1961 Plymouth Service Manual Supplement

SERVI CE MANUAL
SUPPLEMENT
7
awcu~a!
This Plymouth Service Manual Supplement has been prepared
to cover only changes affecting the servicing procedures of the
1961 model cars.
For complete servicing of 1961 Plymouth cars, use the 1960
Plymouth Service Manual in conjunction with this supplement.
For your convenience, the group numbering in this supple-
ment is arranged to correspond to that used in the 1960 Plymouth
Service Manual. Each group contains the latest new informa-
tion concerning the servicing of the 1961 Plymouth car compc-
nents, without repeating recommended procedures for previous
models. Specifications, special tools, torque reference and
service diagnosis, when they apply, appear in the individual
group.
The procedures and specifications contained in this manual
were in effect at the time the manual was approved for printing.
Chrysler Corporation reserves the right to change procedures
and specifications without notice and without incurring obliga-
tion.
CHRYSLER CORPORATI ON
To obtain extra copies of this manual,
Order by Number 81-571-0038
C H R Y S L E R C O R P O R A T I O N
PL YMOUTH l DE SOT0 l VALI ANT DI VI SI ON
SERVICE DEPARTMENT
DETROIT 31, MICHIGAN
81.5714038
15M-SD 8. T O-8 4 0
LI THO I N U.S.A.
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GROUP I NDEX
ZOUP TITLE PAGE
0 l ubri cat i on- Mai nt enance
3
1 A
ccessories
7
2 Front Suspension
3 Ax l e - Re a r 13
4 Br akes 16
6 Cl ut ch
19
7 Cooling System 2 0
8 Electrical-Instruments 2 5
9 Engi ne- Engi ne Oi l i ng I 6 2
11 Exhaust 81
13 Fr ame 8 2
14 Fuel System 8 2
16 Propeller Shaft- 1 0 2
Universal Joints
17 Springs-Shock Absorbers 103
19 St eer i ng Gear s
21 Transmissions 113
22 Wheel s- Beari ngs- Ti res 142
23 Body- Sheet Met al 142
24 Ai r Condi ti oni ng
I
LUBRICATION-MAINTENANCE 3
1961 MODELS
SAVOY (6 Cyl .) RP1-L (8 Cyl .) RP2-L
BELVEDERE (6 Cyl .) RP1-M (8 Cyl .) RP2-M
FURY (6 Cyl .) RP1-H (8 Cyl .) RP2-H
PLYMOUTH VEHI CLE NUMBERS
All vehicle numbers contain ten digits. The vehicle
number is a code which tells the make of car (1st
digit), model of car (2nd digit), year built (3rd digit),
assembly plant (4th digit) and vehicle serial number
(last six digits).
VEHICLE NUMBER LOCATION The vehicle
number (serial number) is located on a plate which
it attached to the left front door hinge pillar post.
a ENGINE NUMBER LOCATION On 6 cylinder
engines, the engine model, cubic inch displacement and
manufacturing date are all stamped on top of a boss,
located on the right side of block opposite number
one cylinder next to the cylinder head. See illustration.
On 318 cubic inch V-8 engines, the number is located
on the left front face of the cylinder block in position
B as shown. On 361 cubi c i nch V-8 engi nes, the
/
number is located on the right side of cylinder block
next to the water pump housing in position A.
BODY NUMBER LOCATION The body number is
stamped on a pl ate attached to the engi ne si de of
dash or front of radiator yoke.
1st Digit 2nd Digit 3rd Digit 4th Digit
2-Plymouth (6 Cyl.) 1. L ow 6. Suburban-Medi um 1961 1. Detroit
3-Pl ymouth (8 Cyl.) 2. Medium 7. Suburban-Hi gh 5. Los Angeles
3. High 8. Taxi 6. N ewar k
5. Suburban-Low 9. Special 7. Valley Park
GROUP 0
LUBRI CATI ON AND MAI NTENANCE
Listed are the new Lubrication and Maintenance pro- NOTE: The rubber bushings used on these
cedures for the 1961 Pl ymouth cars. These new cars are designed to grip the contacting
procedures al so appl y to the 1960 model s where metal parts firmly and operate as a flexible
appl i cabl e. Al l other Lubri cati on and Mai ntenance medium between these parts. The use of any
remain the same as outlined in the 1960 Plymouth lubricant will destroy the necessary friction
Servi ce Manual . and cause premature failure of the rubber.
4 LUBRICATION-MAINTENANCE
LUBRICATION AND MAINTENANCE
CAPACITIES
MODEL 6 Cyl. 8 Cyl. Golden Commando
Crankcase (a) . . . . . . . . . .
Cooling (b) . . . . . . . . . . .
Fuel Tank (c). . . . . . . . . . . . . . .
R e a r A x l e . . . . . . . . . . . . .
Tire Pressure (d)
4 qts. 5 qts. 5 qts.
13 qts. 20 qts. 16 qts.
20 gal. 20 gal. 20 gal.
31/ 4 pts. 31/ z pts. 31/ z pts.
F r o n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 24 24
Rear. . . . . . . . . . . . 22 22
(24 Suburban) (24 SuErban)
Transmissions
Torqueflite 8. . . .
Torqueflite 6. . . . . . . .
PowerFlite . . . . . . .
Manual 3 Speed (Standar d V- 8 Eng.)
Manual 3 Speed (Gol den Commando Eng.)
Manual 3 Speed (6 Cylinder) . . . . . . .
-
14 pts.
-
5 pts.
18 pts.
20 pts.
5 pts.
21 pts.
41/ 4 pts.
(a) Add 1 qt. if filter is changed (c) Suburbans 22 gallons
(b) Add 1 qt. for heater (d) 28 psi for fully loaded Suburban
Key To Lubrication and Maintenance Chart
Key
AA-Automatic Transmission Fluid Type A
Suffix A
AF-Anti -freeze
AP-Ai r Pressure
C-Check Condition of
CAC-Carburetor Ai r Cl eaner
CL-Chassi s Lubri cant
DCL-Distributor Cam Lubricant-Part No. 1473595
DPO-Dri pl ess Penetrati ng Oi l -Part No. 830669
EO-Engine Oil
EOF-Engi ne Oi l Fi l ter
GL-4-For API Service GL-4 as defined by MIL-L-2105B
HTF-High Temperature Heavy Duty Brake Fluid
Conforming to SAE 7ORl and 70R3
MCL-Speedometer Cable Lubricant Part No. 1243632
ML-Lubriplate Part No. 1064768
MP-Multi-Purpose Gear Lubricant
MSO- Speedometer Lubricating Oil Part No. 1265805
PSF-Power Steering Fluid Part No. 2084329
RF-Reverse Flush
RR-Rust Resistor
S-Manifold Heat Control Valve Solvent Part No. 1879318
SC-Safety Check-Brakes, Steering, Exhaust, Wipers,
Mirrors, Tires, Horn, Lights, Glass
Key
SGL Sure-Grip Lubricant Part No. 1879414
SSL-Stainless Stick Lubricant Part No. 1064769
UJl-Universal Joint Lubricant No. 1
UJ2-Universal Joint Lubricant No. 2
UBM-Short Fiber Wheel Bearing Grease, Medium
At THE FIRST 1,000 MILE SERVICE
AND THEREAFTER AT
2,000 MILE OR 2 MONTH INTERVALS
Key
CL-Upper Ball Joints (2)
CL- Lower Ball Joints (2)
CL-Tie Rod Ball Ends (4)
CL-Clutch Torque Shaft (1)
CL-Gearshift Tube and Lower Support Assembly (1)
MP or GL-4-Manual Steeri ng Gear-Check Level
PSF-Power Steeri ng-Check Level
EO-Parking Brake Linkage (Man. Trans.)
MP or GL-4-Rear Axl e-Check Level
SGL-Rear Axl e-Sure Gri p-Check Level
AA Automati c Transmi ssi on-Check Level
MP or GL-4-Manual Transmission-Check Level
ML-Foot Operated Parking Brake
EO-Di stri butor-Oi l Cup
DPO-Door Hinges and other hard to lubricate places
LUBRICATION-MAINTENANCE 5
Key
SSL-Door Lock Striker Plates, Dove Tail Surfaces
S-Manifold Heat Control Valves
ML-Door Check Arms, Hood Hinges, Hood Lock
DPO-Door Lock Assembly
ML-Door Lock Cylinders
ML-Deck Lid Lock
ML-License Plate Mounting Panel Springs and Pin
DPO-Tai l Gate Hi nges
ML-Tai l Gate Locks
SSL-Tail Gate Striker Plates, Dove Tail Surfaces
ML-Fuel Tank Access Cover Hinge and Pin
EO-Engi ne Oi l Change
SC-lo-Point Safety Check
EO-Engine Ventilation Air Cleaners
C-Ti res-Ai r-Wear-Forei gn Matter
C-Brake Lines and Hoses
HTF-Master Cyl i nder Check Level
EOF-Engine Oil Filter Change (First change at
3000 miles)
AT 4,000 MILE INTERVALS
EOF-Engine Oil Filter Change
Rotate Tires
AT 10,000 MILE OR 12 MONTH
INTERNALS
-Closed Crankcase Ventilation System--
Disassemble and clean
WBM-Front Wheel Beari ngs-Check Brake Li ni ng,
Wheel Cylinders, Hoses
MSO-Speedometer-with tube and wick or oiler
MCL-Speedometer Cabl e
EO-Di stri butor Wi ck
DCL--Distributor Cam
ML-Gear Shi ft Lever
AA-Automatic Transmission Maintenance and
Fluid Change
CAC-Install New Carburetor Air Cleaner Element
AT 20,000 MILE OR TWO YEAR
INTERNALS
MP or GL-4-Drain and Refill Manual Transmission
Key
MP or GL-4-Drain and Refill Rear Axle
(SGL for Sure-Grip)
UJl Bal l and Trunni on Uni versal J oi nt-Di sassembl e,
Clean, Inspect, Repack
UJ2-Cross and Roller Universal Joint-Disassemble,
Clean, Inspect, Repack
MP-Front Door Intrusion Guard Pivots
1. ENGINE VENTILATING SYSTEMS
All engines have an air cleaner on the cylinder head
cover to clean the incoming air. As optional equipment,
al l engi nes (except i n Cal i forni a) can be equi pped
with an air cleaner on the road-draft (outlet) tube.
These air cleaners should be washed in kerosene and
reoiled with SAE 30 engine oil at each 2,000 mile-2
month interval. In smog or dusty areas the air cleaners
may need attenti on as often as 500 mi l es, and i n
extremely dusty areas, almost daily.
California cars are equipped with a valve and tube
extending from the cylinder head cover to the carbu-
retor throttle body. The valve should be removed,
disassembled and cleaned with carburetor cleaner P/ N
1643272 every 10,000 mi l es. When the car i s used
constantly in short-haul driving or when the engine
idles for long periods of time, the valve will require
more frequent attention,
2. CARBURETOR AIR CLEANER
The carburetor air cleaner assembly should be re-
moved from the carburetor, disassembled, cleaned and
reassembled at not longer than 5,000 mile intervals. In
smog or dusty areas, the assembly should be cleaned
more often. The cleaning element should be replaced
every 15,000 miles or every third removal.
( 1) Remove the air cleaner from the carburetor as
an assembly.
(2) Remove the cleaning element from the housing.
(3) Gently blow the dirt from the element by hold-
ing the compressed air nozzle at least two inches from
the inside screen and blowing outward.
(4) Blow the dirt out of the housing.
(5) Check the element for punctures, using a bright
light. Discard an element that is punctured.
(6) Wipe the element support*plate free of dirt.
(7) Place the smaller end of the element inside
the turned-up edge of support plate in the housing.
The bottom of the element must be inside the
flange.
(8) Install the cover and tighten the wing nut se-
curely.
6 LUBRI CATI ON-MAI NTENANCE
3 . MANUAL TRANSMI SSI ON
Check the lubricant level at 2,000 mile or two month
intervals, each time the car is lubricated. Replenish
when the level is below the filler hole. Do not mix lubri-
cants. Drain and refill at 20,000 mile or 2 year intervals.
Multi-Purpose Gear Lubricant or GL-4 Lubricant re-
quires: SAE 80 above -10F. and SAE 75 below -10F.
Automatic Transmission Fluid, Type A, Suffix A
may be used as a field option for all climates.
4. AUTOMATI C TRANSMI SSI ONS
The procedures for performing the 10,000 mile main-
tenance servi ce (or fi l l i ng after recondi ti oni ng) are
not changed but the amount of fluid used in the proc-
ess varies us follows.
Use five quarts in all automatic transmissions as the
initial fill before starting the engine.
After the engine has run at idle for two minutes and
each push button has been depressed at least for two
seconds, add one quart to the TorqueFlite 6 and three
quarts to PowerFlite or TorqueFlite transmissions.
Final addition of fluid should not bring the level
above the Add One Pint mark. For PowerFlite the
level can be 1/2 inch below this mark: for TorqueFlite
1/4inch below and for TorqueFlite 6 the level can be
?& inch below the Add One Pint mark.
5. REAR AXLE (Ex c ept Sur e-Gr i p)
Check the lubricant level at each 2,000 mile or two
month interval when the lubricant is at operating tem-
perature. Replenish when the level is below the filler
hole.
The approved lubricants are Multi-Purpose lubricants
designated for API Service GL-4 as defined by MIL-L-
2105B: SAE 90 for temperatures above --1OF; SAE 80
for temperatures below -1OF; SAE 75 for temperatures
bel ow -30-F.
Drain and refill at 20,000 mile or two year intervals.
6. SURE-GRI P DI FFERENTI AL
Rear axles equipped with Sure-Grip differentials re-
quire Sure-Grip Lubricant P/ N 1879414. This is an all-
temperature lubricant which should be drained and
refilled at 20,000 mile or two year intervals.
7. DOOR LOCK CYLI NDERS
Place a small amount of Lubriplate on the notched
edge of the key. Rotate the lock cylinder several times.
Pull key out and wipe off excess grease. Repeat this
procedure until the key comes out of the cylinder clean.
8. DOOR LOCK I NTRUSI ON GUARDS
At 20,000 mile or two-year intervals, remove the
front door trim pads and apply Lubriplate to the in-
trusion guard pivots. While the trim pad is off, inspect
the vacuum tubing and other parts inside the door.
9. POWER STEERI NG
Use Power Steering Fluid, P/ N 2084329 ONLY. This
fluid is to be used throughout all temperature ranges.
10. PREPARATI ON OF NEW CARS
FOR STORAGE
Proper protection of new cars not scheduled for im-
mediate delivery is important to prevent possible fu-
ture difficulty and owner dissatisfaction.
When a car is placed in temporary storage, the en-
gine working parts are subject to corrosion and rust
formation within a short time due to condensation. This
can result in sticking of valves, tappets and rocker
arms and also cause excessive piston ring and valve
guide wear.
To prevent these conditions, the following storage
preparations should be performed :
Regardless of the length of time a car is to be stored,
the cooling system should be checked for leaks. Be
sure that sufficient anti-freeze solution is provided to
protect against temperature variations during the stor-
age period. A minimum concentration of 20% glycol
anti -freeze (freezi ng poi nt +15 F.) i s requi red for
rust protection.
STORAGE FOR 30 DAYS OR LESS of cars
which can be driven from one location to another, not
in excess of 2 to 3 miles:
( 1) Add one can (6 oz.) of Fuel Detergent and
Valve Lubricant in the gas tank for each five gallons
of gas.
(2) Operate engine with this mixture for five min-
utes at approximately 1000 r.p.m. NOTE: NO addi-
tional treatment is required when car is re-
turned to storage after moving from one loca-
tion to anot her .
(3) Check and recharge battery if specific gravity
is 1.230 or less.
STORAGE OVER 30 DAYS when engine will
not be started during storage period.
(1) Add one can (6 oz.) of Fuel Detergent and
Val ve Lubri cant to each fi ve gal l ons of gas i n the
tank. Al so, add one can (16 oz.) of Crankcase De-
tergent and Rust Inhibitor to the crankcase oil.
01
aerate engine for five minutes as outlined above.
(2
) Drain fuel tank and operate engine until car-
ACCESSORI ES 7
buretor runs dry. NOTE: This oper at i on ai ds in
pr event i ng the carburetor from being con-
taminated with gums that nor mal l y f or m in
gasol i ne as a result of prolonged exposure to
oxygen in the air.
(3) Remove spark plugs and pour two ounces of
Crankcase Detergent and Rust Inhibitor into each cyl-
inder through spark plug openings. Turn the engine
several revolutions with starter to distribute oil on the
cylinder walls, and reinstall spark plugs.
(4) Remove cylinder head covers. Using a clean
paint spray gun with dry air, coat rocker arms and
shaft, valve springs, push rods and valve stems with
Crankcase Detergent and Rust Inhibitor.
STORAGE FOR 60 DAYS OR MORE is con-
sidered long term, requiring additional preparation.
The following procedure is very important.
(1) Protect engine and fuel system as outlined
above in STORAGE OVER 30 DAYS, steps 1
through 4. The car should be completely lubricated
and the fluid checked in the transmission, rear axle
and steering gear for recommended level. For great-
est protection car should not be moved or operated
after preparations are completed.
(2) Place car on blocks to relieve weight on tires.
Replace missing valve caps, clean oil or grease from
tires and maintain recommended inflation pressure.
NOTE: If car cannot be blocked up, check
tire pressure frequently and maintain at
recommended pressure. Avoid weight on tires on
one position only. Do not store near direct sunlight or
other heat sources. Painting tires does not provide pro-
tection against deterioration. Do not store cars near
electrical devices such as motors or switches. These
are an active source of ozone, a major cause of rubber
aging and checking. The same applies to gasoline
and lubricants, which emit rot-producing vapors.
(3) Check and fill the master cylinder if necessary,
to the proper level with Super Brake Fluid. Work the
brake pedal several times every 20 to 30 days to avoid
sticking of cylinder pistons and cups.
(4) Block standard transmission clutch pedal down
to the floor board in a completely released position
to avoid the clutch disc sticking to the flywheel or pres-
sure plate.
(5) Remove the battery-check and recharge if
the specific gravity is 1.230 or less. Place in storage
and recharge every 30 days to prevent sulphation. Be
sure the electrolyte level covers the plates. To avoid
freezing, the temperature in the storage area should
be maintained above 32 degrees F.
(6) Close windows and other openings regardless of
whether the car is stored outdoors or indoors to pre-
vent entry of dust. Cover exposed bright surfaces in-
cluding body mouldings, door handles, name plates,
medallions, etc. with Chromium Protector Wax. If wax
is accidentally applied over paint, it can be removed
by wiping with a soft lint-free cloth dampened with
white unleaded gasoline.
(7) Remove the factory-installed plastic seat covers
to prevent the possibility of staining the upholstery due
to condensation. If it is necessary to store cars out-
doors, cover seat cushions and backs with heavy
paper to prevent fading from sunlight. This also applies
to inside storage if the car interior is partially exposed
to sunlight. Protect from extremely strong sunlight by
taping heavy paper over all windows.
NOTE: When a car is removed from storage,
it will not be necessary to remove the deter-
gent oils previously installed in the engine.
This oil is a lubricant and will readily mix
with engine oil.
GROUP 1
ACCESSORI ES
The windshield wiper is equipped with blades that
have a replaceable rubber filler, when the rubber is
deteriorated, it is no longer necessary to replace the
complete blade assembly.
All other accessories installed on 1961 Plymouth
cars remain the same as those used on the 1960 models.
Complete servicing procedures can be obtained by
referring to the 1960 Plymouth Service Manual.
1. WI NDSHI ELD WI PER BLADE
FI LLER REPLACEMENT
Removal
( 1) Raise the wiper blade approximately 6 inches
from the windshield and tilt the blade to expose the
arm and blade lock under the wiper arm (Fig. 1).
(2) Depress the lock lever and disengage the blade
assembly from the wiper arm.
8 ACCESSORIES
!
/
f!\ ,
WIPER ARM
*/ -.
.k
WIPER BLADE
KNOB 12)
61 xl 42
Fig. l-wiper Arm and Blade (Disassembled)
(3) Holding the blade assembly at the center, de-
press one of the small plastic knobs (Fig. 1).
(4) With knob depressed, slide the bracket off of
the tension arm and rubber filler.
(5) Withdraw wiper filler from remaining bracket
and tension arm assembly. Discard old rubber filler.
installation
(1) Insert the new filler into the clamps of the
bracket and tension arm assembly.
(2) Slide the mating bracket over the end of the rub-
ber filler.
(3) With the plastic knob depressed, engage the
end of the tension arm into the slots of the bracket and
release the knob.
(4) Elevate the end of the wiper arm from the wind-
shield and holding the lock lever depressed, engage
the wiper blade slot over the pivot pin of the wiper
arm.
(5) Release the lock lever and lower blade and arm
assembly to the windshield.
2. WIPER ARM ADJ USTMENT
(1) Operate wiper and observe travel and parking
position of wiper blade.
(2) Loosen wiper arms at pivots.
(3) Operate motor several times and turn off wiper
switch (Do not use ignition switch), this permits motor
to stop at normal parking position.
(4) Position wiper blades at the lower windshield
moulding and tighten pivot nuts. (Variable speed
motors only).
(5 j For single speed motors position wiper blades
one inch above moulding and tighten pivot nuts.
(6) Operate wipers and observe travel of both
blades.
(7) Wet windshield and again operate blades and
observe wiping pattern.
3. RADIO CONDENSER INSTALLATION
With the use of thermal instrument gauges, a new
voltage limiter is mounted on the rear of the instrument
cluster. The voltage limiter reduces battery voltage to
approximately 5.0 volts by the means of vibrator points.
The high sensitivity of the radio may pick up the arc-
ing of these points and the addition, of a condenser
will absorb this arcing or static.
The mounting bracket of the condenser is slotted
and may be inserted under the head of the attaching
screw (Fig. 2) without removing the voltage limiter.
The wire lead of the condenser is attached to the pro-
vided output post of the limiter.
Figures 3 and 4 shows the schematic wiring dia-
grams for the two model radios.
VOLTAGE LI MI TER
ON REAR OF
NT CLUSTER)
CONbENSER
Fig. 2-Radio Condenser Installation
61X328
a
ACCESSORIES
9
-
-
10
FRONT SUSPENSION
Fi g. 4-Radi o Wi r i ng Di agr am (Model 109)
GROUP 2
FRONT SUSPENSI ON
The Service Procedures for the Front Suspension
Group remain the same as those shown in the 1960
Plymouth Service Manual with the following excep-
tions :
Front Suspension Height has been changed to 2%
inches on Suburbans and cars equipped with heavy
duty springs.
When installing the torsion bar, be sure the rear
anchor is positioned approximately 60 degrees down
from the horizontal (at 4 oclock position) then engage
front end of torsion bar in hex opening of lower con-
trol arm until full contact of torsion bar and lower con-
trol arm shaft is made. Install lock ring in rear of rear
anchor, then move torsion bar rearward until it con-
tacts the lock ring. After installing adjusting bolts, seat
and swivel, adjust Front Suspension Height as neces-
sary.
Figure 1 shows an exploded view of the Front Sus-
pension.
MODELS . . . , , . . . . .
STEERING AXIS INCLINATION.
C A M BE R. . . . . . . . . . . . . . . . . . . . .
CASTER (Manual Steering) . .
(Power Steeri ng) . .
TOE-IN . . . . . . . . . . . . . . . .
SPEClFlCATlONS
RP1-RP2
. . . . . . . . . . . . . . . . . . . . .
. , , . . . , . . . . . . . . . . . . .
sl/ z to 71/ 2
. . . . . . . . . . . . . . . . * . .
Left + / 2 f 1/ d (+/ 2 Preferred)
Right +1/ 4O k 1/ 4 (+1/ 4 Preferred)
. . . . . , . . . . . . . .
- Y2 IL Y2
. . . . . . . . . . . . . . . . . . .
+!!1 ?h
. . . . . . . . . . . . . . . . . . . . . . . . . . .
& inch to 5% inch
(l/ s inch Preferred)
FRONT SUSPENSION
11
SPECIFICATIONS (Contd)
TOE-OUT ON TURNS. . . . . 211,~ (Al) Inner Wheel,
When Outer Wheel is 20
TREAD
Front . . . . . . . . .
Rear. . . .
W H E E L B A S E ( I n c h e s )
Suburban Models (Inches),
C - 485.
c-3409..
c- 3479.
c-3553..
C- 3556.
C-3560..
... .......................... 60.9
. . . . . . . . . . , . . . . . . . . . . . . . . . . . 59.7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . 122
SPECIAL TOOLS
Torque Wrench--Foot Pounds
Gauge-Camber and Caster
Gauge and Scr i ber - Toe- I n
Remover and Installer-Shock Absorber Lower Bushing
(All Models)
Installer-Lower Control Arm Bushing
Wrench (socket)- Ball Joint Assembly to Upper and
Lower Control Arm
C-3564 .
C- 3608.
C - 3669
C-3675 .
C - 3696
c-3710 . .
(All Models)
DD-435. . . . . . . . . Turntable ~-Wheel Aligning
SP-3233A. . . . . . . Adapter-Use with Tool C-3669
Remover-Ball Joint Stud (All Models)
Gauge-Front End Height and Level
Remover and Installer-Upper Control Arm Bushing
Wrench, Camber and Caster Adjusting (long)
Wrench, Camber and Caster Adjusting (short)
Upper Control Arm Bushing Remover and Installer
TORQUE REFERENCE
Ball Joint in Control Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm
Bumper Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Nut Outer 3/i. ............................................
Inner s/ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Bolt Nut.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Bushing Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Control Arm
Bumper Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Bracket Cam Bolt Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sway Eliminator Shaft
Cushion Retainer Bolt Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Bracket Screw.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Shock Absorber
Upper Mounting Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Mounting Nut.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Knuckle to Brake Support Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Knuckle to Steering Knuckle Arm Nut. . . . . . . . . . . . . . . . . .
Foot-Pounds
125 Min.
135
100
Inch-Pounds
200
180
100
100
50
200
65
35
150
100
25
55
55
50
AXLE-REAR 13
GROUP 3
REAR AXLE
The Service Procedures for the Rear Axle Group re- i ce Manual except for the procedures l i sted i n thi s
main the same as outlined in the 1960 Plymouth Serv- Supplement.
TYPE.
DRIVE GEAR TYPE, . .
RATI OS
Manual Three-Speed. .
Optional-Mountain Ratio.
T o r q u e F l i t e S i x .
PowerFlite .
TorqueFlite E i g h t .
A v a i l a b l e .
R I N G G E A R S I Z E .
SPECIFICATIONS
RP-1
225 Cu. In.
RP-2 RP-2
318 Cu. In. 361 Cu. In.
Semi-Floating
Hypoid
RAM MAN.
383 Cu. In.
Conv. Sure-Grip Conv. Sure-Grip
3.55* 3.58 3.58 3.58
3.91 3.91
3.31 3.58
3.55
3.31 3.58
3.58
2.93 2.93
3.31 3.58
81/ 4 in. **
Conv. Sure-Gri p
3.31 3.58
3.31 ii3
2.93 3.58
83/ in.
Conv.
3.23
.
3%
.006 to .009 inch
.OOO to 903 inch
RING GEAR TO DRIVE PINION
CLEARANCE
(at point of minimum backlash)
DIFFERENTIAL CASE RUN-OUT
DIFFERENTIAL SIDE GEAR
CL EA RA N CE . ,001 to .012 inch
A X L E S H A F T E N D P L A Y . .
,013 to ,023 inch
DRIVE PINION BEARING PRELOAD
20-30 in. lbs. without seal
L UBRI CA N T CA PA CI TY (PI N TS).
3% (6 Cyl .1
*83/4 in. Ring Gear and 3.31 Ratio-Standard on 6 Cyl. Taxicab and Heavy Duty Package
**83/ 4 in. Ring Gear- Standard on 6 Cyl. Cars with Sure-Grip Axles
3% (8 Cyl .1
SPECIAL TOOLS
C-292.F2. . . . . . .Axle, Pinion and Differential Case Roller Bearing Puller Set
C-406-A. . . . . . . . Differential Bearing Adjusting Wrench
C-413. . . . . . . . . .Rear Axle Shaft Outer Bearing Cup Driver
C-452, . . . . . . . . . Universal Joint Flange Puller
C-485. . . . . . . . . . Torque Wrench (Foot-Pounds)
r
1
14 AXLE-REAR
SPECIAL TOOLS (Contd)
C-496. Pi ni on and Transmi ssi on Compani on Fl ange or Yoke Pul l er
C-499. .Axle Shaft Puller
C- 637. A xl e Shaf t and I nner Oi l Seal Pul l er
C-685 I n ch - P o u n d T o r qu e Wr en ch
C- 745 Rear A xl e Shaf t Oi l Seal I nstal l i ng Sl eeve
C - 758- D 3 Pinion Setting Gauge Set
C - 839. Rear Axl e Shaft I nner Oi l Seal Dri ver
C - 8 4 5 . Uni versal Wheel and Hub Pul l er
C- 3005. . Foot- Pound Tor que Wr ench
C - 3 2 1 4 . .Pinion Oil Seal Puller
C - 3 2 8 1 Compani on Fl ange Hol di ng Wrench
C - 3339. .Dial I n d i cat or
C- 3565 A xl e Shaf t Outer Seal Dr i ver
C- 3656 . Pi ni on Oi l Seal Dr i ver
D D - 996 .Pinion Bear i n g I n st al l er
DD- 999. .Flange or Y oke I nstal l er
D D - 1 0 0 5 . Differential Case Side and Cross Shaft Roller Bearing Driver
DD- 1014. .Repair Stand- Di f f er enti al Car r i er
TORQUE REFERENCE
(Foot-Pounds)
A x l e S h a f t N u t s . . . . . .
Brake Support Plate to Housing Mounting Bolt Nuts . . . .
Differential Carrier to Axle Housing Bolt Nuts. . .
R e a r A x l e D r i v e G e a r t o C a s e B o l t s . . . . . . . .
Di fferenti al Beari ng Cap Bol ts. . . . . .
Rear Axle Drive Pinion Companion Flange Nut. . . . . .
145 (Min.)
30 to 35
45
45
90
240 (Min.)
1. REAR AXLE SHAFT END PLAY
Axle shaft end play is .013 to .023 inch. A minimum
of .013 inch end play is required since a loss of end
play results when the axle housing and axle shaft ex-
pand by different amounts during warm up. Less than
.013 inch end play can result in excessive bearing pre-
load, under this condition, causing shorter bearing life.
2. DRI VE GEAR AND PI NI ON BACKLASH
The drive gear and pinion backlash should be .006
to .009 inch at point of minimum backlash.
3. PI NI ON BEARI NG PRELOAD
If the original pinion bearing is to be reinstalled, the
preload setting should be as follows:
Minimum Drag Torque-Zero, but with no end play.
Maximum Drag Torque-13 inch-pounds.
4. PI NI ON PRE-LOAD (Pi ni on wi t h Spac er )
The illustration used in the 1960 Service Manual on
Page 11, Figure 20, was incorrect. The correct illustra-
tion is shown here (Fig. 1).
The rear axle used on Plymouth cars equipped with
a 383 cubic inch engine, incorporates a drive pinion not
using a pinion shaft spacer. When setting the Pinion
Depth of Mesh and Pinion Bearing Pre-Load, proceed
in the sequence as follows:
5. PI NI ON WI THOUT BEARI NG SPACER
I NSTALLATI ON USI NG TOOL C-758-D3
(Fi g. 2)
Depth of Mesh
The position of the drive pinion with respect to the
ring gear (depth of mesh) is determined by the loca-
tion of the bearing cup shoulders in the carrier and
by the thrust portion of the pinion in back of the rear
bearing. The thickness of a pinion spacer washer suit-
able for the carrier can be determined by using Tool
C-7.58.D3.
(1) Install the pinion locating spacer SP-2921 on the
main body of Tool C-758. Place large end of rear bear-
ing over shoulder of spacer and insert tool in the car-
rier.
(2) Pl ace front beari ng (smal l end down), com-
pression sleeve SP-535, centralizing washer SP-534 and
compression nut SP-533 on the main body.
(3) Wi th the nose of the carri er up, pl ace fl ange
AXLE-REAR 15
PINION LOCATING WASHER OR SHIM
---L-11 /
b ASSEMBLY OF SP-526
-i.
j/
V
SP-1730
57x 152
Fig. l-Setting Pinion Bearing Pre-Load with Tool C-758-D2-3
holding Tool C-3281 on the compression sleeve. Allow
the assembly to rotate while tightening the nut 25 to
35 inch pounds torque.
(4) Rotate the tool several times in each direction
to align the bearing rollers and recheck the torque.
(5) With the proper pre-load on the bearings, invert
the carrier in the stand. Install gauge block SP-528 in
the end of the too1 with allen screw.
(6) Position arbor SP-561 (part of Tool C-758) in the
differential bearing pedestals of the carrier. Center the
arbor so that an approximate equal distance is main-
tained at both ends.
(7) Position the differential bearing caps and attach-
ing bolts on the carrier pedestals.
(8) Between the arbor and each cap, insert a piece
of .002 inch feeler stock. Tighten the cap attaching bolts
securely.
(9) Select a washer that will fit between the tool
gauge block and arbor. This fit must be snug but not
too tight, similar to the pull of a feeler gauge. This
washer is suitable for measurement, not for installa-
t i on.
(10) To select a washer for installation, read the
marking on the end of the pinion (-0, -1, -2, +1
+2, etc.) when the marking is -, add that amount
to the thickness of the washer selected in step (9).
When the marking is +, subtract that amount. Ex-
ample: With a washer .086 inch thick and a pinion
marked -2, install a washer .088 inch thick (.086 +
.002 = .088). Exumple: With a washer ,086 inch thick
and a pinion marked +2, install a washer .084 inch
thick (.086 - .002 = ,084) or when a washer ,086
inch thick is too loose and .088 inch too tight, use .088
and the pinion marking.
(11) Remove the differential bearing caps and ar-
bor from the carrier.
ASSEMB1.Y y&J,-
OF SP-5;!6 +--J L---i ----I
I,
- -
TIGHTEN GAUGE TO q
40-50 FOOT POUNDS AND DETERMINE
PINION LOCATING WASHER 0NI.Y 60X168
Fig. 2-Setting Pinion Bearing Pre-Load with Tool C-758-D3
16
BRAKES
(12) Reverse the carrier in the stand so the nut of
the tool is up and leave tool in carrier, ready for bear-
ing preloading.
(13) While supporting the lower portion of the tool
in the carrier with one hand, remove the tool nut, tool
centering washer and compression sleeve. Lower the
tool down and out of carrier.
( 14) Remove the pinion front bearing cone from the
carrier.
Pinion Bearing Pre-Load
(1) Place spacer SP-2921 on main body of Tool
C-758 with the shoulder up. Place the selected pinion
spacer, spacer sleeve SP-2920 and the rear bearing on
the tool.
(2) Insert the tool in carrier, install the orlgmal shim
pile and the front bearing. Install the compression
sleeve SP-535 (square hole down), centralizing washer
SP-534 and tool nut SP-535.
(3) Tighten tool nut to 240 foot-pounds using holding
Tool C-3281 on the compression sleeve to hold the as-
sembly in several positions to make a complete revolu-
tion while tightening. Remove holding tool and rotate
assembly several turns in both directions to align the
bearing rollers. Re-check torque to 240 foot-pounds
(torque may have diminished as bearing rollers were
aligned by rotating).
(4) Correct bearing pre-load readings can only be
obtained with the nose of the carrier up. Use inch-
pound torque wrench, C-685. With the handle of the
wrench floating, read the torque when the wrench is
moving through at least one full rotation. Correct read-
ing is 20 to 30 inch-pounds (without seal) and should
be uniform during the full rotations. If bearing pre-load
is more than 30 inch-pounds, a thicker shim should be
used under front bearing. If the bearing pre-load is less
than 20 inch-pounds, a thinner shim should be used.
Shims are available in thicknesses of .OlO, .012, .014
.016 and .018 inch.
(5) Remove the tool with shim pack, bearing cone,
pinion locating washer, and spacer from the carrier and
the tool.
(6) Install the correct washer on the pinion shaft.
The washer has a chamfer on one side. This chamfer
must face the pinion gear thrust surface.
(7) Position the rear bearing cone on the pinion
shaft (small side away from the pinion gear). Make
certain the contacting surfaces of the correct washer,
pinion gear, and contacting surface of rear bearing
cone are perfectly clean and free of any foreign par-
ticles. Install the rear bearing cone onto pinion shaft
with Tool DD-996.
(8) Install the selected shim pack.
(9) Lubricate front and rear pinion bearings with
heavy oil.
(10) Insert the pinion shaft up through the carrier
and install the front bearing.
( 11) Install the oil seal in carrier with driver C-3656
with lip of seal toward the bearing.
(12) Start the companion flange on the pinion shaft,
completing the installation of the companion flange
with installing Tool C-496 or DD-999. Remove the tool.
(13) Install the plain washer (concave side of
washer down) and nut. Hold companion flange with
holding Tool C-3281 and tighten nut to 240 foot-pounds
torque. Rotate the assembly several times in both di-
rections to align the bearing rollers. Recheck torque to
240 foot-pounds (torque may have diminished as bear-
ing rollers were aligned by rotating).
GROUP 4 AND 5
PARKI NG AND SERVI CE BRAKES
Servicing Procedures for the 1961 Model parking
and service brakes remain the same as outlined in the
1960 Plymouth Service Manual except as listed in this
Supplement.
(a) Parking brake pedal and release handle.
(b) Fitting and aligning brake shoes.
(c) Police-Special service brakes.
(d) Brake bleeding procedure.
(e ) Service brake adjustment.
BRAKES 17
SPECIFICATIONS
SERVICE BRAKE
TYPE. . . . . . . . . . . . . . . . . . . . . . . . .
DRUM DIAMETER (Front-Rear)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Police Special).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINING TYPE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Police Special).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T h i c k n e s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wi dth-(118 Wheel base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Police Special).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(122 Wheelbase, Suburban Model) . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE SHOE RETURN SPRING TENSION POUNDS
(Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERCENT OF BRAKING TORQUE
(Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Rear) . . . . . . . . .
DIAMETER OF WHEEL CYLINDER BORE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAMETER OF MASTER CYLINDER BORE.
. . . . . . . . . . . . . . . . . . . .
PISTON CYLINDER CLEARANCE (All Bores). . . . . . . . . . . . . . . . . .
BRAKE PEDAL FREE PLAY (Manual Brakes) . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL FREE PLAY (Power Brakes)
. . . . . . . . . . . . . . . . . . . .
PARKING BRAKE
TYPE (Automatic Transmission)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Manual Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L O C A T I O N . . .
DRUM DI AMETER (Automati c Transmi ssi on)
(Manual Transmission).
L I N I N G T Y P E ( E x t e r n a l ) .
(Internal) . .
WIDTH. . .
THICKNESS. . . . . .
L I N I N G TO DRUM CL EA RA N CE. .
C-650.. Bl eeder Hose
c-745. Seal Protector
C-837B. Fi l l er (Wheel )
C- 845. Pul l er (Wheel )
C-3080. Hone (Wheel Cylinder)
c- 3229 Pliers (Power Brakes)
C349A Adapter (Bleeder)
. .
.
SPECIAL TOOLS
C-3496
C-3508.
C-3512.
C-3578.
c-3579.
MT-19-H
TORQUE REFERENCE
Hydraulic-Total Contact
Internal Expanding
11
12
Molded Asbestos
Molded Metal Embedded Asbestos
Cyclebond
X4
2 Front 2 Rear
21/ z Front 21/ z Rear
21/ 2 Front 2 Rear
45 to 55
60%
40%
1 l/ 8
1 / 8
,003 to .0065
Not Required
/6 t0 l/g
Internal Expanding
External Contracting
Rear of Transmission
7 inch
6 inch
Woven Compressed Asbestos
Moulded Asbestos
2 inch
5/ 32 inch
.015 to .020 inch
Par ki ng Br ake Cabl e Br acket Bol t.
Parking Brake Lever to Instrument Panel.
. . .
Parking Brake Adjusting Bolt Cover, Bolt.
.
Parking Brake Drum Flange Bolt Nut s6. .
3/8 . .
. . . .
756..
Foot-Pounds
20
20
35
50
Rear Wheel Brake Support to Axle Housing, . . . . . . . . . . 35
Tank (Bl eeder)
Gauge [Power Brakes)
Wrench
Ring (Power Brakes)
Pilot (Power Brakes)
Brake Shoe Gauge
Inch-Pounds
130
95
CLUTCH 19
or stands, back off the brake shoe adjusting cams to
the fully released position. (Wheel cylinder cups will
contract and compress trapped air in the bleeder screw
area).
(4) Clean the dirt from all wheel cylinder bleeder
valves.
(5) Attach brake bleeder hose C-650 to the bleeder
valve of each wheel cylinder as they are bled.
(6) Pl ace open end of bl eeder hose i n an uncon-
taminated clear jar. (Clean fluid may be reused).
CAUTION: Water and any type of mineral
oil derivative such as gasoline, engine oil,
etc., will contaminate brake fluid. It is ex-
t remel y important that the container used to
catch the brake fluid be clean, free from mois-
ture and must never have contained mineral
oil in any f or m.
(7) Open brake bleeder and bleed for a minimum
of thirty seconds with a constant air pressure of twenty
five pounds in bleeder tank.
(8) Bleed all wheel cylinders in the following order.
Right rear, left rear, right front lower, right front upper,
left front lower and left front upper.
(9) Remove bleeder adapter and tank.
(10) Determine that reservoir is full and install cover
and gasket.
(11) Readjust al l brake shoes.
5. BRAKE SHOE ADJUSTMENT
Front Wheels
(1) Wi th the vehi cl e el evated and wheel s free to
turn, turn both adjusting cams of the same wheel in
the direction the wheel rotates in a forward motion.
(2) Rotate brake cams i ndependentl y unti l each
brake shoe seats firmly in the brake drum and locks
the wheel. Back off each adjusting cam until no drag
is felt when wheel is rotated.
Rear Wheels
(1) Rotate the front brake shoe adjusting cam in
the direction the wheel rotates in a forward motion un-
til the brake shoe is firmly seated and wheel is locked.
Back off the adjusting cam until no drag is felt when
wheel is rotated.
( 2 ) Rotate the rear brake shoe adjusting cam in the
direction the wheel rotates when in a backward mo-
tion until the brake shoe is firmly seated and the wheel
is locked. Back off the adjustment until no drag is felt
when wheel is rotated.
(3) Apply brakes several times and recheck brakes
for drag.
( 4 ) Recheck fluid level of master cylinder.
NOTE: Use only Heavy Duty Brake Fluid.
GROUP 6
CLUTCH
Servicing procedures for the Clutch Group remain the
same as outlined in the 1960 Plymouth Service Manual.
There are some changes in the Specifications.
SPEClFlCATlONS
Models
Clutch Models. . . .
O u t si d e D i amet er of D i sc.
Number of Springs in Pressure Plate
Type . . . . . . . . . .
6 Cylinder
Borg and Beck
or Auburn
9% in.
10 in. spec. equip.
91/ 4 in. B & B-9 spri ngs
91/ 4 in. Auburn 3 springs
10 in. B & B--9 springs
Single Plate-Dry-
8 Cylinder
Borg and Beck
10 in. Std.
lOI/ in. spec. equip.
10 in. B & B-9 springs
101/ z in. B & B-9 springs
11 in. B & B-12 springs
(361 & 383 cu. in engines)
-Ventilated
20 COOLING SYSTEM
Type
91/4 in. Auburn . . . . . . . . . .
91/4 in. Borg & Beck . . . . . .
10 in. Borg & Beck. . . . . . .
10 in. Borg & Beck. . . . . . .
lOl/, in. Borg & Beck. . . .
11 in. Borg & Beck. . . . . . .

