
Disassembling Transmission ............................... 97 Specifications.............................................................. 113
Extension Housing Bushing Replacem ent........ 105 Tightening Reference................................................ 115
Transmission Installation ........................................ 107
GENERAL INFORMATION
The A-230 three speed transmission (Fig. 1) has two the gear and the transmission case. The alignment of
synchronizer units, providing clash free shifting in the needle type roller bearings within the gear is
all forward gears. maintained by six thrust washers (one being used
A pad has been provided on the right side of the between the rows of roller bearings and one at each
transmission (Fig. 2) for identification numbers. end).
Sample Number: PP 230 3262 2220 The reverse idler gear is also supported on needle
The first two letters identify the manufacturing type roller bearings.
plant. The next three numbers are the transmission The gearshifting is manually operated through shift
model number. The following four numbers are a date control rods to the transmission. Any forward gear
of manufacture code. The last four numbers are a may be engaged while the vehicle is in motion
sequence number. through the use of synchronizing clutches.
The main drive pinion (input shaft) is supported The transmission may be used as an aid to deceler
by a ball bearing in the transmission case and an olite ation by downshifting in sequence without double
bushing pressed in the end of the crankshaft. clutching or gear clashing, due to the fact that all
The mainshaft (output shaft) front end is supported forward speeds are synchronized. The service pro
by roller bearings in the end of the main drive pinion cedures covering the A-230 transmission used on all
and a ball bearing retainer in the front of the exten vehicles so equipped is identical to the following
sion housing. The output end of the mainshaft is service procedures except where noted.
splined to the sliding universal joint yoke, which is I MPORTANT: Some internal transmission parts are
supported by a bushing in the extension housing. different from standard on vehicles with high per
The countershaft gear is supported by a double row formance engines. These "special" parts are listed in
of needle type roller bearings at each end and the applicable Parts Catalog; therefore, be sure they are
thrust is taken on thrustwashers between the ends of used when replacement is necessary.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
HARD SHIFTING (a) Incorrect clutch adjustment. (a) Refer to Clutch Group for corrections.
(b) Improper linkage adjustment. (b) Perform linkage adjustment as out
lined in “Gearshift Linkage Adjust
ments."
TYPICAL SHIFT LEVER
S'—"(
SPEEDOMETER
DRIVE ASSEMBLY
/ BACK-UP
D R A IN PLUG LIGHT SWITCH
DRIVE P IN IO N
RETAINER
FILL PLUG*
ID EN TIFIC A TIO N
PY627 NUMBER PAD PY628
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(c) Synchronizer clutch sleeve damaged, (c-d-e) Causes noted can only be cor-
(d) Synchronizer spring improperly in- rected by disassembling transmission
stalled. and replacing damaged or worn parts.
(e) Broken or worn synchronizer stop
rings.
TRANSMISSION SUPS (a) Linkage interference. (a) Inspect and remove all linkage inter
OUT OF GEAR ferences.
(b) Gearshift rods out of adjustment. (b) Adjust gearshift rods as outlined in
“Gearshift Linkage Adjustments.”
(c) Synchronizer clutch teeth worn. (c) Disassemble transmission and re
place parts as necessary.
(d) Clutch housing bore or face out of (d) Refer to Clutch Group for correction
alignment. procedure.
TRANSMISSION (a) Excessive end play in countershaft (a) Replace thrust washers,
NOISES gear.
(b) Loose synchronizer hub spline fit on (b) Inspect mainshaft and synchronizer
mainshaft. hub and replace parts as necessary.
(c) Damaged, broken or excessively worn (c) Replace worn gears,
gear teeth.
(d) Rough or pitted bearing races or balls, (d) Replace worn bearing.
SERVICE PROCEDURES
TRANSMISSION REMOVAL clearance.
(2) Remove housing retaining bolts and lift shift
(1) Remove shift rods from transmission levers. mechanism from case (Fig. 4).
(2) Drain fluid from transmission. (3) If shaft “0 ” ring seals need replacement, pro
(3) Disconnect propeller shaft at rear universal ceed as follows: Pull shift forks out of shafts.
joint. Mark both parts to reassemble in same position. (4) Remove nuts attaching operating levers to the
Carefully pull shaft yoke out of transmission exten shafts. Disengage levers from flats on shafts and re
sion housing. move.
CAUTION: Be careful not to scratch or nick ground (5) Remove burrs from shafts before removal from
surface on sliding spline yoke during removal and housing to avoid scoring the bores which would cause
installation of the shaft assembly. leakage after reassembly.
(4) Disconnect speedometer cable and back-up light (6) Push gearshift lever shafts through housing
switch leads. bores and remove.
(5) Some models have exhaust systems which will
have to be partially removed for clearance. See Ex Drive Pinion Retainer a n d Extension Housing
haust Systems, Section 11. (1) Remove bolts holding drive pinion bearing re
(6) Install engine support fixture C-3487A, engaging tainer to front of transmission case.
the hooks in holes in frame side member. Be sure (2) Slide retainer and gasket forward off the drive
support ends are up against underside of oil pan pinion. Pry pinion oil seal from bearing retainer. To
flange. avoid leakage around the new seal, do not nick or
(7) Raise engine slightly with support fixture. Dis scratch the bore in which the seal is pressed, or the
connect extension housing from removable center
surface on which seal bottoms.
crossmember.
(3) Tap drive pinion forward carefully with a brass
(8) Support transmission with a suitable jack and
drift, as far as possible to provide maximum disassem
remove center crossmember.
(9) Remove transmission to clutch housing bolts. bly clearance for mainshaft removal (Fig. 5).
Slide transmission toward rear until drive pinion shaft (4) Rotate cut away part of second gear next to
clears clutch disc, before lowering transmission. countershaft gear for mainshaft removal clearance
(10) Lower transmission and remove from under (Fig. 6).
vehicle. Thoroughly clean exterior of unit. (5) Also shift 2nd-3rd synchronizer sleeve forward
for the same reason.
DISASSEMBLING TRANSMISSION (Fig. 3) (6) Remove bolt and retainer securing speedometer
G earshift Housing a n d Mechanism pinion adapter in extension housing (Fig. 2). Carefully
(1) Shift transmission to second gear for shift fork work adapter and pinion out of extension housing.
E-Bodies.org
E-Bodies.org
Ref. Ref. Ref. Ref. Ref. R ef.
No. Name No. Name No. Name No. Name No. Name No. Name
1. Gear First 14. G asket 27. S h aft, O u tp u t 40. G asket 53. L ever 66. W asher
2 . R ing 15. E xtension 28. W asher 41. Seal 54. N u t , L o c k in g 67. R o lle r
3. S p r i n g 16. B u sh in g 29. R o l le r 42. S n a p R in g 55. S w itc h 68. G e ar, I d l e r
4. S le e v e 17. Seal 30. W asher 43. S n a p R in g 56. L ever 69. W asher
5 . S t r u t s (3 ) 18. Y oke 3.1. R o lle r 44. B ea rin g 57. B o lt 70. S haft
6. S prin g 19. S n a p Ring 32. W asher 45. P i n i o n , D rive 58. G asket 71. Key
7 . S n a p Ring 20. R ing 33. C ou n tersh aft 46. R o l le r 59. L ever, Inte rlo ck 72. W asher
8 . B u s h in g 21. S p rin g 34. W asher 47. S n a p R in g 60. Lever 73. P lu g , F il l e r
9 . G e a r, R e v e r s e 22. S le e v e 35. R o l le r 48. C ase 61. F ork 74. G e ar, C l u tc h
10. B ea rin g 23. S t r u t s (3) 36. W asher 49. P l u g , D r a in 62. S prin g 75. G e ar, C l u tc h
11. S n a p R ing 24. S p rin g 37. R o l le r 50. F o rk 63. S n a p Ring 76. Key
1 2 . S n a p R ing 25. Ring 38. W asher 51. Lever 64. W a s h e r 77. G asket
13. R etain e r 26. G e a r, S e c o n d 39. R etain e r 52. H ousing 65. G e a r, C o u n te rs h a ft
(7) Remove bolts that attach extension housing to (2) Remove idler gear with arbor in place to retain
rear of transmission case. rollers.
(8) Tap with plastic hammer to break gasket seal (3) Remove both thrust washers (Fig. 8).
and carefully guide housing off rear of mainshaft. (4) Grasp mainshaft assembly and remove through
rear of case (Fig. 8).
Idler G ear and M ain sh aft (Fig. 7)
(1) Insert arbor Tool C-464 in case to push reverse Countershaft G e a r and Drive Pinion
idler shaft and key out of case (Fig. 7). (1) Using a mallet and arbor Tool C-4112 tap coun
SLEEVE IN
tershaft rearward and remove key. Continue to drive
SLEEVE IN
2ND GEAR NEUTRAL
SYNCHRONIZER SLEEVES
' MOVED FORWARD
£
/ * ;M
w A s *" ■ \ \
DRSVE \ MAINSHAFT
PINION
,0"
% iP \ INSTALLED
\ HERE,
\ THE LONG
\SHOULDER
BOLT
ACTS AS A IDLER
COVER ; / SHAFT
LOCATING
SHIFT FORKS
DOWEL POSITION CUT AWAY
AREA O N 2ND GEAR
A
COUNTERSHAFT
PY630
NEXT TO CLUSTER
-GEAR FOR CLEARANCE PY 632
Fig. 4 — A - 23 H W ith S hift Mechanism Assy*, Pinion
Bearing Retainer, a nd Extension Housing—Removed Fig. 6 —Position 2nd G ear and Shift Sleeves fo r
Clearance
BRASS
ROD MAINSHAFT BEARING
RETAINER
MAINSHAFT
;; A /
i t # m
DRIVE PINION
ASSEMBLY X
M A IN S H A F T ASSEMBLY IDLER SHAFT
PY631 A N D KEY
ARBOR FOR
ROLLERS PY633
Fig. 5—Tap D rive Pinion Forward fo r M ainshaft
Pilot Clearance
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, mp
S N AP R IN G
'•qr
\
BEARING OUTER RACE
COUNTERSHAFT
GEAR
PY636
Fig. 8 —M ainshaft Assembly—Removal or Installation
countershaft out of case, maintaining contact between Fig. 10—Snap Ring on Pinion G e ar Bearing—Removal
shaft and arbor so that washers will not drop between
them (Fig. 9).
(2) Lower countershaft gear to bottom of case to
permit removal of main drive pinion. f t
(3) Remove snap ring from pinion bearing outer
race (Fig. 10).
(4) Using a plastic hammer, drive the pinion into
case and remove through rear (Fig. 11). - : 9 i ' - 9
(5) If bearing is to be replaced, remove snap ring ■ ■ v ‘V - '
and press bearing off the pinion gear shaft (Fig. 12). ■ p v
(6) Lift countershaft gear and arbor assembly out
through rear of case (Fig. 13).
M a in s h a ft Disassembly
(1) Remove the snap ring from front end of main \
COUNTERSHAFT GEAR A N D ARBOR
shaft which retains the 2nd-3rd synchronizer clutch ASSEMBLY LY IN G IN BOTTOM OF CASE
PY637
gear (Fig. 14).
(2) Slide the 2nd-3rd synchronizer assembly off end Fig. 1 1—Drive Pinion and Bearing A s s e m b ly —
of mainshaft along with the 2nd gear stop ring (Fig. Removal or In sta lla tio n
15).
COUNTERSHAFT
SNAP RING PLIERS
ir-t.•?;
f i
SNAP RING
DRIVE PINIO N
a8£- •■ :\ ■ GEAR SHAFT
- ■
ARBOR
FOR ROLLERS
\
COUNTERSHAFT GEAR
PY641
E-Bodies.org
RETAINER MOUNTING BOLT HOLES (4)j_______ 2N D GEAR
■S;OP R IN G
v IH H H IH IIH H H I
Ht / ■ p b
?
■ :*' t / / ■
>•;' ’ ■ **
. *r
; (. -v 9
\
STOP RING
LUG
\
2ND-3RD
HOLE FOR P IN IO N B EARING RETAINER D R A IN SYNCHRONIZER ASSEMBLY PY644
PY638
Fig. 13 —Countershaft G ear and Arbor Assembly— Fig. 15—2nd~3rd Synchronizer Assembly and Stop
Removal or Installation Ring—Rem oval or In sta lla tio n
(3) Remove 2nd gear from mainshaft (Fig. 16). THRUST FLANGE
O H M AINSHAFT
(4) Spread snap ring in mainshaft bearing retainer
to disengage it from bearing groove and slide retainer
off the bearing race (Fig. 17).
(5) Remove snap ring securing bearing to mainshaft
ft.
(Fig. 18).
(6) Set up parts in arbor press to force bearing off
mainshaft. By supporting front side of reverse gear it * JV;r*9' . v *
can push the bearing off shaft as pressure is applied
to shaft (Fig. 19). When bearing clears shaft, don’t let
FIRST GEAR
parts drop through.
(7) Remove from press and slip off the end of shaft, SECOND GEAR PY645
1
/ /
SNAP RING V- 'f 1 m-
PLIERS
\
G R O O V E IN
^BEARING RACE
Fig. 14—Sim p Ring—2nd-3rd Synchronizer Clutch Fig 1 7 —S n a p Ring Spread, to Remove or Install
Gear to M ain sh aft—Rem oval o r Installation Retainer on M ainshaft Bearing
E-Bodies.org
S N A P R IN G MAINSHAFT GR O O VE FOR 1ST GEAR
PLIERS BEARING B EARING S N AP R IN G
/ \\
H I
NO STOP RING ON REVERSE
M A IN S H A F T
SIDE OF SYNCHRONIZER
B EARING
^ S N A P R IN G REVERSE
GEAR PY653
1ST GEAR
\
1ST-REVERSE
- PRESS R A M SYN C H R O N IZER
ASSEMBLY PY654
\
B EARING
PRESS BED
1ST-REVERSE
M A IN S H A FT SYN C HRO NIZER ASSEMBLY PY655
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THRUST FLANGE BETWEEN COUNTERSHAFT GEAR ROLLER
1ST AND 2ND GEARS
ASSEMBLY A,*801?
SPECIAL TOOL
CLUTCH GEAR SPLINES
AND SNAP RING GROOVES
; - - ROLLER THRUST WASHER
STOP RING 1ST GEAR PY656 " “'"■'GEAR THRUST WASHER PY649
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CLUTCH GEAR SNAP RING
(POSITION LONG HUB FORWARD)
STOP RING
STRUTS
\
CLUTCH SLEEVE
FORWARD
ASSEMBLY ARBOR STRUT SPRINGS (2) PY203
SPECIAL TOOL
Fig. 2 8 —I st-Reverse Synchronizer—Disassembled
COUNTERSHAFT PY657
ring seats in bearing groove (Fig. 17).
Fig. 2 6 —Countershaft—Installation
(21) Place second gear over front of mainshaft with
Turn the assembly over on the stop ring and install thrust surface against flange (Fig. 16).
second strut spring with tang in a different strut. (22) Install properly indexed stop ring and 2nd-3rd
(14) Slide 1st gear and stop ring over rear end of synchronizer assembly against second gear (Fig. 15).
mainshaft and against flange which separates 1st and (23) Install 2nd-3rd clutch gear snap ring on shaft
2nd gears (Fig. 23). (Fig. 14).
(15) Slide lst-Reverse synchronizer assembly over (24) Move 2nd-3rd synchronizer sleeve forward as
mainshaft, indexing the hub slots to 1st gear stop ring far as practical (limited by need to retain struts in
lugs (Fig. 22). place) and install front stop ring (coated with grease
(16) Install clutch gear snap ring on mainshaft (Fig. to hold it in position) inside sleeve with lugs indexed
21). to struts.
(17) Slide reverse gear and mainshaft bearing in (25) Rotate cut out on second gear so it is toward
place and take to press, to force bearing on shaft (Fig. countershaft gear for clearance (Fig. 6).
20 ). (26) Now slowly insert mainshaft assembly into
(18) Support inner race of bearing and press shaft case (Fig. 8) tilting it as required to clear cluster gears
through to shoulder (Fig. 31). and finally entering the pilot rollers in the drive
Be sure snap ring groove on outer race is forward. pinion gear.
(19) Install bearing retaining snap ring on main If everything is in proper position the bearing re
shaft (Fig. 18). tainer will bottom to the case without force. If not,
(20) Spread snap ring in mainshaft bearing retainer check to see if a strut, pinion roller, or stop ring is
groove and slide it over the bearing. Be sure snap out of position.
STRUTS
STOP RING
CLUTCH GEAR
1ST-REVERSE
SYNCHRONIZER SLEEVE (POSITION LONG
FORWARD
HUB FORWARD)
/ 5 STOP RING
S EC O N D LUG-STOP RING
STOP R IN G GEAR PY642
'SNAP RING TO CLUTCH GEAR PY202
E-Bodies.org
PRESS RAM-
1ST GEAR
wmmmm
*v ;?"9' ?*v:
■ F
SYNCHRONIZER
CLUTCH GEAR SLOT FOR STRUT
. SLEEVE PRESS BED
REVERSE GEAR
I*
\
PLATES
SUPPORTING
CLUTCH GEAR : -IN N E R RACE
C l: SEARING
STOP R IN G L U G -
I
Tool C-3974.
T A N G O N SPRI N G
I N S I DE STRUT
ft
ROLLERS
\
STEP®. INSTALL STRUT SPRING py650'
E-Bodies.org
■L O C A T IN G K E Y W A Y
-T O O L
FOR B E A R IN G
| RETAINER
VENT _
PA S S A G E
NN125
SHIFT LEVER
( T Y P I C A L ) H i
IN TE R LO C K LEVERS
seal
1ST-REVERSE \ V
SH IFT S H A F T \ X I
N N361 SH IFT FO RKS ' X 1
Fig. 3 4 —Removing Extension Housing Seal
P IV O T PIN
T O O L IN S T A L L IN G
"E " CLIP —
INTERLOCK PIVOT
\
<G T O C .
\
(1
>R E M O V IN G
END
r 2ND-3RD
SHIFT SHAFT
" O " RING
OIL SEAL
INTERLOCK
LEVER SPRING
PY648
IN S T A L L IN G E N D N U43
E-Bodies.org
position (straight up) and install shift forks through in clutch housing bore.
bores and under both interlock levers. (3) Roll transmission slowly forward until pinion
shaft enters clutch disc. Turn pinion shaft until splines
Install G earshift Mechanism are aligned, then work transmission forward until
(37) Position the 2nd-3rd Synchronizer sleeve in seated against clutch housing. Do not allow trans
transmission to rear (in 2nd gear). Position the lst- mission to "hang" after pinion shaft has entered the
reverse synchronizer sleeve to middle of travel (in clutch disc.
neutral) (Fig. 4). Place the shift forks in the gearshift (4) Install transmission to clutch housing bolts and
mechanism in the same positions. tighten to 50 foot-pounds.
(38) Install gasket and gearshift mechanism on (5) Using a pointed drift, align crossmember bolt
transmission using special shoulder bolts. One bolt holes, then install attaching bolts. Tighten to 30 foot
has an extra long shoulder which enters the transmis pounds (Fig. 39 or 40).
sion case acting as a locating dowel pin. This hole is (6) Remove engine support fixture and disengage
at center rear of case (Fig. 4). Tighten bolts evenly to hooks from holes in the frame side rails. Install ex
15 foot-pounds. tension housing to rear engine mount bolts and tight
(39) Install speedometer drive pinion gear and adap en to 40 foot-pounds. On Challenger models the en
ter being sure range number, stamped on outside of gine mount to center crossmember bolt and nut, loose
adapter, representing number of teeth on gear, is in assembled to this point, should now be torqued to 50
6 “O” clock position (Fig. 40). foot-pounds.
(7) Referring to “Gearshift Linkage Adjustment”,
TRANSMISSION INSTALLATION connect shift control rods to transmission levers and
connect speedometer cable.
Place a small amount of Multi-Purpose lubricant (8) Carefully guide front universal joint yoke into
around inner end of pinion shaft pilot bushing in fly extension housing and onto mainshaft splines. Con
wheel and on pinion bearing retainer pilot, for clutch nect propeller shaft to rear axle pinion yoke aligning
release sleeve. Do not lubricate end of pinion shaft, the marks made at removal.
clutch disc splines or clutch release levers. (9) Reconnect exhaust pipes (if removed). Tighten
(1) With transmission on a suitable jack, slide as bolts securely.
sembly under vehicle. (10) Fill transmission. See Lubrication Section for
(2) Raise transmission until drive pinion is centered detailed recommendations.
TIGHTENING TORQUE
200 IN. LBS.
Y
40 FT. LBS.
V
30 FT. LBS.
V
E-Bodies.org
TRANSMISSION EXTENSION
HOUSING
TIGHTENING TORQUE
BOLT (2)
50 FT. LBS.
❖
30 FT. LBS.
%
40 FT. LBS.
$
PY171
\
BOLT AN D
WASHER | OIL SEAL
ADAPTER RETAINER
RING
NN90A . 6 O ’CLOCK POSITION NN362
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ADAPTER LOCK RING joint. Mark both parts to reassemble in same position.
Carefully pull shaft yoke out of transmission exten
sion housing.
CAUTION: Be careful not to scratch or nick ground
surface on sliding spline yoke during removal and
installation of the shaft assembly.
(3) Remove extension housing yoke seal (Fig. 34)
with Tool C-3985.
(4) To install a new seal, position seal in opening of
NP2 extension housing and drive it into housing with Tool
Fig. 4 3 —Installing Speedometer Pinion Seal in C-3972 (Fig. 36).
A d ap ter (5) Carefully guide front universal joint yoke into
assembly so that the number on the adapter, corre extension housing and on mainshaft splines. Connect
sponding to the number of teeth on the gear, is in the propeller shaft to rear axle pinion shaft yoke aligning
6 o’clock position as the assembly is installed (Fig. 41). the marks made at removal.
(7) Install retainer and bolt, with retainer tangs in (6) Fill transmission to level of fill plug (Refer to
adapter positioning slots. Tap adapter firmly into ex Lubrication Section).
tension housing and tighten retainer bolt to 100
inch-pounds. GEARSHIFT LINKAGE ADJUSTMENT
(8) Fill transmission to level of fill plug (Refer to
Lubrication Section). A -230 Column Shift
(1) Remove both shift rod swivels from transmis
EXTENSION HOUSING YOKE SEAL sion shift levers (Fig. 44).
(2) Make sure transmission shift levers are in neu
Replacement tral (middle detent) position.
(1) Place drain pan under yoke seal. (3) Move shift lever to line up locating slots in bot
(2) Disconnect propeller shaft at rear universal tom of steering column shift housing and bearing
■ STRG. COL.
«2ND—3RD ROD
2ND—3RD LEVER
1ST-REVERSE LEVER
1ST-REVERSE ROD
FWD. _ Y I
CUP L L /\ cup
ASSEMBLED VIEW PLAIN WASHERR I N . /
PLAIN WASHER
GROMMET FWD.
BUSHING
PLAIN WASHER
PLAIN WASHER
1ST-REVERSE ROD PLAIN WASHER
BOLT SWIVEL
1ST-REVERSE ROD
2ND—3RD ROD
DETAILS AT TRANSMISSION
DETAILS AT STEERING COLUMN PY694
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CROSS-OVER SLADE IK NEUTRAL
reverse lever at transmission. Install washers and clip.
Tighten swivel bolt to 100 inch-pounds.
(7) Remove gearshift housing locating tool, unlock
ignition switch and shift column lever to neutral posi
tion.
(8) Adjust 2nd-3rd rod swivel by loosening clamp
bolt and sliding swivel along rod so it will enter 2nd-
3rd lever at transmission. Install washers and clip.
Tighten swivel bolt to 100 inch-pounds.
(9) Remove tool from cross-over blade at steering
column and shift through all gears to check adjust
ment and cross-over smoothness.
(10) Check for proper operation of steering column
lock in reverse and second gear positions. With proper
SCREWDRIVER NP556A linkage adjustment, column should lock in reverse
position and should not lock in second position.
Fig. 4 5 —H olding Crossover Blade in N e u tra l Position
housing. Install suitable tool in slot and lock ignition Three Speed Floor Shift Mechanism
switch. (Figs. 4 6 or 47)
(4) Place screwdriver or suitable tool between cross
over blade and 2nd-3rd lever at steering column so Removal
that both lever pins are engaged by cross-over blade (1) Disconnect negative (ground) cable from bat
(Fig. 45). tery.
(5) Set lst-Reverse lever on transmission to reverse (2) Loosen lock nut and unscrew shift knob.
position (rotate clockwise). (3) To remove console, if so equipped, see pro
(6) Adjust lst-reverse rod swivel by loosening clamp cedure in “Body” section 23.
bolt and sliding swivel along rod so it will enter 1st- (4) Remove retaining screws from floor pan boot
SCREW AND WASHER ASSEMBLY (3) KNOB
NUT
WASHER (2)
SCREW (4)
COVER
BOOT ASSEMBLY
/STEERING COLUMN
GEARSHIFT
SELECTOR
COLUMN LEVER
LOCK
SPACER (3) 2ND AND 3RD ROD
ROD
MECHANISM
E-Bodies.org
GEARSHIFT KNOB
SELECTOR LEVER
SCREW A N D WASHER
ASSEMBLY (3)
ROD — COLUM N LOCK FRONT
CLIP (2)
2ND A N D
3RD ROD
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and retainer and slide up and off shift lever. portion of lower boot up above floor pan opening).
(5) Remove shift lever attaching screws and remove (6) Attach shift lever to mechanism with three
lever. mounting screws, grommets and spacers.
(6) Remove retaining clips, washers and shift rods (7) Slide boot and retainer over shift lever and
from shift mechanism levers under floor pan. fasten to floor with four screws each.
(7) Remove bolts securing shift mechanism to trans (8) To install console, if so equipped, see procedure
mission extension housing mounting plate and remove in “Body” section 23.
the unit. (9) Install shift knob and its lock nut on shift lever.
(10) Reconnect battery ground cable and test shift
I n s t a l la t io n a n d A d j u s t m e n t (Figs. 4 6 o r 4 7 ) ing action for smoothness.
(1) Position shift mechanism on transmission exten
sion housing mounting plate and secure with the three C o lu m n L o c k L in k a g e A d j u s t m e n t
mounting bolts. (If equipped with lower boot, place For removal or installation of these parts, follow
boot on mechanism first and insert long mounting bolt the arrangem ent of parts shown in (Fig. 48).
through unit and boot before attaching to mounting (1) Loosen the adjustable rod locking bolt.
plate). (2) Place transmission in reverse gear.
(2) Fabricate a lever alignm ent tool from 1/16 inch (3) At the steering column, line up locating slots
thick sheet metal to dimensions shown in figures 46 at bottom of shift housing and bearing housing. Install
or 47. suitable tool in slots to hold alignment. A strip of
(3) Insert lever alignment tool into slots in levers m etal 1/16 inch thick and 1/4 inch wide, held in place
and mechanism fram e to hold levers in neutral cross with tape will do.
over position. (4) Tighten adjustable rod locking bolt to 125 inch-
(4) Place transmission levers in neutral (middle de pounds and remove tool from column.
tent) position and adjust shift rod swivels so rods will (5) The steering column should now lock when
install freely to levers. transmission is in reverse gear but should not lock in
(5) Secure rods with proper washers and clips and any other gear.
remove alignm ent tool. (If so equipped, work flange
SPECIFICATIONS
3-SPEED TRANSMISSION
(A-903 6 CYL ONLY)
E-Bodies.org
3-SPEED TRANSMISSION
(A-230 ALL SYNCHRONIZED)
198-225 340
Engine Displacement (Cu. In.)_______ 318 383
Gear Ratio
First ................................................ 3.08 2.55
Second ............................................ 1.70 1.49
T h ir d ................................................ 1.00 1.00
Reverse .......................................... 2.90 3.34
Downshift Speed Limits
3rd to 2nd ....................................... 45 to 15 mph
2nd to 1st ....................................... 25 to 0 mph
Lubricant U.S. Pints IMP. Pints
C apacity.......................................... 4-3/4 4
Type ................................................ Auto. Trans. Fluid AQ—ATF Suffix “A” or (Dexron)
Gear Type .......................................... Helical
Tolerances
Clutch Housing Face Squareness .006 Max.
Clutch Housing Bore Run-Out . . . .008 Max.
4-SPEED TRANSMISSION
(A-833)
Heavy
std. Duty
Gear Ratio
First ........................................................ 2.66 2.65
Second .................................................... 1.91 1.93
T h ird ........................................................ 1.39 1.39
Fourth .................................................... 1.00 1.00
Reverse ................................................. 2.58 2.57
Gear Type .................................................. Helical
(Except Reverse)
Tolerances
Countershaft Gear End P la y ............... .015" to .029"
Clutch Housing Face Squareness . . . .006" Max.
Clutch Housing Bore R un-O ut............ .008" Max.
Lubricant—Capacity and T y p e ................ U.S. Pints IMP. Pints
D a r t .......................................................... 7 5- 3/4
C hallenger.............................................. 7-1/2 6-1/4
Warm Climate—Multi-Purpose Gear Oil S.A.E. 140
Cold Climate—Multi Purpose Gear Oil . S.A.E. 80 or 90 or
Auto. Trans. Fluid AQ—ATF Suffix “A” or (Dexron)
Downshift Speed Limits
4th to 3rd .............................................. 50 to 25 mph
3rd to 2nd .............................................. 25 to 15 mph
2nd to 1 s t .............................................. 15 to Zero mph
TORQUEFLITE TRANSMISSIONS
Transmission Models A-904 A-727
TY PE............................................................................. Automatic Three Speed with Torque Converter
TORQUE CONVERTER DIAMETER ................(Std.) 10-3/4 inches 11-3/4 inches
(High Perf.) 10-3/4 inches
OIL CAPACITY—TRANSMISSION AND U.S. Imperial U.S. I mperial
TORQUE CONVERTER ........................................... Measure Measure Measure Measure
Use Automatic Transmission Fluid Labeled
Type AQ-ATF, Suffix “A" or "Dexron” ..(Std.) 17 Pts. 14 Pts. 19 Pts. 16 Pts.
(High Perf.) 16-1/2 Pts. 13-1/2 Pts.
COOLING METHOD .................................................. Water-Heat Exchanger
LUBRICATION ................... ........................................ Pump (Rotor Type)
E-Bodies.org
A-904 A-727
CLUTCHES—Engine Cu. In........... 198-225-318 225-318-340-383-440-426
Number of Front Clutch Plates 3 3 4 3 3 4 4 4 5
Number of Front Clutch Discs . 3 3 4 3 3 4 4 4 5
Number of Rear Clutch Plates . 2 2 3 3 3 3 3 3 3
Number of Rear Clutch Discs . 3 3 4 4 4 4 4 4 4
GEAR RATIOS ............................... First Second Third Reverse
45 to 1 1.45 to 1 1 to 1 2.20 to 1
PUMP CLEARANCES
Outer Rotor to Case B o r e ........ .004" to .008"
Outer to Inner T i p ..................... .005" to .010"
End Clearance—R o to rs ............ .0015" to .003”
PLANETARY ASSY. END PLAY . . . .006" to .033" .010" to .037"
DRIVE TRAIN END PLAY............ .030 to .089 .037" to .084"
CLUTCH PLATE CLEARANCE
Front Clutch ............................... .042 to .087" (3 Disc) .036 to .086" (3 Disc)
.056 to .104" (4 Disc) .024 to .125" (4 Disc)
.066 to .123 (4 Disc
High Perf.)