CLUTCH FIXTURE SPACERS
Clutch Assembly
Model Number
Auburn 100131- 1 . . . . . . . . . . . . . .
Borg and Beck 1529........
Borg and Beck 1525. . . . . . . . . . . . . . . . . . . . . . .
Borg and Beck 1505. . . . . . . . . . . . . . . .
Borg and Beck 1506. . . . . . . . . . . . . . . . .
Borg and Beck 1527. . . . . . . . . . . . . . . . .
CLUTCH PRESSURE SPRINGS

Clutch
Assembly
Model No.
100131-1
1529
1525
1505
1506
1527
Number of Springs
and
Identification
3 dark blue
9 orange
9 no paint
9 no paint
6 no paint
3 white
6 no paint
6 orange
Spring Pressure
and
Checking Height
254-280 lbs. @ ls6 in.
165-175 lbs. @ 11/z in.
189-201 lbs. @ 11/2 in.
189-201 lbs. @, 11/z in.
189-201 lbs. @ 11/2 in.
239-251 lbs. @ 11/z in.
189-201 lbs. @ 11/x in.
165175 lbs. @ 11/2 in.
Size
91/4 inches
91/4 inches
10 inches
10 inches
101/2 inches
11 inches
Fixture C-585
Spacer Number
19
18
20
20
42
19
SPECIAL TOOLS
C-585A. Co mpr e s s i ng Fi x t ur e
C-585-32 Block
C-585-33 Cover Support Pl ate
C-647. Testing Fixture
C-730. Pilot Studs
C-860. Reamer
C-869. Arbor
C-870 Arbor
C- 3005. . Tor que Wr e nc h
C-3181 . Bushi ng Instal l er
C-3185.. Bushing Remover
C- 3339. Di a l I ndi c a t o r
TORQUE REFERENCE
Clutch housing to cylinder block screws . . . . . . . . . . . . . .
Clutch cover assembly to flywheel screws
91/4 and 10 in. spec. equip. clutch 5/16 in. bolt. . . . . .
10 and lOl/, in. clutch 3/ in. bolt, . . . . . . . . . . . . . . . .
11 in. clutch 3/8 in. bolt . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission to clutch housing screws . . . . . . . . . . . . . . .

.........
.........
.........
.........

Foot-Pounds
50
15
30
30
40
GROUP 7
COOLI NG AND ACCESSORY BELT DRI VES
The Cooling System servicing procedures remain the erence.
same as outlined in the 1960 Plymouth Service Manual NOTE: The component parts of the 225 cu.
with the following exceptions: in. engine water pump are not serviced sep-
a. Servicing the fluid fan drive. arately. Therefore, if replacement of internal
b. Thermostat removal, testing and installation. parts are required, replace the water pump
c. Changes in Specifications, Tools and Torque Ref- assembly.
COOLING SYSTEM 21
Engine Type
CAPACITY
With Heater . . .
Wi thout Heater. . . . .
RADIATOR TYPE .
TRANSMI SSI ON OI L COOLER
(with Auto. Transmission)
T y p e
L o c a t i o n
RADIATOR PRESSURE CAP
Type . .
Pressure Setting.
FAN
No. of Blades. . .
D i a m e t e r . .
FLUID FAN DRIVE TYPE.. ,
(with Air Conditioning)
THERMOSTAT
T y p e .
Setting
WA TER PUMP TY PE:::::::. . ::::
RADI ATOR TO FAN CLEARANCE,
RADIATOR TO FAN CLEARANCE
F A N S H R O U D T Y P E . .
SPECIFICATIONS
225 cu. in.
14 qts.
13 qts.
Tube & Spacer
318 cu. in. 361-383 cu. in.
21 qts. 17 qts.
20 qts. 16 qts.
Tube & Spacer Tube & Spacer
Concentric Tube Concentric Tube Concentric Tube
Rad. Bottom Tank Rad. Bottom Tank Rad. Bottom Tank
Pressure Vent
14 psi
4
17 in.
Pressure Vent Pressure Vent
14 psi Std.-16 psi A.C. 14 psi Std.- ~-16 psi A.C.
4 Std.-7 A.C. 4 Std.-7 A.C.
18 in. 18 in.
Silicone Fluid
Filled Modulating
Speed
Pellet
180F.
Centrifugal
Ball Bearing
3/4 in. + l/ 4 in.
Pellet Pellet
180F. 180F.
Centrifugal Centrifugal
Ball Bearing Ball Bearing
3/4 in. i l/ 4 in. 3/4 in. t l/ d in.
3/4 in. + l/ 4 in. 1 in. * 5/4 in.
Box Box
SPECIAL TOOLS
C-412. Puller-Fan Hub
C- 3250 Pl i er s - - H ose Cl amp
C - 3 4 6 8 . . Installer -Water Pump Bearing and Shaft
C-3476.. Pul l er---I mpel l er Metal I nsert
C- 3499. . Gauge- Pr essur e Testi ng
C - 3514. . G u n - F l u sh i n g
C-3832.. Adjusti ng--Power Steeri ng Pump Bel t
C - 3 8 4 1 Adjusting Alternator Belt
TORQUE REFERENCE
Foot-Pounds
Water Pump Bolts. . . . . . .
Fan Attaching Bolts
Thermostat Housing Bolts, .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16m-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1. FLUID FAN DRIVE
The fluid fan drive unit is a silicone fluid filled cou-
pling connecting the fan to the fan pulley. The unit is de-
signed to provide the necessary driving force to main-
tain cooling at low speeds and to limit the top fan speed
at high engine speeds, thus making more power avail-
able to the rear wheels and eliminating fan noise that
might otherwise be encountered with the large seven
blade fan.
The fan drive should not be serviced. Replace if de-
fective.
22
COOLING SYSTEM
2. TESTING THE FLUID FAN DRIVE
Overheating
If the fan drive operates below its minimum design
speed, engine overheating may result at low car speeds.
Check as follows:
(1) Cooling system must be at room temperature
for test.
(2) Mark fan blade with white or yellow chalk or
crayon.
(3) Attach timing light to engine, set engine speed
to about 1700 rpm, and then adjust engine speed until
fan blade mark is stopped by timing light.
(4) The drive should be replaced if the engine
speed at which the fan is stopped is below 1550 rpm.
Excessive Fan Noise
If the fan drive fails to properly limit the top fan
speed, excessive fan noise may result. Check as fol-
lows :
( 1) Check engine speed at which timing light stops
the fan as in Overheating above.
(2) The drive should be replaced if the engine speed
at which the fan is stopped is above 1800 rpm.
3. THERMOSTAT
The thermostat is actuated by a pellet containing a
copper-impregnated wax. As the temperature of the
pellet increases, the wax expands and opens the valve.
A 180 thermostat is standard equipment. With this
thermostat, ethylene glycol base permanent type anti-
freeze must be used. If an alcohol type anti-freeze is
desired, a 160 thermostat must be installed.
If the thermostat does not close completely when
cold, the engine will warm up slowly and heater per-
formance may be inadequate. Poor heater performance
may also be due to the valve opening at too low a
temperature. Too high a valve opening temperature or
a valve that will not open can cause overheating.
Thermostat Removal
( 1) Drain the cooling system down to thermostat
level or below.
(2) Remove the upper hose from the thermostat
housing using pliers C-3250.
(3) Remove thermostat housing bolts and remove
thermostat and housing.
Thermostat Testing
(1) Visually inspect thermostat to make sure valve
closes tightly. If valve does not close completely due
to dirt, sand, or other foreign material, clean valve and
seat. If valve does not close tightly when clean, install
a new thermostat.
(2 ) Gently force the valve open and insert a l/8
wide strip of .003 feeler stock into the opening and
allow the valve to close. If the feeler stock will not
hold in place, discard the thermostat.
(3) Suspend the thermostat, by the feeler stock
strip, in a container of water. Make sure the thermo-
stat does not touch the sides or bottom of container.
(4) Heat the water (stir the water continuously to
insure uniform temperature) and check the water
temperature at which the thermostat falls off the feeler
strip. Do not touch the sides or bottom of the container
with the thermometer. The thermostat should drop off
at a water temperature of from 175 to 185. If it is
outside of this range discard it.
(5) The thermostat valve should be wide open (ap-
proximately 45 angle) at a water temperature of
from 195 to 205. Discard the thermostat if it is not
within this range.
Thermostat Installation
( 1) Using a new gasket, position the thermostat so
that the pellet end is toward the engine and attach with
bolts through the thermostat housing.
(2) Fill the cooling system to 1% inches below filler
neck with water and rust resistor or water and anti-
freeze.
4. PROPER BELT TENSION
The satisfactory performance of the belt driven ac-
cessories depends on the maintenance of the proper
belt tension. If the specified tensions are not main-
tained, belt slippage may cause engine overheating,
lack of power steering assist, loss in air conditioning
capacity, reduced alternator charging rates, and great-
ly reduced belt life. To avoid any such adverse ef-
fects, the following service procedure should be fol-
lowed
(1) Retighten all belts to the specified used belt
tension at new car preparation. See Belt Tension Speci-
fications.
(2) Retighten all belts at the 2,000 mile check-up.
(3) Check all belts by the torque or deflection
method at servicing and retighten if needed.
(4) The new belt tension specifications should be
used on all belt replacements.
NOTE: Any belt that has operated for a
minimum of a half-hour is considered to be
used.
There are two methods by which belt tensions can
be properly established.
5. TORQUE METHOD
All alternator and power steering pump belts can be
r -
.
;
COOLING SYSTEM 23
tightened to the specified tension (see Specifications) Other belts can also be tightened by this method if
by use of a torque wrench. The alternator belts are ten-
si oned by usi ng Speci al Tool C-3841 and a torque
the adjusting bracket has a square hole. To tighten
wrench. The power steering belts are tightened by in-
belts by the torque method, loosen all mounting bolts
serting the torque wrench in the square hole provided
and appl y the speci fi ed torque to the accessory or
in the pump mounting bracket on the 225 and 318 cu.
idler. Tighten all mounting bolts while the torque is
in. engines, and by using Tool C-3832 and a torque
applied to the accessory. If it is not possible to use the
wrench on the 361 cu. in. engine. torque wrench because of clearance, use an extension.
BELT TENSI ON SPECI FI CATI ONS-225 Cu. I n. ENGI NE
TORQUE METHOD
Torque (ft.-lbs.) to be applied to components
ACCESSORY NEW BELT
POWER STEERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . 80
ALTERNATOR , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BELT TENSI ON SPECI FI CATI ONS-318 Cu. I n. ENGI NE
TORQUE METHOD
Torque (ft.&s.) to be applied to components
ACCESSORY NEW BELT
POWER STEERING BRACKET. . . . . . . . . . . . . . . . . . . . 70
ALTERNATOR
With Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Without Air Conditioning, . . . . . . . . . . . . . . . . . . . . . . 30
A/ C IDLER BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FAN IDLER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
BELT TENSI ON SPECI FI CATI ONS-361 CU. I N. ENGI NE
TORQUE METHOD
Torque (ft.-lbs.) to be applied to components
ACCESSORY NEW BELT
POWER STEERING BRACKET. . . . . . . . . . . . . . . 45
ALTERNATOR
With Air Conditioning. . . . . . . . . . . . . . . . . . . . . 100
Without Air Conditioning . . . . . . . . . . . . . . . . . . . . . . 30
FAN IDLER . . . . . . . . . . . . . . . . . . . . . . . . 50
,
*Any belt that has operated for a minimum of a half-hour is considered to be used.
USED BELT*
45
20
USED BELT*
50
10
20
40
30
USED BELT*
45
65
20
35
6. DEFLECTI ON METHOD
sible to use the torque method, as it is a less accurate
All belts can also be tightened by measuring the de-
substitute. To tension the belts by the deflection method,
flection of the belt at the mid-point between two pulleys
loosen all mounting bolts and use a bar to apply ten-
under a five-pound push or pull. A small spring scale
sion to the belts being careful not to damage the ac-
can be used to establish the five-pound load. See Fig-
cessory. Tighten the mounting bolts and check the de-
ure 1 for correct location at which to measure deflec-
flection. (See Belt Tension Specifications). It may be
tion.
necessary to repeat this procedure several times to
This method should be used only when it is not pos- establish the correct tension.
24
COOLING SYSTEM
BELT TENSION SPECIFICATIONS
Belt Deflection Method
Def l ec t i on (I nc hes) To Be Appl i ed at Mi dpoi nt Of
Bel t Segment Under a 5 l b. l oad. See Fi g. 1
ACCESSORY
USED BELT*
225 318 361-383 225
Cu. In. Cu. In. Cu. In. Cu. In.
Power Steering . . . . 343 543
%6 1%
Fan Belt Idler . . . . . . . .
3/16
Vi3
A l ter nator - Wi thout A/ C. . l/ 4 l/ 4 vi
%2
W i t h A / C . . - %6
-
A/ C Belts.. . . . . . . . . . . - l/ 4 3/ s
*Any belt that has operated for a minimum of a half-hour is considered to be used.
NEW BELT
318
Cu. In.
/;6
%2
%2
X3
A3
361-383
Cu. In.
%6
%6
%2
l/ 4
Fi g. l -Bel t Def l ec t i on l oc at i ons
i
ELECTRICAL-INSTRUMENTS 25
GROUP 8
ELECTRI CAL
Listed are the new Electrical Service Procedures and plicable. All other Service Procedures remain the same
Specifications for the 1961 Plymouth cars. The new
as outlined in the 1960 Service Manual.
procedures also apply to the 1960 models where ap-
BATTERY
The 1961 standard equipment battery for all models pl ate-70 ampere hour-12 vol t battery as opti onal
is a 9 plate-50 ampere hour-12 volt battery, with a 13
equipment.
SPECIFICATIONS
All Models
V ol tage . .
Capacity. . . . . . . . . . .
Ground Terminal
Number of Plates. . . . . . . . . . .
Model . . . . . . . . . .
12 volts
50 Ampere Hour
Negative
9
Auto-Lite 11 -HS-SOB
Standard-Wi l l ard MB-2450
Gould-National 1 lB-OE-50
Optional&Auto-Lite 12HB-70B 13 plate-70 Amp. Hr.
Willard MB-27-70-13 plate-70 Amp. Hr.
STARTING MOTOR
Listed are new Service Procedures and Specifications Built Starting Motor remain the same as outlined in the
coveri ng the Chrysl er Bui l t Sol enoi d Shi ft Starti ng 1960 Plymouth Service Manual.
Motor. Service Procedures for the Folo-Thru Auto-Lite
Car Model Usage. . . . . . . . . . . .
Starter Model. . . . . . . . . . . .
Voltage . .
N o. of Fi el ds.
N o . o f P o l es .
Brushes. . . .
Spri ng Tensi on.
Drive. . . . . . .
.
.
.
SPECIFICATIONS
(CHRYSLER BUILT STARTER)
. . . . . . . . . . . . ..............
. . . . . . . . . . . . .
RP2
1889100 (318 Cu. In. Eng.)
1889200 (361-383 Cu. In. Eng.)
.
. .
. .
. .
. .
. .
. .
End Play. . . . . . . . . . .
Free-Running Test
Voltage. . . . . . . . . . . .
Amperage Draw. . . . . . .
Mi ni mum Speed rpm. . . .
......
......
......
......
......
......
.
.

12
4
4
4
32 to 48 ounces
Solenoid Shift
Overrunning Clutch
.005 Minimum
11
78 Amps. Maximum
3800 Minimum
26
Stall Torque Test
ELECTRICAL-INSTRUMENTS
Torque Foot-Pounds, . . . . . . . . . . . . . . . . . . 8.5
Voltage. . . . . . . . . . . . . . . . . . . . . . . 4
Amperage Draw, . . . . . . . . . . . . . . . . . 350
Pinion to Housing Clearance. . . . . . . . . . . . . . . l/ 8 plus or minus Y32
Between Pinion Stop and End of Pinion
Solenoid Switch
Pul l - i n Coi l . . . . . . . . . . . . . . . . 20.0--22.2 Amps at 6 volts
Hold-in Coil, . . . . . . . . . . . . . . . 11.2-12.4 Amps at 6 volts
SERVICE DIAGNOSIS
1. STARTER FAILS TO OPERATE
(1) Weak battery or dead cell in battery.
(2) Ignition switch defective.
(3) Loose or corroded battery cable terminals.
(4) Open ci rcui t, wi re between i gni ti on-starter
switch and ignition terminal on starter relay.
(5) Defective drive unit.
(6) Defective solenoid or solenoid switch.
(7) Defective starting motor.
(8) Armature shaft sheared.
2. STARTER FAILS AND LIGHTS DIM
( 1) Weak battery or dead cell in battery.
(2) Loose or corroded battery cable terminals.
(3) Internal ground in windings.
(4) Grounded starter fields.
(5) Armature rubbing on pole shoes.
3. STARTER TURNS, BUT PINION
DOES NOT ENGAGE
(1) Starter clutch slipping.
(2) Wrong starter pinion clearance.
(3) Broken teeth on flywheel drive gear.
(4) Armature shaft rusted, dirty or dry, due to lack
of lubrication.
4. STARTER RELAY DOES NOT CLOSE
( 1) Battery discharged.
(2) Defective wiring.
(3) Neutral starter switch on automatic transmission
faulty.
(4) Check starter rel ay.
(5) Check ignition-starter switch.
5. RELAY OPERATES BUT SOLENOID
DOES NOT
(1) Faulty wiring, open circuit wire between starter-
rel ay and sol enoi d termi nal and sol enoi d actuati ng
terminal post.
(2) Faulty solenoid switch or connections.
(3) Solenoid switch contacts corroded.
(4) Broken lead or loose soldered connection inside
solenoid switch cover.
6. SOLENOID PLUNGER VIBRATES BACK
AND FORTH WHEN SWITCH IS
ENGAGED
(1) Battery low.
(2) Faul ty wi ri ng.
(3) Lead or connecti ons broken i nsi de sol enoi d
switch cover or open hold-in winding.
(4) Sol enoi d defecti ve.
(5) Check condition of moisture on solenoid con-
tacts (cold weather conditions).
7. STARTER OPERATES BUT WILL. NOT
DISENGAGE WHEN IGNITION-STARTER
IS RELEASED
(1) Broken solenoid plunger spring or spring out
of position.
(2) Defective ignition-starter switch.
(3) Defecti ve sol enoi d.
(4) Pinion clearance improperly adjusted.
(5) Solenoid plunger stuck in solenoid.
(6) I nsuffi ci ent cl earance between wi ndi ng l eads
and main contactor in solenoid.
(7) Defecti ve rel ay.
1. DESCRIPTION
ment can be made by removing the commutator bear-
The Chrysler Corporation built starter motor is a 12
ing end head.
volt four-coil assembly. The starter drive is an over- 2. TESTING STARTER CURRENT RESISTANCE
running clutch type with a solenoid shift type switch
AND CURRENT DRAW
mounted on the starter motor.
(1) Test battery. If it tests I.210 specific gravity or
The brush holders are riveted to a separate brush less, engine at normal operating temperature, charge
plate and are not serviced separately. Brush replace- battery.
27
(2) Test circuit resistance and starter current draw.
(3) Disconnect the positive battery lead from bat-
_ tery terminal post. Connect an 0 to 300 scale ammeter
between disconnected lead and battery terminal post.
(4) Connect a test voltmeter with .lO volt scale di-
visions between battery positive post and starter switch
terminal at starter.
(5) Crank engine cmd observe readings on volt-
meter and ammeter. The voltage should not exceed .12
volt per 100 amperes of current. The current should not
exceed 150 to 250 amperes. A reading of voltage that
exceeds .12 volt per 100 amperes indicates there is
high resistance caused from loose circuit connections,
defective cable, burned switch contacts or, in some
instances, a short in starter which causes a voltage
leak. A current that is high and is combined with slow
cranking speed, indicates that starter should be re-
moved and repaired.
3. REMOVAL OF STARTI NG MOTOR
( 1) Disconnect cable at battery.
(2) Remove starter cable at starter.
(3) Disconnect solenoid lead wire from solenoid.
(4) Remove the bolts attaching the starting motor
to the flywheel housing and remove the starter motor
and housing seal.
4. TESTI NG THE STARTER MOTOR
( BENCH TEST)
Free Running Test
( 1) Place starter in vise and connect a fully-charged,
12 volt battery to starter as follows:
(2) Connect a test ammeter (100 amperes scale)
and carbon pile rheostat in series with battery posi-
tive post and starter terminal.
(3) Connect voltmeter (15 volt scale) across starter.
(4) Rotate carbon pile to full-resistance position.
(5) Connect battery cable from battery negative
post to starter frame.
(6) Adjust rheostat until battery voltage shown on
voltmeter reads 11 volts.
(7) The current draw should be 78 amperes maxi-
m u m at 3800 minimum rpm.
Stall Test
( 1) Install starter motor in test bench.
CAP
I \ FORK
BRUSH SET- - - \
I
;I
H&J SlNG
CLUTCH
Y
1 1
WASHERA
WASHER
BRUSH SPRING
I)
\
POLE PIECE
iCREW
FRAME
Fi g. I -St art i ng Mot or (Ex pl oded Vi ew) (Typi c al )
6 1 x l 8
SHIFTER FORK
.
\
\ STOP RETAINER
SNAP RING
SPACER WASHER
61x23
Fi g. & Removi ng or I nst al l i ng Shi f t er Fork
will wash lubrication from clutch.
(3) The drive unit may be cleaned with brush moist-
ened with cleaning solvent and wiped dry with cloth.
7 . BRUSHES AND SPRI NGS-REPLACEMENT
(1) Brushes that are worn more than % the length
of the new brush, or are oil-soaked, should be replaced.
The brushes and springs can be replaced after remov-
ing the commutator end head and brush plate.
(2) Lift the brushes, disengage the brushes from the
brush holders and remove the brush plate.
(3) Disconnect field lead wires at solenoid con-
nector (Fig. 3).
(4) Remove the screw attaching the ground brush
terminal to the field frame and raise the brushes and
terminal up and away from the field frame (Fig. 7).
NOTE. The leads are not equal in length.
Check brush leads before cutting to insure
proper length at installation.
Fi g. 7-Removi ng or I nst al l i ng Ground Brushes
Ter mi nal
(5) Clip the brush leads at the ground terminal and
at the field coils.
(6) Open the brush lead clips to remove the old
brush leads.
(7) When resoldering the brush leads, make a
strong, low resistance connection using a high tem-
perature solder and resin flux. Do not use acid. DO
not break shunt wire when removing and installing
ground brushes.
(8) Brush springs can be removed by spreading the
retainers and disengaging the springs from the re
tainer legs.
(9) Measure the brush spring tension with a spring
scale hooked under the spring near the end. Pull the
scale on a line parallel to the edge of the brush and
take a reading just at the spring end leaves the brush.
Spring tension should be 32 to 48 ounces. Replace
springs that do not meet specifications.
8. TESTI NG THE ARMATURE
Test i ng t he Ar mat ur e f or Shor t Ci r c ui t
Place armature in growler (Fig. 8) and hold a thin
steel blade parallel to core and just above it, while
slowly rotating armature in growler. A shorted arma-
ture will cause blade to vibrate and be attracted to
core. Replace a shorted armature.
Test i ng Armat ure f or Ground
Touch armature shaft and end of a commutator bar
with a pair of test lamp prods (Fig. 9). If lamp lights,
it indicates a grounded armature. Replace grounded
armature.
Test i ng Commut at or Run-Out , Ref ac i ng
Place armature in pair of V blocks and check run-
out with dial indicator. Check both shaft and commuta-
tor. A. bent shaft requires replacement of armature.
Fi g. 8-Test i ng Armat ure f or Short
Pole shoes that are loose and not properly seated may
cause armature core to rub pole shoes. This will de.
crease starter efficiency and damage the armature
cor e.
11. SERVI CI NG THE BUSHI NGS
Inspect armature shaft bearing surfaces and bush-
ings for wear by placing core in vise equipped with
soft jaws. Do not squeeze tightly. Try commutator end
frame, the drive end frame, and armature support
bushings for wear by placing them on shafts and
checking for side play. Replace commutator end
frame and bushing assembly if bushing is worn. Also,
replace drive end bushing if it is worn. The bushing
should be well soaked in SAE 30-W engine oil before it
is installed.
12. SERVI CI NG THE DRI VE UNI T
Place drive unit on shaft and, while holding arma-
tu-e, rotate pinion. The drive pinion should rotate
smoothly in one direction (not necessarily easily),
but should not rotate in opposite direction. If drive unit
does not function properly, or pinion is worn or burred,
replace drive unit.
13. ASSEMBLI NG THE STARTER
(Ref er t o Fi gure 1)
( 1) Lubricate the armature shaft and splines with
SAE 10-W oil or 30-W rust preventative oil.
(2) Install the starter drive, stop collar (retainer),
the lock ring and spacer washer.
(3) Install shifter work over the starter drive spring
retainer washer with narrow leg of fork toward com-
mutator (Fig. 6). This is important, if fork is not prop-
.erly positioned, the starter gear travel will be re-
stricted causing a lockup in the clutch mechanism.
(4) Install drive end (pinion) housing on arma-
ture shaft, indexing shifting fork with slot in drive end
housing.
(5) Install shifter fork pivot pin (Fig. 5).
(6) Install armature with clutch drive, shifter fork,
and pinion housing, slide armature into field frame
until pinion housing indexes with slot in field frame.
(7) Install the solenoid and boot assembly (Fig. 4).
Tighten bolts to 60-70 inch pounds torque.
(8) Install the ground brushes (Fig. 7).
(9) -Connect the field coil leads at the solenoid con-
nector (Fig. 3).
( 10) Install the brush holder ring (Fig. 2) indexing
tangof ring in hole of field frame.
(11) Position the brushes in brush holders. Be sure
the field coil lead wires are properly enclosed behind
the brush holder ring and that they do not interfere with
the brush operation.
61x28
Fig. 13-Checking Starter Drive Pinion Clearance
(12) Install thrust washers on commutator end of
armature shaft to obtain .010 inch minimum end play.
(13) Install commutator end head.
(14) Install through bolts and tighten to 40 to 50
inch-pounds.
14. ADJ USTI NG STARTER DRI VE GEAR
(PI NI ON) CLEARANCE
( 1) Place starter assembly in vise equipped with
soft jaws and tighten vise sufficiently to hold starter.
NOTE: Place a wedge or screwdriver be-
t ween the bottom of the solenoid and the
starter frame to eliminate all deflection in the
solenoid when mak i ng the pinion clearance
check.
(2) Push in on solenoid plunger cage (Fig. 13)
(NOT THE FORK LEVER) until plunger bottoms.
(3) Measure clearance between end of pinion and
pin stop with plunger seated and pinion pushed toward
commutator end. The clearance should be / s inch. Ad-
just for proper clearance by loosening solenoid at-
taching screws and move solenoid fore and aft as re-
quired.
(4) Test starter operation under a free running test
(Paragraph 4).
15. I NSTALLI NG THE STARTER
(1) Before installing starter, be sure starter and fly-
wheel housing mounting surfaces are free of dirt and
oil. These surfaces must be clean to make good elec-
trical contact.
(2) Install starter to flywheel housing seal.
(3) Install starter from beneath the engine.
(4) Tighten attaching bolts securely.
(5) Attach wires to solenoid switch or starter ter-
minal.
(6) Install battery cable and test operation of starter
for proper engine cranking.
32 ELECTRICAL-INSTRUMENTS
ALTERNATOR AND VOLTAGE REGULATOR
Servicing Procedures and Specifications for the 1961 Plymouth Alternator and Voltage Regulator are new.
ALTERNATOR SPEClFlCATlONS
Special Equipment
Standard Equipment (Heavy Duty)
Engine . . . . . . . . . . 170-225 cu. in. 170-225 cu. in.
Alternator Number 2095060 2095425
Rated Output 35 Amperes 40 Amperes
Voltage. 12 Volts 12 Volts
Alternator Pulley Diameter 2.75 in. Single Groove 2.75 in. Single Groove
Brushes _........ 2 2
Condenser Capacity .5 microfarad (minimum) .5 microfarad (minimum)
Fi el d Coi l Draw . 2.38 amperes minimum to 2.75 amperes maximum
at 12 volts, rotating alternator by hand; or 2.97
amperes minimum to 3.43 amperes maximum at 15
volts at 70 degrees Fahrenheit, alternator operating
at 750 R.P.M.
Current Output
(Minimum) at 1250
Engine R.P.M. (cold) 35 Amperes 40 Amperes
ALTERNATOR SPECIFICATIONS
Special Equipment
(Heavy Duty)
Standard Equipment Air Conditioning
E n gi n e 318 cu. in. 318 cu. in.
Alternator Number 2095060 2095425
V ol tage. 12 Volts 12 Volts
Alternator Pulley Diameter . . . . . . . . . . 2.75 in. Single Groove 2.75 in. Single Groove
B r u s h e s . 2 2
Condenser Capacity .5 microfarad (minimum) .5 microfarad (minimum
Field Coil Draw ..,...,... ..___,..,.,...... 2.38 amperes minimum to 2.75 amperes maximum
at 12 volts, rotating alternator by hand; or 2.97
amperes minimum to 3.43 amperes maximum at
15 volts at 70 degrees Fahrenhert, alternator op-
erating at 750 R.P.M.
Current Output
(minimum) at 1250
engine R.P.M. (cold) . 35 Amperes
40 Amperes
ALTERNATOR SPECIFICATIONS
Special Equipment Special Equipment
Standard Equipment Heavy Duty
Air Conditioning
Engi ne. 361-383 cu. in. 361-383 cu. in.
361-383 cu. in.
A l t e r n a t o r N u mb e r . 2095060 2095425 2095100
40 Amperes
ALTERNATOR SPECIFICATIONS (Cont d)
Special Equipment Special Equipment
Standard Equipment Heavy Duty Air Conditioning
Voltage . . 12 Volts 12 Volts 12 Volts
Alternator Pulley Diameter 2.75 in. Single Groove 2.75 in. Single Groove 3.00 in. Twin Groove
B r u s h e s . 2 2 2
Co nde ns e r Capac i t y . .5 microfarad (min.) .5 microfarad (min.) .5 microfarad (min.)
Field Coil Draw
2.38 amperes minimum to 2.75 amperes maximum at 12 volts, rotating alterna-
tor by hand; or 2.97 amperes minimum to 3.43 amperes maximum at 15 volts at
70 degrees Fahrenheit, alternator operating at 750 R.P.M.
Current Output
(minimum) at 1250
engine R.P.M. (cold) 35 Amperes 40 Amperes 40 Amperes
Alternator Voltage
VOLTAGE REGULATOR SPEClFlCATlONS
R e g u l a t o r N o . 2095700
Volts, . . 12
Gr o und Po l ar i t y . Negative
Point Gap .015 inch plus or minus ,001 inch
Air Gap.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,048 to ,052 inch
Measure gap with gauge back of stop. Contacts closed with ,052 inch gauge installed. Con-
tacts open with .048 inch gauge installed.
Start and operate the engine at 1250 r.p.m. Turn on the lights and electrical accessories
to create enough electrical load, that 15 minutes of operation will stabilize the regulator tem-
perature. Measure the temperature at the regulator by holding a reliable thermometer two (2)
inches from the regulator. Turn off the lights and other electrical load. Read the test voltmeter.
With a fully charged battery and 15 amperes flowing in the circuit, the voltmeter reading
should be within the specifications shown in the chart below.
TEMPERATURE
IN DEGREES 0 25 48 70 95 118 140
Mi ni mum Setting 14 13.9 13.8 13.7 13.6 13.5 13.4
t o t o t o t o t o t o t o
Maxi mum Settinq 14.6 14.5 14.4 14.3 14.2 14.1 14.0
c-744. .
C- 828.
SP-3375.
SP-3380.
SP-3381.
SP-3383.
C-3615.
C-3769.
c-3770.
c-3771
C-3772.
SPECIAL TOOLS
Test Lamp
Voltage Regulator Tool Kit (Insulate the Bending Tool)
Adapters--Bearing Remover
Remover-Rectifier
Installer-Rectifier End Housing Bearing
Support-Bearing Remover
Remover-Pulley
Installer-Drive End Housing Bearing
Remover -Rectifier End Housing Bearing
Remover--Support Bearing
Installer-Rectifier
,
/
I
I
/
I
t
/
I
/
I
I
I
/
I
35
UOPER CONTACT
61X232
Fi g. 3-Volt age Regul at or (Cover Removed)
molded plastic bracket which is attached to the regu-
lator frame by two screws. The upper contact bracket
is connected to the IGN terminal by a fusible wire
(Fig. 4). The lower contact bracket is connected to
ground by a fusible wire. The armature is connected
to the insulated FLD terminal.
The main components of the alternator are the two
end shields, the stator, the rotor and the rectifiers. The
two end shields are held together by three through
bolts. The shields are vented at both ends and around
the outer diameter. Cool air is drawn in through the
ends and out over the stator windings through the
outer diameter vents. The stator assembly consists of
an internally-slotted laminated stationary armature
having three sets of windings, one end of each of the
windings is connected in parallel to one positive
case rectifier, and to one negat i ve case rectifier and
is sandwiched in between the two end shields (Fig. 5).
The rotor (Fig. 6) consists of a circular field coil en-
cased between the two six fingered, overlapping sec-
J PPER FUSIBLE WIRE
\
ADJUSTABLE
BRACKET
J
LOWER CONTACl
& /FUSIBLE WI RE
r
FUSIBLE WIRE
BRACKET
ATTACHING
SCREW
,IL WIRES
61X235
Fi g. 4-Vol t age Regul at or Fusi bl e Wi r es
4 / HEAT SINK
ATIVE
TIFIERS
STATOR
>
: INSULATED
-RECTIFIER
Fi g. 5-St at or and Rec t i f i er End Shi el d Assembl y
tions which are the pole pieces. The rotor produces an
effective 12 pole rotating magnetic field. The ends of
the field coil windings are connected to slip rings at
the rear end of the rotor. The battery current is sup
plied to the field coil windings through the ignition
switch, the regulator, the brushes, and the slip rings.
The rotor shaft is supported at the drive end by a
pre-lubricated ball bearing. At the opposite end, the
rotor shaft is supported by a prelubricated roller bear-
ing.
In the alternator, the alternating current is converted
to direct current through ,six silicon rectifiers (Fig. 5).
Three of the rectifiers have negative polarity cases and
are pressed into the die cast aluminum end shield.
These rectifiers are in the ground side of the system.
The remaining three rectifiers have positive polarity
cases and are pressed into a die cast aluminum heat
sink. The heat sink is electrically insulated from the
end shield but has sufficient area to absorb the heat
from the rectifiers that are pressed into it.
INGS
Fi g. &Rot or Assembl y
36 ELECTRICAL- INSTRUMENTS
Silicon rectifiers have a very high resistance to the
flow of an electrical current in one direction, but a very
low resistance in the opposite direction. Therefore with
the proper polarity, the low resistance allows current
to flow from the alternator to the battery. The high re-
sistance prevents current from flowing from the battery
to the alternator. Because of the high resistance which
does not allow current to flow from the battery back
through the alternator, no circuit breaker is required
as in the D.C. regulator. The alternating current is
converted by the rectifiers to direct current and flows
into the battery circuit.
CAUTION: When installing a battery, al-
ways be sure the negative post of the battery
only is connected to ground. A battery that is
installed and connected backwards may re-
sult in burning out the rectifiers.
2. TESTING THE ALTERNATOR SYSTEM
(On Vehi c l e)
With the battery fully charged and in good condition
and engine at normal operating temperature, proceed
with the test as follows:
CAUTION: Never ground the alternator field
circuit as this will result in damage to the
voltage regulator.
Charging Circuit Resistance Test
( 1) Disconnect the wire from the BAT terminal
of the alternator.
(2) Connect a O-50 ampere scale D.C. test ammeter
in series with the alternator BAT terminal and the
wire which was disconnected from the alternator
BAT terminal.
NOTE: The ammeter leads and the test am-
meter must be in good condition and all con-
nections should be clean and tight.
(3) Connect a voltmeter (calibrated in tenths) posi-
tive lead to the BAT wire that was disconnected from
the alternator and connect the voltmeter negative lead
to the battery positive post.
(4) Start the engine and adjust the engine speed to
produce 10 amperes from the alternator. The voltage
reading should not exceed .2 volt. If there is higher
voltage drop, clean and recheck charging circuit re-
sistance. A voltage drop test across each connection
will locate any bad connections.
Current Output J est
( 1) Disconnect the battery ground cable.
(2) Disconnect the field lead at the alternator and
at the regulator.
(3) Connect a O-50 ampere scale D.C. test am-
meter in series with the alternator BAT terminal and
the wire disconnected from the alternator BAT ter-
mi nal .
(4) Connect a jumper between the alternator BAT
terminal and the alternator field terminal.
(5) Connect battery-starter tester (equipped with a
carbon pile rheostat) across the battery.
(6) Connect the test voltmeter positive lead to the
alternator BAT terminal and ground the test volt-
meter negative lead to the alternator housing.
(7) Connect the battery ground cable.
(8) Install a tachometer, start the engine and ad-
just the engine speed to 1250 rpm.
(9) Adjust carbon pile to maintain 15 volts on test
voltmeter while making tests. Turn off immediately
when test is completed. The current output should be
within the limits shown in Specifications. If the out-
put is slightly lower (3 to 4 amperes) it may be an in-
dication of a possible open rectifier or other alter-
nator internal problems. If the output is considerably
lower, it may be an indication of a possible shorted
rectifier or other alternator internal problems. In either
case the alternator should be removed and tested on
the bench before disassembly.
Before the alternator is removed and while the am-
meter is connected in circuit it is possible to test the
rotor field current draw. Stop the engine. Note the re-
verse current reading on the ammeter, and the battery
voltage reading on the voltmeter. The rotor field coil
draw should be 2.38 amperes to 2.75 amperes at 12
volts. If the test ammeter does not have a reverse cur-
rent scale, reverse the test ammeter leads at the out-
put terminal and field terminal on the alternator.
A low rotor field coil draw is an indication of high
resistance in the field coil circuit; may be brushes,
slip rings or field coil connections. A high rotor field
coil draw indicates a possible shorted field coil.
Voltage Regulator J est (On Vehicle)
( 1) Disconnect jumper lead from the alternator
field terminal and BAT terminal.
(2) With engine at normal operating temperature,
connect the test ammeter in series with the alternator
BAT terminal and the wire disconnected from alter-
nator BAT terminal.
(3) Connect the test voltmeter positive lead to the
alternator battery BAT terminal and ground the volt-
meter negative lead to the alternator housing or reg-
ulator base.
NOTE: No current reading on test ammeter
would indicate a blown fuse wire inside of
the voltage regulator between the upper sta-
tionary contact and the IGN terminal. The
new fusible wires must be securely soldered
at upper and lower connections (Fig. 4).
(4) Start the engine and adjust the engine speed to
1250 rpm and with ammeter reading 10 amperes by
turning on lights etc. Operate for 15 minutes to stabi-
37
TEMPERATURE
IN DEGREES 0 25 48 7o 95 118 140
Minimum Setting 14 13.9 13.9 13.7 13.6 13.5 13.4
t0 to to t0 to to to
Maxi mum Setting 14.6 14.5 14.4 14.3 14.2 14.1 14.0
lize the temperature (cover in place). Temperature
checked with a reliable thermometer 2 inches from the
cover. With engine speed at 1250 R.P.M. and with
15 amps flowing in the circuit, voltage should be as in
the above chart.
(5) Increase engine speed to 2200 R.P.M. with 5
amps flowing in the circuit, voltage should not exceed
previous readings by more than .7 volts.
NOTE: There will be a slightly higher voltage
at higher engine speeds, however this in-
creased voltage must not exceed .7 volt at
any temperature range. If the voltage reading
is considerably less than the values shown in
the chart, t est t he battery specific gravity to
be sure battery is fully charged. If the volt-
age reading is mor e than .7 volt, the regula-
tor is improperly adjusted or ground side fuse
wire is blown.
.
Some test equipment include a 1/ 4 ohm fixed re-
sistance that may be placed in the charging circuit,
which in effect will simulate a fully charged battery.
Be sure to follow the test equipment manufacturers
recommendations, for the use of the r/ 4 ohm fixed re-
sistor, when testing the Chrysler Corporation built
alternator.
If the regulator setting is outside.the limits shown on
the chart, the regulator must be removed to remove
the cover. To adjust the voltage setting, bend the reg-
ulator lower spring hanger down to increase the
voltage setting, or up to decrease the voltage setting.
Use an insulated tool (Fig. 7) to bend the spring
hanger. Do not short circuit between t he spring
hanger and the base or spring. Grounding
the spr i ng hanger will damage the regulator.
NOTE: If repeated readjustment is required
it is permissible to use a juniper wire to
ground the regulator base to fender splash
shield for testing, in lieu of reinstalling the
regulator each time. However , it is important
that the regulator cover be replaced, the r eg-
ulator connections correctly connected, and
the regulator satisfactorily insulated by the
fender c over to prevent grounding the r eg-
ulator terminals or resistances. When testing,
the regulator must be at the same attitude (or
angle) as when installed on the car.
Fi g. 7-Adj ust i ng Spri ng Tensi on
(6) If the alternator and regulator tested satisfac-
torily, turn the ignition switch off. Disconnect the bat-
tery ground cable. Disconnect the test instruments. Cor-
rectly connect the leads at the alternator and the
regulator. Connect the battery ground cable.
CAUTION: Be sure the negative post of the
battery is always connected to ground. In-
correct bat t ery polarity may damage the al-
ternator rectifiers. Do not ground the alter-
nator field circuit, as this may damage the
regulator.
3. VOLTAGE REGULATOR ADJ USTMENTS
Air Gap
(1) Remove the voltage regulator from the vehicle.
(2) Remove the voltage regulator cover.
(3) Check air gap by connecting a t est lamp be-
tween a 12 volt battery negative terminal and the ig-
nition IGN terminal of voltage regulator. Connect a
jumper wire from the battery positive terminal to the
field FLD terminal of voltage regulator.
(4) Insert the .048 inch wire gauge Tool C-828 be-
tween the armature and the magnet core next to the
stop pin on the spring hanger side (Fig. 8).
(5) Press the armature plate down until it contacts
the wire gauge. Contacts should just open and test
light should go dim.
NOTE: Press down on armature plate and
not on contact spring.
ARMATURE
\
CONTACT POINTS
Fi g. 8-Chec k i ng Ai r Gap Fi g. 9-Removi ng or I nst al l i ng I nsul at ed Brush
(6) Insert the .052 inch gauge in the same position 5. BENCH TESTS
and depress armature plate. Upper contacts should
Field Circuit
remain closed and test lamp should remain bright.
If the alternator field coil draw has not been tested
If adjustment is required, adjust the air gap by
loosening contact bracket screw (Fig. 4) and moving
on the vehicle it may be tested on the test bench as
fol l ows :
contact bracket as required.
NOTE: Make sure air gap is checked with
(1) Connect a source of 12 volt DC. current and a
test ammeter in series to the field terminal and to
contact bracket screw fully tightened.
ground.
Point Gap
The field current draw at 12 volts should be 2.36
(1) Set l ower contact gap to .015 i nch (pl us or
amperes minimum t o 2.75 amperes maximum while
minus .OOl inch) by bending lower stationary contact
turning the rotor shaft slowly by hand. If a generator
arm.
test bench is available make the following test: With
(2) Press the armature plate down so that the ar
alternator operating at 750 rpm, the field current should
mature rests on the nylon stop, release and recheck
be 2.97 amperes minimum or 3.43 amperes maximum
contact gap. .
at 15 volts @70 degrees F.
NOTE: Press down on armature plate and
6. ALTERNATOR DISASSEMBLY
not on contact spring.
To prevent possible damage to the brush assemblies,
Spring Tension
they should be removed before proceeding with the
Always make this adjustment by bending the lower
disassembly of the alternator. The insulated brush is
spring hanger. If the voltage was found to be too high,
mounted in a plastic holder that positions the brush
bend the lower hanger UP. If the voltage was low,
vertically against one of the slip rings.
bend the lower hanger DOWN.
(1) Remove the retaining screw, lockwasher. nylon
Install the regulator and repeat the test as outlined
in Paragraph 2 Voltage Regulator Test-On vehicle.
If further adjustment is necessary, adjust spring ten-
sion only. If adjustment is attempted on the car, do
not short circuit between the spring hanger