.022 to .079" (5 Disc)
Rear C lu tc h .............................................................. .032 to .055" .025 to .045"
SNAP RINGS
Front and Rear Clutches
Rear Snap Ring (Selective) ................................. .060 to .062" .060 to .062"
.068 to .070" .074 to .076"
.076 to .078" .088 to .090"
Output Shaft (Forward End) ................................. .040 to .044" .048 to .052"
.048 to .052" .055 to .059"
.059 to .065" .062 to .066"
THRUST WASHERS
Output Shaft to Input Shaft (Selective) ..................................... .052 to .054"
(Natural)
.068 to .070"
(Red)
.083 to .085"
(Black)
Reaction Shaft Support to Front Clutch Retainer (Selective) .. — .061 to .063"
(Green)
.084 to .086"
(Red)
.102 to .104"
(Yellow)
Driving Shell Thrust Plate—Steel (2) ......................................... .034 to .036"
Front Planetary Gear to Driving Shell ......................................... .060 to .062"
Rear Planetary Gear to Driving Shell ......................................... .060 to .062"
Front Annulus Gear S u p p o r t.......................................................... .121 to .125"
Front Clutch to Rear Clutch .......................................................... .043 to .045"
Front Clutch to Reaction Shaft S u p p o r t.................................... .043 to .045"
Output Shaft to Input S h a f t .......................................................... — .062 to .064"
Driving Shell Thrust Plate—Steel (1) ........................................ — .034 to .036"
Rear Planetary Gear to Driving Shell ......................................... — .062 to .064"
Front Planetary Gear to Annulus G e a r ................. ..................... — .062 to .064"
Front Annulus Gear to Driving Shell ................................... ....... — .062 to .064"
Front Clutch to Rear C lu tc h ......................................................... — .061 to .063"
Rear Planetary Gear to Annulus G e a r ................. ....................... — .034 to .036"
BAND ADJUSTMENTS Engines Turns* Engines Turns*
Kickdown (Front) ................. .............................. All 2 All Except 426 2
426 Cu. In. 1- 1/2
Low-Reverse (Internal)........................................ All Except 318 3-1/4 All 2
318 Cu. In. 4
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SPEEDOMETER PIN IO N GEAR CHART
ALL CAR LINES—ALL TRANSMISSIONS
NUMBER OF TEETH ON PINION GEAR LISTED UNDER EACH AXLE RATIO
Tire Tire
Size Size 2.45:1 2.71:1 2.76:1 2.93:1 2.94:1 3.23:1 3.54:1 3.55:1 3.91:1 4.10:1
6.45 x 14 B78 x 14 30 35 38 42
6.95 x 14 C78 x 14 29 34 37 41
D78 x 14 29 33 37 40
7.35 x 14 E78 x 14 28 28 30 30 33 36 40
7.75 x 14 24 27 27 29 29 32 35 35 39 41
8.25 x 14 G78 x 14 24 27 27 29 29 32 35 38
8.55 x 14 H78 X 14 26 26 28 31 34 37
F78 x 14 25 27 28 30 30 32 36 39
D70 x 14 29 34 37 41
E70 x 14 29 33 37 37 40 42
F70 x 14 25 27 28 30 30 32 36 36 39 41
F78 x 15 29 31 35
7.75 x 15 24 27 27 29 29 32 35 38
8.25 x 15 24 26 27 28 28 31 34 38
G78 x 15 26 26 28 31 34
8.55 x 15 26 26 28 31 34
8.85 x 15 25 26 27 30 33
9.15 x 15 L84 x 14 25 26 27 30 33
H78 x 15 25 26 27 30 33
J78 x 15 25 26 27 30 33
G70 x 15 26 27 29 31 35
E60 x 15 29 34 37 37 41 43
F60 x 15 25 28 28 30 33 36 40 42
TIGHTENING REFERENCE
Foot Foot
Manual A-903, A-230 3-Speed Pounds Pounds
Back Up Light Switch ................................. 15 Gearshift Operating Lever Nuts ................. ...... 18
Extension Housing Bolts ............................. 50 Transmission to Clutch Housing B o lts ---- -----50
Extension Housing to Cross Member Bolts 40 Transmission Cover Retaining B o lts .................. 12
Drive Pinion Bearing Retainer B o l t s .......... 30 Transmission Drain P l u g ............................... ...... 25
Foot Foot
Manual A-833 4-Speed Pounds Pounds
Back Up Light Switch ................................... 15 Reverse Detent Spring R e ta in e r................. 50
Drive Pinion Bearing, Retainer B o lts .......... 30 Reverse Detent Spring Retainer P l u g ........ 24
Extension Housing to Case B o l t s ............... 50 Shift Lever N u ts .............................................. 18
Gearshift Housing Bolts ............................... 15 Transmission Drain P l u g ............................... 25
Gearshift Operating Lever Nuts ................. 18 Transmission to Clutch Housing Bolts — 50
Pounds Pounds
Torqueflite A-904 and A-727 Foot Inch Foot Inch
Cooler Line Fitting ..................................... 110
Cooler Line N u t ............................. ............... 85 Oil Filler Tube Bracket B o lt......................... ......... 150
Converter Drain P lu g ..................................... 110 Oil Pan B o l t .................................................. .........150
Converter Drive Plate to Crankshaft B o lt.. 55 Oil Pump Housing to Transmission
Converter Drive Plate to Torque Case B o lt................... ................................ .........175
Converter Bolt ........................................... 270 Output Shaft Support B o l t ......................... .........150
Extension Housing to Transmission Overrunning Clutch Cam Set S c r e w ....................40
Case B o lt....... ............................................. 24 Pressure Test Take-Off P l u g ..................... ..........75
Extension Housing to Insulator Reaction Shaft Support to Oil Pump Bolt.. 160
Mounting B o l t .......................................... 40 Reverse Band Adjusting Screw Lock N u t.. 35
Governor Body to Support B o l t ................. 100 Speedometer Drive Clamp Screw .......................100
Kickdown Band Adjusting Screw Lock N u t. 29 Transmission to Engine B o l t ..................... 28
Kickdown Lever Shaft P l u g ....................... 150 Valve Body S c r e w ........................................ ..........35
Neutral Starter S w itc h ................................. 24 Valve Body to Transmission Case Bolt— 100
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-------------------------------------------------------------------------------- GROUP 2 2
WHEELS-BEARINGS-TIRES
CONTENTS
Page Page
BEARINGS (FRONT WHEEL) ....................... 6 Collapsible Spare Tire .............................. 3
Removal (Without Disc Brakes).............. .......6 Inflation of T ire s ........................................ 2
Removal (With Disc Brakes).................... .......6 Radial Ply Tires ........................................ 3
Cleaning and Inspection .......................... .......7 Rotation of T ire s .............. ......................... 2
Lubrication ................................................ .......6 Repairing Tire Leaks.................................. 4
Installation (Without Disc Brakes).......... .......7 Tire Noise Complaints.............................. 4
Installation (With Disc Brakes) .............. .......7 Tire Wear Patterns.................................... 4
Bearing Adjustment.................................. 8 Tire Tread Wear Indicators...................... 4
GENERAL INFORMATION............................ 1 Wide Tread 70 Series T ire s ..............— 3
SERVICE PROCEDURES.............................. 1 WHEELS ........................................................ 5
SPECIFICATIONS............................................ 8 Tire— Wheel Balance................................ 5
TIGHTENING REFERENCE................ .......... 11 Tire and Wheel Runout............................ 6
T IR E S .............................................................. 1 Wheel Covers ............................................ 6
Care of Tires— Cleaning .................... .............1
GENERAL INFORMATION
The original equipment Load Range B (4) ply Tire wear and vehicle stability are affected greatly
rating bias belted factory installed tires on your by tire size, tire pressures, wheel rim size, distribu
vehicle are designed and tested to meet all normal tion of load within the vehicle, wheel alignment, road
operating requirem ents. These tires are superior surface conditions, and driver operating habits.
tires for the vehicle and provide the best overall Tires used at low speeds, in cool climates, and with
perform ance for normal operation; furtherm ore, the light loads will have longer life than tires used for
ride and handling characteristics match the vehicle’s high speed driving in hot climates with heavy loads.
requirem ents. With proper care they will give ex Abrasive road surfaces will accelerate tire wear.
cellent reliability, traction skid resistance and tread Driving habits have more effect on tire life than
life. any other factor. Careful drivers will obtain, in most
The bias belted (bias breaker) represents a com cases, much greater mileage than severe or careless
plete departure in tire design. This type of tire drivers. Rapid acceleration and deceleration, severe
construction has the body plies, or layers of cords, application of brakes, high speed driving, taking
running at a bias or criss-crossed angle to the circum turns at excessive speeds, striking curbs and other
ference (Fig. 1). In addition, a rugged two-ply glass obstacles are just a few of the driving habits which
fiber circumferencial belt is added directly under will shorten the life of any tire.
the tread. To obtain maximum vehicle stability and tire life
The advantages of bias belted tires which are the vehicle should be equipped with the recommended
most im portant to the owner are: Superior ride and suspension application including the proper tire size
handling, improved tread life, improved traction and the recommended full rated load should not be
and skid resistance and improved high speed dur exceeded. See Minimum Tire Size—Tire Pressure and
ability because of cooler operating tem peratures. Vehicle Load Chart in this section.
SERVICE PROCEDURES
TIRES
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CROSS-BIASED
CASING PLIES
RADIAL PLY
HAS BELTED
(BIAS BREAKER)
_ ... . . \ . -
y v ‘A*
' -;V x sv"9 ■ ^ ' x\
"99 i
■;';: 59 1
! « ■■■■■■ j&glB i
-99^
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NU551A
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no later than every second oil change and should be
in correct balance to obtain the most uniform tread
LEFT FRONT RIGHT FRONT
wear. Tire inspection at every oil change is recom
mended and if irregular tread wear is evident, ro
tation of tires is suggested at that time. Be sure to
always adjust tire pressures properly after rotation,
especially on station wagons. If vehicle is equipped
with styled wheels or a collapsible spare tire, follow
the 4 tire rotation illustration. Proper tire rotation
at the recommended intervals reduces the possibility
of tire noise and equalizes tire wear. Figures 2 and LEFT REAR RIGHT REAR
3 are the recommended sequence for the rotation
of tires. Under conditions of severe service (trailer
towing) they should be rotated more frequently. SPARE KP23A
Uneven tire wear is frequently the cause of tire Fig. 3 —Tire Rotation Diagram —5 Tires
induced noises which are attributed to rear axle
gears, bearings etc. Unnecessary work is often per acceptable on your vehicle if the size is listed in
formed on other chassis components in an effort the above charts. The use of oversize tires of this
to correct tire noises. construction (that are not listed above) may cause
interference with vehicle components under ex
R a d ia l P ly T ir e s trem es of suspension and steering travel and may
Your vehicle is designed for bias belted or cross cause tire damage. For maximum satisfaction these
bias tires of the sizes indicated. The use of radial tires should be used only in sets of five and under no
tires is not recommended particularly on station circumstances should they be used on the front only.
wagons. Should these radial tires be desired then If snow tires are used they m ust also be of the same
tire sizes and road wheel diam eters m ust be selected wide tread— low profile 70 Series design.
to m aintain ground clearance and load capacity
equivalent to the minimum specified tires. Radial ply C o lla p s ib le S p a r e T ire
tires must be used in sets of five (5), and under no The collapsible spare tire has an approximate
circumstances should they be used on the front tread life of 2000 miles and its continued use other
only. If snow tires are installed on the rear wheels than for emergency purposes is not recommended.
bias belted or cross bias tires must be mounted on The original tire should be repaired and reinstalled
the front wheels. Not doing this will result in over at the first opportunity.
steer and could possibly cause spins on wet or icy
roads. The safest policy is never intermix radial ply INFLATION
tires with bias belted or cross bias tires.
Caution: Keep hands off m etal parts of inflator as
W i d e T r e a d 7 0 S e r ie s T ir e s
is becomes extremely cold during inflation.
The use of 70 Series wide tread bias belted or
1. Remove the tire from storage location and
cross bias (again radial not recommended) tires is
mount on vehicle with valve stem nearest the ground.
LEFT FRONT RIGHT FRONT 2. Remove valve cap from tim e valve stem.
3. Remove plastic cap from inflator and place in
flator outlet over tire valve.
4. Hold inflator in position for one minute after
tire in completely inflated.
NOTE: It is recommended that the collapsible spare
tire pressure be checked and adjusted to 32 PSI as
soon as possible after installation.
To stow collapsible spare tire, remove air by re
moving tire valve stem core with valve cap. Flatten
tire and replace core and cap. Stow tire in proper
LEFT REAR RIGHT REAR luggage compartm ent location.
NOTE: The inflator for the collapsible spare tire is
good for one inflation only. A new inflator must be
NP158 purchased from your local dealer after every in
flation.
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REPAIRING LEAKS
Leaks between the tire and wheel require the re
moval of the tire. Leaks in the tire can often be re
paired without removing the tire. Always follow the
equipm ent m anufacturers recommendations.
Tools used for dismounting and mounting tires
m ust be smooth, free from sharp edges or burrs
which could damage the tire or wheel rim.
The tire m ust be completely deflated before the
tire beads are removed from the seats. Before
m ounting the tire on the wheel, make sure all rust
scale is removed from the wheel rim. A mild soap
solution applied to both tire bead surfaces will aid
in installation. E ither a commercial type bead ex
pander or a rope tourniquet can be used to seat the Fig. 5 —Tire Tread W ear Indicator
tire beads. or vibration drive the car over a smooth portion of
When installing wheels on the vehicle, progres highway at various speeds and note the effect of
sively tighten wheel nuts in sequence shown in (Fig. acceleration and deceleration on noise level. Axle
4) to proper torque specifications, 55 foot-pounds for and exhaust noise change in intensity under these
D art and 65 foot-pounds all other models. conditions, while tire noise will usually rem ain con
stant. If after road testing the vehicle it was de
T ir e T r e a d W e a r I n d ic a to r s term ined that tires may be causing the noise,
Your potential driving, cornering and braking trac balance all tires very carefully and inflate to 50 psi.
tion decreases as your tires wear. Furtherm ore, as the Drive the car over the same route at the same speeds
tread depth is decreased the tires have less resistance as before to determ ine whether the disturbance
to road hazards and are more likely to hydroplane on has been changed. If the disturbance is changed or
wet pavement. Tread wear indicators have been pro eliminated by overinflating the tires, continue the
vided to assist you in determ ining when your tires are road test by deflating one tire at a time to normal
worn so as to require replacement. These indicators pressure. When the disturbance returns, the last
are molded into the bottom of the tread grooves and tire deflated will usually be the offender. Tire thum p
will appear as approximately 1/2 inch wide bands (sometimes referred to as “tram p”) usually occurs in
when this tread depth has been reduced to 1/16 inch the speed range of 20-40 MPH and can usually be
(Fig. 5). Tire replacem ent due to tread wear is neces located this way. If you have a “thum per”, replace
sary when these indicators appear in two or more the tire.
adjacent grooves or a localized worn spot eliminates Tire roughness can be caused by a single tire with
all the tread. two or more “thum p” spots in it, or by two or more
thumping tires at speeds of 40-70 MPH. To isolate
T ire N o is e o r V i b r a ti o n C o m p la in ts the cause of this condition, you may have to substi
To determ ine w hether tires are causing the noise
tute the spare for each of the four tires, with all
tires inflated to normal pressure. Tire roughness is
recognized as a low-frequency rumble or vibration
and is very sim ilar to driveline vibration. Positive
separation of the two disturbances can only be ac
complished by using a known set of good tires or by
towing the vehicle with the propeller shaft removed.
To correct tire roughness, replace the offending tires.
T ire W e a r P a tte r n s
A n inspection of the tires, together with informa
tion as to locality of vehicle operation will usually in
dicate w hether abnorm al wear is due to operating
conditions or to mechanical faults which should be
corrected. Various types of abnormal tire w ear with
their causes and corrective action are shown in (Fig.
6 ).
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RAPID W EAR RAPID W EAR CRACKED W EA R O N FEATHERED BALD
A T SHOULDERS AT CENTER TREADS O N E SIDE EDGE SPOTS
m If
v J L
C O N D IT IO N
CAUSE
IN FLATION
o G Oo
IN FLATION INFLATION OR
EXCESSIVE
SPEED
CAMBER
®© f11I
TOE
—
UNBALi^NCED
D Y N A M IC OR
ADJUST PRESSURE TO ADJUST ADJUST FOR
STATIC
CORRECTION SPECIFICATIONS W H E N CAMBER TO TO E-IN
BALANCE
TIRES ARE C O O L SPECIFICATIONS 1 /8 INCH
WHEELS
NN2
Fig. 6 —Tire W ear Patterns
U n d e r in fla tio n T o e -in o r T o e - o u t T r e a d W e a r
For the maximum results in stability and handling, Excessive toe-in or toe-out causes wear on the edges
ride quality and tire life, tire inflation pressures of the front tires. An excessive amount of either toe-
should not be allowed to go below the recommended in or toe-out actually drags the tire instead of letting
inflation pressures. W hen a tire is underinflated, this the tire roll true. This wear condition will usually
results in much faster wear of the shoulders than of produce a tapered or feathered edge on the outside
the center of tread. ribs. Have the toe-in or toe-out adjusted to specifica
O v e r in f l a ti o n tions to correct.
W hen tire inflation pressures are m aintained within
the specifications the tire will wear evenly over the B a ld S p o t , C u p p e d o r S c a llo p e d T ire
entire tread. A tire th at is overinflated wears much T read W e a r
faster in the center of the tread. Cupping, scalloping and bald spotting of tires is
associated with wear on a car driven mostly at high
C ra cked T reads way speeds without the recommended tire rotation
This is the result of alternate under and over in and with unbalance conditions. Regardless of the
flation, exceeding the recommended full rated load, cause of cupped wear on either front tire, no align
high tem perature and high speed driving. ment or balance job can prevent future excessive
E x c e s s iv e C a m b e r W e a r wear of the spots. Once a front tire acquires flat or
Excessive wheel camber, either positive or nega cupped spots additional wear will continue at a rapid
tive causes the tire to run at an angle to the road. One rate. To correct this condition, tire rotation and
side of the tread wears much more than the other. For wheel balance are necessary. A cupped tire will
best corrective results have the front wheel camber partially true itself up on a rear wheel.
adjusted to specifications.
WHEELS
All models use steel drop center wheels. The safety TIRE-WHEEL BALANCE
rim wheel (Fig. 7) has raised sections between
the rim flanges and the rim well. Initial inflation of The need for tire and wheel assembly balancing is
the tire forces the bead over these raised sections. indicated by heavy vibration of the steering wheel
Tire-wheel separation under extrem e hard cornering when driving at speeds above 40 miles an hour.
is prevented by air pressure and these safety humps. Static (still) balance is equal distribution of the
Furtherm ore, in case of a tire failure, the raised sec weight of the wheel and tire around the spindle, so
tions help hold the tire in position on the wheel until that the assembly has no tendency to rotate by itself.
the car can be brought to a safe stop. An assembly that has a heavy spot is statically out
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the m easurem ent is made so that “flat-spotting” of
the tire (from being parked) does not affect the ru n
out m easurement.
(1) Attach dial indicator C-3339 to a firm base so
it will be held steady while taking the runout readings.
(2) Place plunger of dial indicator against one of
the center ribs of the tire tread and rotate the
assembly slowly to measure radial runout. This mea
surem ent should not exceed .080 inch.
(3) To m easure lateral runout, position the dial in
dicator against the side of the tire. This m easure
m ent should not exceed .105 inch.
Rotating the tire on the wheel may reduce runout
or it may be necessary to take dial indicator m easure
m ents of the wheel itself in order to determ ine
which unit has the excessive runout. Measure runout
at the protected areas “A” and “B” (Fig. 8), where
Fig. 7—Safety Type Rim the tire bead pilots. The radial runout, “A” should
of balance and can produce a bouncing motion. not exceed .035 inch. The lateral runout “B”, should
Correction for static unbalance is made by first not ex ceed .045 inch.
finding the location of the heavy spot, then adding NOTE: Under no circumstances should point indicat
sufficient weight to counterbalance it (follow the ed by "C" be used for measuring wheel runout as
equipm ent m anufacturers recommendations.) Half this metal has been sheared in the manufacturing
the balance weight should be added to the inside of process and is not an even surface.
the wheel and the other half to the outside to prevent
excessive dynamic unbalance. WHEEL COVERS
A wheel and tire, to be in dynamic balance, m ust
first be in static balance and also be in balance from To avoid damaging the wheel covers during re
inside to outside. A wheel not in dynamic balance can moval and installation, care should be used to be sure
produce wobble or shimmy. the forces are applied to the correct area of the
covers. To install the wheel covers, insert the tire
TIRE AND WHEEL RUNOUT valve through the cover valve hole and seat this por
tion of the cover completely. Apply force 180° from
Wheels and tires may be m easured for both radial the valve hole to complete the installation. When re
and lateral runout. Radial runout (eccentricity) is moving the wheel covers, pry completely loose 180°
the difference between the high and low points on the from the valve hole first. Continue prying toward the
tread of the tire; lateral runout is the “wobble” of valve hole until covers are loose. Do not remove
the wheel a n d /o r tire. the wheel cover at the valve stem hole. The covers
Prior to m easuring the wheel or tire for runout, are structurally stronger at the outer circumference
the accuracy of the drum at the mounting bolts should to withstand the force required for removal and in
be determ ined. The car should be driven a short stallation. Use a rubber end m allet when installing
distance and immediately lifted off the ground before the covers.
BEARINGS
FRONT WHEEL BEARING LUBRICATION (3) Remove thrust washer and outer bearing cone.
(4) Slide wheel, hub and drum assembly off the
Front wheel bearing lubricant should be changed spindle.
at the recom mended intervals or at the tim e of nor (5) Drive out inner oil seal and remove bearing
m al brake reline. Lubricant should not be added to cone.
that already in the bearings.
R e m o v a l ( w ith Disc B r a k e s )
R e m o v a l (w i t h o u t D isc B r a k e s ) (1) Raise vehicle so front wheels are free of floor.
(1) Raise vehicle so front wheels are free of the (2) Remove wheel cover and loosen and remove
floor. wheel nuts and remove wheel and tire assembly.
(2) Remove wheel cover, grease cap, cotter pin, (3) Remove grease cap, cotter pin, nut lock and
nut lock and bearing adjusting nut. bearing adjusting nut.
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Fig. 8—Runout Cheeking Area
(4) Remove bolts that attach disc brake caliper even with inner diam eter of bearing cups.
assembly to steering knuckle. (3) Force lubricant between bearing cone rollers
(5) Slowly slide caliper assembly up and away from or repack using a suitable bearing packer.
brake disc and support caliper assembly on steering (4) Install inner cone and a new seal, with Up of
knuckle arm. CAUTION: Do not leave caliper as seal facing inward. Using Tool C-3893, position seal
sembly hang by brake hose, as possible brake hose flush with end of hub. The seal flange may be dam
damage may result. aged if tool is not used.
(6) Remove thrust washer and outer bearing cone. (5) Clean the spindle and apply a light coating of
(7) Slide wheel hub and disc assembly off the wheel bearing lubricant over the polished surfaces.
spindle. (6) Install wheel tire and drum assembly on spindle.
(8) Drive out inner seal and remove bearing cone. (7) Install outer bearing cone, thrust washer and
adjusting nut.
C le a n in g a n d I n s p e c tio n
(1) Clean the hub and drum assembly and the bear I n s t a l la t io n ( w ith D isc B r a k e s )
ings in kerosene, m ineral spirits or other similar (1) If bearing cups were removed, start new cup
cleaning fluids. Do not dry the bearings by air into hub evenly, driving them flush with hub using a
spinning. soft steel block and hammer. Seat cups against shoul
(2) Examine bearing cups for pitting, brinnel ders of hub, using a soft steel drift and hammer.
m arks or other imperfections. If cups are damaged, (2) Fill hub grease cavity (Fig. 9) with recom
remove them from the hub with a soft steel drift mended bearing lubricant, see Lubrication Group 0.
positioned in the slots in the hub. Lubricant should be even with inner diam eter of
(3) Bearing cup areas in the hub should be smooth bearing cups.
without scored or raised m etal which could keep the
cups from seating against shoulders in hub.
(4) The bearing cones and rollers should have
smooth, unbroken surfaces without brinnel m arks.
The ends of the rollers and both cone flanges
should also be smooth and free from chipping or
other damage.
I n s t a l la t io n (w i t h o u t D isc B r a k e s )
(1) If the bearing cups were removed, start the
new cups into hub evenly, driving them flush with hub
using a soft steel block and hammer. Seat cups
\\ \ 'V THRUST WASHER
/ NUT
against shoulders of hub, using a soft steel drift and NUT
hammer. NH165
(2) Fill hub grease cavity (Fig. 9) with recom
mended wheel bearing lubricant. Lubricant should be
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(3) Force lubricant between bearing cone rollers to 45 to 60 foot-pounds.
or repack using a suitable bearing packer. (9) Install tire and wheel and tighten wheel nut
(4) Install inner cone and a new seal with lip of to specifications.
seal facing inward. Using Tool C-3893, position seal
flush with end of hub. The seal flange may be dam A d ju s tm e n t
aged if tool is not used. (1) Tighten wheel bearing adjusting nut to 90
(5) Clean the spindle and apply a light coating of inch-pounds while rotating wheel.
wheel bearing lubricant over the polished surfaces. (2) Position nut lock (Fig. 10) on nut with one pair
(6) Install hub and braking disc assembly on spindle of slots in line with cotter pin hole.
and install outer bearing cone, th ru st washer and (3) Back off adjusting nut lock assembly one slot
adjusting nut. and install cotter pin. The resulting adjustment should
(7) Slowly slide caliper assembly down on brake be zero (no preload) to .003 inch end play.
disc assembly and position correctly. (4) Clean the grease cap, coat inside with wheel
(8) Install caliper assembly over disc and align bearing lubricant (do not fill) and install.
m ounting holes. Install mounting bolts and tighten (5) Install wheel covers and lower vehicle to floor.
SPECIFICATIONS
MINIMUM TIRE SIZE AND INFLATION PRESSURES— DART
Your vehicle, when equipped with the minimum specified tire size shown in the Minimum Tire Size Chart and
inflated to the corresponding maximum vehicle capacity pressure listed in Tire Pressure Chart, is designed to
operate at any load up to and including the maximum vehicle capacity at all normal highway speeds (up to
75 mph). Owners who prefer a softer ride may use the optional reduced inflation pressure if the load carried
is five passengers or less (750 pounds maximum) and the vehicle speed does not exceed 75 mph.
Inflation Pressure—Cold
Engine Minimum Standard Maximum Vehicle Reduced Maximum Tire Optional
Equipment
Cubic-Inch Air Conditioning Tire Wheel Capacity Vehicle Load Vehicle Load Allowable
Displacement Size Size Caoacitv Ranae Tire & Wheel
With Without Front Rear Front Rear (Lbs.) Size
198 & 225 X X D78-14 4-1/2J 30 30 24 24 1100 B A*
318 X D78-14 4-1/2J 30 30 26 26 1100 B A*
318 X D78-14 4-1/2J 30 30 24 24 1100 B A*
340 X X E70-14* 5-1/2J 28 28 24 24 1100 B
* Chain Clearance
Tire snow chains are not recommended for use with some tire sizes, as indicated on the Tire Size Chart
by the symbol *, because of possible fender interferences. In an emergency, chains may be used on these
tires if the vehicle is moderately loaded and driven cautiously.
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Equipment Inflation Pressure—Cold
Engine Air Minimum Standard Maximum Vehicle Reduced Maximum Optional
Cubic-Inch Conditioning Seats Tire Wheel Capacity Vehicle Load Vehicle Tire Allowable
Displacement Size Size Capacity Load Tire & Wheel
With Front Rear Front Rear (Lbs.) Range Size
With Out Bench Bucket
225 & 318 X X X E78-14 5J 25 28 — — 800 B A, B
225 & 318 X X X E78-14 5J 26 30 24 28 950 B A, B
340 X X X X E60-15* 7JJ 28 32 26 28 800+ B
383 X X X X F70-14** 6JJ 25 28 — — 800+ B C*
440 X X F70-14 6JJ 25 28 — — 800 B C*
440 X X F70-14 6JJ 28 32 24 28 800 B C*
426 X X F60-15* 7JJ 28 32 24 28 800 B
+950 Lbs. when equipped with Bench Seats. **F78-14 on H&P Price Class.
A—E70-14 (5-1/2JJ) C—E60-15 (7JJ) N.A. All 225,318,383, or 440
B—F70-14 (6JJ) (N.A. 225,340, 426, or 318 with Convertible with air conditioning.
2.76 axle. 11" or Disc Brakes and Heavy Duty
Suspension Required.
1. For All Load Conditions Up To And Including Vehicle Maximum Capacity. Vehicle Maximum Capacity—
Sedans, Hardtops and Convertible (Bench Seat): Front seat—3 passengers; Rear Seat—2 passengers;
Luggage—200 lbs.; Total 950 lbs. Vehicle Maximum Capacity—Bucket Seat: Front seat—2 passengers;
Second Seat—2 passengers; Luggage—200 lbs.; Total—800 lbs.
2. Optional Reduced Vehicle Loading For Improved Ride. Front Seat—2 passengers; Second Seat—1 pas
senger; Luggage—0; Total—450 lbs.
* Chain Clearance
Tire snow chains are not recommended for use with some tire sizes, as indicated on the Tire Size Chart
by the symbol*, because of possible fender interferences. In an emergency, chains may be used on these
tires if the vehicle is moderately loaded and driven cautiously.
SPECIFICATIONS
22-9
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TRAILER TOWING TIRE SIZE AND INFLATION PRESSURES—DART
Inflation Maximum
Engine Tire Wheel Pressure Vehicle Tire
Cubic-Inch Size Size (Cold) Capacity Load
Displacement (Lbs.) Range
Front Rear
225 & 318 D78-14 5-1/2 J 30 30 1100 B
340 E70-14 5-1/2 J 30 30 1100 B
Inflation Maximum
Engine Tire Wheel Pressure Vehicle Tire
Cubic-Inch Size Size (Cold) Capacity Load
Displacement (Lbs.) Range
Front Rear
225 & 318 E78-14 5-1/2 JJ 28 32 800+ B
340 E60-15 7 JJ 28 32 800+ B
383 & 440 F70-14 6 JJ 28 32 800+ B
1. Cold inflation pressures must not exceed 32 pounds per square inch (PSI) for 4 ply rating (load range B)
and 40 psi for 8 ply rating (load range D) tires. These tire pressures may increase as much as 6 psi when
hot. Do not reduce this normal pressure buildup. Cold tire inflation is defined as the pressure after the
vehicle has been inoperative for at least three hours and driven less than one mile.
2. All tires must be inflated 4 psi more than specified in the chart but not to exceed pressures indicated above
in note No. 1 for sustained speeds above 75 mph. Sustained speeds above 75 mph are not recommended
when the 4 psi pressure adjustment would require pressures greater than the allowed maximum indi
cated on the tire sidewall.
Eight ply rating (load range D) tires inflated an additional 6 psi, but not to exceed 40 psi, are required for
these instances where maximum vehicle capacity is carried above 75 mph and maximum allowable 4 ply
rating (load range B) tire pressures would be exceeded.
We strongly discourage excessive speed, however, if the vehicle must be driven at sustained speeds over
90 MPH special high speed tires inflated to maximum vehicle capacity pressures are required.
3. The use of tires smaller than the specified minimum or larger than the specified maximum could consti
tute a safety hazard.
4. Cargo loads, particularly in station wagon models, should be distributed as far forward as possible.
5. Vehicles with luggage racks do not have a maximum vehicle capacity greater than indicated in chart.
6. Vehicles with trailer towing packages do not have increased maximum capacity. The allowable passenger
and cargo load must be decreased an amount equal to the trailer tongue load on the trailer hitch.
7. Because of vehicle limitations, oversize, 70 Series or load range D (8 ply rating) tires do not provide in
creased vehicle capacity. They do, however, provide an extra margin of tire service (tread life, etc.). Do
not exceed the maximum tire size stated in chart.
8. Snow tires should not be operated at sustained speeds over 70 mph. These tires should be operated at
maximum vehicle capacity pressures under all load conditions.
9. All tires and especially the wide tread 70 Series, bias belted and radial types must be rotated no later
than every second oil change and should be in correct balance to obtain the most uniform tread wear.
Tire rotation at shorter intervals is recommended if irregular tread wear develops.
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WHEELS Dart Challenger
Type ..................................................................................................... Steel Disc
R im ................................................ . .................................................... Drop Center—Safety Wheel
No. of Wheel N u t s ............................................................................. 5 5
Stud Size ........................................................................................... 7/16"-20 l/2"-20
Stud Hole C irc le ................................................................................ 4" 4-1/2"
Wheel Nut T o rq u e .............................................................................. 55 ft-lbs. 65 ft-lbs.
Bearing Nut Torque (Wheel Spinning)........................................... 70 in-lbs. 90 in-lbs.
TIRES
Type ..................................................................................................... Tubeless
S iz e ......................................................................................... ............. (See Minimum Tire Size Chart
in this Section)
TIGHTENING REFERENCE
Pounds Pounds
Foot Inch Foot Inch
Wheel Bearing Nut (with Wheel Spinning) Wheel Stud Nut
Dart ............................................................ 70 Dart ............................................................ 55
C hallenger.................................................. 90 C hallenger.................................................. 65
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BODY AND FRAME
CONTENTS
Page Page
BODY AND FRAME A LIG N M EN T.............. 93 SEALING ........................................................ 79
CONVERTIBLE .............................................. 68 SHEET METAL-DOORS................................ 28
INTERIOR TRIM AND SEATS .................... 50 WINDSHIELD AND REAR W IN D O W .......... 63
MAINTENANCE AND C A R E ........................ 1 VINYL ROOF COVERING ............................ 86
REFINISHING PROCEDURES .................... 88
GENERAL INFORMATION
" U n i b o d y " C o n s tr u c tio n is one continuous piece from the roof rail to the body
The featured “Unibody” construction is one in sill. Sheet metal seams overlap for improving sealing.
which the body shell and underbody (frame) are Metal cages, welded to the outside of the cowl side
welded into one unit. panels, enclose the retaining nuts for attaching fend
To achieve rigidity and strength of the body-shell, ers and hood hinge supports. Inner hinge reinforce
two additional heavy-duty crossmembers, one under ments assure door alignm ent and maintain proper
the rear seat and the other at the extrem e rear of door adjustm ent.
the body are welded to the box side rails. The radiator support, fender wheelhousings and
Heavy duty roof bows are used providing greater cowl panels are attached to the body, adding structur
strength to the roof panel. The front door hinge pillar al strength to the fore-structure and the body.
INDEX
Page Page
APPEARANCE H eadliners........................................................... 3
ACRYLIC FINISHES—POLISHING ..................... ..... 4 Luggage Compartment ..................................... 4
BRIGHT METALS—POLISHING ................................. 4 Package Shelfs ....................... ......................... 4
CONVERTIBLE Sealers—Leather and Vinyl ............................. 4
Backlight ...................................................................2 S e a t s ..................................................................... 3
Boot ....................... ................................................... 2 Side Cowl Trim Panels ..................................... 4
Top ....................................................................... .....1 Spots and S t a in s ................................................ 2
W e ll............................................................................2 Test for Material T y p e ....................................... 2
GLASS ...........................................................................5 POLISHING
INTERIOR TRIM Acrylic F in is h e s .................................................. 4
Body Cloth—Knit Type ..........................................2 Bright Metals ...................................................... 4
Carpets and Rubber M a ts ............................... ......4 Scratches and Overspray ................................. 4
Color Restoration or C h a n g e ............................. .....4 T IR E S ....................................................................... 4
Door Panels ........................................................ .....3 VINYL ROOF COVERING....................................... 2
General Instructions . . . ..........................................2 DRAIN HOLES .............. .......................... ................... 5
Glove C om partm ent............................................ .....4 LUBRICATION ............................................................ 5
GENERAL INFORMATION
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scrub brush. Use warm w ater and naphtha bar type inches. Allow to dry (a white powder will form). Brush
soap as the cleaning agent. Do not wash in direct or vacuum powder from surface. Repeat operation
sunlight. Scrub with soap suds, starting in the center should any stain remain.
and gradually working toward the edges. Rinse with Entire Insert— Cleaning Only—(Waterspots, dirt,
clean w ater to remove all traces of soap. Allow to dry foodstains, coffee and other w ater borne stains). Vacu
completely before lowering. um or brush off as much of the staining m aterial as
Backlight—The backlight (rear window) is a solid possible. Shield adjacent cushion or back (not to be
tem pered glass. cleaned) to prevent wetting. Use a wiping motion out
Top Boot and Well—Remove all abrasive dust and dirt ward from the contaminated area to the edges of the
from boot and well by brushing or vacuuming. For insert with clean lukewarm w ater and clean cheese
scrubbing, use only a soft, natural bristle hand scrub cloth. Rub with w ater until entire insert is wet. Do
brush. Use warm w ater and naphtha type bar soap. not soak insert. If clear water did not remove soil, use
Rinse with clean water. Use a soft absorbent cloth to cleaner D-5, or equivalent, diluted one part cleaner
dry. to one part water and again clean entire insert.
Entire Insert or Pipe—Cleaning Only—(Grease,
VINYL ROOF COVERING oil, adhesive, crayon, lipstick and similar stains). Wipe
off as much of staining m aterial with clean cotton
In a well ventilated area, saturate a clean cloth with cheesecloth. Wet another piece of clean cheese
recommended Vinyl Roof Cleaner and Conditioner. cloth with the recommended spot rem over and fab
Wipe surface using a circular motion. With another ric cleaner, or equivalent and squeeze out excess
clean cloth, wipe excess m aterial from top. Allow to cleaner until cheesecloth is drip free. Use a wiping
dry for ten minutes. motion outward from the stained area to the edges of
the pipe or bisquit and clean complete area. Unfold
INTERIOR TRIM cheesecloth to expose d e a n areas frequently so stain
ing m aterial being removed is not re-deposited on
Most stains can be removed while they are fresh fabric. Continue until foreign m atter is no longer
and have not hardened and set into the fabric. An ex visible and entire fabric cover or individual pipe or
ception is mud or clay, which should be allowed to bisquit is dampened. In cases of severe staining, a
dry so that most of it can be brushed off. It is help second cleaning may be required. Be sure to use the
ful, to know the nature of the staining m atter so the minimum amount of solvent required to clean affected
correct cleaning agent may be used. area. Excessive solvent may damage the foam under
General Instructions: Use a piece of clean cotton padding.
cheesecloth approximately 3" x 3". Squeeze most of Oil and Water Repellent Application—The cleaned
the liquid from the fabric and it is less likely to leave area must be completely dried before applying repel
a ring. Wipe the soiled fabric very lightly with a lift lent. Perform following operation only in a well ven
ing motion. Always work from the outside toward tilated area. Avoid prolonged breathing of vapors or
the center of the spot. T urn the cheesecloth over as contact with eyes. Using Scotchgard Fabric Protector,
soon as one side becomes stained to prevent working or equivalent, hold spray can 6 to 8 inches from fab
the stain m atter back into the cleaned portion. Use ric and with slow back and forth sweeping motions,
clean cheesecloth as soon as both sides become spray fabric until evenly wet. Be sure to overlap spray
stained. patterns. Repeat spraying operation with a spray pat
Testing For Type of Material—N atural cloth will burn tern perpendicular (at 90 degrees) to the first applica
like string, slow and smoky. Synthetic m aterial such tion. Allow to dry for a minimum of one hour before
as nylon, bum s fast and “balls up” into a hard mass. fabric is sat on.
Sample m aterial for testing can be found under the Spots and Stains—When using water to remove a
seat cushion, sun visor and dome light brackets, or spot, be sure to wash entire section after spot has
back of the trim panels. Another method of testing is been removed to avoid water stains. Before cleaning
to rub the back of a fingernail over the surface of the seats, door panels, headliners, etc., remove as many
m aterial. Synthetic m aterials appear to “whistle” spots as possible.
when this is done. Use a putty knife to break up and remove encrusted
Body Cloth — Knit Type Insert — Spot C leaning — foreign m atter. Vacuum thoroughly.
(Grease, oil, adhesive, crayon, lipstick, sim ilar stains Apply the recommended spot removing agent with
and any stains of undeterm ined origin). Wipe off as a clean cloth or sponge. Work in a wide circle to
m uch of the staining m aterial as possible with clean prevent making a ring and work toward center.
cheesecloth. Using K2R aerosol spotlifter, or equiva Surface Spots—Brush out with a small hand brush,
lent, spray stained area from a distance of 8 to 10 using care not to damage fabric when brushing.
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Deep Penetrating Spots—Apply the spot removing cold water. Remove wax base polishes by sponging
agent by brushing. When spot is thoroughly worked with spot remover.
and saturated, use high air pressure to blow dirt Grease, Oil, Lipstick and Related Stains—Use spot
down through m aterial. Occasionally the entire spot rem over to avoid leaving a ring. Cleaning from out
may not be removed and it will then be necessary to side of spot and work toward center. When spot
cover the area with a light application of dye. has been removed, dry fabric with a clean cloth.
Water Stains— W ater stains in fabric materials can be Urine—Sponge the stain with a clean cloth saturated
removed with a cleaning solution made from one cup with lukewarm soapsuds (mild neutral soap) and then
of ordinary table salt and one quart of water. Vigor rinse well by rubbing the stain with a clean cloth
ously scrub solution into stain and rinse with clean dipped in cold water. Then saturate a clean cloth with
water. W ater stains in nylon and other synthetics a solution of one part household ammonia water and
should be removed with a commercial type spot re five parts water. Apply the cloth to the stain and al
mover compounded for the specific m aterial being low solution to remain on affected area for one min
cleaned. ute; then, rinse by rubbing with a clean wet cloth.
Mildew—Clean area around mildew with warm suds. Nausea— Sponge with a clean cloth, dipped in clear
Rinse with cold water, soak mildew area with solution cold water. A fter most of the stain has been removed
of one part common table salt and two parts water, in this way, wash lightly with soap (mild neutral),
then wash with the recommended upholstery cleaner. using a clean cloth and lukewarm water. Then rub
Rust Stains— Keep rust remover solution away from with another clean cloth dipped in cold water. If any
your skin. Wash hands immediately if exposed. Clean of the stain rem ains after this treatm ent, gently rub
extra well under fingernails. Read instructions on the clean with a cloth moistened with a volatile cleaner.
bottle before using. Wrap a small strip of cloth around Headliners— Cloth Type— Mix a solution of water and
each button to avoid leaving a ring on upholstery a foaming type upholstery cleaner (as shown on the
material. container) to produce thick suds. Use only foam when
Dampen the stained area with water. Apply a com cleaning, as saturation with liquids may result in
mercial rust remover solution. Sponge with clean streaks, spots or shrinking.
water to clean rust from upholstery buttons. Mois On nap type, lay down nap, usually left to right. Do
ten buttons with a few drops of w ater applied with not stop, when washing a headliner. Complete the
a small piece of sponge or cloth. Apply one or more entire operation at one time using the same cleaning
drops of rust remover. Fast dry clean areas with heat solution.
lamps. Starting in a rea r corner, clean only one or two
Chewing Gum and Tar—Avoid using spotting or sections at a time. Thoroughly work suds into cloth
cleaning solution that will dissolve or soften gum or with a natural sponge. Use circular or short back
tar. Place a cube of ice on gum or ta r to harden it. and forth strokes to remove all dirt. When the sponge
Remove as much as possible with a dull knife when glides easily, leaving an even distribution of foam
it is in this hardened state. Moisten rem ainder with and headliner appears clean, finish cleaning with
cleaning fluid and scrub clean. In some cases soak sweeping motions in one direction.
with cleaning fluid and blow the stain through using Hard Board Type—Apply a solution of upholstery
high air pressure. cleaner and water with a sponge. Use circular or
Ice Cream and Candy—Use a putty knife to remove short back and forth stroke and wipe with a dry clean
as much substance as possible. Use care not to dam cloth. If headliner is extremely dirty, wash with vinyl
age fibers of upholstery. Most candy has a sugar base cleaner using the same procedure.
and can be removed by rubbing area with a cloth Vinyl Type—Apply vinyl cleaner with a sponge (or if
wrung out in warm water. An oily type of candy, extremely dirty scrub with a brush) wipe clean with
after using warm water, should be cleaned with an a dry clean cloth.
upholstery type cleaner that will emulsify with the Seats and Door Panels— Mix one pint upholstery
oil. Rinse with water and remove rem aining stains cleaner to one gallon of water. If extremely dirty,
with cleaning fluid. add more cleaner to solution.
Bloodstains— Never use warm or hot water. Use a Do not soak around buttons. Scrub thoroughly
clean cloth w rung out in cold water and rub the stain. with a brush or sponge. Avoid over soaking the
If stain is not completely removed use spot rem over material, do one section at a time only. Frequently
or vinyl cleaner and apply with a brush. stains will be evident when m aterial is damp but will
Wine or Alcohol—Avoid use of soap. Scrub stain with disappear when dry. Use care not to damage fabric
a cloth moistened in luke warm water. Remove re by attem pting to brush out “stubborn” spots. Spots
maining stains with a regular cleaning solution. should be removed before washing. A fter part has
Shoe Polish— Scrub area with a cloth saturated with been scrubbed, remove loosened dirt by rubbing area
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briskly with a clean cotton towel or soft rag. Make for mixing and applying the color must be followed
final strokes on one direction. precisely. Use only those recommended for the exact
Nylon or Synthetic Fabrics—For average conditions m aterial being worked on.
use methods and m aterials used in washing cloth up L eather and Vinyl Sealers— To repair holes cut ma
holstery. W hen m aterial is extrem ely dirty, use m ulti terial about 1/2 inch larger than area being repaired.
purpose cleaner full strength and a stiff scrub brush. Position patch under hole and apply sealer to con
Scrub thoroughly in all directions. Wipe off dirt and tacting areas. Apply masking tape over tear to hold
excess cleaner with a clean cotton towel or soft rags. edges in place until sealer dries. A fter sealer has
Leather, Leatherette or Vinyl Fabric—Use m ulti dried, remove tape and trim all rough edges. Fill
purpose cleaner full strength and a stiff scrub brush. visible cracks with sealer. Use a step application pro
Apply to surface and let set for two (2) minutes then cedure in filling deep cracks. A fter sealer has thor
scrub thoroughly. Clean between all seams and in all oughly dried, sand lightly with #400 grade sandpaper
cracks and underneath beading. Wipe off dirt and until smooth. Apply color to repaired area.
excess m aterial with a clean cotton towel or soft rag. POLISHING—Acrylic Finishes—Polish at least twice
Package Shelf-Hard Board Type— Clean using a solu a year to remove all foreign film. When polishing use
tion of upholstery cleaner. Avoid water logging the one pad, made from cheesecloth or an old “turkish”
backing, dry immediately. towel, to apply polish and another to remove dried
Vinyl Type—Clean using multi-purpose cleaner. Dry film. Test area by rubbing fingers over polished sur
with clean toweling or rags. face. If not thoroughly cleaned, smears of polish
Side Cowl Trim Panels— Leather—Vinyl—Metal will show.
Types—Use multi-purpose cleaner full strength. Use a Sand Scratches—Overspray— Foreign Material—Mi
stiff brush and apply to surface, let set (2) two min nor conditions can be removed using the following
utes then scrub thoroughly. Clean seams, cracks and procedure:
beneath beading. Dry with a clean soft towel or rag. (1) Using oleum spirits, m ineral spirits or kerosene,
Glove Compartment—Some glove compartments are hand sand affected surface with No. 600 paper.
made of a cardboard type material. Do not waterlog. (2) Remove all sanding sludge.
Vacuum thoroughly. Clean with upholstery cleaner or (3) Machine polish the sanded surface using rub
vinyl cleaner. bing compound until the surface is completely free of
Rubber Mat—Vacuum thoroughly and clean with up scratch marks. Blend with adjacent areas.
holstery cleaner or multi-purpose cleaner. Use towel (4) Buff surface with a clean lambs wool pad using
ing or rags to remove dirt and excess cleaner. a liquid type final polish. If the appearance of the
Carpeting—Thoroughly vacuum. Mix one pint of polished a re a . is noticeably different than adjacent
upholstery cleaner to one gallon of water. If carpet areas, completely buff the adjacent panels. If neces
is faded, discolored or spotted, add upholstery tin t to sary, polish complete side or horizontal surfaces to
this solution. To determ ine the right color shade, add assure uniform appearance.
tint in small quantities only. Test by dipping a white (5) Use a clean, soft, cotton cloth, do not use
rag into solution, wring out and inspect shade. The cheesecloth, to hand clean all inaccessible areas.
dye will dry a shade or two darker. W ith a stiff brush (6) Remove all polish or rubbing compound from
apply solution and scrub carpet vigorously. Lay mouldings, medallions, name plates or any other ex
nap down in one direction. W hen dry, fluff carpets terior ornamentation.
by rubbing with a dry brush. Bright Metals—When cleaning anodized aluminum,
Salt Stains—Vacuum carpet thoroughly. Use a solu use care not to rub through the anodized coating.
tion made from w ater and a heavy concentration of All bright m etal should be thoroughly cleaned at least
ordinary table salt. Soak the stained area to loosen em twice a year.
bedded salt (use a wire brush, if necessary). Wash en The product m anufacturer recommendations should
tire carpet with the recom mended cleaner. Additional always be followed. Clean thoroughly, removing all
washing may be necessary for satisfactory results. traces of cleaner from corners. Apply and rub out a
L uggage Compartment—Remove all item s from com coat of good body wax. During winter months and in
partm ent. Use a steel brush to loosen rust and areas in which salt is used, do not rub out wax.
caked dirt and vacuum thoroughly. Wash with up Frequent washing of bright metals by steam neces
holstery cleaner or multi-purpose cleaner and dry sitate more frequent applications of wax.
with clean toweling or rags.
TIRES
Color Restoration or Change—Tints and dyes should
be applied by reliable experienced personnel. Dyes or Do not clean tires with scouring powder, steel wool
tints can be applied when stains persist, after clean or other abrasive type cleaners. Clean white sidewall
ing, or a change in color is desired. The instructions tires with a stiff bristle brush and white sidewall
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cleaner, or multi-purpose cleaner and rinse with clean DRAIN HOLES
water. Scuff marks can be dressed down by sanding
lightly with #400 sandpaper. The drain holes, in th e bottom of cowl plenum
chamber, doors and floor sills (rocker panels) should
GLASS be inspected regularly to insure unobstructed drain
age. Remove road tars, m ud and other foreign m atter
Do not use putty knives, razor blades, steel wool, immediately. Should bare m etal be exposed, surface
or other metal objects to remove deposits from glass. tre a t m etal and refinish.
Interior glass surfaces, including convertible back The drain holes in the q u a rte r panel well areas are
light, should be thoroughly cleaned weekly to rem ove sealed w ith a removable plastic plug. The plugs should
all traces of smoke and other films. only be rem oved whenever it is necessary to clean or
Exterior glass surfaces, including convertible back drain fluids from the well area.
light, are best cleaned with the use of a commer
cially made cleaner. Do not scrape off smears from LUBRICATION
bugs, road tars or other sim ilar objects, use warm
water or the recommended solvents to remove. To maintain ease of operation, the hood, door, deck
During the winter months, snow, ice and frost can lid and tail gate hinges should be lubricated with
be removed with a plastic or rubber type scraper, or the recommended lubricants at the recommended
with a commercially made solvent. Do not use metal intervals. Refer to the Lubrication and Maintenance
objects to remove deposits from glass. Group for type of lubricant and lubrication points.
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Page Page
Sedan Side Reflector .................................................... 23
Adjustments ................................................... 19 RADIATOR YOKE SUPPORT
Regu l a t o r ......................................................... 20 Air Shield and Cross Bar ................................... . 9
R eplacem ent............... ........................... .. 20 R eplacem ent............................................................ 9
Runs ............................................................ 20 SCUFF PLATE............................................................ 8
Trim P a n e ls .................................... ................ 12
SERVICE PROCEDURES
PLENUM
MOUNTING D O O R -^ ^ O ^
ROD
LEFT DUCT
WITHOUT HEATER
RIGHT DUCT NR165
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has been obtained. A fter making any adjustm ent
BUMPER r ^ f a^ that requires shifting of hood, always inspect hood
striker and lock plate alignment.
HINGE REPLACEMENT
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Fig. 5—Hood Latch Release Fig. 7—Cover—Quarter Trim Panel Lower (Sedan)
(2) Position silencer to panel.
(2) Tape leading edge of front door and cowl to
(3) Assemble silencer and panel to cowl side with
screw. fender area to avoid damaging paint.
(3) Remove front bum per assembly.
C o v e r —L o w e r T rim (Fig. 7) (4) Disconnect head lamp wires and remove grille
The lower quarter trim panel cover is attached to extension to fender nuts.
the quarter panel with screws. (5) Remove nuts and screws attaching fender to
cowl, floor sill, splash shields and radiator yoke (Fig.
Scuff P la te s (Fig. 8)
The scuff plates are assembled to the body with 9).
screws (Fig. 8). (6) Remove fender assembly and if necessary re
move fender mouldings, ornam entation and head
FENDERS lamp assemblies.
ALIGNMENT I n s t a l la t io n
The fender should be adjusted to provide for equal (1) Install head lamps, mouldings and ornam enta
spacing at the cowl, door front edge and door top tion.
edge. Alignment should be made at bottom of floor (2) Carefully position fender on studs at cowl side
sill panel, front of hood and door outer panel upper and align fender with mounting holes in radiator yoke.
edge (Fig. 9). Install all screws and nuts.
(3) With fender correctly positioned, tighten screws
REPLACEMENT
and nuts securely.
R em oval
(1) Disconnect battery ground strap.
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FENDER DASH PANEL
EXTENSION
FENDER
MOULDING
HEADLAMP
ADAPTOR
The fender side reflector and bezel assembly is at AIR SHIELD AND CROSS BAR
tached to a recessed area with nuts (Fig. 10). Refer to Figure 11 for air shield and cross bar at
taching points.
RADIATOR YOKE SUPPORT
BUMPERS
REPLACEMENT
Refer to (Figs. 12 and 13) for attachm ent of front
and rear bumpers.
R em oval
(1) Drain and remove radiator.
(2) Remove hood lock striker, horn and head lamp
wiring from yoke support.
(3) From under fenders remove splash shield to
yoke support screws.
(4) Remove support to fram e screws and support.
I n s t a l la t io n
(1) Position yoke support on fram e and install
screws finger tight.
(2) From under fenders, install splash shield to
yoke support screws finger tight only.
(3) When all screws have been installed, tighten
progressively.
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Fig. 13—Rear Bumper Attachment
Fig* I1—Air Shield and Crossbar F ore a n d A f t
Adjustm ent is made at the door hinge half. Adjust
GRILLE only one hinge at a time. Raising outer end of door
ALIGNMENT AND REPLACEMENT moves upper part of door forward, when in closed
position. Lowering lower part of door moves lower
Refer to (Fig. 14) for grille attaching points. When part forward, when in closed position.
assembling grille, install screws into left side first to
laterally align grille to fram e opening. The grille In a n d O u t
m ust be held against front face of fenders at outer Adjustm ent is made at the pillar hinge half. Adjust
edges to avoid stressing or fracturing with Textured only one hinge at a time. Raising outer end of door,
Grilles. Care should be taken to protect grilles from moves upper part of door into door opening. Lowering
high tem perature during repairs. outer end of door, moves lower part of door into door
opening.
DOORS
The service procedures for internal door com LATCH AND STRIKER PIN
ponents do not include obvious operations, such as re
moving door or quarter panel trim panels, testing The front door cannot be locked until the door is
operation of window or inspecting glass fit after ad completely closed. The silent type door latch (Fig.
justm ents or replacem ent have been perform ed. 16) features a rubber isolation of the round striker
pin on the door fram e and those surfaces acting as
ALIGNMENT stops inside the latch. The latch assembly is built into
a sheet m etal pocket on the door face. The striker
Up a n d D ow n pin is attached by a single screw which also allows
Adjustm ent of the door can be made at either the for adjusting. Torque the striker pin screw 30-70
pillar or door hinge halfs (Fig. 15). foot-pounds.
DOOR REPLACEMENT
F ro n t D o o r
Rem oval
On vehicles with electric windows, disconnect wires
from regulator motor and remove from door.
(1) With door in wide open position, place a jack,
with a block of wood on lifting plate of jack, as near
hinge as possible to support door as hinge bolts are
loosened.
(2) Remove door interior trim and hardware.
(3) Scribe a line around upper and lower hinge
plates on door panel.
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YOKE
SCREW AND
WASHER
U-NUT
SCREW
FRONT
NN 522
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The rear door upper hinges are attached to the “B”
post by three screws accessible through an access hole
in the “B” post.
INSIDE HANDLES
W in d o w R egulator H andle
The window regulator handles are retained on the
shaft with an alien set screw.
The handles should be positioned on the shaft in
approximately a horizontal position with the knobs
pointing rearward.
ARM RESTS
Fig. 18—Door W atershields
The arm rests are retained by two m etal screws in
serted at the bottom of the arm rest base. The pad and (2) Remove link from remote control lever and
base can be separated and the pad may be recovered. lock assembly.
(3) Remove control from door and linkage through
TRIM PANELS large opening in door.
I n s t a l la t io n
(1) Position lock assembly in door and connect re
mote control link to lock lever.
(2) Install and torque lock retaining screws 30-50
inch-pounds.
(3) Connect handle to lock link.
(4) Connect locking lever rod (front door only) to
lock assembly.
NN 605
(5) Connect locking lever rod and rem ote control
link to lock.
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L ock C y lin d e r I n s t a l la t io n
R em oval (1) Position cylinder in door and install retainer on
(1) With window in the up position, disconnect cyl cylinder body.
inder link (Fig. 22) from clip on lock lever (4 door (2) Connect the cylinder link to cylinder arm and
only) and from cylinder. to clip on lock lever (4 door models).
(2) On 2 door models, disconnect lock link from clip (3) On 2 door models connect cylinder link to cyl-
on lock lever, remove link control bracket screws
and remove cylinder link from cylinder.
(3) Remove retainer from cylinder body and cylin
der from door.
SEAL-
REMOTE CONTROL
LINK LATCH
NR193
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retainer from link at handle connector.
(2) Depress handle release button and remove link
from handle connector.
(3) Remove handle to door nuts and handle.
I n s t a l la t io n
(1) Position handle in door and install nuts.
(2) Depress handle button and position link over
connector on handle.
(3) Install retainer over link and connector.
Door W e a t h e r s t r i p s
Make sure all weatherstrip particles and cement
are removed before installing new weatherstrip.
S e d a n M o d e ls
! NR192
(1) Apply lower half of weatherstrip, starting at
Fig. 22—Door Lock Cylinder
hinge face at belt line, working fasteners into holes
in shut face of doors.
inder, position link bracket on door face and install (2) Apply a 1/8 inch bead of cement to w eather
screws. Connect lock link to lock. strip seating area on door upper and lower areas.
(3) Install upper half of weatherstrip on door, in
OUTSIDE HANDLE— Front Door dexing at the upper corners.
(4) Work weatherstrip from index points to a point
R em oval
(1) With door glass in u p position, remove nuts midway between them. Avoid puckering or stretching
from mounting studs (Fig. 23) and link from handle to of weatherstrip.
lock.
(2) Lift handle up and out of door. H a r d to p M o d e ls
(1) Index molded end of weatherstrip to the door
and install screw.
I n s t a l la t io n
(1) Position handle into door and engage handle to (2) Starting from molded end, stretch w eatherstrip
lock link. to allow fasteners to index into holes.
(2) Attach stud nuts and test handle operation. (3) Position pillar seal at belt line. Make sure
w eatherstrip dove tails into groove of seal and install
REAR DOOR screws.
O u te r B e lt W e a t h e r s t r i p
The door outer belt weatherstrips are retained in
the door panel with spring type retainers.
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I N D EX P O I NT
M O U L D IN G W SEAL
FOR SEAL
SEAL D R A IN
— RETAINER
TROUGH
I NDEX FLUSH
W ITH
RETAINER
CEMENT
V IE W IN DIRECTION
O F ARROW P
WEATHERSTRIP SEALER
CEMENT
V IE W IN CIRCLE M
VIE W IN M O U L D IN G VIEW IN CIRCLE W
LOCK
DIRECTION OF ARROW S
PILLAR RETAINER
WEATHERSTRIP
SEAL
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STARTING POINT
FRONT
UPPER
PILLAR
STARTING
POINT
VIEW IN DIRECTION
OF ARROW Z VIEW IN DIRECTION
(ALL 2 DOOR) OF ARROW V
(4 DOOR)
NR75A
Fig. 25—V/indcords
(1) Position vent wing into door and align screw D o o r G la s s R e p l a c e m e n t
holes. R em oval
(2) Install screws but do not tighten. (1) Loosen front run channel lower m ounting screw
(3) Install door glass in run channel and regulator (Fig. 27).
arm s and clips. (2) Move channel forward and slide glass out of
(4) Position lower run channel adjusting stud into channels.
door bracket and align window run channel. (3) Remove regulator arm from lift bracket.
(4) Remove glass from door.
(5) Push plug out of lift bracket rivet.
(6) Pinch ends of rivet together and remove glass.
I n s t a l la t io n
(1) Position lift bracket and gasket on glass, install
rivet and plug.
Before installing glass, lubricate regulator slide
channel.
(2) Position glass into door and insert regulator arm
roller into lift bracket.
(3) Position glass into run channels and adjust door
glass.
R e g u l a to r R e p l a c e m e n t
The regulator assemblies are attached by screw and
washer assemblies. When removing, the door glass
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FORE AND AFT
HARDTOP MODELS
justing stud at hinge reinforcem ent.
D o o r G la s s A d j u s t m e n t s (Fig. 2 7 ) (5) Remove vent wing to hinge fence screw and
(1) Raise door glass 2/3 way up. A djust upper washer.
(6) Raise vent wing and door glass, tilt toward lock
attachm ent of rear run channel to center glass be
face of door and disengage regulator arm from glass
tween inner and outer weatherstrips and tighten
lift bracket and remove from door.
screw.
(7) Invert vent wing and door glass assembly and
(2) Raise window, seating top of glass and front
remove adjusting stud, rod and retainer from vent
of vent wing fully against and parallel to roof rail
wing (Fig. 29).
weatherstrip. Tighten vent wing belt line front screw.
(8) Slide door glass out of vent wing channel.
(3) Adjust hinge face stud to align upper edge of
glass to roof rail weatherstrip and tighten nut.
ANTI-RATTLE
(4) Tighten vent wing belt line rear screw.
(5) Position up-stop down against regulator arm
and tighten screw. LIFT BRACKET
R em oval
(1) Remove up-stop from door.
(2) Remove nut and washer from adjusting rod at
bottom of vent wing channel.
(3) At upper rear corner of belt, remove drive NU238
screw from vent wing.
(4) Remove n u t and washer from vent wing ad
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(7) Install drive screw in vent wing at rear belt.
(8) Install up-stop and adjust door glass.
R e g u la to r A s s e m b l y
For a good engagem ent of the glass in the division
channel run, shift the regulator assembly forward. It
is im portant that the glass seat fully in the division
channel. Alignment of the front edge of the glass with
the division channel is also important. Shift the rear
of the regulator assembly up or down (Fig. 32) to level
the glass and align it with the division channel.
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(5) A djust door glass.
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Fig. 36—Quarter Window Adjustment
1/4 inch above wheelhouse and tighten regulator Fig. 3 8 —Quarter Glass Assembly—Sedan
down stop nut.
(3) Lower quarter glass and bracket to bottom of
Glass Replacem ent q uarter panel and install the outer belt weatherstrip.
Rem oval (4) Raise glass and position lift bracket over regu
(1) Lower glass and through front access opening, lator arm roller.
remove clip from regulator arm stud pin (Fig. 37). (5) Insert regulator front arm stud into bushing in
(2) Pull regulator arm stud out of bushing. glass, install clip and adjust glass.
(3) Push up on front of glass, while holding arm
stud until front of glass is clear of stud. R egulator Assembly
(4) Raise and rotate front of glass until lift arm The regulator assembly (Fig. 39) is attached to the
bracket clears regulator arm stud. inner panel with screw and washer assemblies. In
(5) Lower glass to bottom of panel, remove outer spect rollers on regulator studs and apply lubricant to
belt w eatherstrip and remove glass assembly from the slide area of the pivot channel prior to installing
panel. regulator.
Adjustments
(1) Raise quarter window 2 inches above belt line.
(2) Adjust top of front and rear tracks (Fig. 41)
until glass just touches the outer belt weatherstrip
and tighten nuts.
(3) Raise window to the upper weatherstrip and
adjust regulator so glass at front contacts w eather
strip and is parallel to the w eatherstrip bead. Tighten
regulator screws.
(4) Adjust bottom of front and rea r tracks until
upper edge of glass seals against roof weatherstrip.
Tighten nut on rear track only.
(5) Tighten adjusting screw on bottom of front
track to lower brace.
(6) Position front and rea r up-stops (Fig. 42) to
glass lower fram e stops and tighten screws.
(7) Adjust regulator down stop (Fig. 41) so glass
contacts outer weatherstrip lightly for full length.
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Fig. 39—Quarter Window Regultitor
Glass Replacement R egulator Assembly
Rem oval Hard top models use a two arm regulator (Fig. 45).
(1) With glass in mid-position, remove spring nuts To remove the quarter window regulator, it is advis
from regulator arm studs (Fig. 43) and studs from able to first remove the glass. The regulators are at
rollers. tached to the inner panels by screws. A fter the regu
(2) Remove up-stops from lower fram e (Fig. 42). lator and glass have been installed, test the operation
(3) Remove glass assembly from door.
of the regulator and adjust the glass.
(4) Remove slide and roller from glass fram e rea r
track and roller assemblies from tracks in front sec
tion (Fig. 44). Front Roller Track a n d Brace
The front roller track (Fig. 46) is replaced from
Installation between the quarter inner and outer panels with the
(1) Position roller assemblies and slide to front quarter window fully lowered. Disconnect track from
and rear tracks of glass lower frame. brace, remove sleeve nut and washer and rotate track
(2) Insert glass assembly into quarter panel, spring approximately 90 degrees to disengage from rollers
regulator arms inboard and insert studs in rollers when removing.
and install spring nuts.
(3) Install up-stops and adjust quarter window.
UP-STOP D O W N ST O P
IN A N D OUT
IN A N D OUT
UP-STOP
PARALLEL
ADJUSTMENT
IN A N D OUT
IN A N D OUT
NP628
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23-22 BODY AND FRAME-
-ANTI-RATTLE ROLLER
UP-STOP
SECTION A-A
LUBRICANT
REGULATOR
NP629 NP627
JAM NUT
APPLICATION AT CIRCLE A
SPRING NUT
Fig. 43—Quarter Glass Replacem ent—Hardtop Fig. 46—Front Roller Track And Brace—Hardtop
REAR TRACK
SPRING WASHER
ROLLER
ROLLER FRONT BRACE
ROLLER ASSEMBLY
LUBRICANT NP631
Fig. 44—Quarter Glass Assem bly—Hardtop
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SPRING WASHER STABILIZER
DECK LID
Alignm ent
The deck lid hinges (Fig. 50) perm it only slight Fig. 50—Deck Lid Hinge
justm ent at the hinge attaching points. The hinge (3) Remove spring nut retaining hinge to hinge
brackets are welded in place and are not adjustable. bracket (Fig. 50) and remove hinge.
Replacem ent
In stallatio n
The deck lid is attached by two screws on each side. (1) Use a new spring nut and install hinge.
An assistant’s aid is recommended when replacing, (2) Install deck lid and connect torsion bars.
to prevent it sliding rearw ard and damaging the paint (3) Test deck lid adjustm ent.
and also to aid in aligning of the hinge screw holes
when installing. QUARTER PANEL EXTENSION
Hinge Replacem ent Refer to figure 51 for attachm ent application of
Rem oval q uarter panel extension.
(1) Remove the deck lid.
(2) Use care when disengaging a torsion bar as it is TORSION BAR REPLACEMENT
under a load. Disengage torsion bar roller from hinge
being removed. Rem oval
(1) Remove torsion bar (under spring load) from
adjustable slot.
(2) Unwind torsion bar and remove from support
bracket.
(3) Push torsion bar out of roller in hinge arm and
remove from hinge support.
Installatio n
(1) Insert bar into hinge support and position end
of bar into hinge arm roller.
(2) Hook torsion bar into support bracket, and
position end of bar into first adjusting slot.
(3) Move deck lid to various open positions and test
tension of torsion bars.
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Fig. 53—Deck Lid Lock Cylinder
QUARTER
NUT AND\ PANEL taching screws. Side adjustm ent is made at the striker
WASHER attaching bolts.
SCREW
AND
WASHER
D e c k L id L o c k C y lin d e r (Fig. 5 3 )
STONE DEFLECTOR
J-NUT R em oval
STUD
(1) Disengage retainer from lock cylinder.
■SCREW AND WASHER
(2) Disengage quill from latch.
(3) Remove gasket and lock cylinder from deck lid
Fig. 51—Quarter Panel Extension hole.
(4) A djust bars progressively until lid stays in open (4) Remove gasket from lock cylinder.
position.
I n s t a l la t io n
Lock R e p l a c e m e n t (1) Assemble gasket to lock cylinder.
The lock assembly (Fig. 52) are attached by two (2) Install gasket and lock cylinder into deck lid
screws. Scribe location of lock m ounting flanges to aid hole.
in installation. (3) Engage quill into deck lid latch assembly.
(4) Secure deck lid lock cylinder with retainer.
L ock A d j u s t m e n t
Vertical adjustm ent of the locks is m ade at the at- W e a th e r s tr ip
Apply an even continuous coat of cement to entire
weatherstrip contact surface of deck lid opening
(Fig. 54). Make sure molded corners of w eatherstrip
are correctly positioned when installing.
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NUT
BONDED TYPE
PY658
F ig . 5 5 — F e n d e r M ouldings
SECTION A -A
RETAINER
4 -
D O O R M O U L D IN G (SEDAN)
A P PLIC A TIO N
A PPLIC A TIO N
NUT
SECTIONS K -Y
RETAINER
RETAINER
SCREW D O O R M O U L D IN G M O U L D IN G
(CUSTOM 4 DO O R SEDAN)
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REAR UPPER
REAR D O O R M O U L D IN G
(SED AN )
REAR D O O R M O U L D IN G REAR D O O R FRAME M O U L D IN G S
(SEDAN) (SEDAN)
PY660
M O U L D IN G
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SPEED CLIP
NAME PLATE
NAME PLATE
GT-HARDTOP
SWINGER-HARDTOP
NAME PLATE
DART-HARDTOP
PY662
RETAINER
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EXTERIOR ORNAMENTATION
Refer to Figures 55 thru 60 for methods of attach
ing exterior mouldings and ornaments.