and the base. Grounding the hanger will damage the
regulator.
4. ALTERNATOR SERVICING
Removal
.
(1) Disconnect the battery ground cable.
(2) Disconnect the alternator BAT and "FLD"
leads.
(3) Remove the alternator from the vehicle.

ELECTRI CAL-I NSTRUMENTS
39
, DRiJ 4E END SHIELD
END
/
ROTOR
_.
SHIELD
STATOR
/
DRIVE END SHIELD 60X813A
Fi g. 1 l -Separat i ng Dri ve End Shi el d and
Rec t i f i er Frame
Fi g. 13-Separ at i ng Rot or From Dri ve End Shi el d
(5) Remove the three nuts and washers and while
washer, and field terminal and carefully lift the plao
supporting the rotor end shield, tap the rotor shaft
tic holder containing the spring and insulated brush
with a plastic hammer and separate the rotor and end
assembly from the end shield (Fig. 9).
shield (Fig. 13).
(2) The ground brush is positioned horizontally
(6) The drive end ball bearing is an interference
against the remaining slip ring and is retained in a
fit with the rotor shaft. Remove the bearing with puller
holder that is integral with the end housing. Remove
Tool C-3615 and adaptors as follows:
the retaining screw and lift the clip, spring and brush
a. Position the center screw of Tool G3615 on rotor
assembly from the end shield (Fig. 10).
shaft.
CAUTION: Stator is laminated, do not burr
b. Place the thin lower end of the adapters SP-3375
under the bearing equally spaced and the upper end
stator or end shields. of the adapters around the center screw.
(3) Remove the through bolts and pry between the c. Hold adapters and center screw in position with
stator and drive end shield with a thin blade screw-
the tool sleeve (Fig. 14).
driver. Carefully separate the drive end shield pulley
and rotor assembly away from the stator and recti-
CAUTION: Tool sleeve must bot t om o n bear .
fier shield assembly (Fig. 11).
i ng, otherwise adapters may be damaged.
(4) The pulley is an interference fit on the rotor
d. Turning center screw while holding the outer body
shaft. Remove the pulley with puller C-3615 and special
of tool will withdraw the bearing from the shaft.
adaptors SP-3002 (Fig. 12). Note: No further disassembly of the r ot or is
I
.?
Fig. 12-Removi ng Pul l ey Fi g. 14-Rem& vi ne Bear i ng Fr om Rot or Shaft
4 0
ELECTRI CAL-I NSTRUMENTS
required, as the bal anc e of t he r ot or as s em-
bly is not serviced separately.
(7) Remove the output battery terminal nuts and
washers and remove terminal screw and inside capac-
itor (on units so equipped) as shown in Figure 15.
The heat sink is also held in place by the terminal
screw.
(8) Remove the insulator (Fig. 16).
NOTE: Three rectifiers are pressed into the
heat sink and three in the end shield (Fig. 5).
When removing the rectifiers, it is nec essar y
to support the end shield and/or heat sink to
prevent damage to these castings.
7. TESTI NG THE RECTI FI ERS AND STATOR
( 1) Disassemble the alternator as outlined in Para-
graph 16 and separate the wires at the Y connection
at the stator (Fig. 17).
(2) Test the rectifiers with a test lamp equipped
with a number 67 bulb (4 candle power) as follows:
i g. 17Separat e St at or and End Shi el d t o Ex pose
Y Connec t or
Connect one side of test lamp to the positive bat-
post. Connect the other side of the test lamp to
,st probe. Connect another test probe to the neg-
e battery post.
Contact the outer case of the rectifier with one
re and the other probe to the wire in the center of
rectifier (Fig. 16).
Reverse -the probes, moving the probe from the
ifier outer case to the rectifier wire and the probe
le rectifier wire to the rectifier outer case.
the test lamp lights in one direction but does not
t in the other direction, the rectifier is satisfactory.
:mp lights in both directions, the rectifier is shorted.
+st lamp does not light either direction, the recti-
is open.
iOTE: The usual c ause of an open or a
Irted rectifier is a defective capacitor or a
,tery that has been installed in reverse po-
-
41
DRIVER (TOOL)
DRIVE END
SHIELD
61 x251
Fig. 19-Testing Stator for Grounds Fig. 21-Removing a Rectifier
larity. If the bat t ery is installed pr oper l y and
the three leads. If the test lamp does not light the
the rectifiers ar e open, test the capacitor ca-
stator winding is open. See Figure 20.
pacify.
(5) Install a new stator if the one tested is ground-
External Capacitor Capacity .5 microfarad (mini-
ed or open. If the rectifiers must be replaced, pro-
mum).
ceed as follows:
Internal Capacitor Capacity .158 microfarad (min-
a. Cut rectifier wire at point of crimp.
imum).
b. Support the rectifier housing on Tool C.3771. See
(3) Test the stator for grounds using a 110 volt test Figure 21*
lamp (Fig. 19). Use wood slats to insulate the stator
from the rectifier shield. Contact one prod of the test
NOTE: This tool is cut-a-way and slotted to
fit over the wires and around the bosses i n the
lamp to the stator pole frame, and contact the other
shield. Make sure that the bore of the tool
prod to each of the three stator leads. The test lamp
should not light. If the test lamp lights the stator
completely surrounds the rectifier.
windings are grounded.
c. Press the rectifier out of the shield using Tool
(4) Test the stator windings for continuity, by con-
SP-3380 (Fig. 21).

tacting one prod of the test lamp to all three stator
NOTE: The needle r ol l er bearing in the r ec -
leads at the Y connection. Contact each of the three
tifier end shield is a press fit. To protect the
stator leads (disconnected from the rectifiers). The
end shield it i s nec essar y t o support the shield
test lamp should light when the prod contacts each of
with Tool SP-3383 when pressing t he bear -
ing out with Tool C-3770, Fig. 22.
CAPACITOR
/ SCREW
SCREW
PULLEY
SHIELD
SHIELD
1
SULATOR
WA SHE R
HEAT SINK
\
NUT
I
DFTAINFP- \
II
I
42 ELECTRICAL-tNSTRUMENTS
/
L TERMINAL
NYLON
nE*D,L,c \NACUFP
\
/ T--m-- I \
i&INSERT
60xl281A O5.nnll.V ,.-a 1-m.
Fi g. 23-Al t er nat or Di sassembl ed)
/
BEARING
ROTOR
/
WASHER
FIER
SCREW
8. ASSEMBLI NG THE ALTERNATOR (Fi g. 23)
3772 (Fig. 24).
(1) Support the heat sink or rectifier end shield on NOTE: Clean all w ires -v--- - ,,AEqm..~.
circular plate, Tool 813-3377. (4) Crimp the new rectifier wire to the wires CBS-.
(2) Check the rectifier identification to make sure
connected at removal.
the correct rectifier is being installed. Refer to the serv- (5) Support end shield on Tool SP-3383 so that the
ice parts manual for rectifier identification. notch in support tool will clear the raised section of
(3) Start the new rectifier into the casting squarely the heat sink and press the bearing into position with
and press the rectifier into the casting with Tool C- Tool SP-3381 (Fig. 25).
CAL-INSTRUMENTS
43
Fi!
and lock nuts.
El . 27-I nst al l i ng Pul l ey Fi g. 26-~l nrt al l i ng Dri ve End Shi el d and Bearing
on Rot or Shaf t
NOTE: New bearings are pre-lubricated, (12) Make sure the heat sink and insulator are in
additional lubrication is not required. position and tighten the lock nut.
(6) I nsert the dri ve end beari ng (wi th beari ng (13) Position the stator on the rectifier end shield..
shield towards rotor) in the drive end shield and in- Make sure that all of the rectifier connectors, and stcrtor
stall the bearing retainer, washers and nuts to hold leads, capacitor lead (internally installed) will not
the bearing in place. interfere with the rotor fans.
(7) Position the bearing and drive end shield on (14) Position the rotor and shield assembly on the
the rotor shaft and while supporting the base of the rectifier end shield. Align the through bolt holes
rotor shaft, press the bearing and shield in position on through the drive end shield, stator and the rectifier
the rotor shaft with arbor press and Tool C-3769 (Fig. end shield (Fig. 11).
26). (15) Compress stator and both end shields by hand
CAUTION: Make sure that the bearing is i n-
and install the through bolts, washers and nuts.
stalled squarely at installation; otherwise,
(16) I nstal l the i nsul ated brush (Fi g. 9), lock-
damage to the bearing will result. Press the
washer, nylon washer, and terminal attaching screw.
bearing on the rotor shaft until the bearing
(17) Install the ground brush (Fig. 10) and at-
contacts the shoulder on the rotor shaft.
taching screw.
(8) Install pulley on rotor shaft. Shaft of rotor must
(18) Rotate the pulley slowly by hand to be sure
be supported in a manner so that all pressing force is
that the rotor fans do not hit the rectifiers and stator
on the pulley hub and rotor shaft (Fig. 27).
connectors.
NOTE: Do not exceed 6600 pounds pressure.
/nstallation
Press the pulley on the rotor shaft until the (1) Install the alternator and adjust the drive belt
pulley contacts the inner race of the drive end according to the instructions in ACCESSORY BELT
bearing. DRIVE Group 7 of the 1961 Service Manual Supplement.
(9) Some alternators have the capacitor mounted (2) Connect the output and field leads.
internally. Make sure the heat sink insulator is in (3) Connect the battery ground cable.
place. (4) Start and operate the engine, and observe the
(10) Install the output terminal screw through the alternator operation.
heat sink and end shield (Fig. 15). (5) Test the current output and regulator voltage
( 11) Install the insulating washers, lockwashers setting, if necessary.
. .
I GNI TI ON SYSTEM
Listed are new Service Procedures and Specifications cylinder, 318 cu. in. engine. Service Procedures for the
covering the Chrysler Built Distributor used on the 8 Auto-Lite Distributors remain the same as outlined I N
the 1960 Plymouth Service Manual, except for some same as outlined in the 1960 Plymouth Service Man-
changes in the Specifications. Service Procedures for ual except as described in this Supplement.
the 6 Cylinder Chrysler Built Distributors remain the
DISTRIBUTOR SPECIFICATIONS
Chrysler Part No.. . . 1889750
Model. . . . . . . . . . . . . . . . . . . . . . . . . . Chrysler Built
E n g i n e M o d e l U s a g e . . . 170 cu. in.
Car Model Usage. . . . . . . . . . . . . . . . . . . RPI - Taxi
Advance-Automati c (Di stri butor Degrees at Di stri butor RPM) 0 @ 325 to 475
0 to 2.5 @475
6 to 8 @, 820
11.5 to 13.5 @, 1925
Advance-Vacuum (Di stri butor Degrees at I nches of Mercury) 0 t@ 4.7 to (1.1
5.5 to 8 @ 11
9.5 to 12.5 @14.5
Breaker Poi nt Gap ,017 to ,023
Dwell Angle. . . . . . . . 36 to 42
Breaker Arm Spring Tension . 17 to 21.5 oz.
Ti mi ng. . . . . . .
21/ 2 BTC
Condenser Capacity. .25 to ,285 mfd.
Shaft Side Play. . . . . . . . .OOO to .003*
Shaft End Play (After Assembly). ,003 to .OlO
Rotati on. . . . . . .
Clockwise
Spark Plug Type Standard AG-52
Taxi AG-82
Size.
14 MM
Gap. . . . . . .
-035
Firing Order. . . 153624
Co~........................................................ Chrysl er Auto-Li te Chrysl er Essex
1688212 200567 2095223 62-160-2
Primary Resistance @, IO-80F.. . . . . 1.65-l .79 ohms 1.41 1.55 ohms
S e c o n d a r y R e s i s t a n c e @70-80 F.. . 8OOC-9200 ohms 9200-10600 ohms
Bal l ast R esi st or . . . . . . . . .
2095501 -
Resistance @ 70-80 F. . . 0.6 ohms
Current Draw (Coil and Ballast Resistor in Circuit)
Engi ne Stopped. . . . .
3.0 Amperes
Engine Idling . . . . . . . . . . . . . 1.9 Amperes
*When distributor is new or after rebuilding (new bushings and/ or new shaft installed), service wear tolerance
should not exceed .OOS.
\
C h r y s l e r P a r t N o . . 2095270
Model. . . .
Chrysler Built
Engi ne Model Usage. 225 cu. in.
Car Model Usage. , RPI
Advance-Automati c (Di stri butor Degree at Di stri butor RPM)
0 @ 250 to 450
0 to 2 @ 450
5.5 to 7.5 @ 1000
10.5 to 12.5 @I 2200
Advance-Vacuum (Di stri butor Degrees at I nches of Mercury).
0 @ 4.9 to 6.9
4.5 to 7 @ 9.5
7.8 to 10.3 @J 12
Breaker Point Gap ,017 to ,023
DISTRIBUTOR SPECIFICATIONS (Cont d)
Dwell Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 42
Breaker Arm Spring Tension.
. . . . . . . . . . . . . . . . . . 1.1:::
. . . . . . . . . . . . . . . . . . . . . . . 17 to 21.5 oz.
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21/ 2 BTC
Condenser Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 to ,285 mfd.
Shaft Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ooo to .003*
Shaft End Play (After Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . ,003 to ,010
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clockwise
Spark Plug Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG-52 Standard
AG-82 Taxi
Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MM
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ../ . .
.035
Firing Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153624
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrysler Auto-Lite Chrysler
Essex
1688212 200567 2095223 62-160-2
Primary Resistance @ 70-80 F . . . . . . . . . . . . . . . . . . . . . . . . . 1.65-1.79 ohms 1.41-1.55 ohms
Secondary Resistance @ 70-80 F . . . . . . . . . . . . . . . . . . . . . . . . 8000-9200 ohms
9200-10600 ohms
Ballast Resistor . . . . . . . . . 2095501
Resistance @~ 70-80 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.6 ohms
Engine Stopped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Amperes
Engine Idling ............. . . . . . . . . . . . . . . . . . . . . .
1.9 Amperes
*When distributor is new or after rebuilding (new bushing and/ or shaft installed), service wear tolerance should
not exceed ,005.
Chrysler Part No., . .
Model ... .._...._._.....__..._.......
Engine Model Usage
C a r M o d e l U s a g e ,
Advance -~Automatic (Distributor Degrees at Distributor RPM).
1838505
Chrysler Built
318 cu. in.
RP2, with 2 BBL Carb.
Automatic Transmission
0 @ 335 to 565
0 to 2 @565
2 to 4 @s 800
8 to 10 @J 2300
Advance ~ Vacuum (Distributor Degrees at Inches of Mercury).
0 @6.8 to 9.2
6.5 to 9.5 @> 13
12 to 15 @17
Breaker Point Gap
,014 to .019
Dwell Angle
27 to 32
Breaker Arm Spring Tension
17 to 21.5 oz.
Ti mi ng. .
10 BTC
C o n d e n s e r C a p a c i t y ,
.25 to 285 mfd.
Shaft Side Play. .
,000 to .003
Shaft End Play (After Assembly), ,003 to ,010
Rotation. . . . .
Clockwise
Spark Plug Type. .:
A-42
Size _........ ~~.~~.~~..~~.~......~~.~....~~..
14 MM
G a p . . . ..,..,_,,.,....,.,.,...,.,.................... ,035
Firing Order
..i:::::::: .,,, :,:::::::::::::::::::: C h r y s l e r
18436572
Coil .,,. Auto-Lite Chrysler
Essex
1688212 200567 2095223 62-160-2
P r i m a r y R e s i s t a n c e @, 70-80 F . . 1.65-1.79 ohms 1.41-1.55 ohms
Secondary Resistance @a 70-80 F.. 8000-9200 ohms
9200-10600 ohms
46
DISTRIBUTOR SPECIFICATIONS (Cont d)
Ballast Resistor. . .
2095501
Resistance @, 70~80 F.. . .
0.6 ohms
Engine Stopped . . ,
3.0 Amperes
Engine Idling, .
1.9 Amperes
*When distributor is new or after rebuilding (new bushings and/or shaft installed), service wear tolerance should
not exceed .005.
1889710
Chrysler Built
318 cu. in.
0 @, 295 to 405
0 to 2 @, 405
3.5 to 5.5^ @, 600
7.5 to 9.5 @ 2200
0 @ 4.5 to 6.6
4 to 7 @j 9.5
8.5 to 11.5 @ 13.2
.014 to .019
27 to 32
17 to 21.5 oz.
10 BTC
.25 to ,285 mfd.
,000 to .003*
,003 to ,010
Clockwise
A- 42
14 MM
.035
18436572
Chrysler Part No.. . . . . . . .
Model. ,.,._..,_.._..............__... . . . . . . . . . . . . . .
E n g i n e M o d e l U s a g e .
. .
Car Model Usage. . . .
Advance-Automatic (Distributor Degrees at Distributor RPM).
Advance-Vacuum (Distributor Degrees at Inches of Mercury)
B r e a k e r P o i n t G a p ,
D w e l l A n g l e ,
T i m i n g .
C o n d e n s e r C a p a c i t y .
Shaft Side Play.
Shaft End Play (After Assembly)
Rotation . .
Spark Plug Type. . .
Size. . .
G a p ,
Firing Order . . . .
Coil. . . .
. . . . . .
. . . . .

1 1
Lnrysier Aut o - Li t e Chr y s l e r Essex
1688212 200567 2095223 62-160-2
1.65 -1.79 ohms 1.41-l .55 ohms
8000-9200 ohms 9200-10600 ohms
2095501
0.6 ohms
P r i m a r y R e s i s t a n c e @ 70.80 F . .
Secondary Resistance @, 70-80 F.
.
B a l l a s t R e s i s t o r , . .
Resistance @, 70-80 F.. .
Engine Stopped . ........ ...... I .
3.0 Amperes
E n g i n e I d l i n g , ...............
1.9 Amperes
*When distributor is new or after rebuilding (new bushings and/or shaft installed), service wear tolerance should
not exceed .005.
Chrysler Part NO., . . . . . . . . . . .
Model. . . . . . . . . . . . . . . . . . . . . .
Engine Model Usage. . . . . . . . . .
Car Model Usage . . . . . . . . .
..............
....... .....
..............
2095647
Chrysler Built
318 cu. in.
Manual Transmission
DISTRIBUTOR SPECIFICATIONS (Contd)
Advance-Automati c (Di stri butor Degrees at Di stri butor RPM) 0 @ 270 to 430
0 to 2 @430
4.5 to 6.5 f@ 800
Breaker Point Gap. . .
Dwell Angle.
Ti mi ng.
C o n d e n s e r C a p a c i t y . . .
Shaft Si de Pl ay.
Shaft End Play (After Assembly).
R o t a t i o n .
Spark Plug Type
S i z e .
G a p
Firing Order.

.