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FRAME HOOK
REAR
I n s t a l la t io n
SHELF (1) With an assistant, position hood on hinges and
DEFOGGER
OPENING install bolts. Do not tighten.
BODY SIDE
SILL
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COWL SIDE PANEL
INNER
SPRING NUT
SCREW
COWL SIDE TRIM
LEFT SIDe \
COWL
SIDE SPRING NUT
TRIM RIGHT SIDE
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I n s t a l la t io n and inspect for leaks.
(1) Position yoke support on fram e and install
screws finger tight. AIR SHIELD AND CROSS BAR
(2) From under fenders, install splash shield to Refer to Figure 11 for air shield and cross b a r at
yoke support screws finger tight only. taching points.
(3) When all screws have been installed, tighten
BUMPERS
progressively.
(4) Attach horn and light wires to yoke support FRONT AND REAR BUMPER
with plastic straps. Refer to Figures 12 and 13 for front and rear
(5) Install radiator and hoses, fill cooling system bum per attaching points.
GRILLE
Refer to (Fig. 14) for installation of grille assembly
to car. Care should be taken to protect textured grilles
from high tem perature during repairs.
DOORS
The service procedures for internal door compo
nents do not include obvious operations, such as re
moving door or quarter panel trim panels, testing
operation of window or inspecting glass fit after ad
justm ents or replacem ent have been performed.
ALIGNMENT
Up a n d D ow n
Adjustm ent of the door can be made at either the
pillar or door hinge halfs (Fig. 15).
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FENDER BRACKET SCREW HOOD SCREW
SUPPORT'
COWL
BRACKET! DASH PANEL
SHIM
SIDE SILL
AIR SHIELD
PY32
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Fig* 1 1 — A irsb ield A nd Crossbar
SCREW
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23-34 BODY AND -FRAME-
NUT
BRACKET
CUSHION GUARD
BUMPER
WASHER CUSHION
BOLT
% I3 -R e o r Bumper Application
U-NUT
SCREW
SCREW YOKE
FENDER
U-NUTS
NAM E PLATE 'N A M E PLATE
NAM E PLATES GRILLE BEZEL
APPLICATION
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TAPPING PLATE
PY463
REAR ^ 9 ^ FRONT
N N 522
Pig. f#~D@ or Latch S trike r A djustm ent LOCK CYLINDER— DOOR LOCK (Fig. 19)
(1) Place handle assembly (front door outside) face
LATCH LINK (Fig. 17) down.
(2) Position cylinder assembly to handle assembly.
Assemble link, front door latch (Fig. 17) to lever of (3) Position spacer to cylinder and handle assem
handle assembly, (close clip). bly.
(4) Secure cylinder with screws.
DOOR LOCK CYLINDER LINKAGE (Fig. 18)
REMOTE CONTROL (Fig. 20)
(1) Connect link front door latch key cylinder to (1) Assemble s e a l- th r u door panel access hole and
lever portion of key cylinder. position to rem ote control lever, press to secure.
(2) Insert lower end of link (Item #1) into latch (2) Position control assembly to attaching holes in
locking lever retainer. door.
LINK REMOTE CONTROL
SCREW AND
WASHER
ACCESS
HOLE
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Fig. 23—Door Trim Panel
Fig. 21—Outside Handle—Latch Link CARPET AND FINISH PLATE TO DOOR
(3) Secure with screw and washer. (Fig. 24)
OUTSIDE HANDLE— LATCH LINK (Fig. 21) (1) Place door trim panel on bench.
(2) Loosely assemble carpet and base assembly to
(1) Assemble gasket to handle and link assembly. door trim panel.
(2) Position handle and gasket assembly to door (3) Secure base with nuts.
outside panel. (4) Secure carpet assembly with retainers and bend
(3) Secure with nut and washer. over tabs.
(4) Insert lower end of link (part of handle assem
bly) into latch lever release and close clip. DOOR LOCKING KNOB (Fig. 25)
FRONT DOOR LATCH LOCKING CONTROL Position knob to control assembly shaft and with
(Fig. 22) knob in a unlocked position secure with screw and
washer to front door latch locking control.
(1) Position front door latch to front door inside
panel—thru access hole. AIR SHIELD (Fig. 26)
(2) Secure with screw and washer.
Refer to (Fig. 26) for door air shield application.
DOOR TRIM PANEL INSTALLATION (Fig. 23)
WEATHERSTRIPS AND WINDCORDS
(1) Position and hook door trim panel to inner
panel, align bottom of trim panel to fastener holes, D o o r W e a th e r s tr ip s
tap in place. Make sure all w eatherstrip particles and cem ent
(2) Secure each end with screws. are removed before installing new w eatherstrip or
(3) Secure at arm rest with screws. windcords.
For cars equipped with electric window lift, thread
wire thru cut out in trim panel before positioning to NUT
inner panel.
ACCESS HOLE FINISH
PLATE
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Ffg. 26—Door Airshield
GLASS A d j u s t m e n t s (Fig. 2 7 )
P a r a lle lis m a n d P r i m a r y S e a l
VENTLESS GLASS ADJUSTMENT (1) Raise window completely.
(2) Loosen screw at belt on upper end of front
Numbers shown on glass adjustm ent Reference track.
Illustration (Fig. 27) indicate particular step num ber (3) Align and set front edge of glass to “A” pillar
in adjustm ent procedure. and top edge to roof rail weatherstrip creating a
parallelism with weatherstrip locating bead.
(4) Secure upper screw on front track previously
loosened.
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In -O u t an d Secondary Seal (10) Reposition glass by turning 180 degrees (out
(5) Loosen bottom screws on front track lower sup side up).
port. (11) Assemble stop on glass front.
(6) Loosen bottom screw on rear track support. (12) Secure with screw.
Push front track lower support. Outboard for inboard (13) Assemble fastener to hole provided in glass
contact at weatherstrip. Allow rear track to create it’s and press in to shoulder.
own plane, parallel to front track. (14) Apply lubricant to guide in screw hole and to
(7) Secure previously loosened front track lower screw.
support screws. (15) Position lubricated screw and guide to fastener
(8) Secure rear track lower support screws. in glass and secure.
(9) Secure front track lower support screws. (16) Assemble stop thru rear upper hole in stabi
If additional alignment to "A" pillar or roof rail is lizer bracket, gasket and glass and secure with screw.
necessary, adjust regulator idler arm pivot bracket (17) Assemble bum per to track brackets and press
up or down as required and secure. to secure.
(10) Secure regulator arm pivot guide to panel. (18) Apply lubricant to guide slide surfaces of
Item #17.
Up-Stops (19) Assemble lubricated track and brackets as
(11) Push front Up-Stops bracket down against plas sembly item #17 with bum per attached to guides item
tic up stop on glass (Front End) and secure with #14 and thread on to span glass completely.
screws and washers to belt reinforcement.
(12) Push rear up stop bracket down against plastic VENTLESS DOOR GLASS INSTALLATION
up stop on rear stabilizer and secure with screw and (Fig. 29)
washer to rear bracket belt reinforcement. To install ventless glass the following steps should
be followed:
GLASS ASSEMBLY (VENTLESS) (Fig. 28) (1) Install bum per door glass down stop (Fig. 31).
(1) Position glass on bench. (2) Install pivot bracket front door regulator.
(2) Assemble gasket, door glass stabilizer guide and (3) Install regulator (Manual or electric) (Fig. 33).
support assembly. (4) Install left channel to regulator arm slide (Fig.
(3) Install spacer and support assembly to glass. 30).
(4) Install guide and support assembly. (5) Install lower support front track to front door
(5) Position items 2, 3 and 4 to under side of glass, (Fig. 32).
push weld stud and spacer th ru lowest hole (outside (6) Secure glass guide stabilizer track, up stops, to
surface) snug secure to glass. front door.
(6) Assemble spacer and support assembly to glass. (7) Install glass sub-assembly to door and attach lift
(7) Place washer and support assembly to glass. channel (Fig. 28).
(8) Install screw and washer assembly and support (8) Install rear track.
to glass. (9) Install upstops front and rear to door outer rear
(9) Assemble fastener to lift channel front hole panel belt reinforcement.
provided in glass and press to shoulder.
LIFT CHANNEL (Fig. 30)
SCREW BUMPER
FRONT (1) Apply lubricant.
TRACK
STOP (2) Install lift channel th ru m ajor access hole in
VENTLESS GLASS
LUBRICATION
SPACER
GASKET
SCREW
V
REAR
LUBRICATION STOP
GUIDE
SCREW AND WASHER WASHER
AND SUPPORT
NUT AND WASHER WASHER PY480
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Fig. 30—Lift Channel
door, position to slides on regulator arms and install
by sliding channel on slides with fore and aft move
ment. Fig. 3 3 —Front Door Regulator
(2) Position to attaching holes and snug secure with
GLASS DOWN STOP (Fig. 31) screw and washer.
Position bum per (front door glass down stop) to FRONT DOOR REGULATOR (Fig. 33)
elongated hole provided in bottom center of door
inner panel using m ajor access hole to locate slot and (1) Place operating lever arms in desired position
press to secure. for installation.
(2) Install assembly thru m ajor access hole in door,
LOWER FRONT TRACK SUPPORT (Fig. 32) insert idler arm roller in pivot bracket, position
m ounting plate or electric motor bracket to attaching
(1) Install support and retainer assembly thru m ajor holes in door inside panel.
access hole in door. (3) Secure with screw and washer to manual win
dow regulator or electric window regulator.
INSTALL FRONT DOOR TO GLASS (Fig. 34)
(1) Install glass rear stabilizer track slides, front
track, up-stops and lift fastener to front door glass
opening at belt, hold track from sliding off slides
while installing.
(2) Lower assembly gently to bottom of door, mak
ing sure that glass is outboard of regulator arm s and
front track is inboard of lower support.
(3) Position front track and bracket assembly to
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belt reinforcem ent using access hole in door and snug window is aligned with rear edge of front door glass
secure with screw and washer. by pushing track adjusting stud fore and aft in sup
(4) Position front track and bracket assembly lower port slot. To get secondary seal turn adjusting screw
end to support. in and out as required. Secure jam nut on adjusting
(5) Secure with screw and washer. screw.
(6) Raise glass by hand so that lift channel re a r at
tachm ent slot can be inserted between screw head F ro n t U p S to p
and washer on rear stabilizer assembly. Push lift (6) Push front up stop bracket on front track down
channel rearw ard and secure with loosely installed against slide on lower frome and secure attaching nut.
screw.
(7) Align front slot in lift channel with hole in glass R e a r U p S to p
lift fastener and secure with screw to glass front. (7) Push rear up stup bracket on belt reinforcem ent
down against plastic up stop on glass and secure the
QUARTER PANEL GLASS attaching screws.
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Fig. 39—Slide and Up-Stops
(9) Install down-stop and bum per to front track washer assembly to taped hole in front boss of fram e
(Electric). assembly and secure.
(10) Install up-stop. (5) Assemble stop (quarter glass up position) on
glass, to hole provided in glass, and secure with screw.
PIVOT BRACKET QUARTER WINDOW (Fig. 37) (6) Assemble anti-rattle to quarter window glass
stop.
The Pivot Bracket is welded to the inside section
of the Q uarter Panel. Lubricant should be applied to QUARTER WINDOW FRONT TRACK (Fig. 40)
channel slide contact surfaces using m ajor access
hole in quarter inside panel. (1) Install front track washer stud thru quarter
window glass opening at belt.
DOWN STOP AND BUMPER (Fig. 38) (2) Position upper washer stud to elongated hole
(Electrical) in quarter inside panel, and lower washer stud to
elongated hole in lower support and snug install.
(1) Assemble bum per to down stop. (3) Use nut and washer assembly to install step 2.
(2) Raise glass to half open position.
(3) Install bum per and down stop assembly thru FRONT TRACK ADJUSTER (Fig. 41)
m ajor access hole in quarter inside panel. Position to (Quarter Panel)
front track slots in full down position.
(4) Secure with screw and washer. (1) Position track weld nut and stud assembly on
bench.
SLIDE AND UP STOP TO QUARTER (2) Assemble anti-rattle to up-stop quarter window
GLASS (Fig. 39) glass front.
(3) Sub-assemble up-stop and anti-rattle assembly
(1) Position glass and fram e assembly on bench. item #2 to track assembly item #1 utilizing upper
(2) Apply lubricant to bolt and slide track. weld stud to locate up-stop and snug secure in pull up
(3) Assemble lubricated bolt to washer and slide. position.
(4) Position threaded end of bolt with slide and (4) Secure with nut and washer assembly.
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WASHER STUD
LOWER FRAME SLIDE
LUBRICATOR POINTS RETAINER LOWER FRAME
SLIDE
TRACK REGULATOR
ASSEMBLY
UP-STOP
RETAINER
ANTI RATTLE SCREW
SLIDE A ND WASHER RETAINER
\V tJ Q uarter reo u l a t o r
PY485
W IN D O W (M A N U A L )
Fig. 41—Front Track Adjuster RETAINER
QUARTER W IN D O W (ELECTRIC)
(5) Assemble washer stud upper and lower slide ■\ - PY475
track.
Fig. 43—Quarter Window Regulator
(6) Apply lubricant to points shown in (Fig. 41).
(7) Assemble slide to lubricated center tracks and QUARTER PANEL AIRSHIELD (Fig. 44)
slide to bottom.
I n s t a l la t io n
QUARTER WINDOW REAR RUN (Fig. 42) (1) Apply sealer adhesive to airshield.
(2) Install weatherstrip assembly to holes in quar
(1) Place glass in full down position. te r panel with clips.
(2) Install run and retainer assembly thru m ajor (3) Apply weatherproof tape to weatherstrip, quar
access hole in quarter panel. ter panel, and side sill.
(3) Snap bottom clip on retainer to up-standing (4) Apply adhesive around window regulator in
bracket on wheelhouse, position upper end to panel w eatherstrip and immediately apply air shield.
belt reinforcem ent, align holes and secure with screw.
QUARTER PANEL TRIM
QUARTER WINDOW REGULATOR (Fig. 43)
QUARTER TRIM PANEL INSTALLATION
(1) Assemble arm to glass lower fram e and retainer (Fig. 45)
and quarter window arm to glass lower fram e slide.
(1) Position quarter trim panel, align holes to quar
(2) Place into hole in regulator arm, and press both
ter inner panel.
together to secure. (2) Secure top with screws.
(3) Install regulator assembly (manual or electric) (3) Secure bottom to floor pan with screw.
thru m ajor access hole in quarter inside panel, insert For jobs with electric window lift, thread wire thru
idler arm roller slide in pivot bracket channel position trim panel before positioning to inner panel.
m ounting plate or m otor bracket to attaching holes
in quarter inside panel and secure with screw and FOLDING TOP POCKET PANEL ASSEMBLY
washer. (Fig. 46)
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QUARTER PANEL ADHESIVE QUARTER PANEL
AIR SHIELD
ADHESIVE
PY528
ELECTRIC
WINDOW
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Fig. 47—Pocket Panel Installation
(2) Position bracket to trim panel, secure with
screw.
Fig. 49—Quarter Panel Lamp Bezel and Reflector
(3) Position ash receiver to quarter trim panel and
press in place. (5) Tighten screw.
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LOCK
SCREW
DECK LID
M O U N TIN G
FLANGE
SCREW
M O U N TIN G AREA
H i n g e R e p l a c e m e n t I n s t a l l a t i o n
R e m o v a l
(1) Insert bar into hinge support and position end
(1) Remove the deck lid. of bar into hinge arm roller.
(2) Use care when disengaging a torsion bar as it is (2) Hook torsion bar into support bracket, and
under a load. Disengage torsion bar roller from hinge position end of bar into first adjusting slot.
being removed. (3) Move deck lid to various open positions and test
(3) Remove spring nut retaining hinge to hinge tension of torsion bars.
bracket (Fig. 51) and remove hinge. (4) Adjust bars progressively until lid stays in open
position.
I n s t a l l a t i o n
R e m o v a l
HINGE
UPPER DECK
LUBRICATION PANEL
POINTS
ADHESIVE
HINGE QUARTER DECK DRAIN
TORSION BAR HINGE
VIEW IN
POSITIONING SLOTS
DIRECTION OF ARROW Z
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23-46
BODY AND
FRAME
PY679
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\
RETAINER
M OULDING
V M ADALLIO N
SCREW" APPLICATION
RETAINER
BODY AND
M OULDING
FRAME
M OULDING
PY680
23-47
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23-48
SCREW
BODY AND
FRAME
RETAINER
SCREW RETAINER
FINISH PANEL*
WHEEL MOULDING
DECK
NAME PLATE
DECK UP MOULDING
PY681
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FENDER SIDE M O ULDING
SCREW
PFAR
M O ULDING
BODY AND
FRAME
SECTION A -A
23-49
PY682
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LOCK (Fig. 53) at bottom of deck lid opening. (Avoid puckering or
stretching of weatherstrip around corners). Trim ends
The lock is mounted in the deck lid with screws to overlap .25. Apply adhesive to butt surfaces and
(Fig. 53). Scribe the location of the lock on the mount install under compression to provide a watertight
ing flange to aid in replacement. joint.
DECK LID WEATHERSTRIP (Fig. 54)
EXTERIOR ORNAMENTATION
(1) Apply a coat of adhesive to weatherstrip con
tact surfaces. Refer to Figures 55 through 58 for applications of
(2) Install weatherstrip so that joint will be located exterior mouldings and ornamentation.
Page Page
BELTS— SEAT Trim Panels— I nstrument Panel P a d ................. 50
INTERIOR TRIM Package Shelf ................................................... 54
Console .................................................................... 50 SAFETY BELTS .......................................................... 63
Floor Covering ........................................................ 50 SEATS
Scuff Plates.......................................................... 50 Adjustment .............................................................. 54
Garnish Mouldings ................................................ 50 Back Latch— D a r t .................................................. 55
Glove Box ................... ............................................ 53 Back Latch—Challenger ...................................... 56
Headlining— F a b ric ................................................ 51 Cover Replacement............................................... 58
Hardboard .................................................... ....... 51
SERVICE PROCEDURE
INTERIOR TRIM attaching screws are accessible from within the con
sole.
GARNISH MOULDINGS
FLOOR COVERING
When removing a garnish moulding positioned
under the end of the adjoining moulding, loosen the Scuff P l a t e s
CONSOLES
D a r t - C h a l l e n g e r
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TRIM PAD remove the rear floor covering it is necessary to re
UPPER
move the front seat assembly and the rear seat
cushion.
END The well floor covering on station wagons is held in
OF position with three retainers.
PAD
SOFT HEADLINING
D a r t - C h a l l e n g e r
STRIKER
PIN
SUPPORT
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SCREW SCREW
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S U P P O R T W IR E
RETAINER
UPPER
N P 57 2
N P 573
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SC R EW
LO C K
N U133A
Installatio n
(1) Install latch assembly to inner panel of glove
box door.
(2) Insert lock and key into latch through glove box
face.
(3) Hold cylinder in position and remove key.
(4) Install glove box spring lock catch to upper
flange of instrument panel.
(5) Close door and align to panel, open door and
tighten all screws.
Fig. 9 —H ard Type H eadlining
PACKAGE SHELF PANEL (Fig. 14)
(1) Position upper and lower assemblies together
with screws. The shelf trim panel and silencer pad is retained
(2) Install lamp lens. on the shelf panel with spring type fasteners.
(3) Position glove box to inner panel and secure Installatio n
with screws. (1) Remove the defogger inlet gated section from
(4) Secure hinge to door. new panel.
(2) Install panel retainers and slide panel into posi
tion on shelf panel.
(3) Align retainers with mounting holes, but do
not insert.
(4) Apply cement to panel end extensions and force
retainers into mounting holes using hand pressure.
(5) Install defogger outlet, rear seat back and cush
ion and window garnish mouldings.
SEATS
ADJUSTMENT
To raise or lower the front seat (Figs. 15 and 16)
loosen the adjuster mounting bolt nuts, under floor
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SCREW
PY299
SHEET M E T A L P A N E L
PY444
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Fig. IS —Front Seat Adjuster—D a rt
(2) Install latch assembly on pivot pin and insert FRONT SEAT BACK LATCH— Challenger
outer end of spring in notch on latch. (Fig. 18)
(3) Install flat washer and retainer firmly against
latch assembly. (1) Install latch to back spring assembly before
(4) Install clip and knob on latch. spring is trimmed. Insert bolt through back spring
SEAT F R A M E . S E A T FR A M E ADJU STER S
KNOB
A D JU S TE R A S S EM B LY
A D JU S TE R
SET SCREW
HAND TIGHTEN
SIX WAY ADJUSTABLE
SCREW SCREW
SEAT (BUCKET)
AND WASHER AND WASHER
BELT
SCREW AND WASHER
KNOB g
FLOOR PAN
/
SET SCREW
HAND TIGHTEN
FLOOR PAN
MEMBER)
(" C "
BOLT
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spring by inserting bolt through slot in striker and
ATTACHING HOLES hole in spacer and into tapping plate in cushion
SCREW COVER spring. Note: Difference in striker assembly and quan
MATERIAL
KNOB tity of spacer required for bucket and bench seat.
Striker assembly should be positioned so that bolt will
CONTROL be in mid-way position of slot.
(7) Mount trim m ed back spring to trim m ed cushion
spring by installing pivot bolt through large hole in
PROTECTIVE CAP ‘‘Hockey Stick” and hole in washer and into weld nut
FOR RELEASE
HANDLE
in cushion spring.
FRONT (8) Attach cover to back spring by inserting screw
ESCUTCHEON SEAT BACK
SET SCREW RELEASE LATCH •CABLE PY536
through cover and into back spring. Note: Difference
in cover for bucket and bench seat.
Fig. 17—Front Seat Back la tc h —D art (9) Attach cover to back spring by inserting screw
through cover and into back spring.
and into latch. (See view in direction of arrow Z).
Note: Rod on back side of button in cover passes
(2) Trim back spring assembly.
(3) Install shield to trim m ed back spring. through hole in ssHockey Stick.”
(4) Screw bum per assembly into back spring to (10) Check operation of seat back latch by folding
within .87" of lower edge of lower cross mem ber of back rearw ard to engage lock latch with rod on striker.
back spring. Then press button on cover inboard. It should release
(5) Fasten plate to trim m ed cushion spring by in the latch and allow the seat back to be folded forward.
serting screw through plate and into cushion spring. If latch does not engage rod, move striker forward. If
Note difference in position for bucket seat and bench latch does not disengage from rod* remove spacer
seat (See view in direction of arrow Y). and check operation of latch and re-position bum per
(6) Mount striker assembly to trim m ed cushion as required.
SEAT BACK
HINGE
COVER
BUCKET
BOLT
PIVOT
BOLT
BUCKET
LATCH
SCREW'
BUMPER
C U S H IO N ^ STRIKER
PLATE
'J&T I VIEW IN
STRIKER LATCH J DIRECTION OF
SPACER ARROW Z '
VIEW IN CIRCLE X
VIEW IN DIRECTION OF ARROW Y (LOCK POSITION)
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CUSHION
SEATBACK
SHELF.PANEL
HANGERS
GROMMET
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HEADLINING
ROOF RAIL
SAFETY BELT
PY764
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SNAP
STOWAGE OF TIP
HALF OF SHOULDER BELT
PY763
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V IE W IN CIRCLE Z
P Y 769
V IE W IN D IR E C T IO N O F A R R O W Y
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REAR SEAT SAFETY BELT
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seat frame. All seat frames are attached to the ad incorporates two metal straps which are attached to
justers by studs and nuts. Remove nuts from adjuster brackets welded on the floor pan.
mounting bolts (under floor pan) (Fig. 20) and remove
seat. SAFETY BELTS
Refer to Figures 21 through 29 for application
Rear Seat C u s h i o n
of the seat and shoulder belts.
The rear seat cushion is held in place (Fig. 20) by
inserting the rear edge of the cushion under the seat C over M a t e r i a l I n s t a l l a t i o n
back. The front lower frame of the seat incorporates Prior to installing the original or new cover, make
retainers which fit into slotted brackets welded to certain the spring pad (where used) and pad cover
the floor pan. are centered on the spring and are firmly attached.
Make certain all buttons and medallions (where used)
Rear S e a t B a c k are pulled down securely and locked in position.
The rear seat back (Fig. 20) is held in place by tangs As an aid in attaching the cover correctly, mark
on the seat frame upper edge being positioned over the areas on the spring where the cover was attached
hangers on the shelf panel support. The lower edge with hog rings, screws or drive nails.
Page Page
REAR WINDOW Challenger........................... .................................. 66
Cemented-ln T y p e .................................................. 65 WINDSHIELD (Except Convertible) ....................... 63
D a r t.................................................... ....................... 67 Convertible ........... . . . ......................................... 64
SERVICE PROCEDURE
WINDSHIELD around weatherstrip.
(5) Carefully loosen weatherstrip from glass inner
R e p l a c e m e n t ( E x c e p t C o n v e r t i b l e )
and outer sides.
R e m o v a l
(6) With an assistant supporting one end of wind
(1) Cover cowl, hood and fender area with a protec shield, exert pressure, from inside the car, to force
tive covering. windshield out of weatherstrip and carefully remove
(2) Remove windshield garnish mouldings. from opening.
(3) Remove windshield outer mouldings (Figs. 1, 2 (7) Whenever a glass has cracked from pressure at
and 3) using Tool C-4009. the fence area, remove weatherstrip and correct
(4) Unlock weatherstrip (Figs. 4 and 5) by prying cause of crack. The fence should be straight, smooth
lip of weatherstrip apart, inserting a fibre wedge, and and without burrs or high spots.
with a slight twist to wedge, unlock by moving wedge (8) Inspect weatherstrip for damage.
•C O R N E R M O U L D IN G
M O U N T IN G SCREW
SCREW
LO W ER M O U L D IN G
- /..
'"'CO RNER MOULDING
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(9) On Dart Models inspect weatherstrip lower filler
strip.
Fig. 5 —Windshield W e ath erstrip
I n s t a l l a t i o n
sides and over bottom, force weatherstrip locking tab
(1) Remove all old sealer and cement from original
into locked position (Fig. 5).
weatherstrip if it is being used.
(10) Water test windshield area.
(2) Apply sealer in fence and glass groove portions
(11) Install outer mouldings, wiper arms and
of weatherstrip. On Dart Models install filler strip in
lower part of weatherstrip (Fig. 5). blades.
(12) Install inner garnish mouldings, clean glass
(3) Apply a 3 /8 inch bead of sealer cement com
inner and outer surfaces and remove protective cover
pletely across cowl top panel lower windshield frame
area (Fig. 4). ing.
(4) Position weatherstrip lower section to tab area,
starting at corners install over tabs and work toward CONVERTIBLE MODELS— Challenger
center.
(5) Install weatherstrip on fence at sides and upper R e m o v a l
opening. With hand pressure, seat weatherstrip fully (1) Cover cowl, hood and fender area with a protec
tive covering.
on fence.
(6) With an assistant, slide upper edge of glass into (2) Release top locking mechanisms and push
channel of weatherstrip and using a fibre tool, force header from windshield frame to expose moulding re
weatherstrip lip over glass completely around. tainer screws.
(7) Seat glass in weatherstrip, pounding glass, with (3) Remove wiper arms and blades.
palm of hand using an upward motion. (4) Remove windshield outside mouldings (Fig. 6).
(8) Insert a fibre tool between weatherstrip and (5) Remove inner “A” post side mouldings.
glass, at either corner, slide tool across top, and com
pletely around weatherstrip to seat glass in place.
(9) Using a fibre tool and working across top, down
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(6) Remove sun visors and screws attaching header
trim cap to header.
(7) Pry header moulding up slightly to clear mould
ing from weatherstrip, disengage from header and
remove.
(8) Remove windshield in same method as other
models.
I n s t a l l a t i o n
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Fig. 9 —Spacer Dam Installation
(7) Apply a piece of masking tape over each side of
glass and roof extensions. Slit tape vertically at edge
Fig. 1I—Rear W in d o w Installation
of glass so when glass is installed, tape on glass can
be aligned with tape on body. certain glass will set on rubber spacers and install
(8) Remove glass from opening and place on a pro glass in opening (Fig. 11).
tected surface, with inside surface up. (15) Press glass lightly to adhere adhesive to fence
(9) Primer solution will damage any paint or trim flange.
it comes in contact with. Using a cheesecloth pad (16) Run a flat wooden or fiber tool around entire
saturated with adhesive primer, thoroughly apply to edge of glass to force adhesive into opening between
rear window fence and reveal areas. edge of glass and reveal.
(10) The adhesive begins to cure immediately upon (17) Close car doors gently, do not slam and water
exposure to air. The working life is limited to ap test window. Use a cold water spray, do not run a
proximately 15 minutes. Perform the following steps heavy stream of water directly on freshly applied
as quickly as possible. adhesive. If leaks are evident, work applied adhesive
(11) Insert adhesive tube into a standard household into leak point. Additional material can be applied
caulking gun, install nozzle on end of tube, and punc and worked into leak point.
ture adhesive seal at nozzle. (18) Install garnish and exterior mouldings, clean
(12) Apply a smooth continuous 3 /8 inch bead of glass exterior surface and remove protective covers.
adhesive on glass between glass edge and spacer (19) Leave a window open and do not slam any
dam (Fig. 10). doors for at least one hour. Sufficient pressure could
(13) When positioning glass in opening, alignment build up in a closed car to force the rear window out
must be exact to prevent necessity of moving glass of the opening.
after adhesive contacts fence.
(14) With an assistant and using suction cups on GLASS SUPPORT— Challenger (Fig. 12)
glass, align tape on glass with tape on body, make
(1) Position support assembly to pierced hole in
deck opening upper panel on 2 door hardtop and
frame rear window opening on Challenger RT.
(2) Secure with screw.
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*Fig. 13—Rear Window Preparation
R e a r W i n d o w P r e p a r a t i o n — C h a l l e n g e r Fig. IS —Rear W in d o w Mouldings—Challenger
( F i g . 1 3 )
moulding position flange to retainers and tap into
(1) Apply toluene or lactol spirits to the backlite place.
fence opening around entire perimeter with a damp (5) Telescope lower left moulding assembly into
ened cloth. Immediately wipe area with a clean cloth right moulding and tap in place to secure.
to remove any residue.
(2) Apply a thin even coat of blackout primer to 2 Door R T
complete periphery of fence flange and up the reveal (1) Position upper and side moulding flange to re
surface for a distance of 1/4 inch. Thorough coverage tainers and tap in place. Telescope upper and side
of edge of fence flange and lip of rear window frame moulding into right moulding and tap in place to se
is mandatory to prevent a see through condition. cure.
(3) Allow primer to flash dry for a minimum of 5 (2) Telescope lower corner moulding over rear
minutes. window lower moulding.
(3) Telescope lower corner moulding over lower
R e a r M o u l d i n g R e t a i n e r ( F i g . 1 4 )
section of upper moulding position lower flange to
Position and secure retainers to holes, eight upper retainers and tap in place to secure.
and seven lower.
D a r t M o d e l s
R e a r W i n d o w M o u l d i n g s ( F i g . 1 5 )
R e m o v a l
(1) Position spacers into rear window moulding.
(1) Place a protective covering over deck lid, quar
(2) Position upper and side moulding flange to re
ter panel and read window areas. Remove rear win
tainers and tap into place.
dow mouldings (Fig. 16).
(3) Telescope upper and side moulding into left
(2) Using a fibre wedge, loosen weatherstrip lips
moulding and tap in place to secure.
from inside car.
(4) Position end of lower moulding over side upper
(3) With an assistant supporting glass on outside,
from inside car, push against glass at one of the up
per corners and remove glass and weatherstrip from
fence.
(4) Place glass on a cloth covered bench and care
fully remove weatherstrip.
(5) Inspect polyethylene seal (Fig. 17) and remove
only if damaged.
(6) Remove all sealer from glass, weatherstrip and
fence.
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Fig. 17—R ear Window Seals—D art
Fig. 16 —Rear W in d o w M oulding—D art
I n s t a l l a t i o n
CONVERTIBLE
INDEX
Page Page
ADJUSTMENTS DOWEL BRACKET..................... ................................ ... 71
C a m ........................................................................... ....71 ELECTRICAL TESTS .................................................. 72
Control Link ........................... ................................. 71 FOLDING MECHANISM . . ........................................ ... 69
Door and Glass Alignm ent............... .........................71 FOLDING TOP AND WELL COVER..............................73
Header ......................................................................... 71 OPERATING THE T O P ............. ............................... ... 69
Hinge— Front .......................................................... ... 71 RESERVOIR................................................................. ... 69
Latching Mechanism .............................................. ... 71 SIDE TENSION CABLE.............................................. .. 72
M a jo r...................... ..................................................... 69 TOP DECK TO NUMBER 3 B O W ............................... 76
Minor ....................................................................... ... 69 WEATHERSTRIPS .........................................................73
Roof Side Rail A lignm ent.................................... ...70 Header ..................................................................... .. 73
Shifting Top ............................................................... 72 Roof Side Rail ............... ....... ................................ .. 73
Stack H e ig h t............................................................ ...72 Seals and S ealers.................................................... 73
COVER TO BELT B A R ................................................ .. 79 WELL L IN E R ............................................................... .. 72
CYLINDER HOSE R O U T IN G ........................................70 WEB STRAPS .............................................. ................. 72
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SERVICE DIAGNOSIS
Possible Cause Correction
TOP AND WINDSHIELD Incorrect side rail adjustment. With top header locked in position, ad
HEADERS NOT MEETING just front hinge.
AT CORRECT ANGLE
IMPROPER MEETING Improper power link adjustment. Adjust power link bracket in direction of
(fore and aft) OF TOP movement desired.
AND WINDSHIELD
HEADERS
TOP HEADER NOT Improper header adjustment. Adjust header “fore or aft” to align with
ALIGNED WITH guide dowels.
GUIDE DOWELS
LEAKAGE AT Header latch not properly adjusted. Adjust by turning hook in or out
WINDSHIELD HEADER
SERVICE PROCEDURES
OPERATING THE TOP tric motor, a pump and reservoir assembly, and a
double-throw rotary switch. The wiring and motor are
Raise or lower top only when vehicle is standing protected by a separate external circuit breaker.
still. The cylinders are serviced only as an assembly. The
T Lower T o p
o
reservoir end plate “O” ring is replaceable. The pump
Release safety catch, pull handle down and push top cover plate is serviced as an assembly and the rotors
free of the header. are serviced as a package with the “O” rings.
Be sure the well compartment is free of articles.
ADJUSTMENTS
Operate engine in neutral slightly above idle and hold
switch control to the Down position until top is fully Minor adjustments are provided to assist in aligning
lowered. the top header to the windshield header to prevent
leakage into this area; to improve top frontal area ap
To R a i s e T o p
pearance and assure ease of raising and lowering
Remove boot, operate engine in neutral slightly operation.
above idle and hold switch control in the Up position. They are also provided to assure correct alignment
As dowels seat in their sockets, pull header down firm of the roof side rails with door and quarter glass to
ly and push locking handles forward until catches en prevent leakage. Adjustments are provided to elimi
gage. nate wrinkles in the top material.
RESERVOIR M a j o r A d j u s t m e n t s
DO NOT add fluid to a reservoir until it is installed Major adjustments are at the cam, control link
in its normal position in the vehicle. Adding fluid to
PUMP AND RESERVOIR
the reservoir in a position other than its normal in
stalled position does not allow for fluid expansion and
damage to the reservoir may result.
Measure fluid level only when top is lowered. After
filling reservoir, raise and lower top several times to
expel air that may be trapped in system.
Insufficient fluid in the system may cause slow rais
ing or noise in the pump and motor. Measure fluid
level and if low, look for a leak due to a broken line or
a loose connection. Fill reservoir (use only AQ-ATF
Suffix “A” “Dexron” type transmission fluid) until
fluid runs out of filler hole.
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CUP
(2) Remove ground wire eyelet from support brack
CLIPS et.
(3) Remove cylinder hoses from rear seat back sup
port.
SCREW
(4) Lift motor pump and cylinder hoses out of
wheelhouse and rear seat back clips.
HOSES
A P P L IC A T IO N T O B O D Y
I n s t a l l a t i o n
A T S E C T IO N A - A
(1) Route existing top lift motor pump and cylinder
G R O U N D W IR E hoses thru existing clip on wheelhouse panel and rear
seat back.
H O SE CLIP (2) Position cylinder hose clip to rear seat back
SCREW
support.
P U M P A N D C Y LIN D E R HO SES
(3) Position existing top lift motor ground wire
CLIP eyelet between clip and support bracket.
(4) Secure clips with screw.
V IE W IN CIRCLE B
P Y792
R o o f S i d e R a i l A l i g n m e n t
Fig. 2 —Cylinder Hose Routing
The roof side rail structure (Fig. 3) consists of
bracket and the outer mounting. These adjustments separate rails, hinged together to enable the top to
are necessary to improve roof side rail alignment if fold into the well. The rails must be in good alignment
minor hinge and header adjustment do not completely and parallel to top edges of vent wings, door and quar
correct the condition. ter glass to provide a good weatherseal. Alignment of
the rails is controlled by the side rail structure mount
C y l i n d e r H o s e R o u t i n g ( F i g , 2 ) ing support assembly (Fig. 5) cam (Fig. 6), control
R e m o v a l link and the front hinge set screw (Fig. 3).
(1) Remove screw from clips. The front hinge set screw (Fig. 3) is accessible from
V IE W IN D IR E C T IO N O F A R R O W X
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the bottom surface of the front rail and center rail (3) Position and assemble anti-rattler to dowel
directly below hinge. Little adjustment is possible at bracket.
the hinge. (4) Check alignment of Dowel Pin and Dowel
Bracket.
Door a n d G l a s s A l i g n m e n t
C o n t r o l L i n k A d j u s t m e n t
C a m A d j u s t m e n t
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Stack height should be correct if the control links
have been adjusted as outlined. If control link adjust
ment does not correct stack height, loosen lower two
of the three mounting plate screws (Fig. 5). Force
lower portion of mounting plates to rotate fully for
ward while exerting pressure downward on both sides
at top of side rails. Tighten screws and inspect stack
height after raising and lowering top.
Top S h i f t s T o O n e S i d e
sure lock nut is loose. Tap cam threaded end with a (1) Raise Folding Top 18 inches and prop up.
soft-faced hammer to loosen any paint bond between (2) Remove side tension cable screw.
cam and linkage. (3) Remove cable eye from side rail.
(4) Loosen Front Cover Tension Cable Bracket.
(5) Remove tension table bracket from side rail.
S t a c k H e i g h t
WELL LINER
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Fig. 7—Side Tension Cable
ment to the front face of the liner lower edge approx Fig. 9 —W e ll Liner Attachment
imately two inches wide at the area where liner at weatherstrip inward just enough to contact inner lip.
taches to the upper face of the rear seat back support. Adjust up-stops to limit further upward travel of
Apply cement to the area contacting the wheelhouse glass.
cap. Apply cement to the upper surface of rear seat
back support approximately two inches wide.
Top H e a d e r W e a t h e r s t r i p s a n d W e l t s
screw holes which permit in and out adjustment (Fig. When repairing or replacing a seal, or weatherstrip
10 ). at the header and pillar areas, care should be exer
Raise glass until top edge of glass curls outer lip of cised to see that seals and weatherstrips are firmly
seated in correct alignment and are free of twists.
Clean all areas thoroughly, before installing weather
strips and seals.
R e m o v a l
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SPACER
V IE W IN D IR E C T IO N
OF ARROW Y V IE W IN CIRCLE W V IE W IN CIRCLE R RETAINER
N R 197
N P 523
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N P 53 4
Fig. 13—Removing Staples and Tacks a t Rear Bow erstrip retainers and at rear pillars (Figs. 7 and 15)
if original cover is to be reinstalled tie a cord to one
removed, otherwise damage to the top material may
end of cables prior to removing. When cables are re
result.
moved cord should be left in listing.
(6) Remove staples and tacks (one tack used on
(14) Remove cover from the folding linkage.
each side at binding areas and at centerline area at
(15) Remove rear curtain assembly.
taching top cover to rear bow (Fig. 13).
(7) Prop top off of windshield header and remove I n s t a l l a t i o n
moulding from top header. The moulding attaching The rear curtain, backlight and zipper is serviced
screws are located under the weatherstrip. as an assembly.
(8) Raise top to the 1/2 open position and remove Prior to installing cover, inspect roof bow felt pads
rear roof rail weatherstrip (Fig. 10). Mark location of for moisture or damage. The pads are a press fit in the
retainer screws on roof rail to aid in reassembling, bows. The cover stay pads should be inspected for
and remove retainer. damage and moisture. The stay pads are attached to
(9) Remove top and rear curtain material from the header and roof bows with tacks (Fig. 16). The
roof rail (Fig. 14). rear window zipper top half is tacked to the rear bow
(10) Remove sealing tape, staples, drive nails and (Fig. 12) and the curtain bottom portion is attached
tacks at the top header. to tacking strips (Fig. 17).
(11) Mark location of top material bead on ends of
cover pads and loosen vent wing seals at corners.
(12) Remove front screws from front roof rail
weatherstrip retainers and remove locking flaps from
between retainer and roof rail.
(13) Remove cover cables at front roof rail weath
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Fig. 17—Cover Tacking Strip
The circled numbers shown on the reference illus
trations indicates the particular step number being
read in the installation procedure (Fig. 20 and 21).
(1) Position folding top less trim (in folded posi Fig. 18—Top Deck to No. 3 Bow
tion) to body.
(2) For attaching side flap apply even coat of ad sembly connects to wheelhouse cap. Allow adhesive
hesive approximately 2 inches wide to underside of to dry onto entire area of wheelhouse cap and rear
top header, from latch hook outboard to underside seat back support surfaces, position top well cover
of front rail. and press to bonded surfaces of wheel caps and rear
(3) Open top and adjust to body. seat back support. Fasten edges of well cover assem
(4) Position center, and side to belt bar retainer bly by snap attaching curtain fasteners to studs.
and tacking strip to trim.
(5) Apply even coats of adhesive to upper rear Top Deck To No. 3 Bow (Fig. 18)
flange, header, header center welt, and header side (1) Remove header prop and lower header. Secure
welts. Install center and side welts to header flange. latch mechanism. Align top deck and side quarter as
(6) Assemble stay pad to header using adhesive. sembly material to frame.
Install screw to header. (2) Position centerline locating hole of top deck
(7) Assemble top stay pad to Number 1, 2 and 3
cover assembly to centerline notch of number 3 bow.
bows.
(3) Secure with staples to number 3 bow (staples to
(8) Assemble rear curtain to Number 3 bow, belt
bar retainer and tacking strip. be installed toward front of bow).
(4) Pull taut and align top deck cover assembly at
(9) Assemble rear curtain stay straps to Number 3
bow, belt bar retainer, and tacking strip. reinforcement along number 3 bow.
(10) Assemble side tension cable to deck and side (5) Secure with staples. Also align side quarter
quarter assembly pocket. SPACER - F O L D IN G SPACER - F O L D IN G T O P C O V E R
(11) Assemble tape to rear rail top material re
tainer. Apply an even coat of adhesive to trim retainer
and top fabric. Bond fabric to trim retainer. Assemble
retainer to rear rail.
(12) Secure side tension cable at front and rear
using screws.
(13) Position and secure top deck and side quarter
assembly to Number 3 bow. Assemble side quarters
to belt bar tacking strips (Figs. 18 thru 21).
(14) Assemble top deck and side quarter assembly
to header and rear side rail trim retainer.
(15) Assemble retainer weatherstrip to header.
(16) Assemble wire on binding to Number 3 bow.
(17) Position top to body. Adjust belt bar retainers
as necessary to avoid wrinkles in top material.
(18) Apply an even coat of adhesive along under
side of front face well cover and at area where as-
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WELT — TOP HEADER CENTER
BODY AND
FRAME
PY795
23-77
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23-78
BODY AND
FRAME
CABLE — TOP COVER
SIDE TENSION
TOP DECK
TOP SIDE TENSION CABLE TOP DECK REAR UPPER LOWER EDGE
OF
STAY PAD
TOP FRONT SIDE RAIL TOP REAR CURTAIN
TACKING STRIP
NO. 3 BOW
VIEW IN CIRCLE P SCREW-
SCREW
SCREW
VIEW IN CIRCLE M
VIEW IN DIRECTION
OF ARROW U
SEALER
TOP HEADER
SEALER
TRIM RETAINER RETAINER
NUT
SCREW
WELL COVER
PY794
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binding with top material retainer attached to rear C o v e r t o B e l t B a r ( F i g . 1 9 )
SEALING
INDEX
Page Page
APPLICATION Pillar Area ................................................................ 81
Challenger Quarter Panel— Inside ........................................... 79
Dash Panel Area .................................................... 81 Quarter Panel— Outside ......................................... 79
Door And Deck Lid A r e a ....................................... 82 Roof Rail Area ........................................................ 80
Front Pillar Area .................................................... 83 SERVICE PROCEDURES
Roof Rail Area ........................................................ 82 Testing
Quarter Panel A re a ................................................ 85 Powder M eth o d .................................................... 81
Underbody A r e a ...................................................... 84 Water M eth o d ...................................................... 80
Upper Dash Panel And Cowl Top A re a ................ 85 SEALERS AND COMPOUNDS
Dart Rubber C e m e n t...................................................... 85
Cowl-Dash Panel Area ........................................... 80 Seam Sealer ........................................................... 85
Deck Lid Area ........................................................ 81 Sealing P u tty............................................................ 85
Floor Pan A re a ........................................................ 83
GENERAL INFORMATION
The procedures for weatherstrip sealing and re the component unit.
placement are incorporated with the procedures of The sealing illustrations used in this section show
S U PP O RT
SEALER
QUARTER PANEL
IN S ID E LO W ER PILLAR B O D Y LO C K
SEALER
PILLAR
QUARTER W HEELHOUSE
PANEL O U TE R
IN S ID E W HEELHOUSE
SHELF
QUARTER SIDE SILL
IN N E R
PANEL PANEL \ SEALER
SEALER
QUARTER O U T S ID E E X T E N S IO N <
SEALER SEALER
PANEL SEALER
SIDE SILL T O FL O O R P A N
LO W ER
SEALER
S A FE TY BELT V IE W IN D IR E C T IO N IN N E R
QUARTER W H E E LH O U S E
A N C H O R H O LE / W HEELHO USE OF A R R O W Y
FL O O R P A N PANEL IN N E R
SEALER IN N E R
V IE W IN CIRCLE Z V IE W IN D IR E C T IO N
OF ARROW Z PY756
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ROOF PANEL QUARTER PANEL SEALER SEALER AREAs,
DRAIN TROUGH
SEALER
SERVICE PROCEDURES
TESTING spray simulating rain or a garden hose without the
nozzle and regulate the pressure to an approximate 3
W a te r M ethod inch stream. All water tests must be made starting at
Normally a visual inspection of an area will indicate the bottom of the door opening or weatherstrip and
the area for sealing. When testing with water, use a slowly moving up the joint, seam or suspected area.
SEALER
COWL SIDE PANEL
FRAME
r SEALER
WINDSHIELD UPPER
OUTER FRAME
DASH PANEL
PILLAR
SIDE SILL WINDSHIELD SIDE
FRONT INNER SEALER
SIDE SILL OUTER OPENING
FRONT FLOOR FRAME
DASH AND COWL PANELS PAN NU127
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DO NOT SPRAY OR FLOW
HOLD GUN NOZZLE IN
SEALER IN THIS DIRECTION
DIRECTION OF ARROW
OR FLOW MATERIAL
ADJACENT TO JOINT
APPLICATION OF SEALER
BY FLOW OR SPRAY
HIDDEN SURFACE
EXPOSED SURFACE SEALER
EXPOSED SURFACE
1/ 4 "
3 METAL THICKNESS
—f F— 1/4
METAL THICKNESS
APPLICATION OF SEALER WHERE SEAL
IS REQUIRED BETWEEN WELDED PANELS. NY 1446
F ig . 5 — M e t h o d o f A p p l y i n g S e a le r
Powder Methmd
To test the sealing between the body and the
weatherstrips, it is advisable to use trace powder and
a test bulb. When the powder is sprayed at the point
where a leak is suspected it will leave a trace line
through the point of leakage.
NN291
F ig . 8 — W h e e l h o u s e a n d B e lt B a r
In hard to reach points, such as the dog leg at the
“A” post, blue carpenter’s chalk applied to the weath-
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DOOR
O U T S ID E
DOOR INSIDE
PANEL
VIEW IN CIRCLE Z
PY749
SEALER
D R A IN T R O U G H
VIEW IN DIRECTION
OF ARROW Z
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW W OF ARROW V
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SEALER
FRONT FLOOR PAN
SEAT BELT
FLOOR GEAR REINFORCEMENT
SHIFT OPENING
REINFORCEMENT, SEALER
SIDE SILL
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WHEELHOUSE
23-84
OUTER REAR SUPPORT
FLOOR PAN PLATE WHEELHOUSE
CENTER
FLOOR PAN
BODY AND
VIEW iN CIRCLE V
FRAME
(DUAL EXHAUST SYSTEM)
FLOOR PAN
CENTER RIGHT
QUARTER PANEL
TO REAR FLOOR PAN
FLOOR PAN
CENTER LEFT
FRONT
FLOOR PAN
VIEW IN DIRECTION OF VIEW IN DIRECTION OF
ARROW X ARROW Z PY747
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DEALER
COWL TOP
nFFIFTTO R
DmLfcCTOR // THIS
FRK AQp
R E SEALER
A T° BE KEPT
DASH PANEL
SEALER
SEALER
VIEW IN CIRCLE Z
COWL TOP
SEALER
SEALER
DASH PANEL
DASH PANEL
SEALER
PY753
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VINYL ROOF COVERING
INDEX
Page Page
Air Bubble R em oval.................................................. 87 Cover Replacement.................................................... 86
SERVICE PROCEDURES
COVER REPLACEMENT (3) Apply a thin film of cement to center four
inches of roof panel and vinyl cover.
R e m o v a l (4) When cement becomes tacky, position cover on
(1) Remove windshield, rear window and mould roof aligning centerline marks.
ings. On cemented-in-type windows, remove mouldings (5) Apply cement to one half of roof panel and ex
only. To aid in installation of mouldings, mark clip tension and to the cover half on same side (Figs. 2
hole locations with a.removable type marker. and 3).
(2) Remove roof side mouldings. (6) When the cement becomes tacky position cover
(3) Remove all sealer from drain trough, wind on roof panel.
shield and rear window reveals and pull old cover off (7) Repeat steps 5 and 6 for the opposite side.
of roof panel. (8) Using a new paint roller, pressurize cover to the
roof working from center area toward drain troughs.
I n s t a l l a t i o n (9) Press cover into windshield and rear window
Inspect old existing cement to make certain there reveals using a dull pointed fibre tool (Fig. 4).
are no raised areas or areas without cement. (10) Starting at top center, secure cover to wind
(1) Mask body (Fig. 1) from edge of drain trough shield reveal using staples spaced 1-1/2 inches apart
across upper “A” pillar, windshield and rear window
reveal, top of deck upper and bottom of roof panel at
V IN Y L C O V E R
belt line.
(2) Locate and mark center line of roof panel and
vinyl cover at front and rear ends.
ROOF PANEL
CEM ENT
V IE W IN
CIRCLE Z
M A S K IN G T A P E '
Fig. 1—M asking the Body—Sedan Fig. 3 —Positioning Cover on Roof—H ardtop
NK985A
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F ig . 7 — T r i m m i n g a n d S e a l i n g C o v e r a t W i n d o w s
(20) Apply a bead of sealer to edge of cover and
blend upward to form a seal over staples and cover
F ig . 5 — S t a p l i n g C over a t W i n d o w R e v e a l s — S e d a n edge. Extend seal across trimmed edge on “A” post
(maximum) or tacks 1/2 inch apart (Figs. 5 and 6). (Fig. 7).
(11) Position cover to roof panel extension making (21) Locate and punch holes in cover at roof ex
certain all wrinkles are removed. tension belt line.
(12) Starting at top center, secure cover to rear (22) Trim cover on a line 1/4 inch below belt line
window reveal using staples spaced 1-1/2 inch apart moulding holes and curving upward to meet drain
(maximum) or tacks spaced 1/2 inch apart (Figs. 5 trough (Figs. 9 and 10).
and 6). (23) Apply a bead of sealer to trimmed edge of
(13) Trim fabric at base of windshield reveal, half cover at roof panel and smooth out to form a seal
way between upper and lower edges of pillar mould (Fig. 7).
ing (Fig. 7). Install sealer along entire length of outboard
(14) Trim fabric at base of rear window reveal. trimmed edges of cover material to seal exposed edge
(15) Using a dull pointed tool, press fabric into adjacent to drain trough flange.
drain trough to achieve maximum contact of roof cov (24) Apply a 1/4 inch ball of sealer to index studs
er material to drain trough (Fig. 8). of pillar mouldings.
(16) Grasp outboard edge of cover and while (25) Position moulding by inserting a locating pin
pulling material outward and down, use upper edge in index hole and align moulding.
of drain trough flange as a breakover for draping (26) Using hole in moulding as a guide, drill a .120
material on to outboard drain trough flange face (Fig. diameter hole in pillar and fasten in place with a
8). Care must be taken to avoid pulling loose the cover screw (original installation only).
material applied to base of drain trough. (27) Install side drain trough mouldings (Fig. 9),
(17) Press material against drain trough flange face windshield and rear window mouldings.
for full length of outboard sides of roof cover. (28) Remove masking material and inspect cover
(18) Trim excess material hanging below drain for air bubbles.
trough flange about 1/8 inch above lower edge of
AIR BUBBLE REMOVAL
flange (Fig. 8).
(19) Locate and drill index hole for front pillar (1) Place strips of masking tape over surface of
moulding upper locating boss (Fig. 7). (Original in bubble.
stallation only).
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, D R A IN T R O U G H
'M O U L D IN G SEALER
SEALER
V* INCH
M E D A L LIO N
N R73
Fig. 9 —Sealing Cover a t Sides—Sedan 160 °F.) until bubble area begins to enlarge in cir
cumference. Infra-red heat lamps provide a suitable
(2) Using a No. 19 hypodermic needle and suitable
source of heat.
syringe, insert 3M Vinyl Trim Adhesive No. 8064, or
(6) Remove heat source and allow cover to cool.
equivalent, into bubble area. Extreme care must be
A method of rapid cooling will be beneficial.
used to avoid depositing any adhesive on the top sur
face of the vinyl cover. The perforation must be (7) Using a DRY No. 19 hypodermic needle, punc
made in center of bubble, through masking tape and ture cover 4 times equidistant around outer circum
vinyl material. Approximately 0.5 mil of adhesive ference of bubble to provide an escape route for en
per square inch should be used. trapped solvent and air.
(3) Remove needle and work adhesive to cover (8) After bubble collapses, press cover to metal
affected area by pressing vinyl to roof carefully. surface, starting from one side of bubble and work
This will also transfer some of adhesive to surface of ing toward opposite side until it conforms to metal
vinyl cover. surfaces and all raised surfaces disappear.
(4) Allow cement to dry 5 minutes at room tempera (9) Keep car from hot sunlight and other direct
ture. heat sources.
(5) Heat bubble area with relative low heat (150°- (10) Examine top after a 24 hour period.
REFINISHING PROCEDURES
INDEX
Page Page
Acrylic F in ish es.......................................................... 88 Polishing and Buffing ....................... ........................ 89
Definitions— Technical Terms ............................. ... 88 Refinishing ..........................................................— 90
Galvanized M e ta ls ...................................................... 89 Spot R epairs.............................................................. 90
Paint Charts ................................................................ 91 Rust Protection ........................................ ................ 89
ACRYLIC FINISHES C o a t — D o u b l e
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light pressure of finger. Third is “hard-dry” and is T h i n n e r s
time required for film to become thoroughly hard so Thinners are mixtures of volatile liquids used to
that it may be rubbed and polished. thin lacquer-type finishing materials to proper con
sistency for application.
F e a t h e r - E d g i n g
Ferrous metals are those which are made from iron PAINT REPAIRS ON GALVANIZED METALS
(steel). Non-ferrous metals are those which are not To perform paint repairs on galvanized rocker pan
made from iron or do not present an iron (steel) sur els or any other galvanized steel surfaces, care must
face, such as aluminum, aluminum alloys, brass, cop be exercised when preparing bare galvanized sur
per and magnesium. face to properly accept primer-surfacer and finish
paint. Do not use short cut methods nor inter-mixing
F l a s h
of materials.
This is a term applied to a coat of a product when
enough solvent has passed off for recoating. M e t a l P r e p a r a t i o n
The function of a primer is to form a bond between (3) Treat bare metal panel with MOPAR METAL
the surface and the succeeding product. PREP X12 or equivalent according to label directions.
(4) Rinse with clean water and blow off with com
P u t t y i n g pressed air.
A glazing putty is used for filling in small imperfec
tions which are too deep to be taken care of by sur- R e f i n i s h i n g
facer coats. It may be applied either before or after (1) Apply one light coat of MOPAR Zinc Chromatic
last coat of surfacer. Primer L38 and as soon as thinner flashes off and
within 30 minutes, apply a coat of MOPAR Acrylic
R e d u c e r s Sealer G40 or equivalent.
Reducers are mixtures of volatile liquids used to (2) Apply MOPAR MOPRIME Primer Surfacer G
reduce alkyd, synthetic and orthodox materials to the 37 Gray, G38 Red, G39 Neutral Gray or equivalent.
proper consistency for application. (3) Sand when dry and proceed with application of
finish coats according to the paint manufacturers
S a n d i n g B l o c k
recommendations.
As a rule a sanding block is a flexible rubber block,
so arranged sandpaper may be fastened to it secure RUST PROTECTION
ly. It affords a good grip for operator.
Wherever possible sanding should be done with a Prior to applying any paint to sheet metal, clean
block as it distributes pressures and gives a more area to be repainted with MOPAR MOPREP X ll.
uniform surface. Eliminate all fingerprints. Chemically treat all bare
metal using MOPAR METAL PREP X12. This condi
S u r f a c i n g tions exposed metal to resist rust.
Function of a surfacer is to prepare a smooth
surface for color coats. BUFFING AND POLISHING
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tion should be used not to rub too hard over any of (13) When the color is being changed, wash the
affected areas or on ridges. door jambs and door opening areas. Spray interior.
(2) Tack off area with a clean soft cloth. (14) Remove overspray from exterior and reclean
(3) Buff entire area using a fine buffing com entire surface with MOPAR wax and grease remover
pound MOPAR X14 extra fast dry or X16. MOPrep X ll.
(15) Tack rag the entire surface to remove lint and
REFINISHING dust.
(16) Apply Chrysler Engineer Approved MOPAR
P r e p a r a t i o n A c r y l i c S y s t e m
Acrylic Lacquer Colors. (Four to six double coats).
O v e r O l d A c r y l i c
Refinishing in the field must be done with acrylic
(1) Remove outside accessories, mouldings and
lacquer. Acrylic lacquer can be polished to match
bumper face bars (if necessary).
original finish gloss. Care must be exercised when
(2) Remove silicone polish, wax, or any other sur
face contamination with wax and grease remover selecting paint for refinishing Acrylic Metallics, to
MOPREP X I1. A chemically clean surface allows for select proper paint code.
effective sanding and assures adhesion of under (17) When the color has dried hard, compound and
coats and finish color. polish.
(3) Sand old finish. This operation removes surface
deterioration, feathers out scratches, nicks, stone SPOT REPAIRS
bruises, or any other minor imperfections. Water sand
with MOPAR Multi Purpose #360 grit paper, part No. Procedures for making spot repairs with acrylic
1-1474 or its equivalent. lacquer are the same as for complete panel refinishing
(4) Blow off entire car, using high pressure air to with the following exceptions:
eliminate dirt or dust from blowing out on to the
surface as paint is applied. S e a l e r C o a t s
(5) Mask off the areas not to be painted. If a com Use of a sealer is not practical where a spot re
plete color change is being made, mask off interior pair is demanded, as it is difficult to spray sealer
parts adjacent to door openings to prevent paint spray without leaving an edge. If care is taken in prepara
from soiling interior trim and upholstering. tion of surface, a satisfactory repair is possible
(6) Reclean entire area to be painted with wax and by sanding original finish about 2 or 3 inches be
grease remover, MOPREP X I1, eliminating work yond area where acrylic lacquer will be applied.
man’s fingerprints. Apply lacquer directly on sanded original finish, be
(7) Chemically treat bare metal with MOPAR Metal
ing careful not to overlap color on unsanded enamel.
Prep X12 or equivalent metal conditioner.
A p p l i c a t i o n o f C o l o r C o a t s
P r i m i n g t h e S u r f a c e
This operation is the backbone or foundation for Metallic color can appear to vary in richness. Varia
the finish color. It primes metal to insure adhesion tion can be described as:
and fills minor surface imperfections. Use one of A closed pattern that appears lighter with fine metallic
recommended Mopar lacquer primer surfacers. dispersion.
(8) Apply MOPAR Lacquer Primer Surfacer MO- An open pattern that appears richer with the metallic
Prime part No. G37 gray, G38 red, and G39 neutral flakes less noticeable.
gray or equivalent. A closed pattern is best matched by reducing
(9) To expedite repairs to other surface imperfec MOPAR Acrylic Lacquer Color 150% with MOPAR
tions use MOPAR putties. Spot Check G41 or 42 gray Deluxe Acrylic Lacquer Thinner G35 or equivalent.
type, or G43 or 44 red type or equivalent. An open pattern is achieved by lowering air pres
(10) Sand undercoats. Water sand with MOPAR sure to 20-30 lbs. at gun, reducing MOPAR Acrylic
Multi Purpose No. 400 paper, part No. 1-1475 or finer Lacquer Color 100% with a blend of MOPAR Deluxe
paper (or its equivalent if other sanding methods or Acrylic Lacquer Thinner G35 and MOPAR all Pur
systems are employed). This is the key operation in
pose Retarder G36.
refinishing. Final finish will be as good as the founda
tion over which it is applied.
(11) Respray with MOPrime or equivalent primer C o m p o u n d i n g C o l o r C o a t s
surfacer any area that may have been sanded through Compound sanded area that extends around re
to bare metal in step 10. finish lacquer and then compound lacquer, blending
(12) Resand undercoat with MOPAR Multi Purpose it into enamel. Hard surface of the acrylic enamel
grit No. 400 (Part No. 1-1475) or finer paper. will permit compounding without leaving scratches.
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PAINT BAKE OVEN TREATMENT and headlamp bezels should be covered with paper or
(WITH TEXTURED GRILLES) other material to shield grille assembly from heat be
fore car enters paint bake ovens or be completely
To avoid warpage all models with textured grilles removed from the cars.
PAINT CHART
EXTERIOR COLORS
DART-CHALLENGER
Paint Chrysler Ditzler
Code Color Name Code Code
B3 Light Blue Poly AY2EB3 2018
B5 Bright Blue Poly AY2EB5 2019
B7 Dark Blue Poly AY2EB7 2020
C7 Plum Crazy AY2FC7 2210
E5 Bright Red AY1FE5 2136
F4 Light Green Poly AY2FF4 2133
F8 Dark Green Poly AY2EF8 43786
J5 Sublime AY1FJ5 2128
K2 Go Mango AY2EK2 2201
K5 Dark Burnt Orange Poly AY2FK5 2135
LI Beige AY1BL1 22542
T6 Dark Tan Poly AY2FT6 2129
V2 Hemi Orange AY2EV2 2186
W1 White AY1EW1 2033
X9 Black AY1TX9 9300
Y1 Banana AY1FY1 2211
Y3 Cream AY1DY3 81575
Y4 Light Gold Poly AY2FY4 2117
INTERIOR COLORS
DART
EXTERIOR GLOSS FINISH COLORS
Used On: Integral Door Upper and Lower. Upper Inner Frame. Quarter Panel
Lower “B” Pillar “A" Pillar
Chrysler Ditzler
Color Name Code Code—DDL Remarks
Black AY1TX9 9300
Medium Dark Blue Poly AY2EB7 2020
Medium Tan Poly AY2FT6 2129
Dark Green AY2EF8 43786
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LOW GLOSS FINISH COLORS
Used On: Manual Seat Adjuster (Black only). Console.
Bucket Seat Hinge Cover (White only).
Code-DIA
Dove White AB5EW1 8743 Bucket Seat Hinge
Cover
Jewel Black AB5TX9 9028 Console and Seat
Adjuster
Jewel Black (Semi-Gloss) AB3TX9 9293 Optional For Seat
Adjuster
Puma Tan Poly AB6FT4 23275 Console only.
Bayou Green Poly AB6EF8 43929 Console only.
Code-DIA
Jewel Black AC38VX9 9324 a,b
Baltic Blue Poly AC39EB7 13705 a
Puma Tan AC39FT4 23219 a,b
Bayou Green Poly AC39EF8 43925 a,b
CHALLENGER
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SUEDE FINISH COLORS
Used On: Instrument Panel. Windshield Header Moulding.
"A” Pillar Header Cap Outboard
Convertible Header Moulding and Folding Latch Top Lock.
Grilles and Stereo Speakers.
Ash Receiver Face.
Glove Box Door Outer-Inner with Check Arm.
Rear Shelf Defogger Bezel.
Bucket Seat Hinge Cover.
Jewel Black AC38VX9 9324
Thunder Blue Poly AC39EB5 13848
Puma Tan Poly AC39FT4 23219
Bayou Green Poly AC39EF8 43925
Sunfire Orange Poly AC39FK5 60557
Poppy Red AC38FE5 71764
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Fig. 2 —Body Alignm ent Dimensions (Challenger)
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HEATERS AND AIR CONDITIONING
CONTENTS
Page Page
AIR CONDITIONING 7 HEATERS 1
HEATER
INDEX
Page Page
General Information .................................................. 1 Blower Motor Removal and Installation............... 6
Service Diagnosis ...................................................... 2 CHALLENGER
Service Procedure .................................................... 2 Control Cable Adjustment ....................................... 4
DART Heater Removal and Installation ........................... 4-6
Control Cable Adjustment ...................................... 2 Disassembly and Assembly ..................................... 4
Heater Removal and Installation ........................... 3 Blower Motor Removal and Installation............... 6
Disassembly and Assembly ..................................... 3-4
GENERAL INFORMATION
All models use a “Blend Air” type heater. Fresh strument panel. Direction of the “blended air” is
air enters the heater through the cowl grille and controlled by the “Heat-Defrost” lever on the instru
passes through a plenum chamber to the heater core. ment panel.
A temperature control door in the heater plenum The blower switch determines the speed of the
chamber directs the fresh air either through or past blower motor and the velocity of the air flow from the
the heater core. The amount of “blend” is determined heater outlets.
by the setting of the temperature lever on the in- On Dart models, two fresh air ducts, for warm
DEFROSTER SU PPORT
CABLE ROD
SEAL
~ f — FRESH A IR
DEFROSTER / DOOR
TUBES
GROUND SCREW ■
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weather use, are located under each end of the in Make sure these doors are closed during heater oper
strument panel. By opening the doors on these ducts ation.
fresh air bypasses the heater and is rammed into the Note: The size of the heater inlet hose from the engine
vehicle (Fig. 2). has been reduced to a 1/2 inch diameter on all en
On Challenger models, the ventilator doors are con gines to simplify plumbing connections. The return
trolled by knobs mounted under the instrument panel. hose to the engine will remain at 5/8 inch diameter.
SERVICE DIAGNOSIS
Condition Possible Cause Correction
INSUFFICIENT HEAT (a) Carpet obstructing outlet. (a) Reposition carpet to clear outlet.
(b) Radiator hoses leaking. (b) Correct leak. Replace hoses if neces
sary and bleed system of air.
(c) Obstructed heater hose. (c) Replace heater hoses.
(d) Temperature door not closed or leak (d) Adjust temperature control cable. See
ing. “Cable Adjustments.”
(e) Shut-off or defroster door improperly (e) Adjust the Heater-Defroster Control
adjusted. Cable. See “Cable Adjustments.”
(f) Engine thermostat open. (f) Replace thermostat. See Group 7,
“Cooling System".
(g) Coolant too low. (g) Fill the radiator to recommended lev
el.