10.5 to 12.5 @ 2300
0 @6.8 to 9.2
6.5 to 9.5 @ 13
12O to 15 @, 17
.014 to ,019
27 to 32
17 to 21.5 oz.
5 BTC
.25 to ,285 mfd.
,000 to .003*
,003 to ,010
Clockwise
A-42
14 MM
.035
18436572
Coil Chrysl er Auto-Li te Chrysl er Essex
1688212 200567 2095223 62-160-2
Primary Resistance @, 70-80 F.
Secondary Resistance @ 70-80 F..
1.65-1.79 ohms 1.41--1.55 ohms
8000-9200 ohms 92O0-10600 ohms
Ballast Resistor 2095501
Resistance @ 70-80 F.. . . 0.6 ohms
E n g i n e S t o p p e d 3.0 Amperes
Engi ne I dl i ng. 1.9 Amperes
*When distributor is new or after rebuilding (new bushings and/ or shaft installed) service wear tolerance should
not exceed .005.
Chrysler Part No..
M o d e l . . . . . . . . .
Engine Model Usage .._
Car Model Usage. . . . .
Advance-Automatic (Distributor Degrees at Distributor RPM),
B r e a k e r P o i n t G a p .
Dwell Angle. .
Breaker Arm Spri ng Tensi on.
Ti mi ng. .
Condenser Capaci ty
Shaft Side Play. . .
Shaft End Play (After Assembly).
2095680
IBS-4006F
361 cu. in.
RP2, (Hi. Perf.)
with.4 BBL. Carb.
0 @ 275 to 425
0 to 3 @j 425
7 to 9 @ 775
11 to 13 @ 2050
0 @ 7.5 to 9.2
4.5 to 7.5 @ 12
9.5 to 12.5 @16
,014 to ,019
27 to 32
17 to 21.5 oz.
10 BTC-361 cu. in. Engine
71/ z BTC-383 cu. i n. Engi ne
.25 to ,285 mfd.
.000 to .003*
.003 to ,010
DISTRIBUTOR SPECIFICATIONS (Contd)
R o t a t i o n . . . . . . . . . . . . Counter-Clockwise
Spark Plug Type, . . . . . . . . . . . . . . A-32
S i z e . . . . . . . . . . 14 MM
Gap. . . . . . . . . . . . . . . . ,035
Firing Order . . . . . . . 18436572
coil... . . . . . . . .._..............._.........__............... Chrysl er Auto-Li te Chrysl er Essex
1688212 200567 2095223 62-160-2
Primary Resistance @ 70-80 F.. . . 1.65-1.79 ohms 1.41-1.55 ohms
Secondary Resistance @ 70-80 F.. , . . . . . . . . . . 8OOt-9200 ohms 9200-10600 ohms
Ballast Resistor. 2095501 . . . . . . . . . . . . .
Resistance @, 70-80 F.. . . . . . . . . . 0.6 ohms
Engine Stopped, . . . . . . 3.0 Amperes
Engine Idling. . . . . . . . . . . . 1.9 Amperes
*When distributor is new or after rebuilding (new bushings and/ or shaft installed), service wear tolerance should
not exceed ,005.
SERVICE DIAGNOSIS
1. BURNED OR PITTED
DISTRIBUTOR POINTS
( 1) Dirt or oil on points.
(2) Points misaligned or gap too narrow.
(3) Defective coil.
(4) Wrong condenser or defective condenser.
(5) Alternator regulator setting too high.
(6) Bushings or distributor shaft worn.
(7) Touching of points with hands during installa-
tion.
(5) Coil tower carbon-tracked.
3. CONDENSER FAILURE
(1) Normal fatigue.
(2) Damaged by excessive engine heat or moisture.
4. FOULED SPARK PLUGS
( 1) Carburetor mixture over-rich.
(2) Excessive oil consumption.
(3) Improper plug heat range.
(4) Improper gap adjustment.
2. IGNITION COIL FAILURE
(1) Alternator regulator setting too high.
(2) Coil damaged by excessive heat from engine.
(3) Coil case or tower cracked.
(4) Oil leak at tower.
5. BURNED SPARK PLUGS
( 1) Plugs loose or too tight in the cylinder head.
(2) Carburetor mixture too lean.
(3) Improper plug heat range.
(4) Improper ignition timing.
1. DESCRIPTION
The ignition system consists of two separate circuits.
The battery, ammeter, ignition switch, primary wind-
ing of the ignition coil, distributor contacts and con-
denser, vehicle frame, and the primary wiring make up
the low voltage primary circuit. The secondary high
voltage circuit includes the coil secondary winding,
the distributor cap and rotor, the spark plugs, the high
tension wiring and the vehicle frame.
ignition coil and the distributor cap towers.
The ignition coil tower and the distributor cap should
be wi ped cl ean wi th a cl oth moi stened i n cl eani ng
solvent.
The insulation of the coil lead and spark plug wires
will deteriorate with usage. Leakage to ground and be-
tween the wires will occur, resulting in hard starting
and inefficient engine operation. Old, cracked or dam-
aged wires should be replaced.
2. CHECKING THE SECONDARY CIRCUIT
NOTE: The high tension cables have a non-
The coil to distributor cap lead wire and the spark
metallic string type conductor for improved
plug wires should make good, clean contact in the
radio noise suppression. Care should be taken
i
not to jerk the cables of t he spark plugs or
out of the distributor cap towers (especially if
the engine is hot ; otherwise, the cable may
pull out of its terminal).
Check cables for excessive resi st anc e or
open circuit. Replace the cable if resistance
i s mor e t han 30,000 ohms. Replace the cable
if the terminal has pulled off.
If radio develops excessive noise or if there
is a pronounced engine mi ss, c hec k for de-
fective cables (broken).
The rotor and distributor cap electrodes should be
inspected for burning. Replace the rotor if the elec-
trode is burned on the top or worn too short.
3. DI STRI BUTOR RESI STANCE TEST
This test indicates the resistance of the ignition pri-
mary circuit from the distributor side of the coil, through
the points and the distributor ground. Excessive re
sistance in this portion of the ignition system will pre-
vent the coil from producing sufficient output for good
over-all ignition. To perform test proceed as follows:
(1) Turn the Selector Switch to the CALIBRATE
position and adjust Dwell Calibrator until the Dwell
Meter reads on the set line (test leads separated).
(2) Leave sel ector swi tch i n CALI BRATE posi -
tion, connect tach-dwell red lead to distributor terminal
of coil and black lead to a good ground.
(3) Turn the ignition switch ON. Observe the dwell
meter reading. Meter pointer should be well within
black bar marked DISTRIBUTOR RESISTANCE. If
the reading is zero or outside of black bar, crank en-
gine with the starter until meter pointer moves as far
to the right as possible. (This will indicate that breaker
points are closed.) A reading now within black indi-
cates a normal distributor primary circuit.
If the reading is outside the black bar, high resist-
ance is present in the distributor primary circuit.
.
(4) Remove the test lead from the distributor ter-
minal of coil and connect to the following points:
a. Distributor primary terminal (outside).
b. Distributor primary terminal (inside).
c. Breaker point termi nal bracket (i nsul ated
bracket).
d. Ground side of contact points.
e. Distributor housing.
(5) Repeat test at each connection until a notice-
abl e change occurs i n the meter readi ng. I f a bad
connection or faulty lead is indicated, clean, tighten
or replace as necessary and repeat test (4).
If bad points are indicated, remove distributor for
complete inspection, service, testing and calibration.
4. IDLE R.P.M. TEST
The engine idle r.p.m. setting should be tested and
recorded as it is when the vehicle is first brought into
the shop for testing. This will assist in diagnosing com-
plaints of engine stalling or complaints of creeping and
hard shi fti ng on vehi cl es equi pped wi th automati c
transmissions.
( 1) Turn the selector switch to the calibrate posi-
tion and adjust the dwell calibrator until the dwell
meter reads on the set line (test leads separated).
(2) Connect the red lead of the test unit to the dis-
tributor primary terminal at coil and the black lead to
a good ground.
(3) Turn the selector switch to the 8 LOBE posi-
tion.
(4) Turn the tachometer r.p.m. switch to the 1000
r.p.m. position.
(5) With the engine at normal operating tempera-
ture (off fast idle), momentarily open the throttle and
release to make sure there is no bind in the linkage
and that the idle speed screw is against its stop.
(6) Note engine r.p.m. on 1000 r.p.m. scale and ad-
just the carburetor idle screw to obtain 475500 engine
r.p.m.
5. DI STRI BUTOR POI NT DWELL
The degrees of Dwell of the distributor breaker
points are the degrees of rotation through which the
breaker points remain closed. This is also commonly
referred to as dwell angle or cam angle.
Correct distributor point dwell is essential for good
ignition performance and point life.
(1) Connect the tach-dwell red lead to the distrib-
utor terminal of the coil and the black lead to a good
ground.
(2) Turn the selector switch to the 8 LOBE posi-
tion.
(3) Start the engine and operate at 475 to 500 r.p.m.,
engine at normal operating temperature (off fast idle).
(4) Observe dwell meter reading and compare to
specifications. If the dwell reading is within specifica-
tions, the point gap cam rubbing block and breaker
arm are all in satisfactory condition.
If dwell reading is not within specifications, incor-
rect point gap, defective cam, worn rubbing block or
distorted breaker arm is indicated.
6 . DWEL L VARI AT I ON
This test indicates the mechanical condition of the
distributor. Excessive wear in distributor mechanical
parts cause dwell variations which will effect ignition
timing.
(1) With engine at idle speed and distributor vac-
uum line disconnected and with the test leads con-
nected as in the point dwell test, turn the tachometer
r.p.m. switch to the 500 r.p.m. position.
(2) Slowly increase the engine speed to 1500 r.p.m.
ELECTRICAL-INSTRUMENTS 5 1
then slowly reduce to idle speed while observing the
dwell meter reading.
(2) Disconnect the primary lead wire at the coil.
If the dwell reading varies more than 2 degrees from
(3) Unfasten the distributor cap retaining clips and
lift off the distributor cap.
initial reading between idle speed and 1500 r.p.m., (4) Scribe a mark on the edge of the distributor
Probable wear in the distributor shaft, bushings, or housing to indicate No. 1 position of the rotor as ref-
breaker plate is indicated. Remove distributor for com- erence when reinstalling .the distributor.
plete inspection and testing on a distributor tester. (5) Remove the distributor hold down clamp screw
MOTE: Dwell variation at speeds above
and the clamp.
1500 r .p.m. does not necessarily indicate dis-
(6) Carefully lift the distributor from the engine.
tributor wear.
IMPORTANT
9. DI SASSEMBLY OF DI STRI BUTORS (Fi g. 1)
Dwell and gap of the points must both be (1) Remove the distributor rotor.
within their specified tolerance at t he same
time. If this c annot be accomplished. it is
NOTE: The distributor c ap clamp spr i ngs
ar e held in place by peeni ng the metal
probable that the wrong points ar e installed
or the cam lobes ar e badly wor n.
around t he openings and should not be re-
moved.
7. I GNI TI ON TI MI NG
(2) Remove the retainer attaching the vacuum con-
To obtain maximum engine performance, the dis-
trol unit to the breaker plate advance arm.
tributor must be correctly positioned to give proper ig-
(3) Remove the two screws and lo&washers at-
nition timing.
taching the vacuum control unit to the distributor hous
The ignition timing test will indicate the timiig of
ing and remove the control unit.
the spark at the No. 1 piston at idle (only).
(4) Remove primary lead wire and rubber grommet
( 1) Disconnect the vacuum line at the distributor.
as an assembly.
This will eliminate any chance of vacuum advancing
(5) Remove the two screws and lo&washers at-
the breaker arm plate. The engine should operate on
taching the breaker plate to housing and lift out the
centrifugal advance only when checking the ignition
breaker plate, points and condenser as an assembly.
ti mi ng.
(6) Remove the oil wick from the distributor cam.
(2) Connect the secondary lead of the Power Timing
Remove the spring clips from the oil well in cam (Fig.
Light to No. 1 spark plug, red primary lead to the posi-
2) and remove the cam and yoke assembly and spacer.
tive terminal of the battery and the black primary lead
(7) Clamp the ribbed section of the distributor hous-
to the negative battery terminal.
ing in a vise equipped with soft jaws and attach the
(3) Start the engine and set the idle to 475-500 r.p.m.,
dial indicator to the body of the distributor (Fig. 3)
with indicator plc
engine at normal operating temperature (transmission
in neutral).
cam sleeve.
(4) Using a timing light, observe the position of
(6) Hook the F
timing mark on the crankshaft dampener and check
sleeve and pull on a line with tne phmger or the
against the specifications.
(5) Loosen the distributor clamp screw and rotate
the distributor housing so that the specified timing mark
r:
.,!
mger resti ng agamsr me alstrimuor
Jprmg scale in the bore of the cam
., . , . .
and pointer are in alignment. (Moving distributor hous-
ing against shaft rotation advances timing and with
shaft rotation retards timing).
(16) Tighten the distributor clamp screw after the
timing has been set and recheck timing adjustment
with a Power Timing Light.
(7) When the spark timing is correct, reconnect the
vacuum line to the distributor.
NOTE: As the engine speed is increased, the
timing mark should move down on the vibra-
tion dampener below the pointer if advance
units are functioning.
8. DI STRI BUTOR REMOVAL
(1) Disconnect the vacuum line at the distributor.
Fi g. Z-Ren l ovi ng or I nst al l i ng Di st ri but or
Cam Fel t Wi c k
DIAL INDICATOR
Fi g. 3-Chec k i ng Di st ri but or Shaft Si de Pl ay
gauge. Apply a 5 pound pull and read movement of
the distributor cam sleeve on the indicator. If the side
play exceeds .005 inch, replace bushings and/ or dis-
tributor shaft as follows:
a. Remove the distributor drive collar retaining pin
Distributor. For the Chrysler Built Distributor use Tool
and slide collar off the end of the shaft.
C-3041 with the flat face of adaptor contacting the
b. Use a fine file to clean the burrs from around the
bushing then press the bushing into the distributor un-
til top of bushing is 1.613 inches from top face of dis-
tributor housing. Place a straight-edge on machined
c. Push shaft up and remove it through the top of
surface of housing and measure from bottom face of
the distributor body. Remove the upper thrust washers.
straight-edge to top of bushing. Invert the housing and
d. Remove the shaft oiler and lift out the oiler wick.
install the other bushing (Fig. 6) flush with the face
e. Remove upper bushing with Tool C-3744 (Fig. 4), of the distributor base.
by threading the tap securely into the bushing. Place h. Insert a 3/ 32 inch rod through the housing oiler
spacer over the tap. Install nut and while holding the
hole to see if the slot in the bushing indexes with the
tap, tighten tool nut to remove the bushing. Invert hous-
oiler hole in the housing. If the rod cannot be inserted
kng and remove the lower bushing in the same manner.
through the housing and the bushing, drill a 56 hole
f. Soak the new bushings in light engine oil for ap
through the upper bushing by drilling through the oil
proximately 15 minutes.
wick hole. Remove burrs caused by the drilling opera-
g. Position the new upper bushing with slot in bush- tion.
ing up and in line with oil hole in housing, then press
i. Install the burnishing tool part of C-3041 tool set
the bushing into the distributor housing with Tool and force the burnisher through both the bushings (Fig.
C-3041 and adapter (Fig. 5). The bushing will measure 7). The correct bushing diameter is .4995 to .5000
.094 inch from the top of housing bore for Auto-Lite
Fi g. 4-Removi ng Di st ri but or Shaf t Upper Bushi ng Fi g. 6-I nst al l i ng Di st ri but or Shaf t l ower Bushi ng
ELECTRI CAL-I NSTRUMENTS 53
m Fig. 7-Burn
10. ASSEMBI
(1) Check oy
the weight spril
nor weights.
tishing Distr
-_^____
mibutor
!
point
61x149 start
Housing Bushings
21.5
end (
TRIBUTOR
in or
[gal weight and check 1 2.
Lubricate the gover-
(1
Fig. S-Testing Breaker Arm Spring Tension
surfaces (Fig. 8). Take a reading as the points
to separate. The spring tension should be 17 to
ounces. If not, loosen the screw which holds the
>f the point spring and slide the end of the spring
out as necessary.
I NSTALLI NG AND ALI GNI NG
CONTACT POI NTS
) Remove the old contact points and install a new
.I NG THE~ Dl Sl
aeration of c:entrifr
rigs for distrortion.
(2) Inspect all bearing surfaces and pivot pins for set.
roughness, binding or excessive looseness. NOTE: Touching the contact point faces
(3) Install spacer on the distributor shaft.
with f i nger s during installation will cause
(4) Slide the cam and yoke on the distributor shaft, burning of points during operation.
engage the weight lugs with the slots in the yoke. In- (2) Align the contacts to provide center contact by
stall the cam retaining spring clip. Be sure it is prop bending the stationary contact bracket only. Grip
erly seated in groove of the distributor shaft. bracket next to the contact and bend it away from the
(5) Lubricate and install the two concave upper breaker arm and then bend it back to vertical and
thrust washers for Auto-Lite Distributors or a single check alignment. It may be necessary to repeat bend-
flat thrust washer for Chrysler Built Distributors. Posi- ing process several times to provide perfect align-
tion the washers on the distributor shaft and slide the ment which is necessary for efficient ignition and good
shaft into the distributor body. Position the lower contact life. Never bend movable arm to obtain
thrust washer and drive the collar on the lower end of alignment.
the shaft and install the retainer pin. (3) After aligning the points, readjust the point
(6) Install the oiler wick and oiler. clearance to specifications using dial indicator (Fig.
(7) Install the breaker plate assembly, align the 9).
condenser lead, breaker point spring, primary lead and
install the attaching screws.
(8) Install the felt wick in the top of the distributor
cam.
(9) Attach the vacuum control unit arm to the break-
er plate and install the retainer. Install the vacuum
unit attaching washers and screws.
(10) Check the spring tension, and adjust the con-
tact gap.
( 11) Lubricate the felt pad in the top of the distribu-
tor cam with 3 to 5 drops of light engine oil and install
the rotor.
11. TESTI NG BREAKER ARM
DIAL INDICATOR G
SPRI NG TENSI ON
c_
( 1) Hook a spring scale Tool MT&36 on the breaker
arm and pull in a straight line at right angles to the Fig. 9-Checking Point Clearance With Dial Indicator
SA ELECTRICAL-INSTRUMENTS
(4) Check the dwell angle to show proper degree of
closure. See Paragraph 9, Distributor Point Dwell. The
lock screw should be loosened just enough so that the
stati onary poi nt can be moved wi th a sl i ght drag;
otherwise, it will be difficult to set the points accurately.
After setting the points to correct the clearance, tighten
the lock screw.
13. DISTRIBUTOR LUBRICATION
(1) Add 3 to 5 drops of SAE 1OW oil to the oiler
on the outside of distributor base.
(2) Lubricate the felt pad under the rotor in the top
of the distributor cam with 3 to 5 drops of SAE 1OW oil.
(3) Wi pe ol d grease from surface of the breaker
cam. Apply a light film of new distributor cam grease.
Do not over-lubricate, keep oil and grease
away from the breaker points.
14. CHECKING DISTRIBUTOR ADVANCE
Automatic Advance Curve
Check the model number on the distributor base and
refer to the specifications before making this test.
NOTE: Clamp around the rib section of the
distributor housing. The bottom section of the
distributor housing is not a machined surface
and concentricity would be affected, causing
a wobble.
Mount the distributor assembly (less cap) in a re-
liable stroboscope type distributor tester and proceed
with tests as follows:
(1) Install the vacuum adapter fitting in diaphragm
housing and attach the tester vacuum pump hose to
fitting.
(2) Turn the Tach-Dwell switch to the 8 lobe posi-
tion and the Motor Switch to counterclockwise rota-
tion. Refer to Distributor Advance Specifications in
this Manual.
(3) Turn the battery switch ON.
(4) Adjust the tester speed control to operate the
distributor at 200 distributor r.p.m.
(5) Hold the distributor breaker plate in the full
retard position and align the 0 distributor tester
degree ring with any one of the arrow flashes.
(6) Adjust the tester speed control to operate the
distributor at speeds called for under Specifications
and observe arrow flashes opposite tester deqree ring
to determine degrees of advance.
(7) If the advance is not according to specifications,
corrections can be made by bending the primary and
secondary spri ng tabs to i ncrease or decrease the
spri ng tensi on. The governor spri ng tabs can be
reached through the access hole at the breaker plate.
Rotate the shaft until the proper spring and tab lines
up with the access holes, Insert a screwdriver blade
through the access hole and bend the spring tab to
ward the distributor cam to decrease spring tension
and advance the spark, or away from the distributor
cam to increase the spring tension and retard the spark.
Vacuum Diaphragm Leak Test
With the distributor mounted in distributor tester and
with the vacuum unit attached to the distributor, pro-
ceed as follows:
(1) Install the vacuum adjuster fitting in the vac-
uum unit and turn the distributor tester vacuum pump
on.
(2) Place thumb over the end of the vacuum pump
hose and adjust the regulator control knob to give a
reading 20 inches with hose closed off to insure tester
hose does not leak.
(3) Attach the vacuum pump hose to the adapter
fitting on the vacuum unit. The vacuum gauge should
hold on maximum vacuum obtainable if no leaks exist.
(4) Observe breaker pl ate whi l e performi ng the
leak test to check response of breaker plate to vacuum
advance. There shoul d be i nstant response to the
pull of the diaphragm, moving the plate without a
drag or bind.
(5 ) If leakage is indicated, tighten vacuum adapter
fitting and retest. If leakage is still indicated, replace
vacuum unit assembly.
Vacuum Advance Curve
Perform operations 1 through 5 under Automatic Ad-
vance Curve and proceed as follows:
( 1 j Turn the tester vacuum pump ON. Adjust the
vacuum pump regulator to vacuum test specifications.
See Specifications and observe the arrow flashes on
the tester degree ring to determine the degrees of ad-
!
vance.
(2) If the vacuum advance is above or below speci-
fications. replace the vacuum advance unit.
15. INSTALLATION OF DISTRIBUTOR
( 1) Position the distributor on engine. Align the
rotor with marks previously scribed on the distributor
housing.
(2) Engage the tongue of the distributor shaft with
the slot.in the distributor and the oil pump drive gear.
NOTE: If the engine has been cranked
while the distributor is removed, it will be
necessary to establish the proper relationship
between the distributor shaft and the NO. 1
piston position as follows:
(3) Rotate the crankshaft until the number one pis-
ton is at top of the compression stroke.
(4) Rotate the rotor to the position of the number
one distributor cap terminal.
(5) Lower the distributor into the opening and in-
stall the primary terminal lead, distributor cap, and
ELECTRI CAL-I NSTRUMENTS 5 5
distributor hold down clamp screw. Tighten the screw
finger tight. Make sure all high tension wires snap
firmly in the cap towers.
(4) Connect the secondary lead of a Power Timing
Light to the No. 1 spark plug, the red primary lead to
the posi ti ve termi nal of the battery and the bl ack
primary lead to the negative battery terminal.
(5) Start the engi ne. I dl e the engi ne at 475-500
r.p.m. Rotate the distributor housing so that the speci-
fied timing mark and the pointer are in alignment.
(Moving the distributor housing ugainst the shaft ro-
tation advances the timing and with the shaft rotation
retards the timing.)
(6) Tighten the distributor clamp screw after the
timing has been set and recheck the timing adjustment
with a Power Timing Light.
(7) If the timing is correct, reconnect the vacuum
line to the distributor and remove the timing light from
the engine.
16. SPARK PLUGS
Cleaning and Inspection
Remove the spark plugs. Examine the firing ends of
the plugs for evidence of oil fouling, gas fouling, burned
or overheating conditions. Clean and reset the qaps to
.035 inch.
Oil fouling is usually identified by wet, sludgy de-
posits caused by excessive oil consumption.
Gas fouling is usually identified by dry, black fluffy
deposits caused by incomplete combustion.
Burned or overheated spark plugs are usually iden-
tified by a white, burned or blistered insulator nose
and badly burned electrodes. Improper fuel, inefficient
cooling or improper ignition timing normally are the
cause.
Normal conditions are usually identified by white
powdery deposits or rusty-brown to grayish-tan pow-
dery deposits.
NOTE: Use new gaskets when installing the
spark plugs, tighten plugs to 30 foot-pounds
torque.
The high tension cables should be kept clean and
checked for cracked insulation and loose terminals.
17. IGNITION COIL
The ignition coil is designed to operate with an ex-
ternal ballast resistor. When testing the coil for output,
include the resistor in tests.
Check the coil for external leaks and arcing. Always
make two tests when checking the coil. One when coil
is cold, the other after coil has been warmed up.
To check the high tension circuit, pull the secondary
cable out of the distributor cap center tower. Hold the
end of the cable about i/4 of an inch away from the cyl-
inder head and crank engine with the ignition switch
on. If the spark jumps the l/4 inch gap, the coil can be
considered satisfactory.
18. I GNI TI ON TI MI NG
At low altitudes, with any good grade of recom-
mended gasoline, either regular or premium, the
engine will give its best performance if timed accord-
ing to specifications.
When using lower grade fuels, or after carbon has
accumulated, objectionable spark ping may occur with
the specified timing. In cases of this nature, ignition
timing should be retarded, but not to exceed 5 degrees
of crankshaft rotation later than specified.
At high altitudes or when using higher quality gaso-
line, for example premium where regular is speci-
fied or super premium where premium is specified,
there is less tendency for spark ping. In such cases, im-
proved performance may be obtained by advancing the
spark not to exceed 5 degrees of crankshaft rotation
ahead of specified timing.
Within the foregoing limits, namely, from 5 degrees
ahead to 5 degrees later than specified timing, a good
rule to follow is to advance the spark until a slight ping
is heard when accelerating from 15 mph in direct drive
at wide open throttle.
HORNS- LI GHTI NG SYSTEM-WI NDSHI ELD WI PERS
Servicing Procedures for the above units remain the plete servicing of these units, refer to the 1960 Plym-
same as described for the 1960 model cars. For com- outh Service Manual
I NSTRUMENTS AND GAUGES
Listed are new Service Procedures covering the re-
1. SPEEDOMETER
moval and installation of the Instruments and Gauges.
Test procedures for the units remain the same as out-
Re mo v a l
lined in the 1960 Plymouth Service Manual. (1) Disconnect the battery negative terminal.
56
(2) Remove the four screws attaching the speed-
ometer and instrument panel cover to the base. TWO
screws are located at the front face of the instrument
cluster bezel attaching the panel cover to the cluster
bezel. Two screws attach the speedometer and instru-
ment panel cover to the speedometer and instrument
panel at the front corners of the panel and base (one
screw each side). Remove the panel cover by raising
the front edge slightly to clear the instrument cluster
and careful l y pushi ng the panel toward the wi nd-
shield to disengage the retaining spring clips from the
speedometer and instrument panel base.
(3) Disconnect the high beam indicator light wire,
the ammeter gauge wires and lamp bulb and the oil
pressure warning light socket and bulb.
ometer and instrument cluster and bezel to the speed-
ometer and instrument panel base. Two screws are lo-
cated at rear of instrument cIusters (one each side)
the other two screws attach the cluster bezel to the
base at front of bezel. Remove clusters and bezel as an
assembly.
(5) Disconnect the speedometer cable and speed-
ometer lamp connectors at speedometer head.
ometer to the speedometer and instrument panel base
and remove the speedometer assembly.
lnstallcJtion
( 1) Position the speedometer on the instrument pan-
el base and install the four attaching screws.
(2) Connect speedometer cabl e and speedometer
lamps at speedometer head.
(3) Position the speedometer and instrument cl us-
ters and bezel in the instrument panel base and install
the four attaching screws.
(4) Connect the ammeter wires and lamps.
(5) Position the speedometer and instrument panel
cover on panel base, engaging the retaining spring
clips in the slots of the speedometer and instrument
panel base. Carefully align the cover at the joint of
the base and cover and install the attaching screws.
Install the two screws attaching cover to instrument
bezel.
(6) Connect the battery cable to battery negative
terminal.
2. AMMETER AND/OR OIL PRESSURE
WARNI NG LI GHT
Removal
Perform operations 1 through 4 under Speedometer
Removal and proceed as follows:
(1) Remove the three screws at rear of cluster and
remove the ammeter and ammeter lamp and/ or oil
pressure warning light assembly.
Installation
( 1) Position the ammeter in cluster and install the
attaching screws and lamp socket. Snap in oil pressure
light assembly.
Perform operations 4 through 6 under Speedometer
Installation.
3. TEMPERATURE GAUGE
Removal
(1) Disconnect the battery negative terminal.
(2) Working under the instrument panel, remove
the wires from the terminals on the temperature gauge.
(3) Remove the gauge light bulb.
(4) Remove the two screws attaching the tempera-
ture gauge to the instrument cluster housing and care-
fully withdraw the temperature gauge from the cluster
housing.
Installation
( 1) Carefully position the temperature gauge in the
instrument cluster housing and install the two (2) re-
taining screws.
(2) Install the light bulb in the gauge housing and
connect the wires to the gauge terminals.
(3) Connect the battery ground strap.
4. FUEL GAUGE
Removal
(1) Di sconnect the cabl e at battery negati ve ter-
minal.
(2) Remove the wires from the terminals on the fuel
gauge.
(3) Remove the gauge light bulb.
(4) Remove the two screws attaching the fuel gauge
constant voltage regulator to the instrument cluster
housing and carefully pull fuel gauge out of the clus-
ter housing.
Installation
(1) Carefully position the fuel gauge in the instru-
ment cluster housing and install the two (2) retaining
screws.
(2) Install the light bulb in the gauge housing and
connect the wires to the gauge terminals.
(3) Connect the cable to battery negative terminal.
5. INSTRUMENT CLUSTER ASSEMBLY
AND/OR CLUSTER BEZEL GLASS
Removal
(1 j Disconnect cable at battery negative terminal.
(2) Working from below the instrument panel re-
move the four nuts and lockwashers attaching the in-
strument cluster to the instrument panel and disconnect
all wires and connectors.
(3) Carefully pull the cluster assembly from front
of instrument panel.
!
57
NOTE: Fuel gauge, temperature gauge and remove clock stem knob, (do not remove stem) and
clock can be removed on bench by removing remove the two screws attaching the cluster bezel to
the screws attaching the gauges to the clus- instrument cluster.
ter. To remove the clock, hold the clock stem
I n s t a l l a t i o n
with a suitable tool and remove the clock
knob. Do not remove clock stem. Clock is re-
( 1) Position instrument cluster panel in the instru-
tained to the cluster by studs. nuts and wash-
ment panel and install the attaching washers and nuts.
(2) Connect all wires disconnected at time of re-
ers.
moval.
(4) If necessary to replace the cluster bezel glass,
(3) Connect cable at battery negative terminal.
ELECTRI C WI NDOW LI FT AND POWER SEATS
Servicing Procedures for the above units remain the plete servicing of these units, refer to the 1960 Plym-
same as described for the 1960 model cars. For com- outh Service Manual.
WI RI NG DI AGRAMS
The wiring diagrams for the 1961 model cars are new
and do not apply to the 1960 cars.
TO iHA AND INSTRUMENT PANS WIRING FUEL GAcz TANK NIT
MALE 6,x, 15
Fi g. l -Body and Dome Lamp Wi r i ng Di agr am
(Subur ban)
.
B-
Ill ALTERNATOR
LEFT
HEADL
DIM
lGHT
\
STARTER SOLENOID
- - - - - -
SOLENOID TYPE ONLY
,6 CYLINDER ONLY,
STARTER REM
Fi g. l -c hassi s and i nst r ument
59
RADIO
RIGHT FRONT DOOR
TO SPEEDOMETER HOUSING
AVTOMATIC SWITCH
MALE
TO HE.4TE.e MOTOR WC-4
CIGAR LIGHTER
THREt (3) MALE TERMINALS
FOR BATTERY ITEMS ONLY
SPEEDOMETER HOUSING
W,R,NG CONNECTOR (FEMALE)
INSTRUMENT LlGHT
REAR DEFROSTER
(7) MALE TERMINALS
,SED FOR ACCESSOR
I TEM S- O NLY
AMPERE GAUGE
TO
WI NDSHI ELD WIPE,
MOTOR , SPEEDOMETER LIGHTS
TVRN SIGNAL SWlTC
ATOR LIGHT
WINDSHELD WIPE
SWI TC H
(SINGLE SPEED)
I I I ?I I I II-L-I-
TOP t,FT SWTCH OR TAIL GATE WINDOW LIFT
I I ,111 LEFT TURN SIGNAL LIGHT
,/wP-2 1
I I IPARKIN
E-z--
AUTOMATIC
CHASSIS TO BODY
WlRlNG 8 WAY-
DISCONNCCT
PlLEi
FOOT DIMMER W.iTCH
BACK-UP LIGHT SWlTiii
M~RRORMATIC (WITH
MAIN LlGHTiNt SWITCH
LEFTFRONTDOOR
AIJ TOMPITIC SWlTCH
61 xl 57
Panel Wiring Diagram
L
RlGHTFRONTDOOR SWITCH RIGHT REAR DOOR MOTOR RGHT REAR DOOR OR RIGHT REAR DOOR OR QUARTER MOTOR
C,UARTER SWI TC H
-w-4 FEED
D O W N
/em-- 30AMPERE CIRCVIT BREAKER
SEE CHASSIS AND INSTRUMENT
PA NEL WI RI NG FO R C O WL
CIRCUIT BREAKER FEED
LEFT FRONT DOOR
M.4STERSWITCH LEFTFRONTDOOR MOTOR LEFTREAR DOOR OR QUARTER SWITCH LEFTREAR DOOR OR QUARTER MOTOR
w-,2
1 UP
UP
bv.1
II
II
--w-22--a DOWN
D O W N
--w-l3 W~l3C
-W-23 _ W 23Ae W23C
61x102
Fi g. t -Wi ndow Lift Wi r i ng Di agr am
UP
G RO UND
D O W N
TAILGATE WINDOWLIFTREAR ROOF
SWITCH WITH CHlLD GUARD
KU,., SWITCH IN LEFT
RlGHT REAR DOOR (OPEN WITH
DO O RS LO C KED)
TAlLGATE WINDOWUFT RELAY
FOR CHltD GUARD ONLY
(ON REAR ROOF RAIL)
DO WN RELA Y
THREE LEADS FOR
TAllGATE WINDOWLIFT REAR ROOF SWlTCH
FEED WITHOUT CHILD GUARD,3 SEAT SUBURBAN ONLY
FEMALE MALE
FEED@jfjkwq
D O W N FEMALE
TAllGATE WINDOWLIFT SWITCH
ON INSTRUMENT PANEL WlNDOW LIFT CIRCUIT BREAKER
SEE CHASSIS AND INSTRUMENT TAILGATE WINDOWUFT MOTOR
PANEL WIRING DIAGRAM FOR
B. A.
ClRCUlT BREAKER FEED (ON SIDE COWL)
61 x87
Fi g. 4-Tai l gat e Wi ndow l i f t Wi r i ng Di agr am
C LUTC H SO LENO I D
FRONT RISER
HORlZONTAL
RISER
SIX WAY SEATADJ USTEiSWlTCH
C OWL ClRCUlT BREAKER-
SEE CHASSIS AND
INSTRUMENT PANEL WlRlNG
DIAGRAM FOR FEED CABLE
1 MOTOR SEAT ADJ USTER MOTOR
F-2A
RELA Y
Fi g. & Si x Way Seat Adj ust i ng Wi r i ng Di agr am
6 2 ENGI NE-ENGI NE OI LI NG
Fi g. 6-Body and Dome l amp Wi r i ng Di agr am (ex c ept Subur ban)
GROUP 9
ENGI NE
225 CUBI C I NCH ENGI NE
The 225 cubic inch engine, as shown in Figure 1,
tional view points out internal structure in Figure 2.
is equipped with a new alternator, a spin on type
A closed crankcase ventilation system is a new feature
oil filter, and a new timing indicator. Engine side sec-
where legislation so requires.
SPECIFICATIONS
(225 CUBI C I NCH ENGI NE)
ENGINE
Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Displacement.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure at 1.50 rpm (plugs removed) Wide Open Throttle. . .
Maximum Variation Between Cylinders (any one engine)
. . . . . . . . . . . . . . . .
Firing Order,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-Line OHV
6
3.41
4.12
225 Cu. In.
8.2 to 1
130 to 160 psi
20 psi
l-S-3-6-2-4
Fully Counter-Balanced
ENGINE-ENGINE OILING 63
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing Journal Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Journal Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Out-of-Round Permissible. . . . . . . . . . . . . . . . . . . . . . .
Number Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Desired (Bearing installed I.D. Minus Journal O.D.)
Maximum Clearance Allowable Before Reconditioning, . . . . . . . .
End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Taken By. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finish at Rear Seal Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interchangeability of Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steel Backed Babbitt
2.7495 to 2.7505
2.1865 to 2.1875
.OOl
4
.0005 to .oow
.0025
.0035 to .0085
No. 3 Main Bearing
Diagonal Knurling
Upper Nos. 2, 4
Lower Nos. 1, 2, 4
.OOl, ,002, .OlO U.S.
Drop Forged I Beam
6.697 to 6.701
26.8 oz.
Steel-Backed Babbitt
2.1870 x 1.015
.0005 to .0015
.0025
,006 to ,012
Standard .001 . 002 .010 U.S.
.8995 to .9000
Chain
4
Cylinder Block
,001 to ,003
.005
1.998 to 1.999
1.982 to 1.983
1.967 to 1.968
1.951 to 1.952
2.000 to 2.001
1.984 to 1.985
1.969 to 1.970
1.953 to 1.954
50
.50"
.88
Mechanical
.0012 to .0025
.9040 to .9045
.010" Intake
.020 Exhaust
MAIN BEARINGS (service)
Al l Avai l abl e i n Standard and the fol l owi ng Undersi zes.
CONNECTING RODS AND BEARINGS
T y p e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (Center to Center) . . . . .
Weight (Less Bearing Shells) . . . .
Bearings . . . . .
Diameter and Length. . . . . . . .
Clearance Desired (Bearing Installed I.D. Minus Journal O.D.)
Maxi mum Cl earance Al l owabl e before Recondi ti oni ng, . .
S i d e C l e a r a n c e . . . . . .
.
.
. .
Bearings for Service. . . .
Piston Pin Bore Diameter.
CAMSHAFT
........ * ........
.................
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Taken by. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Desired (Bearing Installed I.D. Minus Journal O.D.) . . . .
Maximum Allowable before Reconditioning, . . . . . . . . . . . . . . . . . . . .
CAMSHAFT BEARING JOURNALS
Diameter
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.3 . . . . . . . . ..t.. . . .................
No. 4. . . .................
CAMSHAFT BEARINGS
Diameter (after reaming)
N O . ~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2. . . . . . . . . . . . . . .
No. 3. . . . . . . . . . . . . . .
No. 4. . . . . . . . . . . . . . .
TIMING CHAIN
...............
...............
...............
. .
. .
. .
. .
. .
. .
. .
.
Number of Links. . . . . . . . . . . . . .
P i t c h . . . . . . . .
Width . . . . . . . . . . . . . . * .
TAPPETS
Type . . . . . . . .
Cl earance i n Bl ock. .
Body Diameter. . . . . . . . . . . . . . . . . . .
Clearance between Valve Stem and Rocker Arm Pad (Engine Hot).
64
ENGINE-ENGINE OILING
PISTONS
Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Land Clearance (Diametral)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance at Top of Skirt.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (std. through ,040 oversize).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Length (overall),
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Groove Depth
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons for Service.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON PINS
Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Piston
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interference in Rod
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pins for Service.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction Offset in Piston
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS
Number of Ri ngs per Pi ston. .
Compressi on
Oil . . . . .
Width of Rings
( C o m p r e s s i o n ) .
( O i l )
Piston Ring Gaps (Compression)
(Oi l Control ).
RING SIDE CLEARANCE
(Compression)
U p p e r
Intermediate . . . .
(Oi l )
VALVES-I ntake
Material . .
.
. . . . .
. . .
................
................
................
................
.................
.................
. . . .
. . .
. .
.
.
Head Diameter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (to gauge dim. Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem Diameter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem to Guide Clearance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.: . . . . . . .
Maximum Allowable Before Reconditioning
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Face Angle
. . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . .
Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift, . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES--Exhaust
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Diameter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (to gauge dim. Line)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem to Guide Clearance.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* . . .
. .
. . .
Horizontal Slot w/ Steel Struts
Aluminum Alloy Tin Coated
,025 to ,030
.0005 to .0015
16 oz.
3.51
.361
,361
,365
Std. ,005, .020, .040 OS.
Press Fit in Rod
.9007--.9009
2.955 -2.975
.00045 to .00075
.0007 to .0012
Standard Only
Toward Right Side of Engine
3
2
1
.0775 to .0780
.1860 to .1865
.010 to ,020
,015 to .055
.0015 to .0030
.0015 to .0030
.0010 to .0030
Aluminum Coated
Carbon Manganese Steel
1.615~~~1.625
4.6878 -4.7028"
.372 to ,373
,001 to ,003
,004
45
Rocker Arm Screw
,375
Nitrogen Treated Manganese
Chromium Nickle Steel
1.355- l ,365
4.6878-4.7028
,371 to ,372
.002 to ,004
Maximum Allowable Before Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Li ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load when Compressed to (valve closed). . . . . . . . . . . . . . . , . . . . . . . . . . . . . .
Load when Compressed to (valve open) . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD
Combustion Chamber, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Run-Out (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Valve Seat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Width (finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Seat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Width (finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Gasket Compressed (thickness). . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION .
Pump Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity (qts.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Pressure at 40 to 50 mph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Drop Resulting from Clogged Filter, . . . . . . . .........
,006
47
Rocker Arm Screw
,360
12
2
l%gK @68-76 l bs.
1%6 @160~172 lbs.
Wedge Type
,002
45
,070 to ,090
45
.040 to ,060
.022
Rotary, Full Pressure
4
Camshaft
45 to 60 lbs.
7 to 9 psi
*When Filter Element is Replaced, Add 1 qt.
SPECIAL TOOLS
Tool Number Tool Name
C-756. . . Cleaner- Valve Guide
C-771 . . . . . . . . Tool- Flywheel Turning
C-823 . . . . . .Hone-Cylinder Bore Resizing
C-897 . . . . . . . . . . Dri ver-Wel ch Pl ug
C-3005 . . . . .Wrench Torque 1.00 Foot-Pound (sensory type)
C-3012, . . . . . . . . . Reamer-Cylinder Bore Ridge
C-3026 . . . . . . . . .Sl eeve- Guide Wear Measuring
C-3028 . . . . . . . . .Reamer Set-Val ve Tappet
C-3059. . . . . . . . . . Tool-Main Bearing Upper Shell
C-3065. . . . . . . . . Gauge-Cylinder Compression
C-3066 . . . . . . . . . . Connector -Timing Light
C-3068 . . . . . . . . Rack- Tappet
C-3132A. . . . . . . Tool-Cam Bearing Removing and Installing
C-3167. . . . . . . . . Stand-Engi ne Repai r
C-3168. . . . . . . . . .Adapter-Engine Repair Stand
C-3221 . . . . . . . . . Tool Piston and Connecting Rod
C-3339, . . . . . . . . . Dial Indicator Set
C-3422. . . . . . . . . ,Compressor-Valve Spring
C-3427. . . . . . . . . .Reamer-Valve Guide .030 Oversize
C-3430. . . . . . . . .Reamer-Valve Guide .OlS Oversize
C-3433. . . . . . . . . .Reamer-Valve Guide .005 Oversize
C-3501. . . . . . . . . .Hone-Cylinder Bore Deglazing
C-3506. Tool- Chai n Case Cover Oi l Seal Removi ng and I nstal l i ng
C- 3626. . Fi xtur es- Cyl i nder H ead H ol di ng
66 ENGINE-ENGINE OILING
C - 3654, R emo v er - O i l F i l t er
C - 3661 P u l l er - M ech an i cal T ap p et
C-3724. Tool --Pi ston Pi n Removi ng and I nstal l i ng
C - 3732. P u l l er Set - D amp er P u l l ey
C- 3743. . Tool - Rear Mai n Bearina Seal I nstal l i ng
- C-3804. . . . . . . . . . Pl ate-Engi ne Li fti ng
C-3805. . . . . . . . . Tool-Piston Ring Installing
C- 3806. Fi xtur e- Engi ne Suppor t
TORQUE REFERENCE
Connecting Rod Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sparkplug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor to Manifold Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain Case Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Housing Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Brace to Aluminum Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Brace to Engine Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Rear Bearing Seal Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Vacuum Line Tube Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting to Frame Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting to Block Nut, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mount Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Flange Nut. . . . . . . . . . . . . . . . . . . . :. . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Support Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Bracket Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Mounting Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Adjusting Strap Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Adjusting Strap Mounting Bolt . . . . . . . . . . . . . . . . . . . . . -: . . .
Intake to Exhaust Manifold Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Heat Control Counterweight Bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Attaching Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Gauge Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Shaft Bracket Bolt. . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . . . . .
Starter Mounting Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Gauge Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump to Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque
Foot-Pounds
45
65
85
30
35
30
200 in.-lbs.
30
40
30
30
30
40 in.-lbs.
95 in.-lbs.
200 in-lbs.
85
45
35
10
30
20
20
200 in.-lbs.
30
30
200 in.-lbs.
15
30
200 in.-lbs.
50 in.-lbs.
20
200 in.-lbs.
130 in.-lbs.
200 in.-lbs.
30
60 in.-lbs.
30
50
180 in.-lbs.
30
Thread
Size
s&24
%6&14
l/ 2-13
14mm
%6-14
3&16
%6-18
3/&16
%6--14
3/&16
3/B-16
3/8-16
Q-20
3/8-24
%6&18
y- 20
36-m
36-14
3/8824
%6-24
36 2 0
3/ 8-24
s/ &24
5/16--18
3/8+6
3j-16
%6-18
%6-18
s/ 8-16
%6el8
#JO-32
y- 20
%6-18
q-20
%6-18
3/4-16
l/ 8 N.P.T.F.
3/ 8-16
%6-14
l/ 4 N.P.T.F.
3/&16
ENG4NE-ENGI NE OI L I N G 67
,.
* /
Fig. l-Engine Assembly
.020H o/s cylinder
Bores
225 cu. in. .OOl U/ S Crankshaft Maltese Cross
M-Z-3 etc. (indicating
#2 & 3 main bearing
journal)
and/ or
R-l-4 etc. (indicating
# 1 & 4 connecting rod
journals)
Top of front pad-Right
side of Block
Crankshaft counterweight
.OlO U/ S Crankshaft X
M-10 (indicates .OlO
U/ S all main journals)
and/ or
R-10 (indicates .OlO
U/ S all rod journals)
Top of front pad-Right
side of block
A Top of front pad-Right
side of block
.008 O/ S Tappets Top of front pad-Right
side of block
ENGI NE-ENGI NE OI LI NG 6 9
1. DI STRI BUTOR
The distributor rotates clockwise.
Re mo v a l :
di recti on) unti l the val ve has l i fted .018 i nch. The
timing of the crankshaft pulley should now read from
12 degrees before top dead center to top dead center.
Readjust lash.
(1 j Remove distributor cap.
(2) Disconnect primary wire and vacuum line.
(3) Remove hold down bolt and remove distributor.
I nst al l at i on:
(3) If the reading is not within the specified limits:
a. Check sprocket index marks.
b. Inspect timing chain for wear.
C. Check accuracy of DC mark on timing indicator.
Before installing the distributor, time the engine as
follows :
3. CRANKSHAFT MAI N BEARI NGS
(1) Rotate the crankshaft until No. 1 cylinder is at
top dead center on firing stroke. At this point, the
straight line on the vibration damper should be under
the 0 mark on the timing indicator which is located
on the left side of the chain case cover.
(2) Rotate the rotor to a position just ahead of the
number one distributor cap terminal.
(3) Lower distributor into opening, engaging the
distributor gear with the drive gear on the camshaft.
With the distributor fully seated on the engine, the
rotor should be directly under the cap No. 1 tower
with ignition points just separating.
(4) Install distributor cap und firmly snap all high
tension wires in the cap towers.
(5) Install hold down clamp and screw and connect
primary wire.
The No. 1, 2 and 4 lower main bearings are inter-
changeable.
The No. 2 and 4 upper mai n beari ngs are i nter-
changeable.
The No. 1 upper main bearing is not interchange-
able and is chamfered on the tab side for timing chain
oiling and can be identified by a red mark on the edge
of the bearing. Upper main bearings are grooved and
lower main bearings are plain and ar e not i nt er -
changeable. The No. 3 upper and lower main bear-
ings are flanged to carry the crankshaft thrust loads
and are not interchangeable with cmy other main
bearings in the engine.
4. OI L FI LTER REPLACEMENT
(6) Adjust timing to specifications using a power
timing light. Connect the vacuum line.
The spin on oil filter should be replaced at the
first 3,000 miles of engine operation and every 4,000
miles thereafter to coincide with an oil change.
2. CHECKI NG VALVE TI MI NG
Removal :
(1) Rotate the crankshaft until #6 exhaust valve is
closing and #6 intake valve is opening. Install dial
indicator so that the indicator pointer contacts the
valve spring retainer on #1 intake valve parallel to
the axis of the valve stem.
(2) Turn #1 i ntake adjusti ng screw i n one com-
plete turn to remove lash. Adjust the dial indicator to
zero. Rotate the crankshaft clockwise (normal running
(1) Remove the outlet vent tube assembly.
(2) Remove the spin on oil filter from filter base
using Tool C-3654.
I nst al l at i on:
(1) Install the spin on oil filter by hand, finger
tip tight. DO not use tool. Then tighten by hand %
turn only.
(2) Install the outlet vent tube assembly.
318 CUBI C I NCH ENGI NE
The 318 cubic inch engine is equipped with a new main the same as outlined in the 1960 Plymouth Serv-
al ternator and a new al umi num chai n case cover. ice Manual.
Servicing Procedures for the 318 cubic inch engine re-
SPECIFICATIONS
(318 CUBI C I NCH ENGI NE)
ENGINE
T y p e . ..____..............................................
Valve Arrangement. . .
Number of Cylinders. .
Bore . . . . . . . . . . . . . . . . . . . .
90 v
In Heads
Opposed
8
3.91
70
SPECIFICATIONS ( Cont d)
Stroke
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Displacement (Cu. In.)
. . . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure ( Speed minimum 150 rpm)
Plugs removed, wide open throttle.
. . . . . . . . . . . . . . .
Maximum Variation between Cylinders (any one engine)
Firing Order,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
........
........
........
. . . .
CYLINDER NUMBERING-from drivers seat, front to rear
L e f t B a n k , . . . . . . . . .
Right Bank . . . . . . . . . . .
CRANKSHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Taken by
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Play.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Desired (Bearing Installed I.D. Minus
Journal O.D.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Clearance Allowable. . . . . . . . . . . . . . .
Finish at Rear Oil Seal Surface. . . . . . . . . . . . . . .
,,... ,....,
. .
. . .
MAIN BEARING SIZES
D i a me t e r a n d L e n g t h , . . . . . . .
MAIN BEARINGS (Service)
Available in Standard and the following undersizes. . . . . .
MAIN BEARING JOURNALS
Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Allowable Out-of-Round. . . . . . . . . . . . . . .
Maximum Allowable Taper. . . . . . . . . . . . . . . . . . . . . .
Center Bearing Run-Out (Total Indicator Reading)
.
. .,
. .
. .
. .
when supported at front and rear main bearing
. .
CRANKSHAFT ROD JOURNALS
Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Allowable Out-of-Round. . . . . . . . . . . . . . . . . . . . . . . .
Maximum Allowable Taper.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS
Length (center to center) . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (less bearing shell) . . . . . . . . . . . . . . . . . . . . . . . .
Bearings, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter and Length. . . . . . . . . . . . . . . . . . . . . . . . . .
Journal O.D.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Clearance Allowable, . . . . . . . . . . . . . . . .
Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD BUSHING
,
: .
, .
T y p e ,....,,...,,,.......,..,......_._..........._........
CAMSHAFT
Drive.......................................................
3.31
318 Cu. In.
9.0 to 1
135- 165 psi
20 psi
l-8-4-3-6-5-7-2
l-3-5-7
2-4-6-8
No. 3 Main Bearing
.002--.007
.ooo5-0015
.0025
Diagonal Knurling
No. lm 2.5015 x 0.872
No. 2-2.5015 x 0.872
No. 3p 2.5015 x 1.151
No. 4-2.5015 x 0.872
No. 5-2.5015 x 1.562
No. l-5--.001, ,002, 003, .010, .012
2.4995-2.5005
.OOl
.OOl
802
2.124-2.125
.OOl
.OOl
6.123
726 gms.
Steel-Backed Grip Type
2.126 x .842
.0005--.0015
.0025
.006-,014
Std. ,001, ,002, ,003, ,010, ,012
Steel Backed Bronze
.9842--.9843 -1.20
Chain
End Play. . .
Maximum Allowable. . . . . . . . .
Thrust Taken by. . . .
Clearance Desired (Bearing Intsalled I.D. Minus
J o u r n a l O . D . )
Maximum Clearance Allowable . .
CAMSHAFT JOURNALS
Diameter.
CAMSHAFT BEARINGS
Diameter, . .
TIMING CHAIN
Number of Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAPPETS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tappets Available in Standard and 001, .008,
.030 O.S. Operating Clearance (hot). . . . . . . . . . . .
PI STONS
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Bore (with .0015 x l/2 feeler stock) . . . . . .
Land Clearance (in bore) . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance (top of Skirt) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (standard through all oversizes) . . . . . . . . . . . . .
Ring Groove Width (upper) . . . . . . . . . . . . . . . . . . . . .
(intermediate). . . . . . . . . . . . . . . . .
(lower). . . . . . . . . . . . . . . . . . . . . . . .
Piston for Service, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON PINS
Tvwe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
Diameter and Length, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Piston (light thumb push at 70 F.) . . . . . . . . .
End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Rod, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pins for Service., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil with Expander. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Ring Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Side Clearance (upper) . . . . . . . . . . . . . . . . . . . . . .
(intermediate) . . . . . . . . . . . . . . . . . .
(lower) . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
.
.
. .
.
. .
.
.
. .
.
*
.002-006
,010
Thrust Plate
.OOl-,003
.005
No. l -1. 998-1. 999
No. 2-l ,982-l ,983
No. 3-1.967-1.968
No. 4 -1,951-l ,952
No. 5-1.5605-1.5615
No. 1-2.000-2.001
No. 2-1.984-1.985
No. 3-1.969-1.970
No. 4-1.953--l ,954
No. 5-1.5625-1.5635
68
,375
1.02
Mechanical
.9040--.9045
.0005 . 0018
. 010 Intake ,018 exhaust
Conformatic with Steel Band
Aluminum-Alloy Tin Coated
5-10 pounds pull
.0219-,024
.0005-.0015
592 gms.
.0795--.0805
.0095 . 0805
.1875--.1890
Std. .005, ,020, .040 O.S.
Full Floating
.9842 x 2.995
.0000 .0005
.004--.026
0001-0004
Std. .003, ,008 OS.
2
1
.010~~.020
.0015-0030
.0015 -.0030
.OOlO--.0030
TORQUE REFERENCE (Cont d)
Foot-Pounds Inch-Pounds
Chain Case Cover (Cast). . . . . . . . . . . . . 35
Clutch Housing Bolt. . . . . . . . . . . . . . . . . . . 30
Clutch Housing Vent Hole. . . . . . . . . 100
Clutch Housing Pan Drain Plug. . . . . . . . . . . 35
Crankcase Vent Outlet Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bolt. . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting
To Engine Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Frame Bracket Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting
To Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing to Cylinder Block. . . . . . , . . . . . . . . . . . . . . . .
Flywheel Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Indicator Tube Bracket. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Base Attaching Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Cover Bolt. . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filler Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Tappet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Damper Bolt. . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . .
. . . 45
85
. . . 20
.
15
135
36
35
35
50
30
100
130
35
15
15
35
30
30
30
27
50
200
Engine
Displacement
318 cu. in.
OVERSI ZE AND UNDERSI ZE
ENGI NE COMPONENT MARKI NGS
Condition Identification Location of Identification
,001 U/ S Crankshaft Maltese Cross Following engine serial number
M-2-3 etc. (indicating
#2 & 3 main bearing
journal)
and/ or Crankshaft counterweight
#1 & 4 connecting rod
journal)
,010 U/ S Crankshaft X
M (indicates .010 U/ S
all main journals)
and/ or
R (indicating .010 U/ S
all rod journals)
Following engine serial number
.020 O/ S Cylinder
Bores
A Following engine serial number
,008 O/ S Tappets *
Following engine serial number
I
ENGI NE-ENGI NE OI LI NG
7 5
361 AND 383 CUBI C I NCH ENGI NE
The 361 and 383 cubic inch engines are equipped fuel. The 383 cubic inch engine has a compression ra-
with a new alternator. The 361 cubic inch engine has a tio of 10.0 to 1 and uses premium grade fuel.
compression ratio of 9.0 to 1 and uses regular grade
SPECIFICATIONS
(361-383 CUBI C I NCH ENGI NE)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore-361 cu. i n. . . . . . . . . . . . . . . . . . . . . . . . .
383cu.in. . . . . . . . . . . . . . . . . . . . . . . . . ::::::::::l:.::::
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure at 150 rpm (plugs removed)
Wide Open Throttle. . . . . .
Maximum Variation Between Cylinders (any one engine) . . . . . . . . .
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER NUMBERING
Left Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Journal Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crank Pin Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Out-of-Round Permissible . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Desired (Bearing Installed I.D. Minus Journal O.D.)
Maximum Clearance Allowable before Reconditioning . . . . . . . . . . . .
End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Taken by. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finish at Rear Seal Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interchangeability of Bearings ......... . . . . . . . . . . . . . . . . . . . . . .
MAIN BEARINGS (Service)
c
All available in Standard and the following Undersizes. . . . . . . . . . . .
CONNECTING RODS AND BEARINGS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (Center to Center), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (less bearing shells) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter and Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cl earance Desi red (Beari ng I nstal l ed I .D. Mi nus J ournal O.D.)
9 0 v
8
4.13
4.25
3.38
361 cu. in.
383 cu. in.
361 cu. in.
9.0 to 1
383 cu. in.
10.0 to 1
361 cu. in.
135-165 psi
383 cu. in.
150 - 180 psi
361 cu. in.-20 psi
383 cu. in.-25 psi
l-8-4-3-6-5-7-2
l-3-5-7
2-4-6-8
2.6245 to 2.6255
2.374 to 2.375
.001"
5
.0005 to .0015
.0025
.002 to ,007
No. 3 Main Bearing
Diagonal Knurling
Upper Nos. 1, 2, 4, 5
Lower Nos. 1, 2, 4, 5
.001, ,002, ,003, ,010, .012
Drop Forged I Beam
6.356 to 6.360
846 gms.
2.375 x .927
.0005 to .0015
Maximum Clearance Allowable before Reconditioning. . . . . . . . . . . .
Si de Cl earance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pin Bore Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust Taken by. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Journal O.D.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Clearance Allowable before Reconditioning . . . . . . . . . . . .
CAMSHAFT BEARING JOURNALS
Diameter
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT BEARINGS
Diameter (after reaming)
No. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING CHAIN
Adjustment .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAPPETS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Valve Stem and Rocker Arm Pad. . . . . . . . . . . . .
PI STONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Land Cl earance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance at Top of Skirt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (std. through ,040 oversize). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Length (overall). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;. . . . .
Ring Groove Depth
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON PINS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.0025
.009 to ,017
Std. ,001, .002, ,003,
,010, .012 U.S.
1.0925 to 1.0928
Chain
5
Cylinder Block
.OOl to .003
.005
1.998 to 1.999
1.982 to 1.983
1.967 to 1.968
1.951 to 1.952
1.748 to 1.749
2.000 to 2.001
1.984 to 1.985
1.969 to 1.970
1.953 to 1.954
1.750 to 1.751
N one
50
30
.88
Hydraulic
.0005 to .0018
.9040 to .9045
Dry Lash
Horizontal Slot w/ Steel
Struts
Aluminum Alloy Tin Coated
.031 to ,037
.0005 to .0010"
732 gms.
3.84
,214
,214
,199
S t d . .005, .020, .040 O S .
Press Fit in Rod
1.0935 to 1.0937
7 7
Length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in Piston.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interference in Rod
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pins for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction Offset in Piston.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS
Number of Rings per Piston.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0 1l......................................................
. . .
Width of Rings
(Compression)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Oil)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rings Gaps (all).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RING SIDE CLEARANCE
(Compression)
Upper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES-Intake
Material
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (to center of valve face)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Allowable before Reconditioning.
. . . . . . . . . . . . . . . . . . . .
Angle of Seat . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES-Exhaust
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Diameter.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (to center of valve face)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stem Diameter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Allowable before Reconditioning.
. . . . . . . . . . . . . . . . . . . . .
Angle of Seat. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS
Number. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free Length.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load when Compressed to (valve closed).
. . . . . . . . . . . . . . . . . . . . . . .
Load when Compressed to (valve open)
. . . . . . . . . . . . . . . . . . . . . . .
Valve Spring I.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD
Number Used
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion Chamber.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Runout (maximum)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Valve Seat Angle
Seat Width (finished). . . . . . : : : : : : : : : : 1 : : : : : .. : .. : : 1: : : : : 1: : 1: : : ..
Exhaust Valve Seat Angle.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Width (finished)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.555 to 3.575
.OOo45 to .00075
.0007 to .0012
Standard Only
Toward Right Side of Eng.
3
2
1
.0775 to .0780
.1860 to .1865
.013 to .025
.0015 to .0030
.0015 to .0030
.0010 to .0030
Silicon-Chromium Steel
361-383-2.08
4.79
.372 to ,373
,001 to .003
.004
45
None
,389
Nitrogen Treated Manganese
Chromium-Nickel Steel
1.60
4.79
.371 to .372
.002 to ,004
,006
45
None
.389
16
2.34
1.860 @ 95-105 lbs.
1.470 @ 187-203 lbs.
1.010 to 1.030
2
Wedge Type
,002
45
.060 to .085
45
040 to ,060
78
SPECIFICATIONS (Cont d)
Cylinder Head Gasket
Compressed (thickness) . . . . . . .
002
ENGINE LUBRICATION
Pump Type . . . . . . . . . . . . . .
Rotary, Full Pressure
Capacity (quarts) . . . 5*
Pump Drive. . . . . . . . . . . . .
Camshaft
Operati ng Pressure at 40 to 50 mph.
45 to 65 lbs.
Pressure Drop Resulting from Clogged Filter. . . .
7 to 9 lbs.
*When Filter Element is Replaced, add 1 Quart.
OIL PUMP - INSPECTION LIMITS FOR REPLACEMENT
Filter Base Surface. . . . .
. . . . . . . . . ,015 inch or more
Outer Rotor Length, . . . . . . .
,943 inch or less
Outer Rotor Diameter. . . . . . . . . . . . .
2.469 inch or less
InnerRotorLength...........................................................
.942 inch or less
C l e a r a n c e O v e r R o t o r - O u t e r . . . . . . .
. .
004 inch or more
Inner. . . . . . . . . . . . .
.005 inch or more
Outer Rotor Clearance, . . . . . . . . . . .
.012 inch or more
Clearance Between Rotor. . . . . . . . . . .
.OlO inch or more
SPECIAL TOOLS
C - l 19, .Cylinder B o r e I n d i c a t o r
C- 385. Pi s t o n Ri ng Co mpr e s s o r
C-647, Valve Spring Testing Fixture
C- 756, . .Valve Gui d e Cl e a ne r
C-897. Core Hole Plug Driver
C-3026. .Valve Gui de Wear Checki ng Sl eeves
C- 3028. .Tappet Bo r e Re a me r
C-3033. .Engine Front End Pul l er Ki t
C - 3 0 5 2 . Distributor Drive Shaft Bushing Puller
C-3054. Spark Plug Socket
C-3059, .Main Bearing Upper Shell Remover and Replacer
C-3068 .Tappet and Push Rod Carri er
C-3132. .Camshaft Beari ng Remover and Repl acer
C- 3160. .Tappet Che c ki ng Pl i e r s
C- 3167. .Engine Re pa i r St a nd
C- 3221 .Piston and Connecting Rod Remover and Replacer
C-3339, Dial Indicator
C- 3422. .Valve Spr i ng Co mpr e s s o r
C- 3427. Re ame r (.030 O. S. )
C - 3 4 3 0 . .Reamer (.015 O . S . )
C- 3433, . Re ame r (.005 O. S. )
C-3466. Engine Lifting Plate
C- 3487. Engi ne Suppor t Fixture
C-3501. .Cylinder Bore Surfacing Hone
C-3506. .Chain Case Cover Oil Seal Remover and Replacer
C-3509. . Camshaf t Gear Instal l er
C-3625 .Rear Mai n Beari ng Oi l Seal I nstal l er
C-3626. .Cylinder Head Holding Fixture
C-3628. Piston Ring Remover and Replacer (361 cubic inch engine)
C-3648. .Valve Stem Length Gauge
C - 3 6 5 4 Oil Filter Remover and Replacer
C-3661. Tappet Remover
C - 3662. .Engine Repai r Stand A daptor
C-3613. Pi ston Ri ng Remover and Repl acer (383 cubi c i nch engi ne)
C-3684. . . . . . . Piston Pin Remover and Replacer
79
TORQUE REFERENCE
Connecting Rod Nut-Plain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing Cap Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug. ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Lockbolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor to Manifold Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain Case Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Rear Bearing Seal Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover Stud and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Vacuum Line Tube Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Clamp Bolt. . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting to Frame Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting to Block Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Front Mounting to Frame Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Support Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .
Fan Belt Idler Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Belt Idler Pulley Bracket Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .
Flywheel Housing to Cylinder Block Bolt. . . . . . . . . . . . . . . . . . . . . , . . . .
Flywheel Housing Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Attaching Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .
Alternator Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Adjusting Strap Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Adjusting Strap Mounting Bolt. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Heat Control Counterweight Bolt. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . .
Oil Pan Bolt. . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Attaching Bolt., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Attaching Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Shaft Bracket Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Mounting Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Damper Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Tappet Cover End Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump To Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Housing to Cylinder Block Bolt. . . . . . . . . . . . . . . . . . . . . . . .
A/ C Compressor to Engine Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque
Foot-Pounds
45
70
85
30
35
7
15
30
30
30
135
40 in.-lbs.
95 in.-lbs.
15
8.5
45
20
30
40
20
20
15-18
45
30
SO
7
30
20
15
30
40
50 in-lbs.
35
15
10
35
30
30
50
15
9
30
30
30
Thread
Size
3/ 8 24
%6-14
l/ 2 13
14mm
56-14
%6-24
H6-18
3/&16
3/&16
3/8-16
3/4-16
l/!-28
3/8-24
%b 1 8
$2-20
%6 2 0
l/ 2-13
3/ 8 -16
56-20
3/ 8-24
3/8- 24
%6-18
%6- 20
3/&16
36-14
IA-20
s/ 8-16
%6-24
%b 1 8
3/& 16
3h 16
#lo-32
5&18
S-18
36-18
3/8-16
3/4-16
3/-16
86-14
%6&18
G-20
+16
3/8-16
3& -16
80 ENGI NE-ENGI NE OI LI NG
Engine
Displacement
361 cu in.
383 cu. in.
OVERSI ZE AND UNDERSI ZE
ENGI NE COMPONENT MARKI NGS
Condition Identification Location of Identification
,001 U/ S Crankshaft Maltese Cross Top pad-Front of engine
M-2-3 etc. (indicating
#2 & 3 main bearing
journal)
#1 & 4 connecting rod
journals
.OlO U/ S Crankshaft X Top pad-Front of engine
M-10 (indicates .OlO
U/ S all main journals)
R-10 (indicates ,010 U/ S
all rod journals)
,020 O/ S Cylinder
Bores
A Top pad-Front of engine
.008 O/ S Tappets *
Top pad-Front of engine
1. FRONT ENGI NE MOUNTS - 318, 361,
383 CUBI C I NCH ENGI NES
For better stabilization of the engine, frame bracket
studs and prevailing torque nuts are now used in place
of bolts. Heat shields have been added to protect the
mounts.
Removal:
(1) Disconnect throttle linkage at transmission and
at carburetor.
(2) Raise hood and position fan to clear radiator
hose and radiator top tank.
(3) Remove prevai l i ng torque nuts from frame
bracket studs.
(4) Raise the engine just enough to remove front
engine mount assembly.
Installation:
( 1) Install mounts on the engine and tighten nuts
to 45 foot-pounds torque.
(2) Slide heat shields over engine mount bolts and
install the second nuts. Tighten nuts to 45 foot-pounds
torque.
(3) Lower the engine and install washers and pre-
vailing torque nuts on frame bracket studs. Tighten
nuts to 75 foot-pounds torque.
CLOSED CRANKCASE VENTI LATI ON SYSTEM
1. DESCRI PTI ON
tion of the valve is to regulate the flow of crankcase
Closed crankcase ventilation is effected by means
ventilation at various throttle positions.
of air drawn into the crankcase through the oil filler
The system will operate effectively as long as nor-
cap, circulated through the engine, and drawn out of
mal maintenance is applied. The valve and tube are
the cylinder head cover by manifold vacuum into the
subject to fouling with sludge and carbon formation
combustion chambers and dispelled with the exhaust
due to the nature of the materials carried by the ven-
gases. (Fi g. 1).
tilating system.
The system consists of a ventilation valve installed
in the outlet vent cap on the cylinder head cover, and
2. SERVI CE PROCEDURES
a tube connected between the outlet vent cap and the
At regular intervals of 10,000 miles, the regulating
lower part of the carburetor throttle body. The func-
valve and the tube running from the valve to the car-
le body should be removed from the en-
gine, disassembled and cleaned thoroughly.
valve seat squarely and will not close properly .
sequently, the engine will not idle properly due to the
NOTE: Under cold weather conditions,
entrance of too much air into the intake manifold. If
when vehicles are operated at slow speeds
the spring has been stretched the same trouble may
with low engine temperatures, more rapid
occur.
If improper action of the spring is suspected due to
accumulations of harmful fumes may be
present in the engine. Under these conditions
spring being distorted, bent or etched from corrosive
of operation the valve and tube must be
action, the valve assembly should be replaced.
cleaned more frequently than specified
above. How ever , no specific mileage recom-
mendation can be made under these condi-
tions. Frequency of cleaning must be dictated
by experience.
Disassemble the valve (Fig. 2) and clean the valve
parts with any good solvent cleaner and blow dry with
compressed air.
When reassembling the valve parts, be sure to at-
tach the spring on the valve by pushing the end coil
over the tapered end of the valve, over the ridge and
into the groove machined just under the head of the
61X213
valve. This is very important. Unless the spring is
Fi g. P-Crank c ase Vent i l at i on Val ve
properly assembled. the valve will not contact the
(Di sassembl ed)
GROUP 11
EXHAUST SYSTEM
The Exhaust System used on the 1961 Plymouth
the 1960 Plymouth Service Manual for service pro-
passenger cars is identical to the 1960 system. Refer to
cedures.
l
82 FRAME
TORQUE REFERENCE
Foot-Pounds
V-8 ENGINES
Ball Joint Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe Support Clamp Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing Bracket Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-CYL. ENGINES
Exhaust Pipe Flange Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake to Exhaust Manifold Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold to Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. . . . .
. . . .
.
. . . . .
. . .
.
. .
.
20
30
4 0
10
15
.
30
15
10
GROUP 13
FRAME
The same type of stub frame used wi th the 1960 sions and Service Procedures remain the same as out-
Models is used on the 1961 Models. The Frame Dimen- lined in the 1960 Plymouth Service Manual.
GROUP 14
FUEL SYSTEM
The Service Procedures for the 1961 Fuel System System, use the 1960 Pl ymouth Servi ce Manual i n
remain the same as outlined in the 1960 Plymouth
conjunction with new procedures and specifications
Service Manual except as listed in this Supplement. outlined in this Supplement.
For compl ete servi ci ng of the 1961 Pl ymouth Fuel
BBS CARBURETOR
,
The service procedures and adjustments covering adjustments.
the new BBS carburetors, shown in Figures 1 and 2, (3) Cl osed crankcase vent system (mandatory
are the same as covered in the 1960 Plymouth Service equipment on all cars for the state of California).
Manual with the following exceptions: (4) The choke unloader setting has been changed
(1) Synthetic rubber tipped fuel inlet needle (re- to 3/ 16.
quiring a new procedure for setting the float). (5) Accel erator pump setti ng changed to % on
(2) I dl e speed, i dl e mi xture and fast i dl e speed BBS3097S and BBS3129S. (Refer to Specifications.)
BBS CARBURETOR
SPECIFICATIONS
CARBURETOR
Type. . . . . . . Ball and Ball Single Throat Ball and Ball Single Throat
Model Standard
M a n u a l T r a n s m i s s i o n .
A u t o ma t i c T r a n s mi s s i o n
Bore . . . . . .
Venturi . . . . . . .
Main Metering Jet
Standard . . .
One Step Lean. . . .
Two Steps Lean. . . . .
S t e p - U p Wi r e ( S t a n d a r d )
Diameter . .
BBS3098S
BBS3099S
l/igC
l!&
# 120-206S # 120-206S # 120-206S # 120-209s # 120-209s
# 120-215S # 123-215S # # 123-211s #123-211S
# 123-214# $123-214s # 123-214s , 123-210s 4 123-210s
75-999 75-1426 75-991 75-1208 75-1208
(.029) (.031) (.026) (.023) (.023)
Taxi -
*BBS-3129s
*BBS3129S
lY?
1 1/4
*BBS3128S BBS3097S
*BBS-3 128s BBS3097S
1 l/16 1%
11% 11/4
ADJUSTMENTS
Float Setting .. . . . . .
Choke Unloader, . . . .
Accelerator Pump (Top of Plunger
and Air Horn). . . .
Idle Mixture Screw (turns open)
Idle Speed R.P.M. (curb idle). .
Fast Idle Speed (engine hot and
screw on SECOND step of cam)
W %232n %2,
3h6 3/16 346
52
2936
2yg
1
550
2%2u
1
550
**3 11
/4
1
550
**3 if
/4
1
550
1600 1800 Std. 1800 Std. 1800 Std.
-
1600 Auto. 1600 Auto. 1600 Auto.
2w
1
550
1800
CHOKE
Control. . . . . . . . . .
Type. . . . . . . .
Setting . . . . . . . . . .
*For use with closed crankcase vent system--
* *Accelerator Pump in Short Stroke.
Thermostatic Coil Spring
Well
On Index
WeII Well
On Index On Index
-mandatory for California cars.
Well Well
On Index On Index

84
FUEL SYSTEM
j i,
FUEL SYSTEM 8 5
APPLY PRESSURE TO RET
TO SEAT FULCRUM PIN
,
FUEL INLET NEEDLE
5
Fi g. 3-Synt het i c Rubber Ti pped Fuel I nl et Needl e, Seat
MAIN BODY INVERT&
,.
and Gask et (Ex pl oded Vi ew)
1. SYNTHETIC RUBBER TIPPED FUEL INLET
NEEDLE
Fi g. 4-Chec k i ng t he Fl oat Set t i ng
hape. Recheck as described in Step 4 above.
-- ----mt that the float lip be perpendicular
slanted not more than 10 degrees
.-Jl- ---L-- 11-- 11--t .~ . (1
The carburetors for the 1961 model cars are equipped
original s
with a new synthetic rubber tipped fuel inlet needle. The
It is very nripur L(
needle tip is a rubber material which is not affected
to the needle or
by gasoline and is stable over a wide range of tem-
away from the net
/
/
peratures. The tip is flexible enough to make a good
seal on the needle seat, and to give increased resist-
3. FAST IDLE HHHH
ante to flooding.
Curb and Fd
~tf wnsn me wxn IS ser correcuy.
,M I Nnc Y /uI :& l . Cm--..-a-
-CU.. II.YLI\ ,..nnnn rspuru,e
. -__I . ast Idle Adjusting Screws)
IX the fast idle cam, refer to Figure 5, then
as follows :
?en the throttle valve and hold the choke
the fully closed position. This will position
rl,r. _..,.
at the fast idle index position.
the throttle valve. The index mark
Id split the center of the fast idle
screw, as shown in Figure 5.
--l;,.-*--nt is necessary, bend the fast idle
- - - uL HHH angle, using Tool Tl09-213. until
mark on the cam indexes with the fast idle
screw.
!
2. CHECKING OR SETTING THE FLOAT *
To indc
proceed (
HEIGHT (1) 01
The use of the new inlet needle requires a new
valve in
procedure in adjusting the float setting. Care should
the fast ibrG c-UIII
be taken to perform this operation accurately in order
(2) Now close
to secure the best performance and fuel economy.
on the cam shou
To correctly set the float height, when the carburetor
adjusti ng -I---- -
is being overhauled, proceed as follows:
I f an ~~~~~~~~~~~
(1) Install the floats with the fulcrum pin and pin
connector ma d 4
retainer in the main body.
the index
(2) Install the needle, seat and gasket in the body adjusting
and tighten securely. (See Figure 3.)
(3) Invert the main body so that the weight of the
A
floats only, is forcing the needle against the seat.
(4) Using Tool T109-239 or a T scale, check the
INDEX MARK
ON FAST IDLE
float, as shown in Figure 4. There should be 7/ 32
inch from the surface of the fuel bowl to the crown
of each float at the center.
CAM
If an adjustment is necessary, hold the floats on the
bottom of the bowl and bend the float lip toward or
away from the needle. Recheck the 7/ 32 setting again
and repeat lip bending operation as required. CAU-
TION: 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
af f ec t c or r ec t level of fuel i n the bowl. After
being compressed, the tip is very slow to recover its
FAST IDLE
AD,USTiNG\
SCREW
E
b
Fi g. 5-Fc 1st i dl e I ndex Mar k Al i gned
,
8 6 FUEL SYSTEM
The final fast idle speed adjustment must be made
with the carburetor installed on the engine.
4. IDLE SPEED ADJUSTMENT(Curb Idle)