(h) Kinked hose. (h) Reroute to eliminate restriction.
TOO MUCH HEAT (a) Disengaged cable on temperature (a) Connect or replace cable.
door.
(b) Thermostat stuck in closed position. (b) Replace thermostat. See Group 7,
“Cooling System".
BLOWER MOTOR (a) Blown fuse. (a) Check for excessive resistance in cir
NOT OPERATING cuit and replace fuse.
(b) Faulty electrical connection. (b) Tighten all electrical connections.
(c) Faulty blower switch. (c) Replace switch.
(d) Faulty motor. (d) Replace motor.
(e) Faulty resistor. (e) Replace resistor.
SERVICE PROCEDURES
DART MODELS
C o n t r o l C a b l e A d j u s t m e n t s cable housing is flush with edge of the cable mounting
(1) Disconnect the three cables at heater assembly. bracket. Install new clips.
(2) With control assembly removed from instru (3) Install control assembly on instrument panel.
ment panel, position the three control cables so the (4) Place top control lever in center or “Heat”
R ETAINER
G A S K ET
PLATE
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IN LET HOSE
198 A N D 225 C U B IC IN C H E N G IN E
necessary to remove the heater assembly from the (1) Remove seal from around heater motor mount
vehicle. ing studs.
(1) Drain radiator. (2) Remove spring clips holding spacers and heater
(2) Disconnect heater hoses from heater and re motor to heater housing.
move heater hoses to dash panel seal and retainer (3) Remove fan from heater motor.
plate (Fig. 3). (4) Remove mounting support plate from heater
(3) Remove heater motor seal retainer plate and motor.
seal from dash panel (Fig. 3). (5) Remove heater motor resistor assembly from
(4) Disconnect heater-defroster and temperature heater housing (Fig. 1).
control cables from heater assembly. (6) Remove fresh air door seal from either inner or
(5) Remove heater motor resistor wire from re outer heater housing half only.
sistor (Fig. 1). (7) Remove retainer clips attaching heater housing
(6) Remove defroster tubes from heater assembly. halves together.
(7) Disconnect heater housing support rod from (8) Separate heater housing halves.
fresh air duct (Fig. 1). (9) Remove screw attaching seal retainer and seal
(8) Remove heater assembly. around heater core tubes.
(10) Remove heater core tube support clamp.
I n s t a l l a t i o n (11) Remove screws attaching heater core to heater
(1) Position heater assembly on dash panel by slid housing and remove core.
ing four mounting studs into their respective holes in (12) Remove seal retainer and seal from heater
dash panel. core.
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A s s e m b l y (8) Install spacers and retainers on heater motor
(1) Position heater core in heater housing. mounting studs.
(2) Slide seal retainer and seal over heater core (9) Position both housing halves together and in
tubes and up against housing. Install attaching screws. stall retainer spring clips. Add sealer between two
(3) Install heater core to housing screws. halves before putting halves together.
(4) Position support clamp over heater core tubes (10) Install heater motor resistor assembly.
and install attaching screw. (11) Position and cement seal around fresh air door
(5) Install support plate on heater motor. opening.
(6) Install fan on heater motor. Turn fan to make (12) Position heater housing to dash panel seal
certain it does not hit motor support plate. around heater housing mounting studs.
(7) Position heater motor and support plate over (13) Install heater as outlined in “Heater Installa
mounting studs on heater housing. tion”.
SERVICE PROCEDURE
CHALLENGER MODELS
C o n t r o l C a b l e A d j u s t m e n t from housing.
To adjust the temperature control cable, remove (4) Remove one core tube retaining screw from be
the cable retaining clip from the cable at the temper hind housing between core tubes.
ature control door. Place the temperature control (5) Remove two sponge rubber gaskets from core
lever in the minimum heat “LOW” position. Rotate tubes and remove heater core from housing.
the temperature control door crank to the extreme (6) Disconnect blower motor lead from blower
clockwise position and reinstall the cable retaining motor resistor.
clip. Be sure the instrument panel control lever re (7) Remove six sheet metal screws and six retain
mains in the “LOW” position during the adjustment ing clips holding blower motor mounting plate to
(Fig. 1). housing. Separate mounting plate and blower motor
The “Heat-Defrost” cable is adjusted at the instru assembly from housing.
ment panel control end only. Place the control lever
in the “OFF” position, loosen the cable retaining A s s e m b l y
screw in the elongated hole in the flag attached to the Inspect all gaskets and sealing, compound for areas
cable. Move cable housing towards instrument panel that might allow air to escape from housings and re
control to shorten travel of cable at housing. Move place as necessary.
cable housing away from instrument panel control to (1) Position blower motor mounting plate on back
lengthen travel of cable at housing. Tighten retaining of housing and install six sheet metal screws and clips.
screw. From opening in front of housing rotate blower motor
by hand and inspect for alignment.
F r e s h A i r V e n t C o n t r o l C a b l e (2) Connect blower motor lead to resistor. Inspect
Push the fresh air control knob in (leave about 1/8 ground lead for good connection.
inch between knob and panel). Remove the control (3) Place heater core in position and install core
cable clip from the door control crank arm bracket. tube retaining screw from back of housing between
Rotate the crank arm of the door firmly to the closed core tubes.
position (left side counterclockwise; the right side (4) Position front cover on housing and install
clockwise) and reinstall the cable to the crank arm mounting screws and clips, check all doors for align
bracket (Fig. 1). ment.
(5) Place sponge rubber gaskets on core tubes.
H e a t e r D i s a s s e m b l y (6) Seal plenum air seal cuts with a good grade
(1) Remove heater assembly from vehicle as out rubber cement and install assembly in vehicle as out
lined in “Heater Removal”. lined in “Heater Installation”.
(2) Remove nine spring clips and four screws that
hold the front cover to the assembly housing. HEATER REMOVAL
(3) Cut sponge rubber plenum to housing air seal
in two places where the front cover separates cover
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EXISTING STUD IN PLENUM PANEL 4 MOUNTING SCREWS
TEMPERATURE
CONTROL
DOOR CABLE
LEFT FRESH
AIR VENT
HEATER
HOUSING
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(2) Drain coolant from radiator. I n s t a l l a t i o n
(3) Disconnect heater hoses from core tubes at dash (1) Place unit on front floor of vehicle.
panel. Plug core tubes to prevent spilling coolant on (2) Connect wires to blower motor resistor.
interior of car (Fig. 2). (3) Connect bowden cables to air door cranks.
(4) Remove three mounting nuts from studs around
(Cable housings flush with edge of bracket).
blower motor and remove flange and air seal.
(5) Unplug antenna from radio and place wire to (4) Unhook plenum support rod from opening in
one side. plenum chamber, position it in housing with hook to
(6) Remove screw from housing to plenum support ward rear of vehicle. Install retaining screw but do
rod on right side of housing above fresh air opening. not tighten.
(7) Disconnect three air door cables (Fig. 1). (5) Position unit against dash panel. Be sure heater
(8) Disconnect wires from blower motor resistor. core tubes and mounting studs are in their respective
(9) Tip unit down and out from under instrument holes before applying pressure to front of housing.
panel. Hook housing to plenum support rod in position.
(6) Plug antenna into receptacle in bottom of radio.
(7) Place air seal and flange over blower motor.
(8) Install nuts on mounting studs and tighten se
curely, then tighten plenum support rod retaining
screw (Fig. 1).
(9) Remove plugs from core tubes and connect
hoses (Fig. 2).
(10) Connect battery cables, fill radiator, bleed air
from system inspect for leaks and test operation of
heater.
BLOWER MOTOR
R e m o v a l
I n s t a l l a t i o n
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AIR CONDITIONING
INDEX
Page Page
Complete System Discharge and Recharge ........ 19 Operating Instructions For Owners ....................... 7
Evaporator— Heater Assembly Service Procedures.................................................... 24
D art............. ............................................................. 34 Servicing The Compressor....................................... 27
Challenger............................................................... 43 Test Procedures ........................... ............................. 10
Gauge Set Manifold Installation............................. 8
or lower to prevent the heater core from freezing. In extremely slow traffic, additional cooling may
However, this protection does not provide sufficient be required.
corrosion inhibitors for the engine cooling system. When pulling a trailer, when driving through
Summer protection to — 15°F. will provide ade heavy traffic at 10 to 15 mph. or when pulling up
quate inhibitors for protection of engine cooling steep hills additional engine cooling may be re
quired. If any or all of these situations are encoun
system against corrosion. Do not use the same anti
tered, put the transmission in a lower gear. At stop
freeze for more than one year.
lights and other stops put transmission in Neutral
and increase engine speed by pressing accelerator
F a s t C o o l D o w n
pedal.
If the car has been parked in the hot sun, open the
windows and drive the car for several minutes to ex
R a d i a t o r C a p
pel the warm air, and at the same time: Air conditioned vehicles must be equipped with a
(1) Slide the temperature control lever to the radiator cap having a holding pressure of 15 to
“Off” position. 16 psi. Replace the radiator cap that does not test
(2) Push the “Max.-A/C” button. within these specifications.
(3) Move the fan switch to High.
(4) Adjust the four cooling outlet vanes to direct C o n d e n s e r
cooled air to the desired area. Inspect the condenser for obstructions or foreign
(5) Close windows. matter. Clean if necessary.
Any obstruction to the free flow of air across the
N o r m a l C o o l i n g ( C o o l i n g w i t h F r e s h A i r ) condenser will decrease heat dissipation from the
When the desired amount of cooling is obtained condenser, decrease the efficiency of the condenser
with the “Max.-A/C” button, you can continue cooling and, in turn, decrease the evaporator’s efficiency.
with fresh outside air for added comfort by pushing These conditions result in increasing the discharge
the “A /C” button and adjusting the fan switch to pressure and horsepower load on the engine. The use
change fan blower speed. If less cooling is desired, of a bug screen is not recommended as it, too, will
move the fan switch lever to “Low” speed and re decrease the free flow of air.
adjust the cooling outlets for indirect cooling. For Inspect the condenser for bent or damaged fins.
warmer air, move the temperature control lever to The bent fins on the condenser deflect air flow across
the desired temperature. the bent portions, decreasing the condenser area.
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B ug S c r e e n s set, provides the means of connecting the gauge set
Bug screens should not be installed on vehicles manifold hose to the service port. When the adapter
equipped with air conditioner. A bug screen installed is installed at the port and tightened, the stem of the
in front of the condenser will reduce air flow and valve in the service port is depressed, opening the
affect air conditioner performance. Under severe service port valve.
heat conditions a bug screen may cause the engine Discharge Pressure Gauge—at the center of the
to over-heat. manifold set is calibrated to register 0 to 300 psi. For
all tests this gauge is connected to the discharge ser
GAUGE SET MANIFOLD vice port of the compressor. A service port adapter is
used to make this connection. The needle valve, loca
I n s t a l l a t i o n ted below the discharge pressure gauge, is used to
The Gauge Set Manifold is an indispensable test damp out gauge needle oscillations so that accurate
and diagnosis instrument. The gauge set manifold readings can be obtained.
Tool C-3740 has two compound suction gauges and Compressor Inlet Gauge—is mounted at the right
one discharge pressure gauge. Two accurately cali side of the manifold set. This mounting is for conven
brated suction pressure gauges are required for the ience only. There are no passages between this gauge
evaporator pressure regulator valve test. Refer to and the gauge manifold. The compressor inlet gauge
Figures 1 and 2. The hoses are shown in the test il is calibrated to register 0 to 30" of vacuum and 0 to
lustrations for quick references to distinguish the 150 psi. This gauge and the evaporator suction gauge
various adaptations. must be accurately calibrated so that the needles of
Evaporator Suction Gauge—at the left side of the both gauges are exactly at 0 before making tests. The
manifold set is calibrated to register 0 to 30 inches of compressor inlet gauge is connected to the compres
vacuum and 0 to 150 psi. This gauge is connected to sor inlet service port by a special service port adapter.
the suction service port of the compressor, on Chal This gauge is used, when checking the EPR Valve
lenger installations. On Dart installations this gauge is on Challenger installations and is not used on Dart
connected to the compressor inlet service port. A installations which do not use an EPR valve.
special service port adapter, supplied with the gauge Center Manifold Outlet—provides the necessary
NEEDLE VALVE
v ,>
r
DISCHARGE LINE
V
SERVICE PORT ADAPTER *
r COMPRESSOR
INLET SERVICE
PORT
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' ™ H i \
•. INLET SERVICE PO RT
NK1458A
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water not over 125 degrees F. is all the heat required quantities of refrigerant vapor in a small, poorly ven
for this purpose. Do not heat the refrigerant contain tilated room can displace the air and cause suffo
er with a blow torch or any other means that would cation.
raise temperature and pressure above this tempera Although Refrigerant 12 vapor is normally non-
ture. Do not weld or steam clean on or near the sys poisonous, it can be changed into a very poisonous gas
tem components or refrigerant lines. if allowed to come in contact with an open flame. Do
CAUTION: Keep Refrigerant 12 containers upright not discharge large quantities of refrigerant in an
when charging the system. area having an open flame. A poisonous gas is pro
When metering Refrigerant 12 into the refrigera duced when using the flame-type leak detector. Avoid
tion system, keep the suppl y tank or cans in an up inhaling the fumes from the leak detector.
right position. If the refrigerant container is on its CAUTION: Do not allow liquid refrigerant to touch
side or upside down, liquid refrigerant will enter the bright metal.
system and damage the compressor. Refrigerant will tarnish bright metal and chrome
CAUTION: Always work in a well-ventilated room. surfaces. Avoid splashing refrigerant on any surface.
Always maintain good ventilation in the working Refrigerant in combination with moisture is very cor
area. Always discharge the refrigerant into the serv rosive and can cause great damage to all metal sur
ice bay exhaust system or outside the building. Large faces.
TEST PROCEDURES
INDEX
Page Page
Correcting Low Refrigerant L ev el........................... 13 Refrigerant L evel........................................................ 10
Expansion Valve and EPR Valve T e s t ..................... 16 Test System Pressure................................................ 10
Performance Test ..................................................... 14 Testing System For Leaks........................................ 12
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TEMPERATURE-PRESSURE RELATIONSHIP CHART
(FOR REFRIGERANT 12)
Temp. Press. Temp. Press. Temp. Press. Temp. Press. Temp. Press.
F. PSI F. PSI F. PSI F. PSI F. PSI
0 9.2 35 32.6 60 57.7 85 91.8 110 136.4
2 10.2 36 33.4 61 58.9 86 93.3 111 138.4
4 11.2 37 34.3 62 60.1 87 94.7 112 140.5
6 12.0 38 35.2 63 61.3 88 96.5 113 142.6
8 13.5 39 36.1 64 62.5 89 98.2 114 144.7
10 14.6 40 37.0 65 63.8 90 99.8 115 146.8
12 15.8 41 37.9 66 65.0 91 101.5 116 148.9
14 17.1 42 38.9 67 66.3 92 103.1 117 151.1
16 18.4 43 39.8 68 67.6 93 104.8 118 153.2
18 19.7 44 40.7 69 68.9 94 106.5 119 155.4
20 21.0 45 41.7 70 70.2 95 108.3 120 157.7
21 21.7 46 42.7 71 71.5 96 110.0 121 159.9
22 22.4 47 43.6 72 72.9 97 111.7 122 161.2
23 23.2 48 44.7 73 74.2 98 113.5 123 164.4
24 23.9 49 45.7 74 75.6 99 115.3 124 166.7
25 24.6 50 46.7 75 77.0 100 117.2 125 169.1
26 25.4 51 47.7 76 78.4 101 119.0 126 171.4
27 26.1 52 48.8 77 79.8 102 120.9 127 173.8
28 26.9 53 49.9 78 81.3 103 122.7 128 176.2
29 27.7 54 51.0 79 82.7 104 124.6 129 178.6
30 28.5 55 52.5 80 84.2 105 126.6 130 181.0
31 29.3 56 53.2 81 85.7 106 128.5 131 183.5
32 30.1 57 54.3 82 87.2 107 130.4 132 185.9
33 30.9 58 55.4 83 88.7 108 132.4 133 188.5
34 31.7 59 56.6 84 90.2 109 134.4 134 191.0
is made, and when adding to the charge. The Low Pressure Cut-Out switch, which is located
The sight glass is an integral part of the receiver- on the receiver drier, is wired in series with the com
strainer-drier. The outlet line (liquid) from the con pressor magnetic clutch. It cuts off the electrical
denser must be attached to the connection marked power supply to the clutch when liquid refrigerant
IN. The word IN is stamped on the top face of the
inlet connection (Fig. 3). If the receiver-strainer-
drier is reversed and the lines are connected wrong,
the system must be purged, the lines reversed and the
system recharged.
Block the air flow across the condenser to raise the
discharge pressure to 225 to 250 psi, and check the
SUCTION
sight glass for foam. There should be no foam. If sight GAUGE
glass is clear, remove the air restriction from the con VALVE
denser and allow the discharge pressure to return to
normal.
If the foam shows in the sight glass when the dis
charge pressure is 225 to 250 psi, it indicates the
system is low on refrigerant. The proper amount of
C O M P R E S SO R
refrigerant required to complete a full charge may be INLET H O S E
added to the system as follows: Maintaining the dis CONNECTO R
charge pressure at 225 to 250 psi, add refrigerant gas
through the suction side of the system until foam is N K 1448
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HIGH PRESSURE RELIEF VALVE SIGHT GLASS (a) Check the system for leaks and repair as
necessary.
(b) Discharge the system. Check the compres
sor oil level. Replace the switch if it was
RECEIVER DRIER found defective and recharge the system.
NOTE: Whenever the system is inactivated by the low
pressure cut-out switch due to the loss of refrigerant,
refrigerant oil may also have been lost. Therefore, to
prevent damage to the compressor due to operation
without sufficient lubrication, the leak must be re
paired and the compressor oil level checked before
final charge of the system in accordance with instruc
tions under "Oil Level - Compressor".
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CAUTI ON: Do not use the lighted detector in any in the system or refrigerant has been allowed to es
place where explosive gases, dust or vapors are cape by depressing one of the service port valves. For
present. detailed instructions on the proper procedure for
Do not breathe the fumes that are produced by the checking refrigerant level, refer to “Refrigerant Lev
burning of refrigerant gas. Large concentrations of el” TEST 2.
refrigerant in the presence of a live flame become Before adding refrig eran t where cause of low level
dangerously toxic. Observe the flame through the is not known, the system should be tested for leaks.
window of the burner shield, not through the top of Assuming no leaks are present, or that leaks have
the shield. been corrected without discharging the system, pro
If the flame remains bright yellow when the tester ceed with partial charge.
is removed from possible leak point, insufficient air is Install and connect gauge set manifold (Figures 4
being drawn in through the sampling tube, or the and 5).
reaction plate is dirty. (1) Close both of the gauge set manifold valves.
(1) Open the torch valve until you hear a faint hiss Open the gauge set manifold needle valve.
of escaping gas. Light the test torch and adjust the (2) Connect the suction gauge test hose to the
valve until the flame is very small. A small flame will suction service port of th e compressor.
detect large as well as small leaks, whereas a large On Dart installations, install the suction gauge test
flame will detect only large leaks. As soon as the hose to the compressor inlet service port.
reaction plate seen through the window in the burner On all models connect the discharge gauge test
shield becomes red hot, the tester is ready for use. hose to the discharge service port of compressor.
(2) Examine all tube connectors and other possible (3) Connect one end of long test hose to center
leak points by moving the end of the sampling hose manifold outlet, other end to refrigerant dispensing
from point to point. Since R efrigerant 12 is heavier manifold.
than air, it is good practice to place the open end of (4) Close two of the dispensing manifold valves and
the sampling hose directly below the point being test open remaining dispensing manifold valve. Remove
ed. Be careful not to pinch the sampling tube since protective cap from opened valve.
this will shut off the air supply to the flame and cause (5) Screw a can of Refrigerant 12 to the opened
a color change. manifold valve. Be sure gasket is in place and in good
(3) Watch for a change in the color of the flame. condition. Tighten refrigerant can and manifold lock
Small leaks will produce a green color and large leaks ing nut to insure a good seal. Do not over-tighten
a bright blue color. If leaks are observed at tube fit since 6 to 8 foot-pounds is sufficient if gasket is in
tings, tighten the connection, using the proper flare
good condition.
wrenches, and retest.
(6) Turn manifold valve (above the refrigerant can)
R e m o v e S w e e p -T e st C harge completely clockwise to puncture the can. This closes
If the system is free of leaks; or after correcting a the valve and seals the refrigerant in the can.
leak, and if no air conditioning components have been (7) Place the refrigerant in a large pan of w ater
removed, add the necessary refrigerant as described heated to 125°F. Place pan of w ater containing the
under TEST 4 “Correcting Low R efrigerant Level.” If refrigerant can on an accurate scale so the amount
any parts of the refrigerant system were disconnec of refrigerant added can be weighed. Open the refrig
ted, remove the sweep test charge. Close the refrig erant manifold valve.
erant manifold valve so that any refrigerant rem ain (8) Purge all air from test hoses. Air in the system
ing in the container is sealed. Remove the long test will be trapped in the condenser causing abnormally
hose from the refrigerant manifold. Insert the free high discharge pressures and interfering with con
end of this test hose into an exhaust system outlet. densation of the refrigerant.
Open the right-hand gauge set manifold valve a frac (a) Loosen both test hoses at the gauge set m ani
tion of a turn to let the sweep-test charge escape fold. Tighten the hoses as soon as the air is purged.
slowly. Allow the system to discharge until the dis (b) Loosen charging hose connection at gauge set
charge pressure gauge registers zero. Open the left-
manifold. This will purge air from the charging hose.
hand gauge valve to allow any refrigerant trapped in
Tighten connection as soon as air is purged.
the suction side of the system to escape.
(c) Push in “A /C ” button, blower m otor switch on
TEST 4 high.
If necessary, block the condenser to m aintain a dis
CORRECTING LOW REFRIGERANT LEVEL charge pressure of 225 to 250 psi. The system m ust be
Since the refrigeration system is completely sealed, charged through the evaporator suction service port
refrigerant level will not be low unless there is a leak as follows:
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RIGHT "DISCHARGE
GAUGE VALVE"
LEFT "SUCTION
OPEN DISCHARGE
GAUGE VALVE"'
SL ' C9 .< & / '> ■ SERVICE PORT
'• ' H ADAPTER
HOT WATER
125 F
COMPRESSOR
SERVICE
INLET SERVICE
PORT
PORT
ADAPTER
.REFRIGERANT
MANIFOLD SUCTION LINE
NK1439B
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DISCHARGE
SERVICE PORT
ADAPTER
RIGHT " D I SCHARGE
LEFT "S U C TIO N GAUGS v a l v e "
G AU G E VALVE"
CHARGING a
HOT WATER HOSE
123 p
\
<hI ^ \
\ 4- 'IX
,‘"S
‘■*'%
COMPRESSO R INLET
? \ r e f r ig e r a n t . ‘ SERVICE PORT
M A N IF C -}
NK1440A
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perature” and “Inlet Wet Bulb Tem perature” as
registered on the psychometer.
Observe and record “Discharge Air Tem perature”
registered by therm om eter at right hand grille outlet. STEM
P ilo t O p e r a t e d E v a p o r a to r P r e s s u r e TEST 6
R e g u l a to r (EPR) (Fig. 7)
An improved version of the Evaporator Pressure
EXPANSION AND EPR TEST— Challenger
Regulator (EPR) Valve, has been introduced this year. (In Car)
Like the EPR valve, it is entirely self contained,
This test is to be perform ed after perform ing Test
requires no external motivation and is located in the
1 through 5. The gauge set manifold will be connected
suction cavity of the compressor.
as illustrated.
Its purpose is to restrict the flow of refrigerant NOTE: EPR Valve not used on Dart installations.
under light air conditioning loads. This is done to keep
the evaporator pressure high enough to prevent
freeze-up of the condensate on the external surfaces ( I ) P r e lim in a r y C h e c k s
of the evaporator. Such a condition would restrict air Before performing any of the tests listed in Section 3,
flow, and under extrem e circumstances, result in com the following conditions should be established.
plete loss of capacity. (a) System must be adequately charged in accord
The Pilot Operated EPR differs from the EPR (in ance with Test 2.
ternally), in that it contains a built-in pilot valve, (b) Make sure sensing tubes of the expansion valve
which “triggers” the main throttling portion of the are not damaged. Replacing any expansion valve
valve. The valve offers more precise control, and per that has been broken or damaged tube. Be sure
mits system operation at lower ambient tem peratures, sensing tube is properly inserted in its well in the
before evaporator “freeze-up” occurs. suction line. (Fig. 8).
SINGLE UNIT
55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
41 42 43 44 45 46 47 48 49 50 50 50 51 51 52 52 53 53 53 54 54. 55 56 57 58 59 59 60 62 64 66 67 68 69 70 71
INLET AIR DRY BULB TEMPERATURE MUST BE BETWEEN 75° AND 110°F________________ NK1342A
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valve actuator.
(c) Set the engine speed at 900 rpm unless otherwise
specified.
(d) Operate the system for at least ten minutes to
obtain partial stabilization and sufficient reheat
to load the evaporator.
(3) R e q u i r e m e n t s
Check the system as follows and refer to Diagnosis
Chart if findings are different from these specified.
(a) Under conditions in paragraph 2, pressure should
be as follows when the sensing tube of the ex
pansion valve is in its well.
Head Pressure 140 to 210 psi
(b) Under conditions in paragraph 2. Remove the
Fig. 8—Expansion Valve Details
expansion valve sensing tube from its internal
(2) T e s t C o n d itio n s For A ll R e q u i r e m e n t s well and hold it in your hand for several min
E x c e p t 3 (d ) utes until suction pressure stabilizes. The pres
(a) Test must be made at room tem perature of 75 sure shall read:
degrees F. minimum. Evaporator suction pressure 40 psi or m ore.
Under hood tem peratures 86 degrees F. mini Com pressor inlet pressure no m ore than
mum. 4 psi below evaporator suction pressure.
(b) Close the doors and windows, set the air con (c) Under conditions in paragraph 2, immerse 5" of
ditioning controls for maximum A/C, high blow the sensing tube in a container of ice w ater at
er and tem perature lever to maximum tem pera 32 degrees F. (Fig. 9 and 10). The pressure
ture position. should read:
NOTE: Disconnect and plug vacuum hose at water Evaporator suction pressure not more than
40PSI MINIMUM THERMAL MAINTAIN 140 TO 210 PSI
BULB WARM
21 TO 25 PSI THERMAL
BULB IN 32° ICE WATER EXPANSION VALVE
CLOSED
ICE AND WATER 32° F,
\-=. L..e v . . /
THERMAL BULB
\
1
X
DISCHARGE LINE . '
W M SSm
SUCTION LINE'''
r
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MINIMUM OF 35 PSI MAINTAIN 140 TO 210 PSI
THERMAL BULB/WARM
21 TO 25 PSI EXPANSION
THERMAL BULB VALVE
IN ICE WATER CLOSED
£1 ICE AND WATER THERMAL bulb
'0 V >> fl f
i f
NP718C
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EXPANSION VALVE AND EPR VALVE DIAGNOSIS CHART
Head Pressure Below 140 psi Expansion Valve Closed See 4(a)
(Ref. 3 a) EPR Valve Closed See 4(b)
Compressor not Properly Working Replace valve plates &
gaskets of compressor
Low Evaporator Suction Pressure Expansion Valve Closed See 4(a)
Below 23 psi EPR Valve not
(Ref. 3 b) Controlling (open) See 4(d)
High Pressure Differential EPR Valve (closed) See 4(b)
(Ref. 3 b)
Evaporator Suction Pressure Expansion Valve Defective
Between 27 and 40 psi Lack of Capacity See 4(a)
(Ref. 3 b)
Compressor Inlet Pressure EPR Valve See 4(d)
Higher than 17 psi Defective
(Ref. 3 c) Compressor Defective Replace valves plates &
Expansion Valve Known to be Good gaskets of compressor
Evaporator Suction Pressure EPR Valve
Does not Drop Not properly set (high control See 4(c)
(Ref. 3 c) point)
Expansion Valve—Not working See 4(c)
properly (sticking open)
Compressor Defective
Evaporator Suction Pressure EPR not Set Properly Replace EPR Valve
Not Between 23 and 27 psi
(Ref. 3 d)
Compressor Inlet Pressure EPR Valve See 4(d)
Higher than 17 psi Defective
(Ref. 3 d) Compressor Defective Replace valve plates &
Expansion Valve Known to be Good gaskets of compressor
sure then immerse the sensing tube in ice water less. If it is more than 17 psi, the EPR valve is
at 32 degrees F. and read the evaporator suction faulty and m ust be replaced.
pressure which should be below 27 psi. If the If the compressor inlet pressure is still above 17
pressure does not drop to this value, read the psi, inspect the valve plates and gaskets and
compressor inlet pressure. It should be 17 psi or replace them if necessary.
Page Page
Charging the System ................................................ 22 Removing Sweep-Test C h a rg e ................................ 21
Discharge the System ....................... ....................... 20 Replace Receiver Drier ............................................. 21
Evacuate the System ................................................ 22 Sweep-Test Charge ........................... ........................ 20
Refrigerant Service ................................................... 19 Testing the System for L e a k s ................................. 20
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it must be swept with a partial charge, and the entire hand valve to release any vapor trapped at the suction
system tested for leaks. Compressor oil level should side of the system.
be checked and adjusted, if necessary. See “Oil Lev
el”. The drier should be replaced and the system SWEEP-TEST CHARGE
evacuated using a vacuum pump to remove all air and
moisture. The system should be charged with the The purpose of the sweep-test charge is to pressur
proper amount of refrigerant. Detailed instruction for ize the system so that a leak test can be made. The
perform ing these operations follow. sweep-test charge also serves the purpose of drying
the system or sweeping out trapped moisture. Repairs
REFRIGERANT CHARGE and component replacem ent m ust be completed be
fore charging with the sweep-test charge.
(1) Close both gauge set manifold valves and open
Challenger 3 l bs. 2 oz. to the gauge set manifold needle valve.
3 lbs. 6 oz.
(2) Attach the free end of the long hose used for
Dart 2 lbs. 10 oz. to discharging to the refrigerant dispensing manifold.
2 lbs. 14 oz. (3) Attach a single can of Refrigerant 12 to the
dispensing manifold. Place the refrigerant in 125 de
gree water. For detailed instructions on attaching re
DISCHARGE THE SYSTEM frigerant can for charging, see “Charging the Sys
tem ” in this section.
(1) Be sure the valves of the gauge manifold set are (4) With vehicle windows open and hood up, oper
closed before attaching the gauge set manifold (suc ate engine as shown in the following chart:
tion test hose to the suction service port and dis
charge test hose to the discharge service port). Attach Engine
the long test hose to the center connection of the Engine R.P.M.
gauge set manifold. Lead the other end of this hose
into an exhaust ventilation system outlet or to the Challenger 6 Cyl. 1600
outside of the building. 8 Cyl. 1300
(2) Open the gauge set manifold needle valve and Dart 6 Cyl. 1250
close both of the gauge set manifold gauge valves. 8 Cyl. 1000
(3) W ith the vehicle windows open and hood up,
operate the engine as shown in the following chart: (5) Push in “A /C ” button, fan switch on high.
(6) Slowly open the left-hand gauge set manifold
Engine
valve to m eter the refrigerant into the system. When
Engine R.P.M.
the full can of refrigerant has been m etered into the
Challenger 6 Cyl. 1600 system, close the gauge set manifold valves and the
8 Cyl. 1300 refrigerant manifold valve.
If the system has been opened for repair or re
Dart 6 Cyl. 1250 placement, a complete leak test m ust be made to
8 Cyl. 1000
make sure the system is sealed. Also, if the system
has accidentally lost its charge it will be necessary to
(4) Push in “A /C ” button, blower motor switch on perform a leak test while the sweep-test charge is in
high. the system. Stop the engine and disconnect the test
(5) Allow the system to operate at full capacity for hoses and adapters from the compressor service ports.
at least 15 minutes at the rpm shown in the chart step
3. This will cause most of the compressor oil in the TESTING THE SYSTEM FOR LEAKS
system to return to the compressor crankcase.
(6) Push the “Off” button, shut off the engine. Open The leak detector torch Tool C-3569 is a propane
the discharge right-hand gauge valve a small amount. gas-burning torch used to locate a leak in any p art of
This will allow the refrigerant vapor to discharge the refrigeration system. Refrigerant gas drawn into
slowly. the sampling or “snifter” tube will cause the flame to
CAUTION: Do not allow the system to discharge change color in proportion to the size of the leak. A
rapidly since this would sweep some of the refriger very small leak will produce a flame color varying
ant oil out of the compressor. from yellowish-green to bright green. A large leak
(7) Allow the system to discharge until the dis will produce a brilliant blue flame.
charge pressure gauge registers zero. Open the left- CAUTION: Do not use the lighted detector in any
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place w here explosive gases, dust, or vapor are pres If the flame remains bright yellow when the tester
ent. Do not breathe th e fu m es that are produced by is removed from a possible leak point insufficient air
the burning of refrigerant gas. Large concentrations is being drawn in through the sampling tube, or the
o f refrigerant in the p resen ce of a live flame b e reaction plate is dirty.
com e dangerously toxic. O bserve the flame through
th e w indow of the burner shield, not through the top REMOVE SWEEP-TEST CHARGE
o f the shield.
If the system is free of leaks, or after correcting a
(1) Open the torch valve until you hear a faint hiss
leak, if no air-conditioning components have been re
of escaping gas. Light the test torch and adjust the
moved, add the necessary refrigerant as described
valve until the flame is very small. A small flame will
under “Correcting the Low Refrigerant Level.” If any
detect large as well as small leaks, whereas, a large
parts of the refrigerant system were disconnected
flame will detect only large leaks. As soon as the
remove the sweep-test charge. Close the refrigerant
reaction plate seen through the window in the b u rn er
manifold valve so that any refrigerant rem aining in
shield becomes red hot, the tester is ready for use.
the container is sealed. Remove the long test hose
(2) Examine all the tube connectors and other pos
from the refrigerant manifold. Insert the free end of
sible leak points by moving the end of the sampling
this test hose into an exhaust system outlet. Open the
hose from point to point. Since Refrigerant 12 is
right-hand gauge set manifold valve a fraction of a
heavier than air, it is good practice to place the open
turn to let the sweep-test charge escape slowly. Allow
end of the sampling hose directly below the point
the system to discharge until the discharge pressure
being tested. Be careful not to pinch the sampling gauge registers zero. Open the left-hand gauge valve
tube since this will shut off the air supply to the to allow any refrigerant trapped in the suction side of
flame and cause a color change. the system to escape.
(3) W atch for a change in the color of the flame.
Small leaks will produce a green color and large leaks REPLACE THE RECEIVER-DRIER
a bright blue color. If leaks are observed at the tube
fittings, tighten the connection, using the proper flare The system must be discharged and swept with a
wrenches, and retest. test charge before replacing the receiver-drier.
\
VACUUM PUMP
C-3652
^COMPRESSOR INLET
SERVICE PORT
\ S U C TIO N LINE
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To remove the receiver-drier, simply unscrew it (1) Connect gauge set manifold to compressor and
at the fittings and disconnect low pressure cut-out long test hose from gauge set manifold center connec
wires. When installing a new receiver-drier, use new tion to vacuum pump, Tool C-3652, as shown in Fig
“O” rings. Tighten the new unit to 40 foot-pounds. ures 1 and 2.
Do Not overtighten as this might damage the “O” (2) Open both gauge set manifold valves, and the
rings. Connect low pressure cut-out wires. needle valve.
CAUTION: Replacement receiver-drier units must be (3) Start the vacuum pump and operate until the
sealed while in storage. The drier used in these units evaporator suction gauge registers at least 26 inches
is so hungry for moisture that it can saturate quickly of vacuum. If system is tight and pump in good condi
upon exposure to the atmosphere. When installing a tion, vacuum will go as low as 28 inches.
drier, have all tools and supplies ready for quick re (4) Allow vacuum pump to operate with the suction
assembly to avoid keeping the system open any longer gauge registering 26 to 28 inches of vacuum for a
than necessary. minimum of five minutes.
(5) Close both gauge set manifold valves, tu rn off
EVACUATE THE SYSTEM vacuum pump and remove test hose from vacuum
W henever the system has been opened to atmos pump. Leave gauge set manifold connected to com
phere, it is absolutely essential that the system be pressor. Charge system with proper amount of Re
swept with refrigerant and evacuated or “vacuumed” frigerant 12.
to remove all the air and the moisture. If any Failure to pull at least 26 inches of vacuum indi
appreciable amount of air rem ains in the system cates a leak in the refrigeration system or a defective
when it is charged, the trapped air will concentrate vacuum pump. Locate and correct the trouble before
near the top of the condenser and cause abnormally recharging the system.
high discharge pressure. Air in the system will reduce
the condenser’s ability to condense the refrigerant CHARGING THE SYSTEM (Figs. 3 and4)
gas and supply adequate liquid refrigerant to the
evaporator. To evacuate the system, proceed as fol An accurate scale must be used to insure charging
lows: with the proper amount of refrigerant.
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RIGHT "DISCHARGE
GAUGE VALVE"
CHA RG IN G
HOSE
REFRIGERANT
M ANIFOLD
'■M y -
. . V'
SUCTION LINE
NK1445A
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RIGHT "DISCHARGE
DISCHARGE
GAUGE VALVE"
SERVICE PORT
ADAPTER
LEFT "SUCTION
GAUGE VALVE"
CHARGING
HOSE
REFRIGERANT
MANIFOLD
HOT WATER
125 F
COMPRESSOR
INLET SERVICE
PORT
NIG4 4 6 A
SERVICE PROCEDURES
INDEX
Page Page
Anti-Freeze Recom m endations................................. 25 Radiator Pressure C a p .............................................. 26
Compressor Drive Belt A djustm ent......................... 25 Vacuum Control System Adjustments
Handling Tubing and Fittings .......... ...................... 24 and T e s t s ................................................................. 26
HANDLING TUBING AND FITTINGS a fitting is loosened, allow trapped pressure to bleed
off very slowly. Use a suitable tube bender when bend
Kinks in the refrigerant tubing or sharp bends in
ing the refrigerant lines to avoid kinking. Never at
the refrigerant hose lines will greatly reduce the
tempt to rebend formed lines to fit. Use the correct
capacity of the entire system. High pressures are pro
line for the installation you are servicing.
duced in the system when it is operating. Extrem e
A good rule for the flexible hose lines is keep the
care m ust be exercised to make sure that all connec
tions are pressure tight. Dirt and m oisture can enter radius of all bends at least 10 times the diam eter of
the system when it is opened for repair or replace the hose. Sharper bends will reduce the flow of re
m ent of lines or components. The following precau frigerant. The flexible hose lines should be routed so
tions m ust be observed. that they are at least 3 inches from the exhaust mani
The system m ust be completely discharged before fold. It is good practice to inspect all flexible hose
opening any fitting or connection in the refrigeration lines at least once a year to make sure they are in
system. Open fittings with caution even after the sys good condition and properly routed.
tem has been discharged. If any pressure is noticed as “O” rings and fittings must be in good condition.
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The slightest burr or foreign m aterial may cause a The special refrigeration oil supplied for the system
leak. “O” rings and fittings m ust be coated with re is as clean and dry as it is possible to make it. Only
frigerant oil to allow the connections to seat squarely refrigeration oil should be used in the system or on
and to be tightened evenly to the proper torque. Fit the fittings and lines. The oil container should be kept
tings which are not oiled with refrigerant oil are al tightly capped until it is ready for use, and then
most sure to leak (Fig. 1). tightly capped after use to prevent entrance of dirt
The use of proper wrenches when making connec and m oisture. Refrigerant oil will quickly absorb any
tions is very important. Improper wrenches or im m oisture with which it comes in contact.
proper use of wrenches can damage the fittings. Al
ways use two wrenches when loosening or tightening
COMPRESSOR DRIVE BELT ADJUSTMENT
tube fittings to prevent distorting of lines and com Satisfactory perform ance of the air-conditioning
ponents. system is dependent upon drive belt condition and
The internal parts of the refrigeration system will tension. If the proper tensions are not maintained,
remain in a state of chemical stability as long as belt slippage will greatly reduce air-conditioning per
pure-moisture-free Refrigerant 12 and refrigerant oil form ance and drive belt life. To avoid such adverse
is used. Abnormal amounts of dirt, m oisture or air effects, the following service procedure should be fol
can upset the chemical stability and cause operational lowed:
troubles or even serious damage is present in more (1) Any belt that has operated for a minimum of a
than minute quantities. half-hour is considered to be a “used” belt. Adjust
When it is necessary to open the refrigeration sys air-conditioning drive belts at the time of new-car
tem, have everything you will need to service the preparation. See Chart.
system ready so that the system will not be left open (2) Measure drive belt tension at regular service
any longer than necessary. Cap or plug all lines and intervals using torque method, and adjust as needed.
fittings as soon as they are opened to prevent the (3) On all new-belt installations, new-belt tension
entrance of dirt and moisture. All lines and compo specifications should be used when the belt is first
nents in parts stock should be capped or sealed until installed to obtain proper tension. Thereafter, these
they are ready to be used. replacem ent belts should be serviced according to the
All tools, including the refrigerant dispensing above procedure. Always replace belts in pairs if so
manifold, the gauge set manifold and test hoses equipped, otherwise the old belt will have insufficient
should be kept clean and dry. tension and the load will be prim arily on the new belt.
See Chart, Group 7 Cooling.
ANTIFREEZE RECOMMENDATIONS
The Air-Conditioning System requires the engine’s
cooling system to be protected to + 15°F. with a per
m anent type antifreeze for summ er operation. This is
to prevent freezing of the coolant in the heater core.
However, this protection does not provide suffi
cient corrosion inhibitors for the engine cooling sys
tem. Summer protection to — 15 °F. will provide
adequate inhibitors for protection of engine cooling
system against corrosion.
In the springtime, after the w inter’s operation with
the cooling system protected with permanent-type
antifreeze for the tem peratures of the area, it is sug
gested the system be drained and flushed out with
water. When draining, flushing and refilling, have the
V P R E S S 'O K MUT tem perature control lever in the extreme hot position
so the heater core is drained, flushed and refilled.
STEEL TUBING
Install a gallon of perm anent type antifreeze in the
/ system, and add enough water to fill the system.
Do not re-use the old antifreeze. The perm anent
type antifreeze does not lose its antifreeze qualities
NY88^B during the w inter season operation, but the chemical
inhibitors for rust and corrosion prevention are weak
ened and finally exhausted by extended use. Do not
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add new inhibitor to used antifreeze in hope of revi
talizing the used antifreeze.
The chemical inhibitors come in various chemical
compositions, some are compatible, some neutralize
each other, and some form violent reactions to each
other causing foaming and other undesirable reac
tions. Play it safe and use new permanent-type anti
freeze.
RADIATOR PRESSURE CAP
Air conditioned vehicles m ust be equipped with a
15 to 16 psi radiator cap.
A radiator pressure cap testing below these specifi
cations will perm it loss of coolant during a hard pull
on a hot day, or in slow moving traffic, or when the Fig. 3—Adjust Vacuum Test Bleed Valve
engine is stopped on a hot day.
Test the radiator pressure cap, using Tool C-4080 trol system that operates perfectly at the high vacu
(Fig. 2). Before assembling adapter and radiator um provided at engine idle speed may not function
pressure cap to the pump, dip radiator cap and both properly at high engine speeds. Before starting this
ends of adapter into clean w ater to assure a tight seal. test, stop the engine.
Hold the assembled tester in a vertical position with Start the vacuum pump, Tool C-3652, and connect
the radiator cap downward, as shown in Figure 29. to the vacuum test set, Tool C-3707. Adjust the bleed
Stroke the tester pump plunger until the gauge indi valve on the test set to obtain exactly 8 inches of
cates the pressure cap is relieving pressure. It m ust vacuum, with a finger blocking the prod on the end of
relieve at a pressure between 14 to 17 psi. If within the test hose (Fig. 3).
these specifications, reinstall on the radiator. It is absolutely essential that the bleed valve be
These test specifications are for caps tested at adjusted so the vacuum gauge pointer will retu rn to
average altitudes. In high altitudes, the test specifica exactly 8 inches when the prod is covered by a finger.
tions are lowered about one (1) psi for each 2,000 feet Otherwise a false reading will be obtained when the
above sea level. control circuit is tested.
CAUTION: Alternately release and reblock the hose
If the radiator cap does not test within these speci
prod several times. Make sure the bleed valve is ad
fications, replace it with a cap that does.
justed so the vacuum gauge pointer returns to ex
VACUUM CONTROL SYSTEM ADJUSTMENTS actly 8 inches of vacuum when the prod is covered
AND TESTS with a finger.
Disconnect the engine vacuum source hose at the
The test of the push-button operation determ ines
engine intake manifold and insert the vacuum tester
w hether or not the vacuum and electrical circuits are
hose prod into the source hose leading to the control
properly connected and the controls are functioning
switch. Place the vacuum gauge on the cowl so it can
properly. However, it is possible that a vacuum con-
be observed from the driver’s position as the push
buttons are operated.
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NY297A
Page Page
C om pressor.................................................................. 28 Magnetic C lu tc h .......................................................... 27
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___PULLER C-3787
LEAD WIRE
D i s a s s e m b ly
(1) Remove the small snap ring from the drive hub.
(2) Install drive hub puller Tool C-3787 aligning
the three pins of the Tool in the three holes in the hub
and shoe assembly. Tighten the hex head bolt down
until the drive hub is removed from the bearing (Fig.
2).
(3) Remove bearing snap ring from pulley.
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is carried through the entire system by the refriger
ant. Some of this oil will be trapped and retained in
the system when the refrigerant is discharged for test
-TOOL ing or unit replacement. If the compressor is to be re
moved for repair or replacement, measure the re
frigerant oil level in the compressor before the com
BEARING
pressor is removed from the vehicle so that the same
oil level can be established when the new or repaired
compressor is installed on the vehicle.
Too much refrigerant oil in the system can cause
abnormal operating pressures and reduce the per
formance of the entire system.
Complete disassembly and assembly of the com
pressor m ust be perform ed with the compressor re
. moved from the vehicle. On some models however,
Vr-sril*^' NB62
the valve plate and crankshaft gas seal assemblies can
Fig. 4—Installing Bearing In Pulley Assembly be repaired with compressor installed on vehicle.
(Typical) CAUTION: The system must be completely discharged
compressor can be repaired in the field. before attempting to perform any disassembly or re
Figure 5 is a disassembled view of the compressor pair service to the compressor. Before bleeding sys
with the nom enclature of the parts. Some parts are tem down, cover clutch with a cloth to prevent con
serviced individually and some are serviced in pack tamination of clutch pole faces.
ages which include two or more service parts. Refer Before disassembling the compressor, clean exteri
to the parts book for this information. or surfaces thoroughly.
CAUTION: The refrigerant oil used in the compressor Cleanliness is extremely im portant. The work area
HEAD
GASKET
FITTING
BOLT
*>«-----CAP
SCREEN
------ -BOLT
COVER
ROTOR
SHAFT
ROTOR
HOUSING
SEAL
BALL
SPRING
GASKET
SUMP
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m ust be clean and free of air-borne dust and dirt. All (4) Install suction line fitting gasket, spring, fitting,
parts m ust be thoroughly cleaned and blown dry be and tighten the attaching bolts to 8 to 14 foot-pounds.
fore reassembly.
Do not use air to dry the crankshaft front main C om pressor
bearing. Wash bearing in clean m ineral spirits and
shake out all excess cleaning fluid. Saturate bearing Rem oval
(1) Discharge the system. (Refer to “Discharging
with clean refrigerant oil and assemble immediately.
the System.”)
Any dirt in the front main bearing assembly will
(2) Measure and record the refrigerant oil level so
cause noisy operation and possible damage to bearing.
that the oil level of a replacem ent or repaired com
CAUTION: Before reassembly of any unit, al l contact
pressor can be adjusted to the exact level in the
surfaces must be liberally coated with clean refriger
compressor removed from the vehicle. See “Oil
ant oil. Refrigerant oil must be kept in a sealed con
Level.”
tainer until ready for use to prevent entrance of
(3) Disconnect suction line from suction muffler
moisture and dirt. Never use engine oil as a substi
and the discharge line from the muffler fitting.
tute for refrigerant oil.
CAUTION: Plug or cap all the lines as soon as they
are disconnected to keep the moisture out of the
EPR VALVE (Evaporator Pressure Regulator) system.
(4) Disconnect the magnetic clutch-to-control-unit
Dart model installations do not use an EPR valve. wire.
(5) Loosen and remove compressor pulley belts.
R em oval (6) Remove the compressor-to-bracket attaching
(1) Remove the two “EPR” Valve suction line fit
bolts, and remove compressor.
ting bolts, the fitting which also contains the com
pressor suction screen, spring, and the gasket.
(2) Remove the “EPR” Valve and “O” ring from I n s t a l la t io n
(1) Install the compressor to the bracket, and tight
the compressor using Tool C-3822, by rotating the
en the attaching bolts.
valve counterclockwise slightly (Fig. 6).
(2) Install compressor pulley belts.
CAUTION: Do not handle the "EPR" Valve more than
(3) Connect magnetic clutch-to-control-unit wire.
necessary. The valve should be inspected externally
(4) Remove the caps or plugs and connect the suc
and wiped clean with a lint-free cloth. Place the valve
tion line to the suction muffler and connect discharge
in a plastic bag until ready to be installed.
line to the muffler fitting.
CAUTION: When replacing the compressor assem
I n s t a l la t io n bly, the crankshaft should be rotated by hand at least
(1) Install new “O” ring on the “EPR” Valve. two complete revolutions to clear oil accumulation
(2) Lubricate “O” ring with refrigerant oil and in from the compressor head before the clutch is ener
stall “EPR” Valve in the compressor with Tool C-3822 gized to avoid damaging the compressor reed valves.
while rotating the valve counterclockwise.
(3) Install compressor suction screen in the “EPR” O il L e v e l—C o m p r e s s o r
Valve suction line fitting. When a new compressor is installed at the factory,
the compressor contains 10 to 11 ounces of a special
wax-free refrigerant oil. While the air conditioning
system is in operation, the oil is carried through the
entire system by the refrigerant. Some of this oil
will be trapped and retained in various parts of the
system. Consequently, once the system has been in
operation, the amount of oil left in the compressor
will always be less than the original charge of 10 to
11 ounces.
The compressor oil level should be checked as a
matter of routine, whenever the refrigerant has been
released from the system.
(1) Operate the system for 15 minutes at 1000
engine rpm for eight cylinder engines and 1100 en
gine rpm for six cylinder engines. These engine set
tings will provide a compressor speed of approxi
mately 1200 rpm.
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(2) Open car windows and keep engine hood raised.
(3) Press the A/C button and turn blower switch
to high.
On completion of the above operations, shut the air
conditioning off, without changing any of the de
scribed settings.
After the system has been bled down, wait ten
minutes for refrigerant to boil off and then measure
the oil in the compressor by inserting a dipstick
(made up as shown in Figure 7) through the crank
case oil filler hole. Measure the height on the dipstick
and determine the amount of oil in the unit by refer
ring to the following chart:
Dipstick Reading
I nches @ Inches @
ENGINE 6 ounces 8 ounces
Minimum Maximum
225 Dart 1-5/8 2-1/8
225 Challenger 1-5/8 2-1/8
All 8 cylinder engines 1-5/8 2-3/8
Compressor Set
Vertically on Bench 1-5/8 2-3/8
Fig. 8—Valve Plate and Head Removing Lip
Dipstick reading should be at least six ounces and tends to cylinder bores, examine bores to see if they
not more than eight ounces. can be repaired by removing light scoring, scuffing or
If the sump contains less than six ounces of oil, scratches with a crocus cloth. A fter conditioning cyl
add fresh clean refrigerant oil to bring the level to inder bores, clean surfaces of cylinder block, valve
the minimum shown in the table above. Remove any plate and head thoroughly with m ineral spirits.
oil in excess of eight ounces. Use care to remove all shreds of old gasket from
plate, block and head surfaces. Clean attaching stud
C y lin d e r H e a d a n d V a l v e P la te A s s e m b l y holes in the block. If valve plate or cylinder head is
R em oval damaged, replace, using a complete compressor valve
(1) Remove the cylinder head bolts, head and valve plate replacem ent package.
plate assembly. If plate does not separate from head, CAUTION: Do not touch or pry the reed valves.
tap the removing lip on the valve plate lightly with a
plastic hamm er (see Figure 8). Do not pry apart.
I n s ta lla tio n
I n s p e c tio n (1) The valve plate and the cylinder head m ust be
A fter removal of head, plate and gaskets, examine assembled with the reed valve assembly (Fig. 9).
the valves. If valves are broken and the damage ex- (2) Dip the gaskets in clean refrigerant oil. Do Not
Soak. Using the pilot studs as a guide, install the valve
plate gasket, valve plate, cylinder head gasket and
cylinder head, (Fig. 10).
(3) Install the attaching bolts. Tighten each bolt al
ternately and evenly to 18 to 24 foot-pounds (name
plate bolts) and 20 to 26 foot-pounds on the rem ain
ROD DIPSTICK f o r u s e in c o m p r e s s o r c r a n k c a s e
ing bolts.
P is to n a n d C o n n e c tin g R o d
COMPRESSOR / \ ^CRANKSHAFT R em oval
CRANKCASE \d / V /
OIL FILLER X (1) Drain oil from compressor.
PLUG \ / / (2) Remove sump attaching bolts.
(3) Separate the sump from the case by tapping
with a plastic ham m er being careful not to distort the
VIEW OF COMPRESSOR 1 1
FROM FRONT OF CAR L ,----J oil pressure relief spring.
(4) Remove oil relief spring and (rubber) ball from
crankcase.
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(3) Install valve plates and cylinder heads.
REED VALVE ASSEMBLY
(4) Turn compressor upside down. Install pilot
studs, gasket, oil pressure relief ball and spring.
VALVE PLATE
(5) Install the sump over pilot studs (Fig. 11) m ak
ing sure the oil pressure relief spring depresses uni
formly as the sump is lowered on the case.
(6) Tighten sump bolts finger tight to prevent
spring misalignment, then tighten 14 to 20 foot
pounds.
(7) Refill with new refrigerant oil after the com
pressor is installed on vehicle. Do not re-use the oil
that was previously drained.
C r a n k s h a f t B e a r in g H o u s in g a n d G a s S e a l
R e p l a c e m e n t (S y s t e m D is c h a r g e d )
The gas seal may be replaced with the compressor
installed in the vehicle or with the compressor re
moved and placed on a workbench.
Special care should be taken when installing the
Fig. 9—Valve Plate—Installed Position new seal in a compressor mounted on the engine, that
(5) Remove cylinder heads and valve plates. the carbon ring does not fall out Qf its housing.
Before removing the pistons, rods or rod caps, mark Adequate lubrication of the rotating seal assembly
all parts to insure reassembly in the original position. prior to installation on the compressor shaft, will pre
(6) Remove rod caps; remove piston and rod as vent the carbon ring from falling out of place.
sembly from cylinder. If the compressor has been removed from the ve
hicle, it should be placed on its back, to facilitate seal
Inspection replacem ent.
Inspect piston and rings for score marks. Inspect The crankshaft gas seal replacem ent package con
rod bearing for pits and for chipping. Replace parts if sists of the crankshaft gas seal assembly and crank
damaged. shaft bearing housing seal seat plate. Two types of
I n s ta lla tio n crankshaft seals are supplied for service (Fig. 13). If
(1) Remove bearing cap and install piston in bore. the replacem ent package contains the cartridge-type
Use piston ring compressor to prevent ring damage. seal, follow the entire installation procedure given
(2) Install bearing caps, and tighten screws 50 to 60 below. If the replacem ent package contains the uni
inch-pounds. Be sure each cap is installed in its origi tized type seals, follow the appropriate sections only.
nal position.
R em oval
; VAIVI H A T ! O A ' , m , (00| STUDS) (1) Loosen belt, remove clutch, coil and drive key.
^VAIVI H A H ASM Mill Y , % i (2) Remove crankshaft bearing housing seal bolts.
\ CYLINDER HI AD / ' 'f V \ ■ ■ f\ (3) Remove bearing housing from crankshaft, using
\ (, A ’iKt r ^ l V /
two screwdrivers inserted in the slots provided, to
pry the housing from the case (Fig. 12).
(4) Remove bearing housing oil seal.
(5) Remove gas seal seat plate from the bearing
housing. This is part of the gas seal replacem ent pack-
PILOT STUDS
C-590
SUMP
CYLINDER
I HAD RELIEF SPRING
NB 95
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(6) Oil the bearing housing oil seal and install.
(Make certain that the seal is evenly stretched into
position.)
(7) Wipe the seal seat clean with a lint-free cloth,
and re-oil with refrigerant oil.
(8) Install the bearing housing, taking care to en
sure that the “nose” of the crankshaft does not touch
the seal seat in the bearing housing.
\ (9) Insert 5, 1/4 x 20 screws and pull bearing hous
NU15
ing squarely into position. This must be done 1/2 turn
Fig. 12—Removing Crankshaft Bearing Housing at a time per screw so that the ball bearing outer race
age and must be replaced when the gas seal assembly will not be jammed by the bearing housing.
is replaced. (10) Replace drive key in shaft.
(6) Clean the front bearing housing thoroughly. (11) Assemble clutch to compressor and turn crank
shaft by turning clutch arm ature. No more than 10
inch-pounds of torque should be required to tu rn
I n s t a l la t io n crankshaft. If shaft is tight, remove clutch and loosen
(1) Immerse the new seal seat in clean refrigerant
the bearing housing screws until shaft loosens up.
oil and install in the bearing housing with the smooth
Again, slowly tighten screws.
(micro finish) side up. Use a sleeve with the minimum
(12) Check the oil level which should m eet the
inside diam eter of 1-3 /8 " to avoid damaging the
requirem ents of the oil check.
micro finish sealing surface of the face plate. Tap the
(13) Install clutch package on compressor, apply
sleeve lightly until the seal seat is fully seated in the
ing 20 ft-lbs. torque to tighten the clutch center
housing.
m ounting bolt. Install and tighten belts. Evacuate
(2) Before installing the cartridge-type assembly,
system and recharge.
inspect the assembly to make sure that the tangs of
the carbon seal are indexed in the slots of the mating
steel part (Fig. 13). C r a n k s h a ft a n d B a ll B e a r in g s
(3) Immerse the seal assembly in clean refrigerant R em oval
oil, carbon ring up. (1) Remove cylinder heads and valve plates.
(4) Hold the seal assembly firmly at the outside (2) Remove pistons and connecting rods.
edge, at the same time preventing the ring from com The pistons and rods must be completely removed
ing out of position. Do not touch the sealing face of before the crankshaft removal.
the carbon seal. (3) Remove crankshaft and thrust washer from
(5) When the seal bottoms against the crankshaft crankcase.
bearing, inspect the indexing tangs of the carbon ring (4) To remove the crankshaft ball bearing, use a
again. small arbor press. Make sure bearing is properly sup
ported before pressing bearing from shaft.
I n s ta lla tio n
TANGS
(1) Press crankshaft ball bearing on crankshaft
CARTRIDGE TYPE UNITIZED TYPE using a sleeve which bears on inner race only.
NU8
(2) Install crankshaft, making sure the thrust
washer is on the rea r bearing journal before placing
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crankshaft in the crankcase.
(3) Rotate crankshaft to engage the oil pump shaft
in the crankshaft slot.
(4) Install new gas seal and crankshaft bearing
housing. Use a suitable tool (Fig. 14) to assure free
axial movement.
(5) Install pistons and connecting rods.
(6) A fter pistons and connecting rods are installed,
turn the crankshaft to check freeness. Shaft should
turn without binding.
(7) Install oil sump, valve plates and cylinder heads,
using new gaskets.
O il P u m p
R em oval
To remove oil pump, it is not necessary to drain the
refrigerant oil from the crankcase. Fig. I 4—Measuring Crankshaft Axial Movement
(1) Remove oil pump cover plate and oil seal.
(2) Remove drive shaft and rotors. (3) Install outer rotor, and rotate it until it will
slide forw ard over inner rotor cams. Turn compressor
I n s t a l la t io n crankshaft with the oil pump in this position to deter
(1) Install oil pump drive shaft by rotating the shaft mine that rotors do not bind.
until tang end engages in the crankshaft slot. (4) Install oil pump cover plate and oil seal.
(2) Install inner rotor on the drive shaft, engaging (5) Tighten bolts 8 to 14 foot-pounds.
the drive.
DART
Page Page
Blower Motor Removal and Installation ............... ....43 Heater Core Removal and Installation ............... 39-40
Electrical Controls and C ircuits.................................. 36 Inspection and Test Procedures............................... 10
Evaporator Removal and Installation..................... ... 41 Operation of all C ontrols.......................................... 37
Expansion Valve Removal and Installation............... 38 Vacuum Controls and Circuits ............................... 35
General Information . ................................................ ... 34
GENERAL INFORMATION
The combination heater-air conditioner used on the heater unit installed behind the instrum ent panel
Dart Models controls and directs airflow by opening direct cooling air to the floor.
and closing a series of doors. The blend air door, Controls for the system consists of five push but
which controls the tem perature of the heater output, tons, a tem perature control slide lever and a fan
is opened and closed by a bowden cable from the blower switch.
tem perature control slide lever in the instrum ent Push Buttons—Control the source and route of cir
panel. All the other doors, and the heater water flow culating air. “Off” (turns off the entire system); “Max
valve are operated by vacuum actuators. A single A /C ” (maximum air conditioning); “A /C ” fresh air-
blower serves both heater and air conditioner. In fact, air conditioning); “H eat” (for heater use only); “Def”
all of the components in the blower motor circuit are (windshield defrosting).
common to the heater and air conditioner. Temperature Control Slide Lever— Maintains any
Controls and cooling air outlets are integral with desired tem perature by sliding the lever right or left
the instrum ent panel. when operating either the heater or air conditioner
Three cooling air outlets are contained in one unit and controls the automatic cycling of the refrigera
secured to the lower edge of the instrum ent panel. tion system.
Each outlet can be adjusted independently to direct Fan Switch—Perm its selection of “Low,” “Me
air up, down, or to either side. Two fixed outlets in dium ” or “High” blower speed. “Low” (far left),
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“Medium” (center) and “High” (far right) used when let air tem perature, by engaging and disengaging the
operating either the heater or the air conditioner. compressor clutch. (Fig. 1).
Air Directional Vanes—Located on the lower edge
of the instrum ent panel. These are manually adjusted A/C
up, down, or to either side to deflect cool air to suit
requirem ents of driver and passengers. The “A /C ” button re-routes fresh-air door vacuum
to the rod side of the actuator. This opens the fresh-
VACUUM CONTROLS AND CIRCUITS air door and operates the linkage to close the recircu
lating door. The recirculating door and the fresh-air
When testing or adjusting the doors in the distribu door always operate simultaneously. Any tim e one of
tion system, it is necessary to know the correct posi them is open, the other is always closed. All the other
tion of each door for each push-button position. In the doors rem ain in the same position as for MAX A/C
illustrations which follow; air flow is indicated, also operation. (Fig. 2).
which vacuum actuator hoses are activated for each
push-button position. HEAT
Warm Weather Ventilation—Two “summ er” doors
are provided, one below each end of the instrum ent W ith the “HEAT” button in and the tem perature
panel. These doors can be opened manually for fresh control lever all the way to the right, the fresh-air
air ventilation during warm weather. door is opened to the cowl ventilation inlet. At the
Before using the air conditioner be sure both venti same time, the fresh-air door actuator closes the re
lation doors are closed and latched. circulating door. The blend air door is held closed by
a bowden cable from the tem perature control slide
OFF lever so all the airflow from the cowl passes through
the heater core and into the blower. (Fig. 3).
When the heater-air conditioner is off, the fresh- Vacuum is applied to the rod side of the air-condi
air door is closed and the recirculating door is open. tioning door actuator, closing off the passage to the
The air-conditioning door closes off the heater outlet evaporator core, and opening the passage to the
duct and opens the passage to the evaporator coil, and heater-defroster manifold. Since the heater-defroster
the heater water flow valve is closed. (Fig. 1). door is raised, the full flow of heated a ir goes though
the heater outlets, except for a small amount that
MAX A/C bleeds off through the defroster outlets.
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Fig. 3 —Heat Position Fig. 4—Defrost Position
lets. The heater outlets are left open far enough to (a) Push button switch (air conditioner and heater
allow about 30 percent of the blower output to bleed vacuum switch).
off. The other 70 percent is defroster air (Fig. 4). (b) Fan switch (air conditioner and heater blower
The full range of tem perature control is available switch).
during defroster operation, as are all three blower (c) Tem perature control switch (tem perature con
motor speeds. trol slide lever).
The power feed circuit is shown in Figure 5. A 20
ELECTRICAL CONTROLS AND CIRCUITS ampere fuse in the fuse block protects the circuit.
The compressor clutch circuit is energized when
The system is controlled by the following switches: either the “Max A /C ,” (maximum air conditioning) or
C 5B -14D G N -
TEMPERATURE
CONTROL COLOR CODE
C1-T4BK SWITCH BK BLACK
BR BROWN
O i- 1 DBL DARK BLUE
C 2A-18DBL- o DG N DARK GREEN
AIR CONDITIONER
GY GRAY
LAMP
FUSE BLOCK LBL LIGHT BLUE
LGN LIGHT GREEN
1 O
P
OR ANGE
PINK
I *P »y -E 2 A -1 8 0 j R RED
T TA N
a fcife o a i f V VIOLET
LEGEND
W WHITE
W IR IN G SPLICE------ <}>— --------
C1-14BK -C1A-18LGN- INSULATORS VIEW ED FROM TERMINAL SIDE Y YELLOW
* W ITH TRACER
A IR C O N D ITIO N E R 1 , 1 , 1 1 , 1 , 1
COMPRESSOR MALE h L l r I___ 1 FEMALE
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the “A /C” (fresh air-air conditioning) push buttons malfunction. The tests in this m anual have been ar
are depressed. The “Off” button turns off the system. ranged in a logical sequence th a t has proved to be
the surest and shortest route to accurate diagnosis.
Blow er M o to r (Fan Switch) It is recommended that they be followed and per
The power feed line from the push-button switch to formed in the order in which they are presented.
the blower switch is energized only when the ignition Operating m ust be tested as described in the follow
is on and any push button, other than “Off,” is ing sequence:
depressed. (1) Inspect, test, and adjust compressor drive belt.
The fan switch is controlled by moving the control (2) Remove radiator pressure cap.
lever from left “Low” to right “High.” (3) Start engine and adjust engine speed to 1600
rpm for 6 cylinder and 1300 rpm for 8 cylinder
T em perature Control Switch engines. Use a reliable tachom eter.
The tem perature control switch controls the tem (4) Move tem perature control lever to “Off” posi
perature of the evaporator by automatically cycling tion and push the A/C button.
the compressor clutch. As the clutch is cycled on and (5) The fresh air door should be open to fresh air.
off, the tem perature of the evaporator is held at the Open vehicle windows.
setting of the tem perature control lever. (6) Test the blower operation at all three speed
positions. If the blower does not operate correctly,
OPERATION OF ALL CONTROLS refer to “Electrical Controls and Circuit.” Leave the
DART blower switch in the “High” (Hi) position.
(7) The compressor should be running and the air
Satisfactory perform ance of the combined air- conditioning system in operation.
conditioning and heating system is dependent upon
proper operation and adjustm ent of all operating Push Button O p eratio n
controls, as well as proper functioning of all refrig Reduce engine speed to norm al idle. W ith engine
eration system units. The inspections, tests and ad operating at idle speed, vacuum will be high and
justm ents should be used to locate the cause of a vacuum actuators should operate quickly.
M O UNTING BRACKET
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DART PUSH BUTTON CONTROL CHART
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(3) With a rubber seal on the capillary sensing 'FRESH AIR
tube, carefully install the tube in the well located in ADJUSTMENT RECIRCULATION
the suction line as far as it will go (approximately five POINT ACTUATOR
inch depth).
(4) A fter expansion valve is installed, it must be
completely tested. Then the system must be tested for
leaks and recharged.