To make the idle speed adjustment, the engine
FAST IDLE SPEED
ADJUSTING SCREW
must be thoroughly warmed up. A more reliable idle
adjustment can usually be obtained if the car has
been driven a minimum of five miles. For best results,
it is recommended that a tachometer be used in this
adjustment.
Before making the idle speed adjustment, observe
the following precautions:
Because the alternator can charge at idle speeds SECOND STEP
and impose a load on the engine, the headlights
should be turned on (high beam). This will assure
61x79
setting the idle to compensate for the alternator load.
On cars equipped with the automatic transmission,
Fig. 6-Fast Idle Adjusting Screw on 2nd Step of Cam
unsnap the ball joint connection at the accelerator
shaft bellcrank. If this is not done, it is possible that
the carburetor throttle will be held open against the
a tachometer then proceed as follows:
I
stop in. the transmission. The carburetor would there-
( 1) With the engine running and warmed up, open
fore not respond to adjustment of the idle speed screw.
the throttle slightly and rotate the fast idle cam until
After the proper idle speed has been obtained at the
the fast idle adjusting screw will contact the second
carburetor, screw the ball joint connector up or down
(2nd) step of the fast idle cam, as shown in Figure 6.
(2) Release the throttle. The linkage pull back
until the ball on the bellcrank will exactly mate with
the socket. Snap in place.
spring will cause the fast idle adjusting screw to hold
TO make the idle speed adjustment, proceed as
the cam in this position.
fol l ows :
(3) Turn the fast idle adjusting screw clockwise
( 1) Turn the idle speed screw in or out to obtain
(faster) or counter-clockwise (slower) to obtain a
550 r.p.m. (Make sure that the choke valve is fully
fast idle speed, as shown in the Specifications.
open and that the fast idle adjusting screw is not
It should be remembered that this fast idle speed ,
contacting the cam.)
is used to secure the correct adjustment and is never
(2) Adjust the idle mixture screw to obtain the
encountered in normal car operation. In cold weather,
highest r.p.m. While making the adjustment, carefully
engine oils are thicker and engine friction is relatively
watch t he tachometer and notice that the speed can
high. Under these conditions, the above fast idle ad-
be decreased by turning the screw in either direction justments will result in opening the throttle enough
!
from that setting that gave the highest r.p.m. reading.
to keep the engine running. Because conditions can
(3) From the highest idle speed setting turn the
vary widely (such as, lighter oil, an engine with
mixture screw clockwise (leaner) until the speed
more miles, and lower friction, etc.), it is possible to
starts to drop. Turn the screw in the opposite direction adjust the fast idle speed to suit any particular owners
(counter-clockwise) just enough to recover the speed
requirements. The recommended setting, is intended to
that was lost.
meet average conditions and normal operation.
This procedure will assure that the idle has been
set to the leanest mixture possible for smooth idle.
This set t i ng is very important.
6. CHOKE UNLOADER (WIDE OPEN KICK)
Since the correct speed was originally set using the
To check the choke unloader (wide open kick),
speed screw, the speed obtained after finding the refer to Figure 7, then proceed as follows:
leanest smooth idle setting will probably change.
(1) Hold the throttle valve in the wide open posi-
(4) Readjust the speed screw to obtain the correct
tion, insert Tool T109-28 or a 3/ 16 inch drill between
idle speed. Repeat Steps 2 and 3 above.
the upper edge of the choke valve and the inner wall
of the air horn, as shown in Figure 7.
5. FAST IDLE SPEED ADJUSTMENT
(2) I f no drag i s fel t, or i f tw much drag i s
apparent, bend the unloader tang on the throttle lever.
To set the fast idle speed, refer to Figure 6. Connect until correct clearance has been obtained.
8. CHECKI NG THE FLOAT SETTI NG-(On t he
Vehi c l e)
FUEL SYSTEM 87
CHOKE UNLOADER
GAUGE
_rc CHOKE VALVE
HELD CLOSED
TANG ON
THROTTLE LEVER
To check the float setting with the carburetor mount-
ed on the vehicle, proceed as follows:
1) Remove the accelerator pump operating rod and
the fast idle cam link retaining pin.
(2) Remove two of the long air horn attaching
screws and two short screws, then install the two
short screws in place of the two long screws removed.
This will hold the main body to the throttle body.
Tighten screws securely.
THROTTLE VALVE
(3) Remove the remaining air horn screws, then
tilt the air horn far enough to disengage the fast idle
cam link from the fast idle cam. Remove the air horn
and gasket.
Check the float setting as follows:
(4) Seat the float fulcrum pin by pressing on the
HELD WIDE OPEN
61x80
Fig. 7-Checking Choke Unloader Setting
Ac c el er at or Pump and Bowl Vent (Car bur et or s
fulcrum pin retainer,
BBS-3097S and BBS-3 129S Onl y)
There should be enough fuel in the bowl to raise
the float so that the lip bears firmly against the needle.
(1) Back off the idle speed adjusting screw. Open Additional fuel may be admitted by slightly depressing
the choke valve so that the throttle valve can be
the float. If the fuel pressure in the line is insufficient
completely seated in the carburetor bore. Be sure the
to force additional fuel into the bowl, add the necessary
pump connector rod is in the short stroke hole of the
fuel from a clean container. CAUTION: Since the
throttle lever. manifolds may be hot, it is dangerous to spill
(2) Close the throttle valve tightly. Now, measure
fuel on these surfaces. Therefore, take the
the distance between the top of the air horn and the
nec essary precautions to avoid spillage.
end of the plunger shaft. This measurement should be
(5) With only the pressure of the buoyant float
3h.
holding the float lip against the inlet needle, check
(3) To adjust the pump travel, bend the pump
the float setting, using Tool T109-239 or a T scale.
connector rod, using Tool T109-213, at the lower angle There should be 7/ 32 inch from the surface of the
until correct travel has been obtained. bowl (gasket removed) to the crown of the floats at
With the pump plunger shaft correctly adjusted,
the center.
there should be 5/ 64 inch clearance between the top
If an adjustment is necessary, hold the float on the
of the bowl cover and the bowl vent valve. bottom of the bowl, then bend the float lip toward or
away from the needle. Recheck the 7/ 32 inch setting
7. CLOSED CRANKCASE VENT SYSTEM
again, then repeat the lip bending operation as re-
quired. CAUTION: When bending t he f l oat l i p,
The closed crankcase ventilator valve is located
do not allow the lip to push against the
in the crankcase vent tube cap and is connected to
needle as the synthetic rubber tip can be
the carburetor throttle body via a rubber tube.
compressed sufficiently to cause a false set-
The function of the valve is to regulate the flow
ting which will affect correct level of the fuel
of unburned hydrocarbons from the crankcase and
in the bowl. After being compressed, the tip is very
return them to the intake manifold. From here they
slow to recover its original shape.
enter the combustion chamber and then exit via the
It is very important that the float lip be perpendicular
exhaust system as completely burned exhaust prod-
to the needle or slanted not more than 10 degrees
ucts.
away from the needle when the float is correctly set.
For servicing procedures of this valve, refer to (6) Reassemble the air horn as described previous-
Engine section of this Manual.
ly.
8 8 FUEL SYSTEM
BBD CARBURETOR
The service procedures and adjustments covering (2) A new step up piston with two stage step up
the new BBD carburetors, shown in Figure 1, are the rods.
same as covered in the 1960 Plymouth Service Manual (3) A new procedure for setti ng the Accel erator
with the following exceptions: Pump and Bowl Vent.
( 1) Synthetic rubber tipped fuel inlet needle (re- (4) A new procedure for setting the Curb and Fast
quiring a new procedure for setting the float). Idle Adjustments.
BBD CARBURETOR
SPECIFICATIONS
CARBURETOR
Type .
Model
Manual Transmission
Bore
Venturi . . . . . .
Main Metering Jet
S t a n d a r d .
One Step Lean. .
Two Steps Lean. . .
Step-Up Wi re Standard) . .
Diameter (2 stage).
. .
. .
. . . . .
Float Setting (at center of floats),
Bowl Vent Valve (throttle closed).
Choke Unloader. . . .
Idle Mixture Screws (turns open).
Idle Speed R.P.M. (curb idle) . . .
(A i r Condi ti oned car s).
Fast I dl e Speed R.P.M.. . . . . .
............. .
..............
..............
..................
..................
..................
..................
.......... ......
...........
...... ....
...........
...........
...........
...........
...........
CHOKE
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
The needl e ti p i s a rubber materi al whi ch i s not
NEEDLE affected by gasoline and is stable over a wide range
of temperatures. The tip is flexible enough to make
The carburetors for the 1961 model cars are equipped a good seal on the needle seat, and to give increased
with a new synthetic rubber tipped fuel inlet needle. resistance to flooding.
Ball and Ball Dual Downdraft
BBD-2921 S
BBD-2922S
1% 1%6
1% 13/6
#120-213S #120-213S
# 120-212s # 120- 212s
# 120-209s iti 12om-209S
75-1442 75-1429
,021 x ,024 ,024 x ,028
500 500
550 550
1400 1400
Well Well
On Index On Index
FUEL SYSTEM 89
ACCELERATOR PUMP
ROCKER ARM
CHOKE LEVER
BOWL VENT VALVE
FAST IDLE
, C ONNEC TOR ROD
FAST IDLE CAM
IDLE SPEED
ADJUSTING SCREW
MA I N BO DY
ACCELERATOR PUMP
CONNECTOR ROD
IDLE MIXTURE
ADJUSTING SCREWS
IDLE
ADJUSTING SCREW
THROTTLE BODY
THROTTLE LEVER
REPAIR STAND
60x108
Fi g. I -Carburet or Assembl y (BED-2921s and BBD-2922s)
2. CHECKING OR SETTING THE FLOAT (1) Install the floats with the fulcrum pin and pin
HEIGHT retainer in the main body.
(2) Install the needle, seat and gasket in the body
procedure in adjusting the float setting. Care should
and tighten securely. (See Figure 2.)
(3) Invert the main body so that the weight of the
floats only, is forcing the needle against the seat.
To correctly set the float height, when the carburetor
Hold finger *against retainer to fully seat the fulcrum
is being overhauled, proceed as follows:
pm.
FUEL INLET NEEDLE
61x 75
Fi g. 2-Synt het i c Rubber Ti pped Fuel I nl et Needl e, Seat
and Gasket (Exploded Vi ew)
CROWN OF FL0
60x121 A
Fi g. 3-Chec k i ng t he Fl oat Set t i ng
A
90
FUEL SYSTEM
6Ox12OA
Fi g.4-St ep-Up Pi st on and 2 St age Rods Fi g. 5-Chec k i ng Bow l Vent Openi ng
(4) Using Tool T109-230 or a T scale, check the 4. ACCELERATOR PUMP AND BOWL VENT
float, us shown in Figure 3. There should be 9/ 32 inch
from the surface of the fuel bowl to the crown of each
When assembling the accelerator pump to the air
float at the center.
horn, note that the hair pin clip (which opens the
bowl vent) can be placed in any one of the three
If an adjustment is necessary, hold the floats on the
positioning notches. These notches correspond to the
bottom of the bowl and bend the float lip toward or
long, medium and short pump stroke holes in the
away from the needle. Recheck the 9/ 32 inch setting
throttle lever. Normally, the bowl vent clip on the
again then repeat the lip bending operation as re-
pump stem will be at the middle notch and the pump
quired. CAUTION: When bending the flout lip,
operating rod in the medium stroke hole.
do not allow the lip to push against the needle
as the synthetic rubber tip can be compressed
The proper procedure is to adjust the amount of
bowl vent opening instead of measuring and setting
sufficiently to cause a false setting which will
affect correct level of fuel in the bowl. After
the height of the pump plunger.
being compressed, the tip is very slow to recover its
To check or set the adjustment, proceed as follows:
original shape.
(1) Back off the idle speed adjusting screw. Open
the choke valve, so that when the throttle valves are
closed, the fast idle adjusting screw will not contact
to the needle or slanted not more than ten degrees
the fast idle cam.
away from the needle when the float is set correctly.
(2) Be sure the pump operati ng rod i s i n the
medium stroke hole in the throttle lever, and that the
3. STEP-UP PI STON AND 2 STAGE RODS
bowl vent clip on the pump stem is in the center notch.
The transisition from the lean road load mixtures to the
(3) Close the throttle valves tightly. It should be
richer wide open throttle mixtures is made with an
just possible to insert a 5/ 64 inch drill between the
intermediate step. This is accomplished with a com-
bowl vent and the air horn, as shown in Figure 5.
bination of springs at the step-up piston and a two
If an adjustment is necessary, bend the pump operat-
diameter step-up rod, as shown in Figure 4. The
ing rod, using Tool T109-213, at the lower angle, until
/
purpose of this two stage step-up action is to secure
the correct bowl vent opening has been obtained.
best economy in the lower road load speed range This is an important adjustment, since too much
without sacrificing performance at higher speeds. lift at the bowl vent will result in considerable loss in
No change in service procedures is affected, but
low speed fuel economy.
cure should be taken to repair the BBD carburetors
Remember that if the pump operating rod is moved
with the correct parts.
to either the short or long stroke position, a correspond-
FUEL SYSTEM 91
ing change must be made in the location of the bowl
vent clip, and the amount of lift of the bowl vent
rechecked and adjusted.
The accelerator pump travel is automati-
cally taken care of when the bowl vent is
pr oper l y adjusted.
5. IDLE SPEED ADJUSTMENT (Curb Idle)
To make the idle speed adjustment, the engine must
be thoroughl y warmed up. A much more rel i abl e
i dl e adjustment can usual l y be obtai ned i f the car
has been dri ven a mi ni mum of fi ve mi l es. For the
best results, it is recommended that a tachometer be
used i n thi s adjustment. (Before maki ng the i dl e
speed adjustment, observe the following precautions : )
Because the al ternator can charge at i dl e speeds
and i mpose a l oad on the engi ne, the headl i ghts
shoul d be turned on (hi gh beam). Thi s wi l l assure
On cars equipped with the automatic transmissions,
loosen the nut in the sliding link of the carburetor to
bellcrank rod so that the stop in the transmission will
not interfere with the free movement of the carburetor
throttle lever.
To make the i dl e speed adjustment, proceed as
follows :
(1) Turn the idle speed screw in or out to obtain
500 r.p.m. (On cars with air conditioning, set the idle
speed at 550 r.p.m.) Be sure that the choke valve is
fully open and that the fast idle adjusting screw is
not contacting the fast idle cam.
(2) Turn each i dl e mi xture screw to obtai n the
watch the tachometer and notice that the speed can
be decreased by turning the screws in either direction
from the setting that gave the highest r.p.m. reading.
(3) Readjust to 500 (or 550) r.p.m. wi th the i dl e
speed screw.
(4) Turn each idle mixture adjusting screw in the
cl ockwi se di recti on (l eaner) unti l there i s a sl i ght
drop i n r.p.m. Now, turn each screw out counter-
cl ockwi se (ri cher) just enough to regai n the l ost
r.p.m.
This setting is ver y important.
speed screw, the speed obtai ned after fi ndi ng the
leanest smooth idle setting will probably be too fast.
(5) Readjust the speed screw to obtain correct idle
speed. Repeat steps 2 and 4 above if necessary.
After the proper i dl e speed has been obtai ned,
move the sl i di ng l i nk to the rear agai nst the stop
and tighten the nut securely.
To set the fast idle speed, connect a tachometer,
then proceed as follows:
(1) With the engine not running, open the throttle
half way, close the choke valve, then allow the throttle
to close.
The fast i dl e adjusti ng screw shoul d be centered
opposite the index mark on the fast idle cam. If neces-
sary, bend the tang on the choke shaft to secure
proper position of the fast idle cam.
(2) With the engine running and warmed up, and
with the fast idle adjusting screw opposite the index
mark on the cam, turn the fast idle screw either in
or out to secure 1400 r.p.m.
This adjustment may move the screw away from
the index mark. Repeat step 1 above and recheck the
fast idle r.p.m.
WW15 CARBURETOR
The service procedures and adjustments covering cedures).
the Stromberg carburetors, shown in Figures 1 and (3) A new procedure for setti ng the Accel erator
2 are the same as covered in the 1960 Plymouth Service Pump and Bowl Vent.
Manual with the following exceptions: (4) A new procedure for setting the Curb and Fast
( 1) Synthetic rubber tipped fuel inlet needle (re- Idle Adjustments.
quiring a new procedure for setting the floats). (5) A cl osed crankcase vent system mandatory
(2) A new 2 stage Power J et (no change i n pro- on California cars.
FUEL SYSTEM 9 3
WW15 CARBURETOR
SPECIFICATIONS
I
CARBURETOR
,
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode l
Manual Transmission . . . . . . . . . . . .
Automatic Transmission. . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . . . .
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Metering Jet
Standard. . . . . . . . . . . . . . . . . . . . . . . .
1 Size Lean. . . . . . . . . . . . . . . . . . . . .
2 Sizes Lean. . . . . . . . . . . . . . . . . . . . .
Power Jet (2 Stage). . . . . . . . . . . . . . . . .
ADJUSTMENTS
Idle Mixture Screws (turns open). . . . . . .
Idle Speed (curb idle) . . . . . . . . . . . . . . . .
(Air Conditioned cars). . . . . . . . . .
Fast Idle Speed. . . . . . . . . . . . . . . . . .
Fast Idle Speed Cam Index. . . . . . . . . . . .
Bowl Vent (closed throttle) . . . . . . . . . . . .
Vacuum Kick. . . . . . . . . . . . . . . . . . . . . . . .
Float Setting. . . . . . . . . . . . . . . . . . . . . . . . .
Choke Unloader. . . . . . . . . . . . . . . . . . . . .
CHOKE
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ww-15-43
1%
1%6
ww-15-44
1 St1
13%6
*ww-15-45
*ww-15-45
156
13/i6
,053 ,051 ,053
.051K ,049 .051
.049 .041 .049
,028 and .0465 .033 and .055 ,028 and .0465
1% 1% 1%
500 500 500
550 550 550
1250 1250 1250
%4n
I M4
%4
%4 %4 %4
3X4 3X4 3x4
%2 73 w
%4
15/64w
%4
Well
On Index
Well
On Index
Well
On Index
Stromberg
Dual Throat Downdraft
*With closed crankcase vent system-Mandatory on California cars.
VENT VALVE
\
\
+..A
61x163
Fig. 2-Carburetor Assembly (WWl5-45 Closed Crankcase
Vent System)
NEEDLE
The carburetors for the 1961 model cars are equipped
with a new synthetic rubber tipped fuel inlet needle.
The needle tip is a rubber material which is not
affected by gasoline and is stable over a wide range
of temperatures. The tip is flexible enough to make
a good seal on the needle seat, and to give increased
resistance to flooding.
2. CHECKING OR SETTING THE FLOAT
HEIGHT
procedure in adlusting the float setting. Care should
94 FUEL SYSTEM
to the needle or slanted not more than 10 degrees
away from the needle when the float is set correctly.
3. TWO STAGE POWER J ET
The change from the lean road load mixture to the
richer wide open throttle maximum power mixture is
made with an intermediate step. This is accomplished
with a spring loaded two position power jet, actuated by
vacuum on the power jet piston. The purpose of this
61x135 two stage action is to secure best fuel economy in the
Fi g. 3-Synt het ic Rubber Ti pped Needl e, Seat and Gask et
lower road load speed range without sacrificing per-
formance in the intermediate speed range.
During initial or part throttle operation, the vacuum
To correctly set the float height when the carburetor above the piston is sufficient to overcome the com-
is being overhauled, proceed as follows: pression spring and hold the piston in the up position.
(1) Install the float with the fulcrum pin and retain- As the throttle valves are opened the manifold vacuum
ing spring in the main body. drops and the piston compression spring moves the
(2) Install the needle, seat and gasket in the body piston down to open the first stage valve (upper)
and tighten securely. (See Figure 3.) of the power by-pass jet, as shown in Figure 5. This
(3) Invert the main body so that the weight of the meters additional fuel through the upper hole, into
float onl y is forcing the needle against the seat. the main metering system.
(4) Using Tool 73725 or a T scale, check the With increased demand for power and a further
float, as shown in Figure 4. There should be 7/ 32 inch drop in vacuum, the piston moves down an additional
from the surface of the fuel bowl (gasket removed) to amount to open the second stage valve (lower) as
the top of the float at the center. shown in figure 5, and meters an additional amount
If an adjustment is necessary, hold the float on the of fuel through the hole at the bottom of the power
bottom of the bowl, then bend the float lip toward or by-pass jet.
away from the needle, using Tool 73605. Recheck the When the demand for power is satisfied and the
7/ 32 inch setting again then repeat the lip bending throttle opening is decreased, the manifold vacuum
operation as required. CAUTION: Wl hen bending builds up to raise the power piston and closes the
the float l i p, do not allow the lip to push 2nd stage valve (lower) cutting off the supply of fuel
against the needle as the synthetic rubber through the bottom hole of the jet. A further reduction
tip can be compressed sufficiently to cause of power closes the 1st stage valve (upper) cutting off
a false setting which will affect c or r ec t level the supply of fuel through the upper hole.
of fuel in the bowl. After being compressed, the No changes in service procedures are required ex-
tip is very slow to recover its original shape. cept to be sure the Power By-Pass Jet is clean.
POWER BYPASS JET
1ST STAGE
POWER BYPASS JET
2ND STAGE
1ST STAGE 1ST STAGE
ORIFICE ORIFICE
Ii.
OPEN OPEN
,
.
2ND STAGE ORIFICE 2ND STAGE ORIFICE
CLOSED OPEN
61x 5 0
Fi g. 4-Chec k i ng t he Fl oat Set t i ng Fi g. 5-Pow er By-Pas J et (l et and 2nd St age Oper at i on)
FUEL SYSTEM 9 5
4. ACCELERATOR PUMP AND BOWL VENT
When assembling the accelerator pump to the air
horn, note that the horseshoe clip (which opens the
bowl vent) can be pl aced i n any one of the three
positioning notches. These notches correspond to the
l ong, medi um and short pump stroke hol es i n the
throttle lever. Normally, the bowl vent clip on the
pump stem will be at the middle notch and the pump
rod in the medium stroke hole.
The proper procedure is to adjust the amount of
bowl vent opening instead of measuring and setting
the height of the pump plunger.
To check or set the adjustment, proceed as follows:
(1) Back off the idle speed adjusting screw. Open
the choke valve, so that when the throttle valves are
closed, the fast idle adjusting screw will not contact
the fast idle cam.
(2) Be sure the pump rod is in the medium stroke
hole in the throttle lever, and that the bowl vent clip
on the pump stem is in the center notch.
(3) Close the throttle valves tightly. It should be
just possible to insert a 5/ 64 inch drill between the
bowl vent and the vent seat protruding through the
air horn.
If an adjustment is necessary, bend the pump rod.
usi ng Tool T109-213 at the l ower angl e, unti l the
correct bowl vent opening has been obtained. With
the bowl vent set at 5/ 64 i nch openi ng, the pump
travel should measure between 9/ 32 and 5/ 16 inches.
This is an important adjustment, since too much
lift at the bowl vent will result in considerable loss
in low speed fuel economy.
Remember that if the pump rod is moved to either
the short or long stroke position, a corresponding
change must be made in the location of the bowl vent
clip, and the amount of lift of the bowl vent rechecked
and adjusted.
The accelerator pump travel is automati-
cally taken care of when ,the bowl vent is
properly adjusted.
5. IDLE SPEED ADJUSTMENT (Curb Idle)
be thoroughly warmed up. A much more reliable idle
adjustment can usual l y be obtai ned i f the car has
been driven a minimum of five miles. For the best
results, it is recommended that a tachometer be used
i n thi s adjustment. (Before maki ng the i dl e speed
adjustment, observe the following precautions:)
Because the al ternator can charge at i dl e speeds
and i mpose a l oad on the engi ne, the headl i ghts
shoul d be turned on (hi gh beam). Thi s wi l l assure
throttle lever.
To make the i dl e speed adjustment, proceed as
follows :
(1) Turn the idle speed screw in or out to obtain
speed at 550 r.p.m.) Be sure the choke valve is fully
open and that the fast i dl e adjusti ng screw i s not
contacting the fast idle cam.
(2) Turn each i dl e mi xture screw to obtai n the
watch the tachometer and notice that the speed can
be decreased by turning the screws in either direction
(3) Readjust to 500 (or 550 r.p.m.) wi th the fast
idle speed screw.
(4) Turn each idle mixture adjusting screw in the
clockwise direction (leaner) until there is a slight drop
in r.p.m. Now, turn each screw out. counter-clockwise
(richer) just enough to regain the lost r.p.m.
This setting is very important.
speed screw, the speed obtai ned after fi ndi ng the
leanest smooth idle setting will probably be too fast.
speed. Repeat steps 2 and 4 above if necessary.
After the proper idle speed has been obtained, move
the sliding link to the rear against the stop and tighten
the nut securely.
then proceed as follows:
(1) With the engine not running, open the throttle
halfway, close the choke valve, then allow the throttle
to close.
The fast idle adjusting screw should be contacting
the top step of the fast idle cam. If an adjustment is
necessary, bend the fast idle rod at the upper angle
in order to secure proper position of the fast idle cam,
usi ng Tool T109-213.
In making the bench adjustment of the fast idle.
the fast idle speed adjusting screw is contacting the
2nd step of the fast idle cam. (For the engine fast
idle r.p.m. adjustment, the fast idle speed adjusting
screw is contacting the top step of the fast idle cam.)
(2) With the engine running and warmed up, and
with the fast idle adjusting screw contacting the top
96 FUEL SYSTEM
. -
_*
step of the fast idle cam, turn the fast idle adjusting The function of the valve is to regulate the flow
screw in or out to secure 1250 r.p.m.
of unburned hydrocarbons from the crankcase and
return them to the intake manifold. From here they
enter the combustion chamber and then exit via the
The closed crankcase ventilator valve is located in
exhaust system as completely burned exhaust products.
the crankcase vent tube cap and is connected to the For servicing procedures of this valve, refer to the
carburetor throttle body via a rubber tube. Engine Section of this Manual.
AFB CARBURETOR
The service procedures covering the AFB series (2) Synthetic rubber tipped fuel inlet needles (2).
carburetors, shown in Figures 1 and 2 are the same
as covered in the 1960 Plymouth Service Manual, with
(3) Accelerator pump intake check valve.
the following exceptions : (4) Closed crankcase vent system (mandatory
(1) Staged step-up rods and new stepup piston. equipment on all cars for the state of California).
-
I
ACCELERATOR PUMP ARM
PUMP CONNECTOR ROD
IDLE SPEED
AFB CARBURETOR - SPECIFICATIONS

CARBURETOR
T y p e , .
Model
Manual Transmi ssi on
Engine Displacement+
C u . I n . .
THROTTLE BORE
Primary . . .
S e c o n d a r y .
MAIN VENTURI
P r i m a r y . . . .
Secondar y. . . . . . . . . . . . . . . . .
MAIN JET
Primary . . .
Secondary. .
STEP-UP ROD (2 Stage)
Standard .
1 S i z e L e a n .
2 S i z e s L e a n . .
ADJUSTMENTS
-.
AFB-3103S
AFB-3105s
*AFB-3131S AFB-3106S
*AFB-3140S tAFB-2968S *AFB-3133S tAFB-2903s
*AFB-3140S IAFB-2968S @AFB-3133S tAFB-2903S
318 318 361 361 361 383 383 383
156 1%6 l(6 136 136 1 7ibn 136 1 7ibR
136 136 136 136 1 716 1%6 1%6 1 hb
1356 1%6 13/i6 1316 1%6 13.i6 13$6 13$6
13$6 1%6 1%6 13$6 13(6 1%6 156 19$6
,089" ,089
,057 .057
16-160 16-165
16-171 16-162
16-175 16-172
.089
,073
16-162
16-172
16-178
.089 .089 ,089 .089 .089
.0635 ,065 .0689 .0689 .0595
16-161 16-159 16-122 16-157 16-119
16-173 16-173 16-50 16-174 16-45
16-177 16-177 16-39 16-176 16-35
Accelerator Pump (tgp of plunger
to air horn) . . .
fi6
C h o k e U n l o a d e r . . .
VI
Fast I dl e Adjustment ,020
Fast I dl e Speed (r.p.m.). 1800
I d l e S p e e d (r.p.m.). 500
(with air conditioning)
550
Secondary Throttle Lever
A d j u s t m e n t
34
Secondary Throttle Lockout
A d j u s t m e n t . . ,020
Float Setting . . A
Float Drop . p/is
Idle Mixture (both screws
open) . . . . . . 11/ z Turns
CHOKE
7/i6 36 %6 36 36 746
l/ 4
l/ 4 l/ 4 l/ 4 vi l/ 4 A l/ q
.020 ,018 ,020 ,018 ,020 .020 ,009
1800 1700 1800 1700 1800 1800 1500
500 500 500 500 500 500 750
550 550 550 550 550 550 750
3%3
,020
%211
%6
,020 ,020 ,020
32v W w
%6 %6 %6
,020
%2 N
956
.020 ,020
52 752
%S p/is
1 l/ z Turns
Well
On Index
11/ z Turns 1 l/ 2 Turns l$$ Turns 11/ z Turns 1 / z Turns 11/ z Turns
Control, . . . . .
Type, . . . . Well
Setting. . . . . On Index
Well
On Index
Well Well
On Index On Index
Well Well Well
2 Notches 2 Notches 1 Notch
Rich Rich Rich
4 Barrel Downdraft
tSingle Stage Step-up *For use with closed crankcase vent system-Mandatory for California cars
98 FUEL SYSTEM
.. .
OPERATING LEVER\
ST,:, 4 ,,,., : . :
,v,, ..,
-- --- --a--r=--
. . -.---- -.-. -. -- -.
STEP-UP PISTON NI
The change from the low speed, best fuel economy, The carburetors for the 1961 model cars are eauiuoed
road load mixtures to the richer wide open throttle full with new synth
AA
..--. A.-vu-./I, -.,
power mixtures is now accomplished in two steps. This shown in Figure 4. The needle tip is a rubber material
has made it possible to secure best low speed fuel which is not affected by gasoline and is stable over a
etic rubber tinued fuel inIn+ nnndlm= C+C
economy without sacrificing performance in the in- wide range of temperatures. The tip is flexible enough
t
termediate speed range. To do this, there is a new step to make a good seal on the needle seat, and to give
up piston and spring assembly, new metering rods increased resistance to flooding.
with three diameters, and new style primary metering The use of the new inlet needles requires that care
jets, as shown in Ficnrre 3. be used when makinq float adjustments. Avoid anulv-
ZTFP.1 IP
2 STAGE
-.-. -.
PISTON SPRING
STEP-UP PISTON
CO1 fER 1
I 1 I
!
.I
!
I I I
! I
I I
- -
*3 STEPS*
STEP-;P ROD
I
-1 -
CRFW
5
- ~tr-mw I-~PE
6lXlii
61x172
Fi g.3-St ep-Up Pi st on, Rod and J et
Fi g. 44ynt het i c Rubber Ti pped Fuel I nl et Needl e, Seat
and Gask et
FUEL SYSTEM 99
ing any pressure on the floats which might compress
the tip of the fuel inlet needles. The tip can be c om-
pressed sufficiently to cause a false set t i ng
which will affect correct level of fuel in the
bowl.
3. ACCELERATOR PUMP INTAKE CHECK
BALL
The accel erator pump i ntake check bal l was for-
merly accessible from the bottom of the throttle body
flange on previous AFB carburetors. On the 1961 AFB
carburetors, the intake ball check is located inside the
fuel bowl, adjacent to the accelerator pump cylinder.
When overhauling the carburetor, remove the intake
ball check valve and clean thoroughly. When reassem-
bling the carburetor, this check valve should be in-
stalled before the air horn is attached.
The closed crankcase ventilator valve is located in
the crankcase vent tube cap and is connected to the
carburetor throttle body via a rubber tube. (See Fig-
ure 5.) With the ram manifolds, the connection is to
the balance tube between the right and left manifolds.
(See Figure 6.) The function of the valve is to reg-
ul ate the fl ow of unburned hydrocarbons from the
crankcase and return them to the i ntake mani fol d.
From here they enter the combustion chamber and
then exit via the exhaust system as completely burned
exhaust products.
For servicing procedures of this system, refer to the
Engine section of this Manual.
5. REVISED SERVICE PROCEDURES AFFECTING
DISASSEMBLY AND ASSEMBLY OF THE AFB
CARBURETOR
There is a new S shaped link on the accelerator
C A RBURETO R ASSEMBLY n
Fig. 5-Closed Crankcase Vent System
NIPPLE h$ANIFOLD EQUALIZER TUBE
W 61x164
Fig. 6-Closed Crankcase Vent System (Ram Manifold)
pump stem. (Refer to Figure 1.)
To remove the accelerator pump link, proceed as fol-
lows :
(1) Remove the spring clip that holds the throttle
connector rod in the center hole of the pump arm.
(2) Remove the pump arm pivot screw and lift off
the pump arm, at the same time, disengage the link
from the arm and the pump stem.
When reassembling, make sure the large diameter
of the pivot screw enters the hole in the pump arm and
that the shoulder on the screw has not pinched the
pump arm.
Installing the Air Horn
Before installing the air horn, slide the accelerator
pump plunger spring into the cylinder, then install the
pump plunger. Be sure the leather on the plung-
er does not curl up. Continue as follows:
(1) Lower the air horn carefully down on the main
body. This operation must be done accurately.
(2) Be sure the fuel baffl es on the ai r horn sl i de
down in front (bowl side) of the float chamber baffles.
(3) Be sure the accelerator pump shaft is centered
to pass through the hole in the air horn.
(4) Care must be taken to center the small brass
main bleed tubes [see Figure 1) so that they will pass
through the holes in the air horn without being dam-
aged.
When all parts are aligned correctly, the air horn
will drop easily into place.
Idle Speed Adjustment - (Curb Idle)
be thoroughly warmed up. A much more reliable idle
adjustment can usually be obtained if the car has been
driven a minimum of five miles. For the best results,
it is recommended that a tachometer be used in this
100
FUEL SYSTEM
adjustment. (Before making the idle speed adjustment,
CHOKE VALVE
observe the following precautions: )
OPEN\
Because the alternator can charge at idle speeds
and impose a load on the engine, the headlights should
be turned on (high beam). This will assure setting the
idle to compensate for the alternator load.
throttle lever.
To make the idle speed adjustment, proceed as fol-
l ows :
:,m wyNDEX
( 1) Turn the idle speed screw i n or out to obtain
zf+;fE;LE VALVE 1, ._-i?
-----A
MARK ON CAM
,c; FAST IDLE ADJUSTING
speed at 550 r.p.m.) Be sure the choke valve is fully Fi g. 7-Fast I dl e Cam I ndex i ng
open and that the fast idle adjusting screw is not con-
tacting the fast idle cam. speed. Repeat steps 2 and 4 above if necessary.
(2) Turn each idle mixture screw to obtain the high- After the proper idle speed has been obtained, move
est r.p.m. While making the adjustment, carefully the sliding link to the rear, against the stop, and
watch the tachometer and notice that the speed can be tighten the nut securely.
decreased by turning the screws in either direction
Fast Idle Speed Adjustment
(3) Readjust to 500 (or 550 r.p.m.) with the idle
speed screw. then proceed as follows:
(4) Turn each idle mixture adjusting screw in the ( 1) With the engine not running, open the throttle
clockwise direction (leaner) until there is a slight halfway, close the choke valve, then allow the throt-
drop in r.p.m. Now, turn each screw out, counter-clock- tie to close. Release the choke valve.
wise (richer) just enough to regain the lost r.p.m. The fast idle adjusting screw should be centered over
This procedure will assure that the idle has been set the index mark on the fast idle cam. If an adjustment
to the leanest possible mixture for smooth idle. This is necessary, bend the fast idle rod at the angle. using
set t i ng i s very important!
Tool T109-213, to secure proper position of the fast idle
Since the correct speed was originally set using the cam. (See Figure 7).
speed screw, the speed obtained after finding the lean- (2) With the engine running and warmed up, turn
est smooth idle setting will probably be too fast. the fast idle adjusting screw in or out to the specified
r.p.m., as shown in the Specifications.
FUEL PUMP
The fuel pumps used on the 1961 Plymouth Passen-
Refer to the 1960 Manual for specifications and service
ger Cars are identical to those used on the 1960 Models. procedures.
FUEL TANK
The procedures covering the servicing of the fuel
The drain plug has been removed from the fuel
tanks remain the same as described in the 1960 Plym- tanks. This will require a siphoning procedure to drain
outh Service Manual, with the following exception: the tank for repair or removal.
THROTTLE LINKAGE
The throttle linkage used on the 1961 Plymouth V-8 throttle linkage, refer to Figure 1 for complete instruc-
has been changed and a new linkage adjustment in- tions.
corporated. Should it become necessary to adjust the
-. -
e. .-
WI TH AUTOMATI C TRANSMI SSI ON
WI TH
WI TH AUTOMATI C TRANSMI SSI ON
I . -ASSEMBLE THROTTLE LINKAGE IN PLACE.
Z-WITH LOCK NUTS LOOSE IN CARB.@AND TRANS.@RODS,
INSERT A %s DIAMETER ROD@APPROX. 10 LONG INTO
PROVIDED HOLESIN ACCELERATOR SHAFTBRKT. AND LEVER.
%--MOVE TRANS. THROTTLE LEVEROFOREWARD AGAINST STOP
AND TIGHTEN TRANS. ROD LOCK NUT@
4.-DISCONNECT ONE END OF ACCELERATOR PEDAL ROD.@ADJ UST
ITSLENGTH TO PROVIDE A PEDAL ANGLE OF 113 TO 115.
5.-REMOVE %a ROD@FROM ACCELERATOR SHAFT BRKT. AND LEVER
6.-OPEN CHOKE VALVE AND OPEN THROTTLE SLIGHTLY TO RELEASE
FASTIDLE CAM, THEN RETURN THROTTLE TO CURB IDLE.
7.-iL\ OVE REAR OF CARB. ROD ASSY.@REARWARD UNTIL THE STOP
IS CONTACTED, TIGHTEN CARB. ROD LOCK ~t1T.13
WI TH MANUAL TRANSMi SSl ON
1. -ASSEMBLE THROTTLE LINKAGE IN PLACE.
P.-WITH THE LOCK NUT LOOSE IN THE CARB. ROD@
INSERT A 36 DIAMETER ROD@APPROX. 10 LONG
THRU HOLES PROVIDED IN ACCELERATOR SHAFT BRKT.
AND LEVER.
%-OPEN CHOKE VALVE AND OPEN THROTTLE SLIGHTLY
TO RELEASE FAST IDLE CAM,THEN RETURN THROTTLE
TO C URB IDLE.
4.--TIGHTEN CARE. ROD LOCK NUT.@
5.-DISCONNECT TOP END OF ACCELERATOR PEDAL ROD
@.ADJ UST LENGTH OF THIS ROD TO PROVIDE A
PEDAL ANGLE OF 113 TO 115.
&-REMOVE THE %a ROD@FROM ACCELERATOR SHAFT
BRAC KET AND LEVER.
61X219
Fig. l-Throttle linkage Adjustment
102 PROPELLER SHAFT-UNIVERSAL JOINTS
GROUP 16
PROPELLER SHAFT AND UNI VERSAL J OI NTS
The servicing procedures for the Propeller Shaft and These are some changes and additions in the Speci-
Universal Joints remain the same as outlined in the fications.
1960 Plymouth Service Manual except as follows:
For complete servicing of the Propeller Shaft and
Propeller Shaft Angularity checking procedures have Universal Joints, refer to the 1960 Plymouth Service
been revised as outlined in this Supplement. The new Manual.
procedures also apply to the 1960 model cars.
SPECIFICATIONS
PROPELLER SHAFT-Type. . .
Differential Carrier and Propeller
Shaft Anqularity . .
Tubular
Approx. 2 Degrees
_ _
RPl
Length * Diameter
M a n u a l T r a n s . ( e x c e p t S u b . ) . 55 in. 23/4 in.
(Suburban) 59 in. 3 in.
TorqueFlite 6 Trans.
( e x c e p t S u b . )
(Suburban), . : : : : : : : : 11 : : :
55 in. 23/4 in.
59 in. 23/4 in.
TorqueFlite and PowerFlite Trans.
(except Sub.). . . . . .
( S u b u r b a n ) .
UNI VERSAL J OI NTS-Type
Front .
R e a r . . . . .
Lubrication, . . . .
*Length from centerline of trunnion to centerline of rear yoke bearing bores.
SPECIAL TOOLS
C- 552. Tr unni on Pi n Removi ng and I nstal l i ng J i g
(6 Cylinder) -Manual Transmission
C-3313. Trunni on Pi n Removi ng and I nstal l i ng J i g
RP2
Length* Diameter
55 in. 2% in.
59 in. 31/ 4 in.
55 in. 21/ 2 in.
59 in. 23/4 in.
55 in. 23~ in.
59 in. 23/4 in.
Ball and Trunnion
Cross
At 20,000 mile or
Two-year intervals
(8 Cylinder)-Manual and PowerFlite Transmission
(6 Cylinder)-TorqueFlite 6 Transmission
C-3567. Trunni on Pi n Removi ng and I nstal l i ng J i g
(8 Cylinder)-TorqueFlite Transmission
TORQUE REFERENCE
P r o p el l er Sh af t t o T r an smi ssi o n F l an ge Bo l t s.
. . . 35 ft. lbs.
Rear Universal Joint Clamp Bolts. . . . . . . . . . .
170 in. lbs.
1. PROPELLER SHAFT ANGULARITY
The quiet, smooth operation of the propeller shaft
and universal joints depends upon proper alignment
together with the lubrication of the joints at regular
intervals.
The propeller shaft rear joint angle may be obtained
with a spirit level protractor. The angle of the propeller
shaft and the tilt of the axle carrier must be determined
separately and then resolved to give the rear universal
joint angle.
SPRINGS-SHOCK ABSORBERS 103
REBOUND PLATE B
Fi g. l -Chec k i ng Rear Ax l e Angul ar i t y Fi g. 34nst al l i ng Taper ed Wedges
With no extra weight in the vehicle over stcmdard angular tilt of the axle carrier. Also note the direction
equipment, the rear joint angle may be obtained as of tilt.
follows : (4) Place the protractor on the underside of the
(1) Place the vehicle on a hoist, pit, wheel or frame
alignment rack so that the weight of the car is on the
propeller shaft level the bubble and record the angu-
rear wheels.
larity (Fig. 2). This ,value is the tilt of the propeller
shaft. Again note the direction.
(2) Remove the rebound plate and bumper from
the top of the differential carrier housing.
(5) The rear universal joint angle may be resolved
as follows :
(3) Place the protractor on the machined surfaces
of the rebound plate bosses, level the bubble, and
a. If the axle carrier and propeller shaft slope in
record the reading of angularity (Fig. 1). This is the
the same direction, subtract the angles found in
steps 3 and 4.
b. If the axle carrier and propeller shaft slope in
opposite directions add the angles obtained in steps
3 and 4.
(6) The ,rear universal joint angle should be be-
tween 1 and 3 degrees.
(7) If the rear joint angle must be odjusted, tapered
wedges should be added between the rear springs and
the differential housing spring plates (Fig. 3). Select
wedges of proper degree taper so as to obtain the
specified universal joint angle.
Fi g. P-Chec k i ng Propel l er Shaf t Angul ari t y
(8) Recheck the rear joint angle, then install the
rebound plate and bumper assembly on the carrier.
Tighten retaining bolts to 200 inch-pounds torque.
GROUP 17
SPRI NGS AND SHOCK ABSORBERS
The Service procedures for the 1961 model cars
remain the same as those in the 1960 Plymouth Service
There are changes in the Specifications and the
Manual with the following exceptions.
Torque References.
STEERING GEARS
SPECIAL TOOLS
105
C- 3709. Remover and I nstal l er - Spr i ng Eye Bushi ng
TORQUE REFERENCE
Foot-Pounds
Rear Spring Front Pivot Bolt Nuts.. . . . . . .
Rear Spring Shackle Nuts. . . . . . . . .
Rear Spring U Bolt Nuts. . . . . . . . . .
125
40
80
SHOCK ABSORBERS
SPECIFICATIONS
TYPE. . . . . . . . . Oriflow, Double Acting
Hydraulic
SPECIAL TOOLS
C- 3553 .Remover and I nstal l er - L ower Mounti ng A ssembl y
TORQUE REFERENCE
Foot-Pounds
Shock Absorber Mount Nut (Rear) Upper and Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
(Front-Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
: . . . . . . . . 55
(Front-Upper). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Shock Absorber Stud Nut-Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
GROUP 19
STEERI NG
Service Procedures for the 1961 Steering Gears and ing Gears and Pumps, use the 1960 Plymouth Service
Pumps are essentially the same as outlined in the 1960 Manual in conjunction with new procedures and speci-
Plymouth Service Manual with the exceptions as listed fications outlined in this supplement.
in this Supplement. For complete servicing of the Steer-
GENERAL SPECIFICATIONS
Typ,e- . . . , .
Rati o... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._.......___......~.
Gear Shaft Bearings. . .
Worm Shaft Bearings. . . . . .
H i g h P o i n t ( w h e e l s s t r a i g h t a h e a d ) .
Worm and Three Tooth Roller
20.4 to 1
Needle Roller Bearings
Tapered Roller
Notch on Steering Column
Tube Straight Up
SPECIAL TOOLS
C-3332. . . . . . . Remover- Gear Shaft Bearing
C-3333. . . . . . . . . . Driver-Gear Shaft Bearing
c-3350. . . . . . Remover and Installer-Seal
C-3428. . . . . . . . . . Steering Wheel Puller
C-3646. . . . . Pitman Arm Puller
C-3786. . . . . . . . . . Bushi ng-R emoving and Installing Arbor
PLAIN WASHER -----
--Y
\
ER (2)
C OVER
G RO MMET
RUBBER LIP SEAL
J ACKET CLAMP
STEEdlNG WHEEL
LOCKWASHER (2.
BOLT (2)
WORM SHAFT
* / BO LT IUB (UPPER I
VA w
LOCKVcUED
:HOIISING
LOCK WASHER (3)
-
THIS WASHER USED
WITH AUTO TRANS
\ Ah,,
HORN GROUND
LOCK WASHER (2)
PLAIN WASHER (3)
I.&I
FRA ME SI DE- - - - - v- .
RA I L
/
PLAIN WASHER
WASHER
Fig. l-Steering Gear (Exploded View)
P-- .
STEERING GEARS 107
TORQUE REFERENCE
Foot Pounds
Steering Gear to Frame Bolt. . . . . . . . . . . , . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering Gear Pitman Arm Nut .* . . . , . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . , . . . , ). . . . 125
SteeringWheelNut j._............l..,...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering Knuckle Tie Rod Clamp Bolt. . , . . . . . . ..*..*.................................... 15
SteeringKnuckleTieRodEndBallNut.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
IntermediateSteeringArmNut . . . . . . . . . . I.l._L . . . . . . . . . . . . . ..~.~.......................
50
SteeringIdlerArmBoltNut . . . . . . . . . . . . . . . . . . . ...~.,.....l.l..,.... . . . .... . . . . . . . . . 6 0
MANUAL STEERING GEAR
1. DESCRI PTI ON /Fi s rod
. J.1)
f or the omission of t he clutch t or que I
T h e 1961 steeri incorporates a flexible coupling
mounting bracket.
(Fig. 2) which consists of a rubber-fabric disc assem-
bled between two hubs installed between the steering
2. STEERI NG GEAR REMOVAL
gear worm shaft and the steering tube which provides
alignment of the steering gear to the frame side rail
(1) Disconnect battery cable at battery negative
terminal.
and the vehicle body. The steering gear chuck has a
(2) Remove the steering arm nut and washer and
stub worm shaft which extends up a short distance
remove the steering arm from the steering gear cross
above the gear housing. The flexible coupling attaches
shaft with Puller Tool C-3646.
to the worm shaft by a serrated connection and clamp
bolt. The worm shaft has a master serration that
(3) Remove the bolt and washer attaching the lower
coupling to the steering gear worm shaft.
matches with the master serration in the lower hub of
(4) Remove the three nuts, washers and bolts at-
the flexible coupling. The upper hub of the flexible
coupling is integral with the steering tube. The jacket
taching the steering gear to the frame side rail and
tube is held in alignment in the vehicle body by the
slide the steering gear assembly toward the front of
lower jacket clamp assembly which attaches to the
car to disengage the column tube flexible coupling
from the steering gear worm shaft.
brake bracket and the instrument panel clamp. The
face of the steering gear housing is machined flat to
(5) Remove the gear through the engine compart-
ment.
position the gear flush to the frame.
NOTE: With an automatic t r ansmi ssi on a
3. STEERI NG GEAR I NSTALLATI ON
1 A x 7/ 16 x 1% w asher is added to t he
housi ng to f r ame si de r ai l bol t to c ompensat e
(i) Check the steering gear for center by rotating
the worm shaft from one end of its travel to the other
while counting the number of turns. Turn: the worm
IP SEAL
bl:C COUPLING
shaft back one half of the full number of turns. This
* is the exact center of travel.
(2) Locate the master spline in the outer row of ser-
rations on the worm shaft. Mark the master spline.
(3) Enter the steering gear into the engine compart-
ment.
(4) Align the index mark on the outside of the flex-
ible coupling hub with the master spline on the steer-
ing worm shaft (Fig. 3).
(5) Slide the coupling on the worm shaft and in-
stall the gear housing to frame side rail attaching bolts
and nuts.
6 1X237
Fi g. l -st eeri ng Gear and Fl ex i bl e Chupl i ng
(6) Tighten bolts evenly to 50 foot-pounds torque.
(7) Position the flexible coupling bolt hole in line
with the groove on the worm shaft and install the bolt
and lo&washer.
FLEXIBLE COUPLING
i ear wit h
Fi g,
_-.--- --
Fi g. L-Al i gni ng St eeri ng G
Fl ex i bl e Coupl i ng
(8) Tighten the bolt 30 to 35 fgot-nn~~*d~ t
pling and the jacket tube. The outer groove
r -..-:orque.
of seal must be firmly installed on jacket tube
and the two nylon rings (Fig, 5) and lip of the
NOTE: The hor n ground is attached to the seal must be well lubricated w i t h a wheel
\
underside of the coupling by two bolts to c om- bearing grease.
plete the circuit. (3) Hold the steering column so it is centered plus
or minus r/ s inch on the tube while aligning the column
4. STEERI NG GEAR ALI GNMENT (Fi g. 4) support bracket to the firewall and lower column
Check the steering gear shaft for alignment in the
clamp.
steering column seal as follows:
(4) When column is properly located, tighten the
( 1) Loosen the steering column clamp bolts at the
support bracket stud nuts at the firewall and at the
instrument panel.
column clamp to 100 inch pounds torque.
(2) Loosen the lower column clamp bolt and the
(5) Tighten the steering column to instrument panel
support bracket at both the firewall and at the column
clamp bolts to 15 foot-pounds torque.
clamp.
(6) Tighten the lower steering column clamp bolt
nut to 200 inch nounds torque.
NOTE: A rubber l i p type seal i s posi t i oned (7) Reinstall ;he steering gear arm, washer and
between the upper hub of the flexible rou- nut. Tighten to 125 foot-pounds torque.
Fi g. 4-St eeri ng Gear Al i gnment Fi g. 6-Removi ng Worm Shaf t Oil Seal
STEERING GEARS
109
Fi g. 8-I nst al l i ng Worm Shaf t Oi l Seal
5. WORM SHAFT OI L SEAL REPLACEMENT will withdraw the seal assembly from the housing bore.
The steering gear chuck should be removed from the
(2) Place oil seal protector of Tool C-3821 over
vehicle in order to replace the oil seal.
spltnes of steering worm shaft and slide oil seal over
Perform operations 1 through 6 under Manual Steer-
ing Gear Removal and proceed as follows:
the protector with lip of seal toward housing (Fig. 7).
(1) Thread Tool C-3819 far enough into the oil seal
(3) Drive oil seal into housing bore with Tool C-3821
(Fig. 8).
to engage the metal portion of the seal (Fig. 6). Turn-
ing the tool center screw while holding the tool body
(4) Install and align steering gear as outlined under
Steering Gear Installation and Alignment.
STEERI NG COLUMN
1. SERVI CE PROCEDURES NOTE: On manual transmission equi pped
Removal
cars. disconnect the remote c ont r ol to trans-
(1) Disconnect negative (ground) cable from the
mission shifter rods at the r emot e c ont r ol l e-
battery.
vers and swing levers inward to facilitate
(2) Remove the two screws from the underside of
removal.
the steering wheel and remove the horn ring, retainer
(11) Remove clamp bolt from the steering column
and attaching screws.
shaft lower coupling.
(3) Disconnect the horn wire a-t horn switch, remove
(12) Carefully lift the steering column toward the
the horn switch screws and bushings and horn switch.
dash. tapping the lower coupling lightly with a mallet
(4) Loosen the steering wheel nut several turns, in-
until it is free of the worm shaft splines.
stall Puller Tool C-3428 and remove steering wheel nut
(13) Slide the steering gear jacket tube assembly
and wheel.
rearward and remove the complete assembly through
(5) Disconnect the directional signal wires at con-
the drivers compartment.
nectors.
(6) Remove the directional indicator lever.
Disassembly
(7) Remove the two screws attaching the steering
(1) Remove the screw and directional wires cover
jacket tube clamp at the instrument panel and remove
at jacket tube directional switch housing.
( 2) D
t
the clamp.
mconnect directional switch wires at lower
connector so that wires can be pulled through jacket
(8) Move the trim cap up on steering jacket tube
tube for directional switch removal.
and raise the floor carpet to expose the floor panel.
(3) Remove the two screws from the turn signal
(9) Remove the screws attaching the dust pad to the,
floor panel and slide dust pad up on jacket tube.
switch, then remove the switch and wiring assembly
(10) Remove the two nuts holding the lower jacket
from the column jacket.
tube clamp to the steering column jacket bracket.
(4) Remove the snap ring and washer from upper
end of steering column shaft, then withdraw the steer-
/

I
STEERING GEARS
ing column shaft from the jacket tube.
(5) Remove the tapered spacer, spri ng and snap
ring from the upper end of the steering column shaft
and slide the jacket rubber seal off the column shaft.
(6) Remove the jacket tube housi ng by careful l y
straightening the three retaining tabs and tappmg the
bearing out of the jacket tube.
Assembly
(1) Inspect all parts for wear and check the rubber
seal for deteri orati on. Repl ace beari ng i f there has
been any indication of binding before removal of col-
umn tube.
(2) Pack the upper bearing with short fiber grease
and wi th the radi us end of the beari ng (i nsi de di -
ameter) facing downward press the bearing squarely
into the jacket tube until it stops against the bearing
supporting lugs in the jacket tube, using a socket of the
proper size, or a similar tool that will exert pressure on
the outer race only.
(3) Pl ace the l arger washer agai nst the top si de
of the bearing outer race. Bend the three bearing re-
taining tabs down to an angle of 45 degrees (Fig. 1).
Do not exceed the 45 degrees, since this may cause
internal damage to the bearing.
(4) Sl i de the jacket tube rubber seal and nyl on
rings on the steering column shaft.
(5) I nstal l the jacket beari ng snap ri ng i n the
steeri ng col umn shaft l ower groove: I nstal l a new
snap ring if old ring will not fully seat in the groove.
(6) Install spring and tapered spacer (tapered end
up).
(7) Carefully install steering column shaft assem-
bly into the column jacket tube.
(8) Support column tube lower hub on a block of
wood, place upper snap ring on steering column shaft,
pul l down on jacket tube to compress the beari ng
spacer spring sufficient to expose the upper groove in
the steering gear shaft and install the upper snap ring.
Make sure snap ring seats fully in shaft groove.
(9) Apply wheel bearing lubricant to nylon rings
and lip of jacket tube seal and position seal cup and
nylon rings on jacket tube. Large diameter of nylon
rings butt and are retained by the recess caused by
the seal lip. The lip of seal will therefore contact the
outside diameter of the nylon rings instead of the col-
umn tube; small diameters of nylon rings will be on
opposite ends.
(10) Attach a piece of fine wire to the ends of turn
signal wires and thread wires through the jacket tube.
Position directional switch and install switch attaching
screws. Be sure switch operating wires are properly
positioned for cancelling cam on steering wheel hub.
(11) Install connector on directional switch wires
and install harness cover and screw on jacket tube.
Fig. l-Steering Jacket Tube Bearing Installation
Installation
( 1) Enter the jacket tube and steering column shaft
assembly through dash panel from drivers side and
index the lower coupling of steering gear shaft with
steering gear worm shaft.
(2) Index the master groove of the steering gear
worm shaft with filed notch on lower coupling. Tap the
coupling down over the worm shaft splines.
(3) Install and tighten the coupling clamp bolt se-
curely.
(4) Align the jacket tube at the instrument panel
and install the jacket tube clamp and attaching screws.
Tighten screws finger tight.
(5) Install the two nuts attaching the lower jacket
tube clamp to the steering column jacket bracket. Be
sure jacket tube clamp bolt is securely tightened.
NOTE: On manual t r ansmi ssi on equipped
,
c ar s, connect the remote control to trans-
mission shifter rods at the remote control
levers.
(6) Sl i de the dust pad down i nto posi ti on on the
dash panel and install the attaching screws.
(7) Posi ti on the fl oor carpet under the dust pad
and position the trim cap.
(8) Install the directional indicator lever.
(9) Install the steering wheel, making sure cam is
properly located on steering wheel hub.
(10) Install steering wheel nut. Tighten to 40 foot-
pounds torque.
(11) I nstal l horn swi tch bushi ngs and screws. At-
tach horn wire at horn switch terminal.
( 12) Install horn ring, retainer and attaching screws.
(13) Check the steering gear shaft for alignment in
the steering column seal and steering jacket alignment
as outlined under Steering Gear Alignment. Para-
graph 4.
STEERING GEARS 111
(14) .Check the up or dawn deflection of the flex- (Fig. 4) to where the deflection of the disc is less than
ible disc as follows: If the deflection exceeds l/16 l/16 inch with the column jacket tube clamped in
inch the column jacket should be moved up or down place.
POWER. STEERING PUMPS
The power steering pumps on 1961 six cylinder en-
gines and (318 cu in.) eight cylinder engines are the
some as the 1960 (.96 displacement) power steering
pumps. The service procedures remain the same as
outlined in the 1960 Plymouth Service Manual.
PUMP ASSEMBLY
The pumps used on 361 and 383 cubic inch engines
A
ore similar to the six and eight (318 cu. in.) cylinder
PUMP MOUNTING-
1
BRACKET
engine pumps but with greater capacity. The greater
A
capacity pump (1.2 displacement) has larger shaft
and seal diameters, requiring two new service tools;
C-3783 Oil Seal Remover and C-3782 Oil Seal Installer.
This pump is mounted on a pivot type bracket (Fig. 1 ),
which automatically increases belt tension the re-
guired amount, thus providing ample pressure to meet
A,;;LJ;ETNT /
the various load demands of the power steering. Serv-
ice Procedures ore the same for this pump as outlined
PIVOTBOlT
in the 1960 Plymouth Service Manual except for Belt
Tension Adjustment which is described in thii Supple-
me nt . Fig. I-Power Steering Pump and Reaction Bracket
SPECIFICATIONS
Type,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constant Displacement
Maximum Pump Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (.!X Displacement Pump) 850 to 950 psi
1
(1.2 Displacement pump)-1000 to 1100 psi
MaximumFluidFlowat3000rpm.. .. . . . . . . . . . . . . . . . . . 21/, gallons
Type of Fluid.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2084329 Power Steering Fluid
SPECIAL TOOLS
c-3229. . . . . . . . . . Pliers-Snap Ring
C-3309B. . . . . . . . . Gauge-Pressure Check
C-3388. . . . . . . . . . Hose-Coupling
C-3615. . . . . . . . . . Puller-Steering Pump Pulley
C-3840. . . . . . . . . . Seal Driver-Pump Shaft (.96 Displacement Pump)
C-3782. . . . . . . . . . Seal Driver-Pump Shaft (1.2 Displacement Pump)
C-3642 . . . . . . . . . . Seal Puller-Pump (.96 Displacement Pump)
C-3783. . . . . . . . . . Seal Puller-Pump (1.2 Displacement Pump)
c-3643. . . . . . . . . . Supporting Stand (Pump Shaft)
C-3655 . . . . . . . . . .Remover-Pump Flow Control Valve Bore Plug
TORQUE REFERENCE
Foot Pounds
Reservoir to Pump Body Bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Pump Inlet Fitting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .. 30
PumptoPumpBraoketBolts(.96DisplacementPump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pump to Pump Bracket Bolts (1.2 Displacement Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
.
STEERING G@ARS
UNTING BOLTS
.
Fi g. 2--LeeMi ng Pump Br ac k et Mount ing Fi g. 2--LeeMi ng Pump Brac k et Mount i ng Sc rews
. .i.,, .,_
:*I .h+.,,
; TORQUE WRENCH TORQUE WRENCH
(
(TOOL) \
Fi g. 4--Pump Br ac k et and Rubber St op
(2) Install Tool C-3832 over the edge of the mounting
bracket as close as possible to the outer edge of
bracket and insert torque wrench.drive in square hole
of tool (Fig. 3).
(3) Tighten the pump belt until you get a reading
of 45 foot-pounds on the torque wrench.
(4) While holdinq the tension with torque wrench (4) While holding the tension with torque wrench
tighten the bracket mounting bolt nuts enough to hold
the adjustment, then use a torque wrench to thirty foot-
pounds torque.
When the belt is properly adjusted and normal pump
pressures are developed, the pump mounting bracket
will beresting against the rubber stop in the adjustment
bracket (Fig. 4).
(5) If a knocking condition is encountered at the
bracket stop when the engine is running, it would indi-
cate that the rubber stop is missing, or the belt is
worn to the extent that the belt tension cannot be prop
erly adjusted. Adjust the belt tension, or install a new
belt if necessary.
Fi g. 3-Pump Bel t Adj ust ment Fi g. 3-Pump bel r napw menr
(6) If a belt squeal is encountered under heavy
steering load (such as entering a curb-side parking
1. BELT ADJUSTMENT
space), it is an indication that the belt tension is too
loose, or the belt is worn to the extent that the reaction
(1) Loosen the adjustment bracket to engine mount-
bracket cannot properly adjust the belt tension. Ad-
ing bolts (Fig. 2).
just the belt tension or install a new belt if necessary.
1. BELT ADJUSTMENT
POWER STEERING GEAR
Service Procedures for the 1961 Power Steering Gear
Manual. For Complete Service Procedures, refer to the
are the same as outlined in the 1960 Plymouth Service
1960 Plymouth Service Manual.
POWER STEERING
STEERING GEARS
SPECIFICATIONS
113
Ratio. . . . . .
Fl ui d Capaci ty of Power Steeri ng System. .
Type of Fluid. . . . . . . . . .
16to 1
2 Qts.
Use only Part Number 2084329
Power Steering Fluid
/
TORQUE REFERENCE
Steering Wheel Nut. . .
Steering Arm Nut. . .
Steering Gear Housing to Frame Bolt. .
S t e e r i n g V a l v e E n d P l u g . .
Steering Valve Body Attaching Bolts. .
S t e e r i n g C o l u mn S u p p o r t N u t .
Steering Gear Shaft Cover Nut. . . .
Steering Gear Shaft Adjusting Screw Lock Nut
Pressure Control Val ve Body Screws.
Pump Inlet Fitting
SP-3052.
SP-3062.
C-3128
C-321 1.
c- 3229
C-3309B.
C-3318.
C-3332.
c-3333.
c-3350.
C-3388.
C-3402.
C-3428.
C-3633.
C-3634.
C-3638.
C-3646.
C-3650.
C-3676.
C-760. .
MTU-36.
.
. . . .
. .
.
.
. .
. . . .
.
.
. .
.
............
............
............
............
............
............
............
... .......
............
...........
. . .
. .
.
.
. . . . .
.
.
. .
.
SPECIAL TOOLS
Adapter-Steering Gear Shaft Seal Installing
Remover-Adapter Cross Shaft Bearing
Pliers-Snap Ring
Hose--High Pressure
Pliers-Snap Ring
Gauge-Pressure Check
Hose-Low Pressure
Remover-Cross Shaft Bearing
Driver-Cross Shaft Bearing
Remover and Installer-Seal
Hose-Coupling
Puller-Pitman Arm
Puller-Steering Wheel
Nut Wrench-Cross Shaft Retainer
Adjusting Wrench Gear Support Nut
Seal Remover-Gear Worm Shaft
Puller-Steering Arm
Seal Driver-Gear Worm Shaft
Worm Piston Ring-Remover and Installer
Pliers-Snap Ring
Ounce Pull Scale
.
.
.
Foot-Pounds
40
120
50
25
15
110 to 200
110 to 200
50
10
30
114 TRANSMISSIONS
GROUP 21
TRANSMI SSI ONS
STANDARD 3-SPEED SYNCHROSHI FT TRANSMI SSI ON
(6-Cyl i nder , 8-Cyl i nder )
The 3-Speed Synchroshift Transmission used on the the transmissions occur only in the gear ratios.
1961 6-cylinder model cars i s servi ced i n the same The following changes are the only differences from
manner as outlined in the 1960 Plymouth Service Man- those found in the 1960 Service Manual.
ual (pages 145-151). The 3-Speed Synchroshift Trans- The gearshift inter-lock linkage adjustment is the
mission used on the 1961 8-cylinder model cars is also same for six and eight cylinder cars. Refer to adjust-
serviced in the same manner as the transmission used ment procedures outlined in Heavy Duty Transmission
on the 6-cylinder engine equipped cars. Differences in Section in this supplement.
1. Lubricant. . . . .
2. Second Speed Gear End Pl ay.
RATI OS
F i r s t . .
Second. . . . .
Direct. .
Reverse. .
LUBRICANT
Capaci ty (pi nts).
T y p e .

. .
.
. . .
.
.
SPECI FI CATI ONS
SAE 80 Multi-Purpose (GL-4) Above
--lo F., SAE 75 Below -10 F.
Auto. Trans. Fluid Type A, Suffix A,
All Seasons
.002-.011
Drai n and Refi l l (i nterval s). . . . . . . .
GEARS
Type.
TOLERANCES. .
S e c o n d S p e e d G e a r E n d P l a y . . .
C o u n t e r s h a f t E n d P l a y .
Synchronizer Clutch Gear Snap Ring Thickness.
Pi ni on Beari ng Retai ner Gasket Thi ckness.
Countershaft Thrust Washers (two sizes) A
B
C l u t c h H o u s i n g R u n - O u t .
Cl utch H ousi ng Bor e Run- Out. . . . .
.
6 Cyl. 8 Cyl.
2.71 2.12
1.83 1.43
1 .oo 1.00
3.48 2.73
5
SAE 80 Multi-Purpose (GL-4) Above
-10 F., SAE 75 Below -10 F.
Auto. Trans. Fluid Tyye A, Suffix A,
All Seasons
20,000 Miles
Helical
.002-,011
.004--.012
.086~~-.o88
.089--.091
,092 ,094
.095- 097
,009 :011 V
.0135- 0165
.018-,022
.0225-.0275
.062-.064
.057-,059
.003
.003
TRANSMISSIONS 115
i
1
DD-1014. Repair Stand c - 464. . Arbor (idler gearshaft)
C - 3 2 8 1 Holding Tool C -3801. Installer (seal)
C - 452. Puller C -3692. Installer (bushing)
C - 3689. Dri ver C - 3691 Installer (oil seal)
C - 5 7 8 Arbor (countershaft) C -3767. Protector (shift shaft oil seal)
C - 3766. Installer (seal) C -3690. Puller (extension seal)
C-3765 Installer (detent ball) C -3806. Fixture (engine support)
Mainshaft Flange Nut. .
Extension to Case Bolts. . . . . .
Case to Cl utch H ousi ng Bol ts.
Transmission Cover Retaining Bolts.
Pi ni on Bear i ng Retai ner Bol ts.
Operati ng Lever Retai ni ng Nuts.
SPECIAL TOOLS
TORQUE REFERENCE
.
.
..............
..............
..............
..............
..............
..............
Foot-Pounds
175
50
50
Inch-Pounds
180
200
180
3-SPEEDHEAVY-DUTY TRANSMISSION
SPECIFICATIONS
RATIO
First . . 2.55 to 1
Seco n d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49 to 1
Direct. . . . . 1.00 to 1
R ev er se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 to 1
LUBRICANT
C a p a c i t y . . . 41/ 4 Pints
T y p e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 80 Multi-Purpose (GL-4)
Above -10 F., SAE 75 Below -10 F.
Auto. Trans. Fluid Type A, Suffix A,
All Seasons
G e a r s ::
TOLERAN&S
Cl utch Housi ng. .
Clutch Housing Bore Run-Out. . . . . . .
Countershaft End Play.
Thr ust Washer s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Helical
,003 inch
,004 inch
,007 to .012 inch
.057 to ,059 inch
,062 to .064 inch
Second Speed Gear End Play. . . . . . . . . . . ,004 to ,011 inch
C-3281.
C-3834.
C-3765.
C-3806.
C-3837.
C -748.
C -452.
C-3789.
C - 464
SPECIAL TOOLS
Brake Drum Holding Wrench
Cluster Gear Arbor
Detent Ball Holding Tool
Engine Support Fixture
Mainshaft Seal Driver
Mainshaft Seal Puller
Parking Brake Drum Puller
Pinion Seal Retainer Driver
Reverse Idler Arbor
TRANSMI SSI ONS
C- 3650. Shi f ter Shaf t Seal Dr i ver
C-3767. . . . . . . . . . Shifter Shaft Seal Protector
C-3638. . . . . . . . . . Shifter Shaft Seal Puller
C-3301. . . . . . . . . . Snap Ring Pliers
C-484. . . . . . . . . . . Snap Ring Pliers
TORQUE REFERENCE
GEARSHIFT LINEAGE
Hand Lever Pivot Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube Support Clamp Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Rod Swivel Adjustment Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Shift Lever Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Column Support Strut Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Column Support Strut to Master Cylinder Studs. . . . . . . . . . . . . . . . . . . . . .
Grease Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION
Front Bearing Retainer Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension Housing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearshift Operating Lever Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mainshaft Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission to Clutch Housing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE DIAGNOSIS
50
200
70
180
40
85
85
70
200
50
50
180
175
50
1. HARD SHI FTI NG
Possi bl e Causes:
(1) Improper crossover adjustment.
(2) Synchronizer clutch sleeve damaged or broken.
(3) Synchronizer spring improperly installed.
(4) Broken or worn synchronizer stop rings.
(5) Improper gearshift interlock action.
(6) Remote control gearshift rod bushings out of
alignment or too tight, causing the rod to bind.
(7) Improper clutch adjustment.
2. TRANSMI SSI ON SLIPS OUT OF GEAR
Possible Causes:
( 1) Second or direct speed gear synchronizer clutch-
ing teeth worn.
(2) Clutch housing bore or face out of alignment.
(3) Adjustment of gearshift rods.
(4) Linkage interference.
3. TRANSMI SSI ON NOI SES
Possible Causes:
For Bac k l ash Noi se
( 1) Excessive end play in the cluster g .
@i (2) Loose synchronizer hub spline fit o ainshaft.
(3) Loose spline fit on low speed sliding gear to
mainshaft spline.
(4) Loose spline fit of rear mainshaft flange.
For Cont i nuous Noi se
(5) Damaged, broken or excessi vel y worn gear
teeth.
(6) Worn or damaged transmission bearings,
GENERAL I NFORMATI ON
sion housing. The speedometer drive gear is integral
The heavy duty three speed manual transmission
with the mainshaft.
(Figs. 1 and 2) is of the synchromesh type with helical
cut qears to provide silent operation. The countershaft
1. REMOVAL OF TRANSMI SSI ON
gear is in constant mesh and is supported by two rows
( 1) Drain lubricant.
of needle type bearings at each end. The mainshaft is
(2) Disconnect propeller shaft, speedometer cable,
supported by ball bearings at each end of the exten-
speedometer pinion sleeve assembly.