R e c ir c u la tin g D o o r L in k a g e
To adjust the recirculation door, remove the glove
box, push the “ Max A /C ” (Maximum Air Condition
ing) button in. Vacuum will then be applied to the top
of the fresh air recirculation actuator closing the
fresh air door and opening the recirculating door (Fig. ■"'*— RECIRCULATION
DOOR
8 ).
The top connecting rod has a turnbuckle nut and NK1389
lock nut. The length of the rod can be adjusted by
using two 7/16 inch open-end wrenches. The recircu
Fig. 8—Recirculating Door Linkage
lating door should be adjusted to give the maximum
possible opening when the fresh air door is complete forw ard of the instrum ent panel. The core is held in
ly closed. Push in the “A /C ” (Air Conditioning) but position in its cover by four sheet m etal attaching
ton and inspect to see that the recirculating door has screws. The core and cover are removed and installed
moved to its fully closed position. Install the glove as an assembly.
box.
R e m o v a l (Figs. 9 a n d 10 )
HEATER CORE (1) Disconnect battery and remove air cleaner.
(2) Drain cooling system and remove heater hoses
The heater core is located behind a separate cover from the core.
CONTROL ROD TO
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EVAPORATOR MOUNTING STUDS
EVAPORATOR TEMPERATURE
CONTROL SWITCH
AIR TUBE
BOWDEN CABLE
BLOWER MOTOR
GROUND WIRE
NK14Q4
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core, the evaporator housing with the evaporator inlet
and defroster doors. To remove the evaporator as
sembly, it is necessary to remove the heater assembly,
See “H eater Removal.” The system m ust be com
pletely discharged before opening any of the refriger
ant lines.
R em oval
(1) Disconnect elbow assembly and suction lines
from evaporator. Use two wrenches to loosen each of
these connections. Cap all the refrigerant openings to
prevent entrance of dirt and moisture.
(2) Disconnect blower motor wires and air tube.
(3) Disconnect actuator hoses.
(4) Remove mounting stud nuts and remove evapo
Fig. 11 —Weatherseal Positioned rator assembly with blower m otor as a single unit
stripe to rod side) and heater core ground wire. (Fig. 13).
(12) Install right defroster tubing, glove box as (5) Remove defroster actuator, evaporator tem pera
sembly and air outlet assembly. ture control switch, and carefully withdraw the capil
(13) Install heater hoses (Figs. 12 and 13), fill cool lary sensing tube.
ing system, connect battery term inal and install air (6) Remove the weatherseal around the air outlet
cleaner. opening, and remove the attaching cover screws and
(14) Start engine, operate until norm al engine cover.
operating tem perature is obtained and test operation (7) Remove the attaching stud nuts and remove
of heater assembly. evaporator from case (Fig. 15).
EVAPORATOR I n s t a l la t io n
(1) Position evaporator in the case and secure with
The evaporator assembly includes the evaporator attaching stud nuts.
VACUUM HOSES ROD HEATER CORE TO ENGINE HOSE
SIDE— RED STRIPE TO INTAKE MANIFOLD FITTING
OTHER SIDE— WHITE STRIPE
SUCTION HOSE AND TUBE ASSEMBLY
COMPRESSOR SUCTION MUFFLER ASSEMBLY
DISCHARGE MUFFLER AND TUBE ASSEMBLY
DISCHARGE HOSE AND
TUBE ASSEMBLY
WATER VALVE
ASSEMBLY
LIQUID TUBE
ASSEMBLY
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EVAPORATOR TEMPERATURE HEATER A N D
C O N TR O L SWITCH DEFROSTER ACTUATOR
... . V
NWEATHERS EAL
INLET D O O R
ACTUATOR A N D ROD
INLET DOOR IN A /C POSITION N K 1406A
DISCHARGE HOSE A N D
WATER VALVE TO TUBE ASSEMBLY
HEATER CORE HOSE
V A C U U M HOSES (REF)
(ROD S ID E -R E D STRIPE)
(OTHER SIDE— W HITE STRIPE)
WATER VALVE
ASSEMBLY
WATER VALVE TO
SUCTION MUFFLER
ENGINE HOSE
ASSEMBLY
SUCTION HOSE A N D
TUBE ASSEMBLY
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-AIR CONDITIONING 24-43
H
</- ?'A\
N K 1409
CHALLENGER
INDEX
Page Page
Electrical Controls and Circuits ............................. 47 Heater Core Removal and Installation............. 48
Evaporator Removal and Installation..................... 49 Operation of all C ontrols................... ..................... 48
Expansion Valve Removal and Installation............ 48 Vacuum Controls and C ircu its....................... ......... 45
General Information .................................................. 43
GENERAL INFORMATION
The air conditioner assembly installed on Challen The controls and cooling air outlets are integral with
ger models is a combination air conditioning and the instrum ent panel. This system operates on the re
heating unit which is installed inside the passenger heat principle.
compartm ent under the instrum ent panel. (Fig. 1). In the reheat air conditioner unit all the air enter-
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CO W L PANEL
SEALED
BYPASS DO O R A C TU A TO R
DASH PANEL
V IE W IN DIRECTION OF A R R O W A
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ing the system passes through the evaporator coil. justed manually to direct cool air to suit the require
Then either through or around the heater core, de ments of the driver and passengers. (Fig. 2).
pending on the position of the heater core by-pass The center outlets can be rotated to direct air up or
door. All output air tem peratures are controlled by a down; adjustable vanes direct air to either side or
single slide lever in the instrum ent, which operates shut off the air.
the heater water flow control valve through the unit The outlets at each end of the instrum ent panel
by a series of doors, operated by vacuum actuators. are also adjustable or can be shut-off by a dam per
The blower motor is turned on by any of the push operated by a push pull shaft.
buttons except the “Off” button.
VACUUM CONTROLS AND CIRCUITS
C o n tr o ls When testing or adjusting the doors in the distri
Controls for the system consist of five push but bution system, it is necessary to know the correct
tons, a tem perature control slide-lever and a three- position of each door for each push-button position.
position toggle-type fan blower switch. It is also necessary to know which vacuum hoses are
Posh Buttons—Control the source and route of cir activated for each push-button position. In the fol
culating air. “Off” (turns off system); “Max-A/C” lowing illustrations air flow is indicated as the vac
(maximum air conditioning); “A /C ” (fresh air— air uum actuator hoses are activated for each push
conditioning); “Heat” (for heater use only); “Def” button position. (Fig. 3).
(windshield defroster).
Temperature Control Slide Lever-—Maintains any OFF
desired tem perature by sliding the lever right or left The OFF button turns the system off. Vacuum ap
when operating either the heater or air conditioner. plication and door positions are the same as MAX
Fan Switch—Perm its selection of low, medium or A /C position.
high blower speeds—used when operating either the
heater or air conditioner. MAX A/C
Air Directional Vanes—One at each end, and two The MAX A/C button turns on the blower motor
in the center of the instrum ent panel. These are ad and engages the compressor clutch. The vacuum ap-
CENTER
OUTLETS
RIGHT SPOT
COOLER
LEFT SPOT
COOLER
VIEW IN DIRECTION
OF ARROW Z
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SOLID LINE BY-PASS ACTUATOR SOLID LINE BY-PASS ACTUATOR
I N D I C A T E S - " ^ BLACK IN D IC A TES-
E N G IN E V A C U U M ENGINE V A C U U M
W HITE
1H=-WV
RED O P E N -* - -CLOSED OPEN-*— ►CLOSED
SEALED SEALED
PUSH^ PUSH ^ 5
BUTTON BUTTON —
CONTROL 1/ ■ |P==r-"WV
CONTROL
VACUUM
VACUUM 213 4 21 3
SWITCH YELLOW J ACTUATC
A CTUATOR SWITCH J ACTUATC
ACTUATOR
RESTRICTOR RESTRICTOR
a
RELAY I “ RELAY
^ *
ACTUATOR ACTUATOR
W HITE
W HITE |
A IR /C O N D RED A IR /C O N D
A CTUATOR ACTUATOR
R E C IR C U L A T IN G ^ — ^FRESH A IR RECIRCULATING ------► FRESH A IR
OFF, M A X A /C FRESH A /C
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culating door pivots away from the fresh-air inlet and to the heater core. Any desired air tem perature can
closes off the recirculating inlet, supplying fresh air be obtained from the A /C outlets by adjusting the
to the blower, which forces it through the evaporator tem perature control slide lever.
coils and the heater core. The amount of heat added This unit has a heater core by-pass door which al
to the air by the heater core depends on the setting lows a portion of the eool air to pass under the
of the w ater flow control valve lever. heater core, then mix with the hotter air being dis
charged at the bottom of the heater core to give a
DEFROST more even discharge air tem perature at the air con
ditioning outlets. The heater core by-pass door is
When the heater section is operating on Defrost, open during air conditioning operation and closed
there will be a small amount of heat bleed through during heater or defroster operation (Fig. 13).
the heater outlets. Vacuum application will be as in
dicated. The fresh recirculating air door will be open CONDENSATION DRAIN TUBES
to Fresh Air and the Defroster door will be open.
Condensation which accumulates on the bottom of
REHEAT COOLING CONTROL the evaporator housing is expelled through a single
molded rubber drain tube into the engine compart
The air-conditioning refrigeration system operates ment. This tube m ust be kept open to prevent con
at full capacity constantly when either the “Max A /C ” densation from collecting in the bottom of the hous
or “A /C ” button is pushed. (Full capacity meaning ing.
maximum refrigeration according to the existing am
bient tem perature and humidity.) If the discharge air ELECRICAL CONTROLS AND CIRCUITS
from the air conditioning outlets is too cold the air
tem perature may be increased by reheating the air There are two switches, a push button switch (air
after it has passed through the evaporator coil. The conditioner and heater vacuum switch), and a fan
amount of reheating is determ ined by the tem pera switch (air conditioner and heater blower switch).
tu re control slide lever which controls the w ater flow The power feed circuit is shown in (Fig. 4). A 20
A IR C O N D IT IO N IN G
LOW A N D HEATER
PRESSURE SWITCH
SWITCH
18DBL
LEGEND
AIR
C O N D IT IO N IN G SPLICE
COMPRESSOR 1 COLOR CODE
tf BK BLACK
MALE FEMALE
BR BROWN
DBL DARK BLUE
|l— If B DGN D A R K G R E IN
MALE FEMALE
LGN LIGHT GREEN
INSULATORS
VIEW ED FROM T TA N !
TERMINAL SIDE
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ampere fuse in the fuse block protects the circuit. OPERATION OF ALL CONTROLS
The compressor clutch circuit is energized when
either the “Max.A/C” (maximum air conditioning) Satisfactory performance of the combined air-con
or the “A /C ,” (fresh air—air conditioning) push but ditioning and heating system is dependent upon
tons are depressed. The “OFF” button turns off the proper operation and adjustm ent of all operating
controls, as well as proper functioning of all refrig
system.
eration system units. The inspections, tests and ad
justm ents should be used to locate the cause of a
Blow er M o to r fFan Switch) malfunction. The tests in this manual have been ar
The power feed line from the push-button switch ranged in a logical sequence that has proved to be
to the blower switch is energized only when the igni the surest and shortest route to accurate diagnosis.
tion is on and any push button, other than “Off,” is It is recommended that they be followed and per
depressed. formed in the order in which they are presented.
The switch is controlled by moving the control Operating controls must be tested in the following
lever from left (low) to right (high). sequence.
(1) Inspect and adjust compressor drive belt.
Restrictor (2) Open vehicle windows.
A plastic restrictor is installed in the vacuum hose (3) Move tem perature control slide lever to “Off”
leading to the A/C door actuator. This restrictor pro position.
vides some delay in the opening of the A/C door after (4) Start engine and adjust engine speed to 1600
the “HEAT” or “DEFROST” button is depressed. rpm for 6 cylinder engines and 1300 rpm for 8 cyl
This delay gives the blower time to expel condensa inder engines. Use a reliable tachometer.
tion from the evaporator housing through the A/C (5) Push the Max. A/C button in.
outlets before it can be blown onto the windshield. (6) Fresh-recirculating door should be closed to
fresh air.
Should it become necessary to replace the vacuum
(7) Test the blower operation at all three speed
hose leading to the A/C door actuator, the correct
positions. If the blower does not operate correctly,
restrictor should be used.
refer to “Electrical Controls Circuit”. Leave the blow
e r switch in the “Low” position.
EXPANSION VALVE (8) The compressor clutch should be engaged, the
compressor operating, and the air conditioning sys
Rem oval tem in operation. If the clutch does not engage, test
The system m ust be completely discharged before the circuit as outlined under “Electrical Controls and
opening any of the refrigerant lines. Circuits.”
(1) Disconnect equalizer from suction line fitting
(2) Disconnect expansion valve from liquid line and Push Button O p eratio n
evaporator. Use two wrenches to loosen each of these Reduce the engine speed to normal idle. With the
connections. engine operating at idle speed, the vacuum will be
(3) Carefully pull out capillary sensing tube from high and the vacuum actuators should operate
suction line well. quickly.
(4) Remove rubber seal from the capillary sensing If the actuator operation is slow, check the source
tube. Inspect condition of inlet screen. hose connection at the engine manifold.
Push each button to test the over-all operation of
Installatio n the electrical and vacuum controls.
(1) With new “O” rings and clean refrigerant oil The “Push Button Control C hart” summarizes the
on all fittings, connect expansion valve to liquid line actions that should take place when each button is
and evaporator assembly using two wrenches to pre pushed. See “Chart.” Also refer to “Vacuum controls
and circuits.”
vent rotation and twisting of the lines.
If all the controls operate in the proper sequence
(2) Connect equalizer tube to the fitting on suc
but the action of the dampers and doors is slow or
tion line.
incomplete, inspect for mechanical misalignment, or
(3) With a rubber seal on the capillary sensing binding.
tube, carefully insert the tube in the suction line
well as far as it will go (approximately five inches). TEMPERATURE CONTROL CABLE
(4) A fter the expansion valve is installed, it m ust
be completely tested and the system m ust be tested Installation
for leaks and recharged. The cable operated tem perature control valve is
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PUSH BUTTON CONTROL CHART
equipped with a self adjusting control cable. No ad (2) Disconnect battery negative cable.
justm ent is necessary after the initial installation. (3) Drain cooling system and disconnect heater
(1) Place the tem perature control lever, on the hoses at dash panel. Plug core tubes to prevent spill
instrum ent panel, in the center position. ing coolant on interior of car.
(2) Position self adjusting clip on cam lever pin (4) Slowly discharge refrigerant from system.
and place cam lever on w ater valve, in full heat posi (5) Disconnect refrigerant lines at dash panel using
tion. Snap cable housing into retaining clip and cable two wrenches. Leave expansion valve attached to line.
into self adjusting clip. (Fig 5). Cap all refrigerant openings.
(3) Move the tem perature control lever on instru (6) Disconnect blower motor wires and remove
m ent panel to the full heat position to adjust the blower motor cooling tube and blower motor. (Fig.
control. 6 ).
(7) Remove glove box.
EVAPORATOR HEATING ASSEMBLY (8) Remove appearance shield from lower edge of
instrum ent panel.
R em oval (9) Remove left spot cooler duct and air distribu
(1) Remove air cleaner from carburetor. tion housing. (Fig. 7).
(10) Disconnect wires from blower motor resistor,
SELF ADJUSTING CLIP
and antenna wire from bottom of radio.
CABLE RETAINING CLIP (11) Remove radio, see “Radio Removal” Group 1.
CAM LEVER
WATER VALVE
IN ENGINE
COMPARTMENT
VIEW IN CIRCLE A
MM
PUSH BUTTON
CONTROLS
mSm
n
/
TEMPERATURE
\
CONTROL LEVER
MOUNTING STUDS
INSTRUMENT P A N E L -^ 1/ PY194
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TO -A/C SPOT COOLER, SUPPORT PLENUM AIR SEAL
DEFROSTER OUTLET BRACKET EVAPORATOR
AIR... I AIR CONDITIONING \ ACCESS PLATE
, C O NDITIO NING/ DOOR ACTUATOR \
OUTLET I ... /
m .
1
I& .' '¥ # '9'9:■1-1
M
Fig. 7—Air Distribution Housing Removal Fig. 9—Heater Evaporator Assembly (Front View)
(12) Disconnect vacuum harness from back of con core tubes. (Fig. 10). Separate housings.
trol switch. (5) Remove three screws from evaporator core ac
(13) Remove w ater valve cable from bracket on cess plate, remove plate, this will provide access to
left end of housing. two evaporator core mounting screws. (Fi‘g. 11).
(14) Remove nuts from housing m ounting studs in (6) Remove four screws holding evaporator core to
engine compartment. (Figs. 1 and 8). front cover and remove core. (Fig. 12).
(15) Remove rubber drain tube. (7) To remove the heater core, carefully lift left
(16) Remove support bracket from housing to plen half of the housing seal from the rear cover as shown
um panel.
in Fig. 14. Do not remove the entire seal as the lower
(7) Remove unit out from under instrum ent panel.
portion is a water seal.
(8) Remove two core retaining screws from m ount
D i s a s s e m b ly
(1) Carefully remove plenum air seal. (Fig. 9). ing plates and one from between core tubes in back
(2) Disconnect vacuum hose from fresh air door of rear cover. Lift heater core out of housing. (Fig.
actuator and by-pass door actuator. 13).
(3) Remove air seal from heater and evaporator
core tubes. A s s e m b ly
(4) Remove 18 screws holding front and re a r cov (1) Place heat door in up position before placing
ers together and one screw from between evaporator heater core in rear cover.
EVAPORATOR CORE TUBES
FRESH RECIRCULATING HEATER CORE BY-PASS
AIR DOOR DOOR ACTUATOR
HEATER CORE TUBES
MOUNTING STUDS
«<***,L'; ‘ (9
1* I
AIR DOOR
ACTUATOR
EVAPORATOR DRAIN TUBE
TO ENGINE
VACUUM FITTING PY184
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HEATER CORE MOUNTING H O U S IN G SEAL
EVAPORATOR CORE MOUNTING
SCREW LOCATION
\ SCREW LOCATION
f <**-•" \ - -
mas”
Fig. 11 —Evaporator Core Removal
I Fig. J4 —Housing Seal Partially Removed
PY188
m -/
H tA T rR CORE (9) Apply rubber cement to plenum air seal and
install.
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DISCHARGE
LINE
E X P A N S IO N
CAPILLARY V A LVE SUCTIO N
SEN SIN G TUBE
EQUALIZER CONDENSER
TUBE
HEATER
SU C TIO N HOSES
LINE
HEATER EX P A N S IO N
H O S iS V A LV E
WATER V A LVE
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I n s t a l la t io n (8) Install appearance shield to bottom of instru
(1) Position housing up under instrum ent panel. m ent panel.
(2) Connect housing to plenum support bracket. (9) Install glove box.
(3) From engine compartment, install four retain (10) Install blower motor and connect wiring.
ing nuts on housing mounting studs; tighten to 24 (11) Connect blower m otor cooling tube and install
inch pounds. evaporator drain tube.
(4) Connect vacuum harness to back of control (12) Connect refrigerant lines to evaporator core
switch. Place the water valve control cable in its re tubes. Examine “ O” Rings, lubricate fittings and “ O”
taining bracket. ring freely with refrigerant oil. Use two wrenches to
(5) Install radio, See “Radio Installation” Group 1. avoid twisting tubes. (Fig. 16).
(6) Connect all wiring to blower motor resistor and (13) Connect heater hoses to core tubes. Fill cool
plug antenna lead into bottom of radio. ing system.
(7) Install center outlet air distribution housing (14) Evacuate system. Sweep test. Examine for
and left spot cooler duct. leaks.
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Service Department
No. D70-25-2
This bulletin supplements the 1970 Dart Challenger Service
Manual P/N 81-270-0260.
Specifications
and Service
Information
*■ .. .*«**■» ■
MODELS: 1970
Challenger
T /A
(Over)
(T H IS BULLETIN IS SUPPLIED AS TECHNICAL INFORMATION ONLY AND IS NOT AN AUTHORIZATION FOR REPAIRS)
REPRINT OF THIS MATERIAL NOT AUTHORIZED UNLESS APPROVED BY MANAGER OF SERVICE. DODGE DIVISION
&
D odge CHRYSLER
MOTORS CORPORATION CHALLENGER I CHARGER I CORONET I DART I MON/
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The accesso ries and service procedures for the “ T /A ” a re the sam e as outlined in the
Service Manual. C ars equipped with a fiber glass hood P /N 3443685 will have the radio antenna
mounted on the right r e a r q u arter. The antenna cable will be routed down the right side sill
and spot taped in place.
GROUP 5 - BRAKES
The standard brakes on the “ T /A ” a re power disc b rakes in front and 11” diam eter drum in
the re a r. There a re no optional brake system s available. Service procedures and specifications
a re the same as outlined in the Service Manual.
GROUP 9 - ENGINE
The “ T /A ” Challenger is available only with the 340 C.I.D. engine. This engine has been
specially modified in the following areas.
Rocker Arm s - Special offset - C ast iron ad jus ting screw s p r e -s e t to ad ju st - See hemi
package
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OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
340 cu. in. .001' 1U/S Crankshaft R or M Milled fla t on number eight
M-2-3 etc. (indicating No. crankshaft counterweight
2 & 3 main bearing journal)
and/or
R-1-4 etc. (indicating No.
1 & 4 connecting rod
journal)
ENGINE "3 4 0 ”
T y p e ................................ ............................................ 90°V
Number of Cyl i nders . . . . ......................... . .......... 8
Bore ....................................... 4.040"
Stroke ...................................... 3.31"
Piston Di spl acement . . . . . . . . . . . . . . . . . . . . . . . . . 340 cu. in.
Compression Ratio . . . . . . . . . . . . . ----- . . . . . . . . . . 10.5 to 1
Minimum Compression Pressure with Engine Warm,
Spark Plugs Removed, Wide-Open Throttle ........ 110 psi
Maximum Variation Between Cylinders
(any one engine) ......................................... 40 psi
Firing Order . . . ___ . . . . . . . . . ------ . . . . . . . . . . . . . 1-8-4-3-6-5-7-2
Basic: T i m i n g ....—. . . . . . . . . ------------ 21
/20B T C ± 2 1
/2°
CYLINDER NUMBERING (front to rear)
Left Bank ................................ .................................. 1-3-5-7
Right Bank ................................................................. 2-4-6-8
CYLINDER BLOCK
Cylinder tore (standard) . . . . . . . . . ----- . . . . . . . . . 4.040"-4.0420"
Cylinder Bore Out-of-Round
(Max. allowable before reconditioning) .......... .005"
Cylinder Bore Taper
(Max. allowable before reconditioning) . 010 "
Reconditioning Working Lim its
(for taper and out-of-round) ..................... . 001"
Maximum Allowable Oversize (cylinder b o re )........ .040"
Tappet Bore Diameter ............ ................................ .9050"-.9058"
D istributor Lower Drive Shaft Bushings
(press f i t in block) ................... ...................... .0005"-.0040"
Ream to ............................................... .4865"-.4880"
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Shaft to Bushing Clearance .0007"- .0027"
PISTONS
Type Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 . . . . . . . . . . . Autothermic
A lloy Tin Coated
Land Clearance (diametral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ----- .. .019"- .027"
Clearance at Top of Skirt .......................... .......................................................... .0005"- .0015"
Weight (Std. through .040" oversize) . . . . . . . . . . . . . . .................... .. 719 gms.
Piston Length (overall) .................... . .............................. ............. . . . ............... .. 3.545"
Ring Groove Depth
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210"
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ----- . . . . . . . . . . . . . . . . . . . . . .210"
No. 3 ............................................................................................................ .198"
Pistons for Service Std. .005", .020",
.040" Oversize
PISTON PINS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Floating
Diam eter.............. ............................................................................ . . . . .............., .9841 "- 9843"
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.990"-3.000"
Clearance in Piston (Light Thumb Push @ 7 0 °F.) . .0000"- .0005"
End Play .. . ....... .................................................................................. .. .004"- .026"
Clearance in Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0000"- .0005"
Pi ns for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ----- . . . . . . Std. .003", .008"
Oversize
PISTON RINGS
Number of Rings per Piston . . . . . . . . . . ----- . . . . . . . . ...................................................................3
Compression .......................................................................................................................................2
o il . . . . . . . . . 1
Oil Ring Type 3-piece
steel rail
chrome-face
Ring Width
Compression .......................................................................... . . . . . . . . . . . . . . . .0775"-.0780"
O il—Steel rails .......... ............... ...................... .025"
Ring Gap
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010"-.020"
O il—Steel r a ils . ............................................................................................... . .015"-.055"
Ring Side Clearance
Compression ............................................................................................. . .0015"- .0030"
O il—Steel r a ils . .... ................................................................................................. .0002"-.005"
Service Ri ngs
Ring Gap
Compression ...... ............................................................ . . . . . . . . . . . . . . .010"-.020"
O il—Steel rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ----- . . . . . . . . . . . . . . .015"-.062"
Ring Side Clearance
Compression .......... . .0015"- .004"
O il-S te e l rails . . . . . . . . . . . ----- . . . . . . . . . . . . . . . . . . . . ------ -------- . . . . .0002"- .005"
CONNECTING RODS
Length (Center to Cent er). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.123"
Weight (less Bearing shells) . . . . . . . . . ...... .................................................... ...... 758 gms.
Side Clearance (two rods) .................................................................................... .006"-.014"
Piston Pin Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.027"- 1.039"
CONNECTING FDD BUSHING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed Bronze
CONNECTING ROD BEARINGS (Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tri-Metal Steel Backed
Diameter and Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.126" x .842"
Clearance desired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005"- .0020"
Maximum Al lowable ............................................................... . .003"
Bearings for Service ................................................................................................. Std., *001", .002"
.003", .010", .012"
CRANKSHAFT
Type ......................................................................................... ............................. . . Ful Iy Counter-Balanced
Bearings Nos. 1, 2, 3, 4 ............................................... *............ Steel Backed Aluminum
No. 5 .................................................. ............................... . . . . . . . . . . . . . . . . .. . Steel Backed Babbitt
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Thrust Taken By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 3 Main Bearing
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002” -,007"
Maximum Allow able . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010"
Diametral Clearance Desired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005"- .0015"
Diametral Clearance Allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025"
Finish at Rear Oil Seal Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagonal Knurling
MAIN BEARING JOURNALS
D ia m e te r....... ................................................................................................ .. 2.4995"-2.5005"
Maximum Allowable Out-of-Round and/or Taper . . . . . . . . . . . . . . . . . . . . . . . . . . .001"
Bearings for Service A vailable in Standard and the follow ing undersizes . . . . 001", .002", .003",
.010", .012"
CONNECTING ROD JOURNALS
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.124"-2.125"
Maximum Allow able Out-of-Round and/or Taper . . . . . . . . . . . . . . . . . . . . . . . . . . .001"
CAMSHAFT
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller Chain
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed Babbitt
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diametrical Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001"- .003"
Maximum Allow able before Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005"
Thrust Taken by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thrust Plate
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002"-.006"
Maximum Allow able . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010"
CAMSHAFT JOURNALS
Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1 1.998"-1.999"
No. 2 1.982"-1.983"
No. 3 1.967"-1.968"
No. 4 1.951"-1.952"
No. 5 1.5605"-1.5615"
CAMSHAFT BEARINGS
Diameter ....................... No. 1 2.000"-2.001"
No. 2 1.984"-1.985"
No. 3 1.969"-1.970"
No. 4 1.953"-1.954"
No. 5 1.5625"-1.5635"
VALVE TIMING
Intake Opens (BTC) ....................................... 22°
Intake Closes (ABC)......................................................................... ....................... 66°
Exhaust Opens (BBC) ........................................................................................... .... 74°
Exhaust Closes (A T C )................................................................................ . 22°
Valve Overlap ............................. ............................................................................. 44°
Intake Valve Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268°
Exhaust Valve Duration . . . . . . . . . . . . . . . . . . . ----- . . . . . . . . . . . . . . ------ . . . . 276°
TIMING CHAIN TYPE Double Row Roller
Number of Links ............................................................................................ . 68
PrtafT.1 7 . . . . . . . . . 7.7777777:7 .7777777.7.777777777. 77777777777.T77777"-- --------------375t*--------------
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .870"
TAPPETS
T y p e ...................................................................................................................... .... Hydraulic
Body Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9035"-9040"
Clearance in Block .................................................................................. ............... .0010"- .0023"
Service Tappets A vailable Std., .001", .008", .030"
CYLINDER HEAD
Valve Seat Run-Out (Maximum) ...................... ............................................... .. .002"
Intake Valve Seat A n g le ............ ................................................. .......................... 45°
Seat Width (finish) .................................... .060"- .085"
Exhaust Valve Seat Angle .......................................................................... 45°
Seat Width (finish) ........................................................................... ............... .040"-.060"
Cylinder Head Gasket (Thickness compressed) ..................................... .. .030"
VALVE GUIDES
Type.................................................. .......................................................................... Cast in Head
Guide Bore Diameter ................................................................................................. .374"- .375" Std.
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VALVES-( INTAKE)
Head Diameter ...... ............... ....................................................................... ... .. 2.02"
Length (to center o f valve face) ................................................... 4.90n
Stem Diameter (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3715"- .3725"
Stem to Guide Clearance . . . ...... ...................................... .0015"- .0035"
Maximum Allowable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .017"
Face Angl e ------- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve for Service (Oversize Stem Diam.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S td , .005", .015", .030"
L ift(Z e ro Lash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429"
VALVES~( EXHAUST)
Head D iam eter....... .......................................................................................... .. 1.60"
Length to (center of valve face) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.90»
Stem Diameter (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3705"- .3715"
Stem to Guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025",- .0045"
Maximum Allowable .............. ................ .. 0 1 7 '*
Face Angle . . . . ___ . . . . . ___ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°
Valve for Service (Oversize Stem Diam.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S td, .005", .015", .030"
L ift (Zero Lash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 "
VALVE SPRINGS
. N um ber............ ........................................ . . . . . . . . . . . . . . . . . . . . ------ ------- -- 16
' Free Length ............ ............................................................................................. . 1.94"
Load when Compressed to (valve closed
with surge damper removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90 lbs. @ 1-11/16"
Load when Compressed to (valve open
with surge damper removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235-249 lbs. @ 1-7/32"
Valve Springs I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.070"-1.090"
Maximum Allowable Out of Plumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .080"
Valve Spring Installed Height (spring seat to retainer) . . . . . . . . . . . . . . . . . . 1-5/8"-1-11/16"
Using 1/16" Spacer to Reduce Spring Height When Over Specifications . . . . .
ENGINE LUBRICATION
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary Ful I Pressure
Capacity (qts.) ........................................... .......................................................... .. 4 U.S. or 3-1/4
Imperial **
Pump Drive ............................................... .. Camshaft
Minimum Pump Pressure @ 500 R.P.M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PSI
Operating Pressure at 1000 R.P.M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-*65 lbs.
Pressure Drop Resulting from Clogged Filter . . . . . . . ----- . . . . . . . . . . . . . . . . 7-9 lbs.
Oil Filter Type .................... Full Flow
340
______________________________________ ________ Cu. in. Engines
Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015 inch or more
Outer Rotor Length ........................................................................................ ........ ........... .825 inch or less
Outer Rotor D iam eter.......................................................................................... . 2.469'inch or less
Inner Rotor Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825 inch or less
Clearance Over Rotors—Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 inch or more
Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ----- . . . . . .004 inch or more
Outer Rotor Clearance ....................................................................... .................................014 inch or more
Tip Clearance Between Rotors ........................................................................... .................010 inch or more
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The “ T /A ” exhaust system consists of special low re stric tio n two pass m ufflers P /N 3466913
located forw ard of the r e a r axle. Specially designed trum pet type e x haust pipes will mount
under the body side sills and exit forw ard of the r e a r wheels.
The exhaust outlet pipes, brack ets, hangars and installation instructions will be shipped in the
luggage com partm ent for installation by the dealer.
GROUP 14 - FUEL
The 340 C.I.D. “ T /A ” engine is equipped with three (3) two (2) b a rre l Holley carb u re to rs
Model 2300. The throttle linkage adjustm ents and specifications a re the sam e as outlined in the
Service Manual for the 440 six-pack.
CENTER_______ OUTBOARD
Manual Automatic Front R ear
C hrysler No. 3577182 3577183 3577184 3577185
Holley No. R-4791A R-4792A R -4789A R-4790A
Engine Displacem ent 340 340 340 340
T hrottle Bore 1-1/2" 1 -1 /2 " 1-3/4" 1-3/4"
Main Venturi 1-3/16" 1-3/16" 1-9/16" 1-9/16"
Main Metering Jet
Standard 62 61 --- ---
1 Size Lean 61 60 --- ---
2 Size Lean (5,000-10,000 ft.) 60 59 --- ---
Adjustments
Curb Idle Speed 1000 R.P.M . 900 R.P.M . --- ---
F ast Idle Speed
(2nd Highest F ast Idle Cam Step) 2300 R.P.M. 2300 R .P .M .----- ........
Bowl Vent Valve At Idle .005/.025 .005/.025 --- ---
Unloader Adjustment
(Wide Open Throttle) 5 /3 2 ” 5/32" ...... — _—
Vacuum Kick Adjustment #28 (.140") #39(.099") --- ---
F a st Idle Cam Position #53(.059") #53(.059") ---
F loat Setting Dry With fuel bowl inverted adjust float to center of be
Fuel Level Wet
@6 P.S.I. Fuel P re s s u re 9/16" 9/16" 3/4" 3 /4 *
Adjust to bottom of sight plug hole 1 /3 2 w
Service procedures for r e a r springs and shock ab so rb ers rem ain the sam e as those published
in the Service Manual. Rallye suspension with front and r e a r sway b ar and heavy duty shocks
are standard equipment. The r e a r spring cam ber has been increased to provide ground
clearance for the special side outlet exhaust and G-60-15 r e a r tire s.
Service procedures for wheels, bearings and tire s a re the same as published in the Service
Manual. E-60-15 raised white letter tire s are standard equipment on the front wheels.
G-60-15 raised white le tte r tire s a re standard on the re a r. All road wheels are 15 x 7";
collapsible spare tire is standard equipment.
R. H. KLINE
Manager - Service
DODGE DIVISION
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