TRANSMISSIONS 1 1 7

-
TRANSMISSIONS
Fi g. Z-Heavy Dut y Transmi ssi on (Sect i onal Vi ew)
(3) Disconnect gearshift control rods and parking
(61 Remove the extension hmai nn md mni nehqf f
brake cable from transmission.
d
---- ------------ ----I-.= -..- ..*.A*-*aa*
(4) Support engine with Tool C-3806 and remove
bearing.
engine rear mount nuts. Remove crossmember.
(5) Remove transmission to clutch housing bolts.
3. DISASSEMBLY OF TRANSMISSION
(6) Pull transmission back until pinion shaft clears
COMPONENT PARTS (Refer to Fig. 1)
clutch disc and release levers.
Drive Pi n i o n
(7) Lower transmission and remove from vehicle.
( 1) Remove transmission case cover and discard
the gasIket.
2. EXTENSION HOUSING (2) 1
Removal
3emove the four bolts from the drive pinion
bearing retainer and remove the retainer.
oldina
(3) When removing the drive pinion and bearing
assemblv from the trannmiaaion case, (Fig. 3). slide
) ring from the short
l hl v ia hei nn r nmnved
( 1) Apply parking brake and use flange hm
Tool C3281 while removing flange nut and washer. *
(2) Attach puller Tool C452 (if necessary) and re-
the synchronizer front inner stop
move drum and flange assembly.
splines on the pinion as the assem-.1 _-I-__ -= _-.--
from the case.
Remove parking brake assembly.
tension
(4) If necessary, remove seal from rear of the ex-
(4) Remove the snap ring which locks the main
tension housing, using Tool C-746.
drive pinion bearing on the shaft.
_-. -
(5) Remove five bolts and one nut attach
(5) Carefully press the bearing off the pinion shaft
Jng the ex-
housing to the transmission case.
and remove the oil slinger.
I
(6) Remove the mainshaft pilot bearing snap ring
from the cavity in the end of the drive pinion gear.
(7) Remove the 15 roller bearings.
(8) If necessary, remove the seal from the pinion
._
retainer.
Mainshaft
m Assembl y
( 1) Remove the mainshaft rear bearing snap ring
ihe groove in the mainshaft rear bearing bore in from 1
case.
(2)
to the
( 3)
from 1
( 4)
( 5)
using
(61
speed
Fi g. O--Removi ng Dri ve Pi ni c
Sljde the mainshaft and rear bearing. assembly
rear, until the rear bearing is out of the case.
Remove the synchronizer assembly (Fig. 4)
:he mainshaft and out of the case.
Remove the second and third speed shift fork. i
Remove the synchronizer clutch gear snap ring
Tool C-484.
Remove the synchronizer clutch gear, second
gear, and first and reverse sliding gear from
/
TRANSMI SSI ONS 1 1 9
CLUTCH GEAR
SYNCHRONIZER Reverse lder Gear
SLEEVE STOP INNER RING
m*.,,wrm
SYNCH~UNILCK
(1) Using a blunt drift, drive reverse idler shaft
STOP INNER RING
toward the rear of the case far enough to remove key
from shaft.
(2) Drive the shaft out d case, and remove idler
gear and bearing assembly using reverse idler assem-
bly arbor, Tool C-464.
(3) Remove the thrust washers and the 22 needle
bearings.
-SYNCHRONIZER STOP
OUTER RING A%YS.
Gear shi f t Mec hani sm
61x120
( 1) If necessary, remove both lever shaft seals,
#
Fi g. 44ync hr oni zer Assembl y using Tool C-3638.
(2) Using a small punch, remove the low und r8
mainshaft. If the synchronizer clutch gear can- verse gear lever shaft tapered lock pin by driving it
not be removed easily from the mainshaft, toward the top of the transmission case.
position the low and reverse fork and slid- (3) Remove the second and third gear lever shaft
i ng gear to the rear of the case and using a in the same manner.
plastic hammer gently tap the mainshaft (4) Remove the lever shafts f r o m the transmission
back out of the synchronizer clutch gear. case, taking care not to lose the spring loaded detent
(7) Remove the mainshaft and bearing out through balls.
the rear of the case (Fig. 5). (5) Remove the interlock sleeve, spring, pin and
(8) Remove the low and reverse shit fork from the detent balls.
case.
Count er shaf t
4. I NSPECTI ON AND Ci EANl NG
CAUTION: Do n e t drive countershuft t o w a r d Before inspecting, wash each part thoroughly in a
f r ont of t r ansmi ssi on c ase. suitable solvent, then dry. Clean mafnshaft and drive
(1) Using countershaft bearing arbor Tool C-3834, pinion shaft end bearings. Dry by applying compressed
drive countershaft toward rear of case until small key air directly through bearing. Never spin bearing
can be removed from countershaft. with compressed air. Apply a little oil and turn
(2) Drive countershaft the remaining way out the bearing several times by hand.
case, keeping arbor tight against end of countershaft Check bearings for looseness or noise by comparing
to prevent loss of needle roller bearings. with a new bearing. (Be sure to wash grease from new
(3) Remove cluster gear, and the thrust washers bearing, then apply a little oil before making corn-
from the case. parison test).
(4) Remove>roller beariigs (88) spacer rings (4) Inspect fit of beariigs on their respective shafts and
and the center spacer from the cluster gear. in bores. Inspect bearings, shaft, and case for wear, if
installation of new bearing does not correct Conditions.
install a new shaft or repair case as required.
Inspect the mainshaft splines for galling or scoring.
. Inspect bearing mounting surface and snap ring groove.
Slight nicks or burrs can be stoned off. Replace dam-
aged parts. Inspect the g&r teeth and threads on the
inner synchronizer rings and synchronizer clutch gear :
sleeve. If there is evidence of chipped or excessively
worn teeth, replace the part. Make sure synchronizer
I
cl&ch sleeve slides freely on clutchgear. Check the
pins of the outer synchronizer stop ring assembly for
straightness and tightness. Replace stop ring, if pins
; ,
are bent or loose.
f
Replace countershaft cluster gear, if any of its gear
: I
61x2
.Fig. S-Removi ng or I nst al l i ng Mai nshaf t Assembl y
>, ,
, L
;,$?:. .:_
teeth are broken, chipped or excessively worm. Small
nicks or burrs can be stoned off. Check rollers and
countershaft for chips and nicks. Check condition of
_~
1 2 0 TRANSMI SSI ONS
thrust washers, and replace if excessive wear is evi- grease and install them in the cavity at the rear of the
dent. main drive pinion.
Inspect the clutch teeth of the drive pinion. If ex- (6) Install the snao rina.
. _ * <
cessively worn, broken or chipped, install a new pin-
ion shaft. Inspect mainshaft pilot rollers in drive pin-
Count ershaf t
ion for pitting or scoring. If either of these conditions (1) Place the bearing spacer in the center of the
exists replace ,a11 roller bearings. bore in the cluster gear and use arbor Tool C-3834 to
Inspect case at gearshift bosses and operating levers. assist in assembling roller bearings.
Replace rubber lip seals in case, if worn or torn. Check (2) Using heavy grease to help hold them in posi-
interlock sleeve for free movement in its bore. Examine
tion, install a row of 22 bearing rollers next to one end
interlock balls for corrosion. If operating lever shaft
of the spacer.
detents show signs of wear, replace shaft. Check shift (3) Place one of the 4 bearing spacer rings next to
fork for free movement. the row of rollers, and install another row of 22 rollers
Check general condition of transmission case, ex- next to the spacer ring.
tension housing and front bearing retainer. Check all
(4) Install another spacer ring at the outside end
threaded holes and plugs for stripped or pulled threads. of the second row of bearing rollers.
Inspect castings for small cracks and sand holes. (5) At the opposite end of the cluster gear bore,
Check all mating and gasket surfaces for roughness install the remaining spacer rings and bearing rollers
and scratches. in the same sequence as listed in steps 2, 3 and 4.
(6) With a small amount of grease to hold it in
5. ASSEMBLY OF TRANSMI SSI ON
place, install the front thrust washer on the arbor at the
COMPONENT PARTS (Ref er t o
front end of the cluster gear, with the tabs outward.
Fi gs. 1 and 2)
(7) Install the tabbed rear thrust washer on the ar-
Drive Pinion and Bear i ng Assembl y
bor against the rear of the cluster gear with the tabs
( 1) Place the oil slinger on the main drive pinioi
positioned in the grooves provided in the cluster gear.
(8) Install the remaining rear thrust washer plate
with the offset outer portion next to the drive pinion on the rear of the gear and arbor with the step in the
teeth (Fig. 6).
washer facing upward as viewed from rear. Rear
(2) Place the main drive pinion bearing on the thrust washer must be installed with step on
pinion shaft with the outer snap ring away from the O.D. of washer engaged on ledge inside rear
pinion gear.
of case, thus preventing rotcetion of thrust
(3) Press the bearing into position so it is seated
washer plate.
firmly against the oil slinger and pinion gear.
(9) Align the tabs of the front thrust washer ver-
(4) Install the bearing retaining snap ring on the tically to index with the notches in the transmission
pinion shaft, using snap ring pliers Tool C-3301. Be
case, and with the step in the rear thrust washer
sure snap ring is seated in groove.
positioned upward. Position the cluster gear and arbor
(5) Coat the 15 pilot bearing rollers with heavy assembly in the transmission case. Make sure the
thrust washers are not dislodaed from the arbor, and
SLINGER
engage thrust washer tabs in case. grooves, while slid-
ing the assembly into position.
(10) Check the end play of the countershaft. End
play should be ,007 to .012 inch. Thrust washers are
available in two thicknesses.
SNAP RING
(11) Using the countershaft and a soft hammer,
drive the arbor forward out of the cluster gear and
through the bore in the front of the case. .Before driv-
ing countershaft all the way into case, be sure keyway
is positioned in line with key recess provided in rear
of case. Insert shaft key and continue to drive counter-
shaft forward in case until key is bottomed in recess.
Reverse I dl er Gear
DRIVE PINION
57d72A
( 1) Position arbor Tool C-464 in the reverse idler
gear and using heavy grease, install the 22 roller
Fig. &-Drive Pinian Assembly bearings in the gear.
TRANSMI SSI ONS
Fi g. 8-I nst al l i ng Det ent Bal l s (Usi ng Tool C-3765)
_-W AND REVERSE
LEVER
(Fig. 8). to depress the detent ball against spring ten-
sion, push the low and reverse lever shaft firmly into
position so it engages the detent ball.
af t s
(6) Remove the detent ball installing tool.
(7) Install the low and reverse lever shaft lock pin
nshers at each in the case, driving it down firmly from the top using
end of the reverse idler gear, and position the assem- the caution as stated in step (3).
bly in the transmission case with the chamfered end (8) Place the low and reverse fork in the lever
of the gear teeth toward the front. shaft, with the offset toward rear of transmission.
(3) Insert the reverse .idler shaft into the bore at
rear of case with keyway to rear, pushing the arbor
M& shaf t
toward the front of the transmission. ( 1) While holding the low and reverse sliding gear
(4) With keyway aligned with recess in case, drive in position in fork, with the hub extension to rear, in-
the shaft forward, inserting key before the keyway is sert the mainshaft with rear bearing through the rear
obscured. Continue driving shaft forward until key of the case and into the sliding gear.
seats in recess. (2) Place the synchronizer stop ring spring, and then
Gearshi f t Mec hani sm (Fi g. 7)
the rear stop ring on the synchronizer splines of the 2nd
speed gear. Install the 2nd speed gear on the main-
(1) Install two new lever shaft seals (if removed) shaft.
in the transmission case, using seal driver Tool C-3650. (3) I nstal l the synchroni zer cl utch gear on the
(2) Install the 2nd and 3rd speed lever shaft in the mainshaft with shoulder to the front.
bore provided in the transmission case. (4) Select the thickest synchronizer clutch gear snap
(3) Install the 2nd and 3rd speed lever shaft lock ring that can be used, and install it in the mainshaft
pin in the hole in the case boss, starting the pin at the groove. Make certain ring is bottomed all the way
top of the hole, and driving it downward. Drive the pin around in the groove. Snap rings come in four
in firmly so it will not work out of the hole, and will different thicknesses (thin. medium, thick
also prevent the possibility of a lubricant leak at the and ex t ra thick). Use of the thickest ring pas-
pin hole. While the lever shaft lock pins must be driven sible eliminates end play at thig point and
in firmly to prevent leakage or loss of the pin, some provides mor e positive gear engagement i n
caution must be exercised to avoid driving the pin in di;ect drive.
too tightly, causing distortion or mushrooming of the (5) Check clearance between clutch gear and 2nd
pin. This could result in much difficulty if it is neces- speed gear. Clearance should be .004 to .Oll inch. End
sary to remove the pin at a later date. play in excess of .Oll inch may cause 2nd speed gear
(4) Place the interlock parts in position in the case Jump out.
in the following order: Ball, sleeve, spring, pin and (6) Hold the synchronizer clutch gear sleeve and
ball. two outer rings together with pins properly entered in
(5) While using detent ball installer Tool C-3765 the holes in the clutch gear sleeve and with the clutch
122 TRANSMI SSI ONS
gear sleeve engaged in the groove of the 2nd and 3rd
speed shift fork, position the fork in the 2nd and 3rd
speed lever shaft.
(7) While holding the synchronizer parts and fork
in position, slide the mainshaft forward, entering the
synchronizer clutch gear into the clutch gear sleeve
and at the same time entering the mainshaft rear bear-
ing in the case bore..If synchronizer parts are not
positioned as described in steps 6 and 7, it
will not be possible to place them in position
after mainshaft is fully in position, due to
interference with countershaft drive gear.
(8) While continuing to hold the synchronizer parts
in position, tap the mainshaft forward until the rear
bearing bottoms in the case bore.
(9) Install the mainshaft rear bearing snap ring in
place in the groove in the case bore.
Dr i ve Pi ni on
( 1) Install new seal (if removed) in retainer using
Tool C-3789 until it bottoms on the seat of the counter-
bore. Synchronizer front inner ring must be positioned
as outlined in steps 2 and 3 while installing drive pin-
ion, since it will not clear countershaft drive gear teeth
when attempting to install drive pinion with inner ring
installed on drive pinion splines.
(2) Place synchronizer front inner ring in position
in front outer ring, and enter main drive pinion through
case bore.
(3) Engage splines on rear of pinion with inner stop
ring, and tap drive pinion into transmission case until
the outer snap ring on pinion bearing is against trans-
mission case.
(4) Place the drive pinion bearing retainer, without
a gasket, over pinion shaft, and against transmission
case. Whi l e hol di ng retai ner wi th hand pressure
against transmission case, measure the clearance be-
tween the retainer and case, using a feeler gauge.
(5) Sel ect a gasket .003 to .005 i nch thi cker than
the clearance found. This eliminates end play of front
bearing in transmission case and also eliminates dis-
tortion of bearing outer race due to excess pressure.
(6) Install and tighten the front bearing retainer at-
taching bolts to 200 inch pounds.
Ex t ensi on Housi ng
( 1) I nstal l new seal i n extensi on housi ng (i f re-
moved), using Tool C-3837.
(2) Install the extension housing. Tighten the mount-
ing bolts and nut to 50 foot-pounds torque.
(3) Install the parking brake assembly.
(4) Install parking brake drum end flange assem-
bly. Install washer and nut and tighten to 175 foot-
pounds, using flange holding Tool C-3281.
(5) Install drain plug in transmission case.
(6) I nstal l gearshi ft operati ng l evers wi th a fl at
washer and lockwasher under each nut, and tighten
to 180 inch-pounds.
(7) I nstal l pl ug or back-up l i ght swi tch (i f so
equipped), with gasket, tighten securely.
(8) I nstal l speedometer cabl e and dri ve gear as-
sembly.
6. I NSTALLATI ON OF TRANSMI SSI ON
A check of clutch housing bore and face alignment
should be made before installation. Refer to Clutch
Group 6 in the 1960 Plymouth Service Manual for pro-
cedure. A substitute transmission drive pinion shaft
may be used to assist clutch disc alignment.
Place a small amount of short fibre wheel bearing
lubricant around the inner end of the drive pinion shaft
pilot bushing. A sufficient amount will be left at this
location after pressing the excess out of the crank-
shaft cavity. Do not lubricate the bushing or the end
of the transmission pinion shaft, the clutch disc splines
or clutch release levers.
(1) Use extreme care when installing the transmis-
sion. The pinion shaft should be in alignment to enter
the pilot bushing without distorting the clutch disc.
(2) Tighten the transmission to clutch housing bolts
(3) Install the crossmember and engine rear mount
bolts. Tighten the nuts to 35 foot-pounds torque.
(4) Connect propel l er shaft and parki ng brake
cabl e.
(5) Fill transmission with 4% pints of Multi-Purpose
(GL4) SAE 80 above -10F. SAE 75 bel ow -10F..
or Automatic Transmission Fluid Type A, Suffix A
for all seasons.
7. GEARSHI FT CONTROL ADJ USTMENTS
(I n Car)
The following procedure should be used for check-
ing and adjusting gearshift linkage already installed
in a vehicle. (For adjustment made when the linkage
has been removed from the vehicle, see Paragraph 9
Linkage Assembly and Disassembly.)
Gear shi f t Hand Lever Posi t i on
The gearshift tube arm (in which the hand lever
pivots) should be 15 degrees above horizontal with the
transmission in neutral (see Fig. 9). This will place the
hand lever knob approximately 14 degrees above hori-
zontal. The shift rod upper end swivel block adjust-
ment can be changed to position the hand lever cor-
rectly (see Fig. 10).
Gear shi f t Tube Ax i al Free Play
The clearance or movement axially of the gearshift
1
WASHER
RETAINER
SPRING WASHER
-FBRACKET 61x147
Fi g. 9-Gear sh i f t Cont r ol s
tube with the transmission in third gear should be the
same as the transmission in first gear. This adjustment
can be made by loosening the tube support bolt and
tapping the tube support either up or down the column
jacket as required (see Fig. IO).
Cr oss-Over Adj ust ment
With the transmission in neutral, it should be pos-
sible to move the hand lever from its normal 2nd~3rd
axi al posi ti on to the 1st~reverse posi ti on and back
again smoothly. If this cross-over action is ro-ugh or
stepped the 2nd-3rd shift rod swivel block adjustment
should be changed until the cross-over is smooth.
To adjust the cross-over wi th the new swi vel ad-
justment proceed as follows:
( 1) Place transmission in neutral.
(2) Loosen the 2nd-3rd clamp screw.
(3) Push up on the bottom of the shift tube [or have
someone lift on the hand lever) until the cross-over pin
is between the 1st.reverse and 2nd-3rd shift lever hubs
(the parts will not rotate relative to each other under
these conditions).
(4) With the fingers rotate the 2nd.3rd shift lever
to its mid backlash position while maintaining the shift
tube in the position described in step 3.
(5) Tighten the swivel adjustment clamp.
Lubrication
( 1) The lower mechanism of the shift linkage should
be lubricated through the grease fitting provided.
(2) The upper shift tube pivot (riveted to the col-
umn jacket bell) and the hand lever at its inner end
and pi vot hol e shoul d be l ubri cated l i beral l y wi th
regular chassis lubricant.
(3) The transmi ssi on operati ng l ever bushi ngs
should be lubricated with engine oil.
SPACER WASHER
CONTROL ROD
61x119
\_
Fi g. l o-Gearshi ft l i nk age
Interferences
Three major areas of interference should be checked.
These are:
(1) At the gearshift tube floor seal. The gearshift
tube should rotate and travel axially freely in the floor
. seal. There should be no interference with the sides of
the opening in the floor through which the tube oper-
ates. It may be necessary to rotate the tube lower sup-
port to prevent interference at this point.
(2) Approxi matel y 5/ i nch cl earance shoul d exi st
between the outside edge of the gearshift tube bracket
and the frame si de cl utch torque shaft arm. I f the
clearance is insufficient loosen the bracket clamp and
attaching bolts slightly, move the bracket away from
the torque shaft arm and retighten the bolts.
(3) After al l of the above adjustments have been
made or checked, shift the transmission into 3rd gear.
The 2nd.3rd shift rod should clear the top of the clutch
fork by L/4 inch minimum, the top of the clutch torque
shaft by r/ 4 inch minimum and the bottom of the flwr
pan by / 4 inch minimum. The same clearances should
exist with the transmission in 2nd gear.
8. HEAVY DUTY INTERLOCK LINKAGE
On hi gh performance and speci al equi pment cars
(Taxi-cabs, Police cars or cars equipped with 361 or
383 cu. in. engines) a shift linkage interlock is used
to prevent damage to the transmission. All preceding
adjustments and checks are appl i cabl e except the
neutral hand lever position is fixed by the interlock
pin.
Adjustment is as follows :
( 1) Place the transmission in neutral and remove
the 1st.reverse shift rod from the gearshift tube lever.
The interlock pin should extend through the tube sup-
port bracket into the Is&reverse tube lever.
TRANSMISSIONS
-
(2) Adjust the swivel block on the M-reverse shift
rod so the pin will enter the tube lever hole in the mid-
clearance or mid-backlash position. Install the spring
washer, flat washer and clip as shown in Figure 10.
(3) Check the adjustment as follows: Start the en-
gine and run at idle speed. With the transmission in
neutral, push and pull the 1streverse tube lever within
the movement permitted by the interlock pin.
The transmission gears should not scrape as they ap-
proach either their 1st or reverse position. If scraping
occurs going towards 1st gear position (lever traveling
down) the swi vel shoul d be readjusted sl i ghtl y to
shorten the shift rod. If scraping occurs going towards
the reverse gear posi ti on (l ever travel i ng up) the
swivel should be readjusted slightly to lengthen the
shift rod. With correct adjustment the neutral position
of the hand lever is fixed and the gears cannot be
scraped in either direction when applying the above
procedure.
(4) Cross-over is then adjusted as outlined in Para-
graph 7.
9. ASSEMBLY AND DISASSEMBLY
Figures 9 and 10 show exploded views of the various
linkage parts and their proper location and order in
the completed linkage assembly. These figures should
be followed closely when re-assembling the linkage
both in subassembly and reassembly into the vehicle.
Disassembly
( 1) Remove both shift rods by disconnecting the
retaining clips at both ends,
(2) Remove the lower column jacket support strut
and loosen the steering tube flexible coupling.
(3) Remove the column jacket dash clamp and the
column jacket floor seals.
(4) Pull the column jacket and shift tube assembly
(including lower shift tube bracket) up and out of the
car.
(5) Remove the grease fitting from the tube lever
pin retainer. Rotate the retainer and push the tube
lever pin out of the gear shift tube.
(6) Loosen the gearshift tube lower bracket clamp
and sl i de the bracket and l ever assembl i es off the
bottom of the shift tube and jacket. Pull the lever as-
semblies from the bracket.
(7) Remove the hand lever pivot pin and pull the
hand lever out of the shift tube arm.
(8) Pull the shift tube assembly from its upper pivot
in the column jacket bell.
(9) Wash all parts and inspect for wear or damage.
Replace with new parts as necessary.
Assembly
( 1) Clamp the column jacket in a vise with the up-
per shift tube pivot pin on top.
(2) Lubricate the pivot pin generously with chassis
lube. Insert the cross-over spring into the top end of the
shift tube and push the gearshift tube over the pivot
pin. The tube should slip up and down the pivot freely
with the lower end of the tube ?/ s inch off-set to the
column jacket on the hand lever side. If the tube is not
free pull the bottom end of the tube past the % inch
position, adjust the pivot bracket slightly to free up
the pivot. The rivet holding the pivot pin should be
tight; looseness will cause rattle.
(3) Assemble the swivel bushing, tube levers, flat
washer, wave spring, spring retainer and tube lever
pin retainer into the tube support as shown in Figure 10.
(4) If the interlock pin is to be used, position the
nylon bushing in the tube groove, spread the lock
spring over the nylon bushing and push the interlock
pin over the straight ends of the lock spring.
. (5) Push the support and lever assembly over the
tube and column jacket (positioning the interlock pin
through the hole in the support) until the tube lever
pin can be inserted through the lever hub slots and
tube hole.
NOTE: A round pin is used with interlock
linkage. A square headed pin is used with
standard linkage.
(6) Rotate the tube lever pin retainer and screw the
grease fitting into the lower lever hub through the re-
tainer stamping slot.
(7) Lubricate the inner end and around the pivot
hole on the hand lever. Install the rubber bumper on
the hand lever as shown in Figure 9. Then insert the
hand lever into the shift tube arm and assemble pivot
and lock screw. Tighten to 50 inch-pounds torque to
prevent excessive lever looseness.
(8 ) Check the gearshift tube axial free play (see
Paragraph 7). The centerline of the shift tube as held
by the support should be approximately 5/ s inch offset
from the column support centerline (towards hand
lever side of column).
(9) Install the column support assembly into the
vehicle.
(10) Attach the shift rods and adjust linkage as de-
scribed in the foregoing section.
i
TORQUEFLITE TRANSMISSION
)
The service procedures for the 1961 Plymouth Torque-
have been modified by decreasing the clearance be-
Flite Transmission are basically the same as outlined
in the 1960 Plymouth Service Manual. Complete serv-
tween the pressure plate drive lugs and the grooves in
icing procedures may be obtained by referring to the
the piston retainer. Servicing procedures for the clutch
1960 Plymouth Service Manual. However, when servic-
assembly remain the same: however, the new parts are
ing components of the 1961 transmission, refer to the
not interchangeable for earlier transmissions except as
Specifications, Pressures and Charts in this Supplement.
follows :
Certain parts in the rear clutch assembly have been The new pressure plate must be used with the new
changed and are described in this Supplement. piston retainer; otherwise, an interference condition
might exist.
1. REAR CLUTCH
The new pressure plate is also used in the front
The rear clutch piston retainer and pressure plate clutch assembly
SPECIFICATIONS
TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T O R Q U E C O N V E R T E R D I A M E T E R ( I N C H E S ) .
OIL CAPACITY OF TRANSMISSION AND TORQUE CONVERTER.
ME T H O D O F C O O L I N G .
GEAR RATIOS
l-Low. . .
2- Se c o nd. . . . . . . . . . . . . . . .
D - D r i v e .
R-Reverse. . .
N - N e u t r a l .
FRONT-REAR PUMPS
Ty pe . . . . . . . . . . . . . . . . . . . . .
End Clearance (Front Pump),
End Clearance (Rear Pump)
THRUST WASHERS
I n p u t S h a f t .
. .
.
Front Clutch and Sun Gear,
O u t p u t S h a f t .
SNAP RINGS
Kickdown Annulus G e a r .
Rear Clutch. .
Low-Reverse Planet Pinion Carrier,
.
.
.
.
. .
.
.
. .
. .
. .
. Gear (Rotary)
.OOl to .0025 inch
. . .OOl to .0025 inch
Front Clutch (Selective). . . . . . . . . . . . . . . .
Automatic Three Speed with
Torque Converter
11%
121/2 Hi Perf.
18 pts. Automatic Transmission
21 pts. with 121/2 Converter
Fluid Type A Suffix A
Water
e
j 1
1
2.45 t o 1
1.45 t o 1
1.00 t o 1
2.20 t o 1
.115 to .117 inch (Natural)
,097 to ,099 inch (Black)
.078 to ,080 inch (Red)
.059 to .061 inch (Orange)
,062 to ,064 inch
.062 to .064 inch
.060 t o .062 inch
,064 t o ,066 inch
.060 t o ,062 inch
,060 t o .062 inch
,064 t o ,066 inch
,068 t o ,070 inch i
,060 t o .062 inch i
,064 t o .066 inch
!
i
,068 t o .070 inch
I
,
TRANSMISSIONS
~-
SPECIFICATIONS (Cont d)
/.
.s
Transmission
Assembly
Number
1949902
1: 1949905)
(Heavy Duty)
1949906
(Heavy Duty)
(1949907)
(High Perfor.)
(1949808)
(Ram Eng.)
Engine
(Cu. In)
318
318
361
361
361
Front
Kickdown Clutch
Band Cushion
(Back Off) Spring
21/ z Turns Yes
21/ z Turns No
2 Turns No
2 Turns Yes
2 Turns Yes
Number
of
Discs
4
4
4
4
4
Accumu-
lator
Spring
Lbs.
29
16
N one
16
None
Rear Clutch
Discs Spring
Lbs.
4 180
5 280
5 180
5 280
5 180
SPEEDOMETER PINION USAGE CHART
Ti re
Size
750 x 14
and
800x14
Axle
Ratio
2.93: 1
3.31:1
3.58:1
output
Shaft
8 Teeth
8 Teeth
8 Teeth
No. Teeth
17
20
21
Pinion
Color
Red
Light Blue
Yellow
C- 452. . . . . .
C - 5 8 9 .
C- 760. . . . . .
C- 3203A .
C - 3 2 7 6 .
C - 3 2 8 0 .
C - 3 2 8 1 .
C - 3 2 8 3 .
C - 3 2 8 8 .
c - 3 2 9 2 .
c - 3 2 9 3 .
c - 3 3 0 1 .
c - 3 3 3 9 .
c - 3 3 5 5 .
C - 3 3 8 0 .
Puller
.Wrench
Pliers
J a c k
Pilots
Stand
Wrench
Pi l ots
P i l o t s
Gauge
.Gauge
Pliers
Set Di al I ndi cator
Straightedge
W r e n c h
SPECIAL TOOLS
C-3461 .Fixture
C-3487 Support
C-3527. Gauge
C- 3528, Stand- (pr . ) Val ve Body H ol di ng
C - 3 5 2 9 . .Compressor F i x t u r e
C-3531. Tool
C - 3 5 3 3 . Compr essor
C-3575 Compressor
C - 3 5 8 3 . Adapter-for C-3380 Torque Wrench
C-3689 Bushing Remover
C - 3 6 9 0 . Remover
C- 3691. O i l Seal D r i v er
C-3692. Installer
DD-1150. T ach o met er
TORQUE REFERENCE
Accumulator Cover Screws. *
180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BandLeverShaftPlug
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Case to Converter Housing,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
Compensated Throttle Pressure Tap.
120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension to Transmission Case,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSMISSIONS 127
TORQUE REFERENCE (Contd)
Filler Tube Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Pump Housing to Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .
Governor Body to Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Take-Off Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Support Locating Screw.
. . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown Band Adjusting Screw Nut
. . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Regulator Valve Retainer
. . . . . . . . . . . . . . . . . . . .
Line Pressure Take-Off Plug, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low-Reverse Band Adjusting Screw Nut. . . . . . . . . . . . . . . . . . . . . .
Manual Valve Control Cable Housing.
. . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Starter Switch-Initial Electrical Contact plus / 3 to / 2 Turn
Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shaft Support to Case,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Flange Nut
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reaction Shaft to Case, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Clutch Pressure Tap.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Housing to Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Pressure Tap. . .
Servo Apply Pressure Tap.
Torque Converter Cooler Line Fitting. . . . . . . .
C o n t r o l V a l v e R e t a i n e r .
Transfer Pl ate to Transmi ssi on Case. . . .
Valve Bodies to Transfer Plate.
TORQUE CONVERTER HOUSING
Housing to Engine Block 3/ e i nch Screws
%6 i nch Screws.
D u s t C o v e r .
D u s t P l a t e .
TORQUE CONVERTER
Crankshaft Nut or Bolt
Converter Drain Plug.
Dri ve Fl ange Stud.
.
.
.
.
.
. .
.
.
. .
.
.
...........
.......
...........
Foot-Pounds
40
25
35
50
35
20 Max.
25
175
25
40
30
50
55
15-25
35
Inch-Pounds
180
90
70
120
120
200
175
120
120
180
180
120
120
180
55
200
130
SHIFT PATTERN SUMMARY CHART
(WITH 750 x 14 TIRES)
M od el . . . . . . . . . . . . . . . . . . . . . . . . . RP2 RP2 Hi Perf. RP2 Ram Man.
Axle Ratio. . . . 3.23 . . 2.93 3.31 2.93 3.31
Condition Car Speeds
Cl osed Thr ottl e l - 2 Upshi f t 8814 7-13 8813 9915 10-14
Cl osed Throttl e 2-3 Upshi ft. 12-18 11-16 11 ~16 12-18 14-19
Wide Open Throttle 1-2 Upshift. 30-45 2740 39-48 44-54 36-42 I
i
Wide Open Throttle 2-3 Upshift. 6581 58-72 65-78 73-88 59-72 1
3-2 Kickdown Limit, . . 62-79 55-70 63-76 71-86 55-64
3 - l Kickdown L i m i t . 36-42 35541 . 30-43 27-38 32-46
Cl osed Thr ottl e Downshi f t. 7-12 7-12 6 13 5-12 6-11
Aid
128 TRANSMISSIONS
LINE PRESSURE CHART
Push
Button
Position Rear Wheels
Engine
Speed
h4
RP2 Ram Man.
Line Line
Pressure Pressure
(Psi) (psi)
R
N ; : : : : : : : : : : : : : : , : : : : : : : : : : : : : : : : : : 1
Free to Turn 1600 200-240 235-275
1200 85 95 100~110
D (Shifted into Direct)
. . . . . :::::::::::::::::v
Free to Turn 1200 89-91 1044106
2
.:: . . . .
Free to Turn 1200 85 -95 100 110
1. . . . . . . . . . . Free to Turn 1200 85 95 100&l 10
D . . . . . . . . . Free to Turn 3500 93 100 108 115
GOVERNOR PRESSURE CHART
Push
Button
RP2 RP2
Std. Governor Hi Perf.
Engine Governor Engine Governor
(wm)
Pressure
@pm)
Pressure
2 (Second) . Free to Turn 690-790 15 psi 690 790 15 psi
D (Drive).
1 : : : : : : : : : : : : :
Free to Turn 1250 1510 45 psi 1680-1860 45 psi
D (Dri ve). Free to Turn 2560-2790 75 psi 2850 ~-3070 75 psi
RP2
Push Ram Manifold Engine
Button Engine Speed Governor
(rpm)
Pressure
2 ( Secon d ) . . _.__....__..__. ._ .__....____........... Free to Turn 860 -970 15 psi
D (Drive).
D(Drive).. .,., :::::::::::::::.::::::::::::::::::.:.:
Free to Turn 1830~2100 65 psi
Free to Turn 2550-2800 85 psi
POWERFLITE TRANSMI SSI ON
Service procedures for the Z-speed automatic trans-
mission remain essentially the same as outlined in the
1960 Plymouth Service Manual with the following ex-
ceptions :
Governor Pressure chanae-For all PowerFlites with
Governor Car Speed in M.P.H. for Given Axle Ratio*
Pressure 3.31 3.58 3.91
15 12-16 IO-15 10 14
45 23-34 20-30 19-29
60 54-65 48-58 46.- 56
the following tire sizes: 7.50 x 14 and 8.00 x 14. Gearshift Position in Drive-Wheels Free to Turn.
SPECIFICATIONS
Type... . . . . . ._........,,. __..__...................
Automatic Two Speed with
Torque Converter
T or que Conver t er Di amet er ( i nches) , . .
Oi l Capaci ty of Tr ansmi ssi on and Tor que Conver ter ,
l13i4
20 pt. (Automatic Transmission)
Fl ui d-Type A Suffi x A
TRANSMISSIONS 129
Method of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . .
NumberofClutchPlates.............::~~~~:::::::::::::::::::. . .
GEAR RATIOS
L ow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dri ve-Breakaway. .!. . . . . . . . . . . . . . . . . . . . . . . .
Drive Di rect.. . . . . . . . . . . :::::: . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse FRONT-REAR PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Clearance (Front Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Clearance (Rear Pump).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GOVERNOR (3-STAGE)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Governor Valve and Body . . . . . . . . . . . . . .
THRUST WASHERS
Direct Clutch Piston Retainer (Fibre) . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown P l a n e t P i n i o n C a r r i e r .
Kickdown Annulus G e a r ,. .
Pl anet Pi ni on Carri er Housi ng, .
SNAP RINGS
Planet Pinion Carrier Housing.
Kickdown Sun Gear . ..__......................___..
Reverse Annulus Gear. . .
Water
Pumps (Rotor Type)
6
1.72 to 1
1.72 to 1
1 to 1
2.39 to 1
Gear (Rotary)
.0012 to .0022
.OOl to ,003
Centrifugal
.ooo!Y to .002
.078 to ,080
.095 to ,097
,112 to .114
,062 to ,064
,062 to ,064
,078 to ,080
.062 to .064
*.072 to .074
*.082 to ,084
,058 to ,060
.062 to ,064
,078 to ,080
,082 to ,084
,086 to .088
*If this selection of snap rings fails to provide minimum clearance, use kickdown sun gear snap ring (. 058---,060
Tire Axle
Size Ratio
750 x 14 3.31:l
and
3.58:1
800 x 14 3.91:1
output
Shaft
7 Teeth
7 Teeth
7 Teeth
No. Teeth
17
19
20
Pinion
Color
Orange
Dark Blue
Green
C - 4 5 2
C- 484. . .,
C- 589. . _,
C - 7 4 8
C- 760. . ,.
C- 811. . ,.
C3201A.
C3202A. .
C - 3 2 0 4 .
Puller
Pliers
Wr ench
Puller
Pl i ers
Wr ench
Jack
J ack
Driver
SPECIAL TOOLS
C - 3 2 8 7 .
C - 3 2 8 8
c - 3 2 9 2 .
c - 3 2 9 3
c - 3 2 9 4 .
c- 3295.
c - 3 2 9 7 .
c - 3 3 0 1 .
c - 3 3 3 5 .
.Puller
Pilots
G a u g e
G a u g e
St and
Pi l ots
Remover-Installer
Pl i er s
Strai ghtedge
130 TRANSMISSIONS
C-3205. Driver
C-3275. Driver
C-3276, Pilots
C-3278. Driver
C-3279A. .Wrench
C-3280. Stand
C3281..........Wrench
C - 3 2 8 3 . Pi l ots
c- 3339.
C - 3380.
C - 3461.
.
C - 3487.
c- 3529.
c- 3575.
C - 3583.
DD-1150..
Set-Dial Indicator
Wrench
Fixture
.Support
Compressor-Servo Spring
.Compressor
Adapter-For C-3380 Torque Wrench
Tachometer
TORQUE REFERENCE
Case to Converter Housing Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case Oil Line Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case to Reaction Shaft Bolt. . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Clutch Shift Valve Plug Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension to Case Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Pump Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Body Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Locating Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Oil Pressure Take-Off Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown Band Adjusting Bolt Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown Band Lever Shaft Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickdown Strainer Support Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Control Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Starter Switch-Initial Electrical Contact plus % to / z turn . . . . . . . .
Oil Pan Bolt and Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Filler Tube Bracket Bolt Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Filler Tube Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shaft Support Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i . . .
Output Shaft Support Pipe Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Pump Housing Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular Valve Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Band Lever Adjusting Bolt Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Pinion Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Control Lever Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Oil Pressure Take-Off Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Valve Adjusting Bolt Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Control Valve Spring Retainer. . . . . . . . . . . . . . . . . . . . . . . .
Transfer Plate Cover Bolt-Long. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Plate Cover Bolt-Short. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Plate Bolt-Long, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Plate Bolt-Short. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body End Cover Long Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body End Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body End Cover Short Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Clip to Column Jacket Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . :. . . . . . . .
Push Button Box to Instrument Panel, Plate or Bracket Assembly Nut. . . . . . . .
Transmission Cable Bracket Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Housing
Housing to Engine Block--3/ s inch screws, . . . . . . . . . . . . . . . . . . . . . . . . . .
Yi6 inch screws. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Cover. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DustPlate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot-Pounds
45
15
25
40
25
7
75 Max.
Inch-Pounds
120
30
*!
180
90 , I
45
120 1
i
180 i
I
I!
180 I
20
40
25
120
180
50
35
175
45
7
120
25
40
45
45
180
180
25
25
25
70
20
15
30
40
200
130
f
i.
a
I
TRANSMISSIONS
131
TORQUE REFERENCE (Contd)
Torque Converter
Crankshaft Nut or Bolt. . . . . . . . . . . . . . . . . . . . . . . . .
Drain Plug. . . . . . . . . . . . . . . .
.
55
20
TORQUE CONVERTER
The Service Procedures for the 1961 torque converter Manual.
used wi th PowerFlite and TorqueFlite Transmi ssi ons For detailed service procedures for the torque con-
are the same as outlined in the 1960 Plymouth Service verter, refer to the 1960 Plymouth Service Manual.
TORQUEFLITE SIX AUTOMATIC TRANSMISSION
The service procedures for the 1961 TorqueFlite Six and must be followed when performing the operations.
Transmission are essentially the same as outlined in
the 1960 Plymouth Service Manual with the following
NOTE: Figures 1 and 2 have been revised
exceptions.
and should be used when reference is made
The new service procedures in this Supplement can-
to the Hydraulic Control System or when per-
ccl those given in the 1960 Plymouth Service Manual forming Air Pressure Checks.
SPECIFICATIONS
T Y P E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE CONVERTER DIAMETER. . . . . . . . . . . . . .i . .
OI L CAPACI TY-TRANSMI SSI ON AND TORQUE
CONVERTER (Dry Fill). . . . . . . . . . . . . . . . . . . . .
COOLING METHOD. . . .
L UBRI CA TI ON .
CLUTCHES
Number of Front Clutch Plates
Number of Front Clutch Discs.
Number of Rear Clutch Plates.
Number of Rear Clutch Discs.
GEAR RATI OS
l - L o w .
2- Secon d . . . . . . . . . . . . . . . . .
D-Dri ve. .
R - R e v e r s e
N-Neutral. . . . . . .
FRONT-REAR PUMPS
T y p e .
E n d C l e a r a n c e .
DRIVE TRAIN END PLAY.
CLUTCH PLATE CLEARANCE
F r o n t C l u t c h
Rear Clutch. . . . . .
. .
.
.
.
.
.,
.
.
. .
.
. .
.
.
.
. .
.
.
,056 to ,104 inch
,018 to ,036 inch
Automatic Three Speed
with Torque Converter
103/ i nches
14 pts. Automatic Transmission
Fluid Type A Suffix A
Imperial Measure 103/ Pts.
Water-Heat Exchanger
Pump (Rotor Type)
4
4
2
3
2.45 to 1
1.45 to 1
1 to 1
2.20 to 1
Gear (Rotary)
,001 to 0025 inch
,024 to .062 inch
132
TRANSMISSIONS
SPECIFICATIONS ( Cont d)
SNAP RINGS
Front and Rear Clutches
Rear Snap Ring (Selective) ,060 to .062 inch
,068 to .070 inch
,076 to .078 inch
THRUST WASHERS
Output Shaft to Input Shaft (Selective) . . . .052 to .054 inch
(Natural)
.068 to .O?O inch
(Red)
,083 to .085 inch
(Black)
S u n G e a r D r i v i n g S h e l l . . . . ,060 to .062 inch
Driving Shell (Steel). .
,034 to ,036 inch
O v e r r u n n i n g C l u t c h R a c e . ,060 to ,062 inch
Kickdown Annulus Support. .., . . . . . . . .121 to ,125 inch
Front Clutch to Rear Clutch . ,043 to .045 inch
Front Clutch to Reaction Shaft Support . . .043 to ,045 inch
Tire Axle output Pinion
Size Ratio Shaft No. Teeth Color
750 xj14 3.31:1 7 Teeth 17 Green
and 3.54:1 . 7 Teeth 18 Dark Blue
800 x 14 3.91:1 7 Teeth 20 Grey
SPECIAL TOOLS
C - 4 5 2 . Pul l er - Compani on Fl ange
C-484 Pliers Snap Ring
C- 3203- A . J ack- Tr ansmi ssi on
c-3229 Pl i ers-Snap Ri ng
C-3281, : Wrench-Companion Flange Holding
C - 3 2 8 3 Studs-Pi l ot
C-3288, Studs -Pilot
c-3292 Gauge- Low Pressure
C-3293, Gauge High Pressure
c-3335. Straight Edge
C-3339 Dial Indicator
C- 3575 Compr essor - Fr ont Cl utch Pi ston Spr i ng
C-3749 Stand--Valve B o d y
C - 3750. St an d - T r an smi ssi on
c-3751 Installer and Burnisher
(Extension Housing Bushing)
C - 3 7 5 2 . Remover-Front Oil Pump and Reaction Shaft Support
C - 3753. .Remover-Output Shaf t Oi l Seal
C - 3 7 5 4 . Dri ver-Output Shaft Oi l Seal
c-3755 Remover-Extension Housing Bushing
C- 3756. A l i gni ng Tool Fr ont Oi l Pump
c - 3 7 5 7 . Installer-Front Pump Oil Seal
TRANSMISSIONS 133
C - 3758. .Remover-Front P u mp Oi l Seal
C-3759, Assembl y Tool ~-Front Oi l Pump to Reacti on Shaft Support
C- 3760. Compr essor - Rear Cl utch Pi ston Spr i ng
C- 376. 2. A l i gni ng Sl eeve- Rear Oi l Pump Cover
C- 3763. Gauge- Thr ottl e Pr essur e Setti ng
C- 3768. Pr otector - Output Shaf t Oi l Seal
C - 3 7 9 0 . Adapter-Transmi ssi on Band Adjuster
(Use with C-3380 Torque Wrench)
C - 3806. F i xt u r e- E n gi n e Su p p o r t
TORQUE REFERENCE
Band Adjusting Screw Lock Nut. . . . . .
Cool er Li ne Fi tti ng . .
Converter Drain Plug. . . .
Conver ter Dr i ve Pl ate to Cr ankshaf t Bol t.
Converter Drive Plate to Torque Converter Bolt
Extension to Transmission Case Bolt i. . . .
Extension to Mounting Bolt,
Extension Mounting to Frame Nut. . . . . . .
Front Oil Pump Housing to Transmission Case Bolt
Governor Body to Support Bolt. .
Neutral Starter Switch-Initial Contact + / 3 to / 2 Turn
Oil Pan Bolt. . . . . . . . . . . . . .
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . .
Output Shaft Flange Nut. . . . . . . . . . . . . . . . . . . . . .
Pressure Test Take-Off Plug . . . . . . . . . . . . . . .
Reaction Shaft Support to Front Oil Pump Bolt. . .
Rear Oil Pump Cover Bolt. . . . . . . . . . . . . . . . . . . .
Transmission to Engine Bolt. . . . . . . . . . . . . . . . . .
Valve Body Screw. . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Bolt. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Pinion Retainer Screw. . . . . . . . . . . .
SHIFT PATTERN SUMMARY CHART
(WITH STANDARD 3.31-1 AXLE)
TIRE SIZE
CONDITION 750x14 800x14
Closed Throttle l-2 U p s h i f t 7712 7712
Closed Throttle 2-3 Upshift. 11 15 11-16
Wide Open Throttle 1- 2 U p s h i f t . 27-38 28-38
Wide Open Throttle 2- 3 U p sh i f t . 57- 69 58-70
3-2 Kickdown Li mi t. 4 5 6 1 46-63
3-lKickdownLimit...::::::::::::: 26-32 26-33
C l o sed T h r o t t l e D o w n sh i f t . 5 11 511
I . .
.
Foot-Pounds
20
20
55
25
25-30
30-35
5 Max.
15
175
25-30
Inch-Pounds
35
270
150
100
150
35
125
90
17
100
3545
(WITH STANDARD 3.31:1 AXLE)
Car Speed
Tire Size
750x14 800x14 Pressure Limits
17-18 17~19................ 15 psi
28-37 29~37................ 45 psi
58 66 5968 . . _ _ _ . . _ _ . 75 psi
LOW 8. REVERSE SERVO
KICKDQW-N SERVO
.
TRANSMISSIONS
-
_I TORQUE CONVERTER
is=
ACCUMULATOR
l-r
MANUAL VALVI
\I
<I/ 1) CONTR,OL VALVE 1) u
-. PFVFRSF RI OCKER VALVE
CONTROL SYSTEM IN
D (DRIVE) DIRECT
-
GOVERNOR
J
PiMP CHECK VALViS
Fig. I-Hyd:raulic Control System
6Ox397A
TRANSMISSIONS 1 3 5
EUTRAL STARTING
WITCH OPENING
60x362
QUE
Fig. J-Removing Gearshift Control Cable
(7) Rotate engine with Remote Control Switch to
locate two converter to drive plate bolts ,at 4 and 7
oclock positions. Remove the two bolts, rotate engine
with switch and remove the other two bolts.
Fig. 2-Air Pressure Checks
CAUTION: Do not rotate c onver t er or drive
1. TRANSMI SSI ON AND CONVERTER
plate by prying with a screw driver or similar
REMOVAL AND I NSTAL L ATI ON
tool as the drive plate might be distorted.
The transmission and converter must be
Also, the starter should never be engaged if
the drive plate is not attached to the con-
removed and installed as an assembly: other-
wise, the converter drive plate, front pump
verter with at least one bolt or if the trans-
bushing, and oil seal will be damaged. The
mission case to engine block bolts have been
loosened.
drive plate will not support a load; therefore,
none of the weight of the transmission should
(8) Depress 1 (low) push button to position con-
trol cable for removal from transmission.
be allowed to rest on the plate during remov-
al or installation.
(9) Disconnect negative (ground) cable from the
battery.
Removal
(10) Remove the starting motor assembly.
(1) Connect Remote Control Starter Switch, Tool C
(11) Disconnect wire from neutral starting switch
and remove the switch.
763 to starter solenoid and position switch so engine
can be rotated from under vehicle.
(12) Remove push button control cable to trans-
(2) Disconnect high tension wire from distributor
mission adjusting wheel lock screw. Insert screw driver
through neutral starting switch opening (Fig. 3). Push
cap.
(3) Raise vehicle on a hoist or support with stands.
gently against upper projecting portion of cable lock-
(4) Remove cover plate from in front of converter as-
spring, and pull outward on cable to remove cable from
sembly to provide access to the converter drain plug
adapter and transmission case.
and mounting bolts.
(13) Loosen clamp screw and remove throttle link
and lever assembly from the throttle shaft on transmis-
(5) Rotate engine with the Remote Control Switch
to bring the drain plug to 6 oclock position. Drain
the torque converter and transmission.
sion.
(14) Disconnect oil cooler lines at the tra-nsmission
and remove oil filler tube.
(6) Mark the converter and drive plate to aid in
reassembly. The crankshaft flange bolt circle, the in-
(15) Remove speedometer pinion and sleeve as-
ner and outer circle of holes in the drive plate, and the
sembly from the transmission (Fig. 4).
four tapped holes in the front face of the converter all
(16) Remove parking brake adjusting nut cover
have one hole offset so these parts will be installed in
plate and loosen cable clamp bolt on brake support
the original position. This maintains the balance of the
(Fig 5). Disengage the ball end of the cable from the
engine and converter.
operating lever and remove cable from the brake
support.
136 TRANSMISSIONS
60 x 186
Fi g. 4-Removi ng or i nst al l i ng Speedomet er Pi ni on F i g 1.6-Al i gni ng Front Pump Rot ors
emove the converter assembly, remove
.
(17) Disconnect front universal joint and secure
(25) To r
propeller shaft out of the way.
7 clamp from edge
(18) Remove nut and washers securing transmission
slid -
_ _
of bell housing, then carefully
le the assembly out of the transmission.
extension housing insulator to the crossmember. Converter lnstollation
(19) Install engine support fixture, Tool C-3806 and (1) Rotate the front pump rotors with Tool C-3756
raise the engine slightly.
until the two,small holes in handle of tool are vertical
(20) Remove crossmember attaching bolts and re-
(Fig. 6).
move crossmember. (2) Carefully slide the converter assembly over the
(21) Pl ace transmi ssi on servi ce jack under the input shaft and reaction shaft. Make sure the con-
transmission to support the assembly. verter impeller shaft slots are also vertical and fully
(22) Attach a smal l C cl amp to dge of bel l
engage the front pump inner rotor lugs.
housing to hold converter in place during removal of
Check for full engagement by placing a straight-
transmission. edge on the face of the case (Fig. 7). The surface of
(23) Remove the bell housing retaining bolts. Care- the converter front cover lug should be at least / 2 inch
fully work the transmission rearward off the engine
to the rear of the straightedge when the converter is
block dowels and disengage converter hub from the
pushed all the way into the transmission.
end of crankshaft. (3) Attach a small C clamp to edge of bell hous-
(24) Lower the transmission jack and remove the ing to hold converter in place during transmission in-
transmission and converter assembly.
stallation.
Fi g. Cl nt er nal Ex pandi ng Par k i ng Br ak e
(Dr um Removed)
TRANSMISSIONS 137
lnstcillation
(1) Inspect the converter drive plate for distortion
or cracks and replace if necessary.
(2) Coat the converter hub hole in the crankshaft
wi th wheel beari ng grease. Pl ace transmi ssi on and
converter assembly on service jack and position as-
sembly under vehicle for installation. Raise or tilt as
necessary until the transmission is aligned with engine.
(3) Rotate the converter so mark on converter
(made during removal) will align with mark on drive
plate. The offset holes in the plate are located next to
the % i nch hol e i n the i nner ci rcl e of the pl ate. A
stamped V mark identifies the offset hole in the con-
verter front cover. Carefully work the transmission as-
sembly forward over the engine block dowels with
converter hub entering the crankshaft opening.
(4) After the transmission is in position, install bell
housing bolts and tighten to 25-30 foot-pounds torque.
( 5) Install and tighten the two lower drive plate to
converter bolts to 270 inch-pounds torque.
(6) Install the starting motor and connect battery
ground cable.
(7) Rotate engine with remote control switch and
install the other two drive plate to converter bolts.
Tighten bolts to 270 inch-pounds.
(8) Install the crossmember and tighten attaching
bolts securely. Lower the transmission so the insulator
mounti ng rests on, and i s properl y al i gned on the
crossmember. I nstal l mounti ng washers and nut,
tighten nut to 30-35 poot-pounds torque.
(9) Engage ball end of parking brake cable in brake
shoe operating lever and tighten cable clamp bolt.
(10) I nstal l cover pl ate on back si de of parki ng
brake support plate.
(11 j Connect the propeller shaft to the front com-
panion flange.
( 12) I nstal l the speedometer dri ve pi ni on and
sleeve.
( 13) Connect oil cooler lines to the transmission and
install oil filler tube.
(14) Position throttle lever on transmission throttle
shaft and tighten clamp screw.
(15) Have an assi stant engage the R (reverse)
button and hold it firmly depressed. Insert push but-
ton control cable in transmission case, push inward on
cable making sure lock-spring engages cable. Install
control cable adjusting wheel retaining screw.
( 16) Install neutral starting switch and connect wire.
(17) Install cover plate in front of the converter as-
sembly.
(18) Install the transmission case to cylinder block
brace.
The converter cover plate must be bet ween
the case and the brace. The oil line is at-
tached i n f ront of t he brace. Tighten the bolts
holding the brace to the case bef or e attach-
ing brace to the cylinder block.
(19) Refill transmission with Automatic Transmis-
sion Fluid.
Use fi ve quarts of Automati c Transmi ssi on Fl ui d
Type A, Suffix A as the initial fill before starting
the engine. After the engine has run at idle for two
minutes and each push button has been depressed at
least for two seconds, add one quart-additional fluid.
Final addition of fluid should not bring the level above
the Add One Pint mark with the engine stopped.
NOTE: To completely adjust the throttle
linkage, push button control cable, and neu-
tral starting switch, r ef er to Group 2 1, Main-
tenance, Adjustments and Tests in the 1960
Plymouth Service Manual.
2. FLUSHI NG TORQUE CONVERTER
(1) Place torque converter in an upright position
and pour two quarts of new clean solvent or kerosene
into converter through the impeller hub.
(2) Turn and shake the converter so as to swirl the
solvent through the internal parts. Turning the turbine
and stator with transmission input and reaction shafts
will aid in dislodging foreign material.
(3) Position the converter in its normal operating
position with drain plug at the lowest point. Remove
drain plug and drain the solvent. Rotate the turbine
and stator, and shake converter while draining to pre-
vent dirt particles from settling.
(4) Repeat the flushing operation at least once, or as
many times as required until the solvent or kerosene
drained out is clear.
(5) After flushing, shake and rotate the converter
several times with drain plug out to remove any resid-
ual solvent and dirt. Reinstall drain plug and tighten
3. STARTER RI NG GEAR REPLACEMENT
The starter ring gear is mounted directly on the
outer diameter of the torque converter front cover.
With the torque converter removed from vehicle, re-
placement of the gear is as follows:
Removing-Ring Gear
(1) Cut through the weld material at the rear side
of ring gear with a hack saw or grinding wheel (Fig.
8). Be careful not to cut or grind into the front cover
stamping.
(2) Scribe a heavy line on the front cover next to
the front face of the ring gear to aid in locating the
new gear.
138 .-- TRANSMI SSI ONS -.___ --.... ----.--
ne (made during removal) on the front cover. Make
sure the gear is even with scribed line around the
11 circumference of the front cover.
(2) Reweld the ring gear to the torque converter
front cover, being careful to place, as nearly as possi-
ble, the same amount of weld material in exactly the .
same location as was used in the original weld. This
is necessary in order to maintain proper balance of
the unit. Place the welds alternately on oppositesides
,:A )
,I .~~F:,,
of converter cover to minimize distortion.
,.,I
, >.K:
i .
,$ I( .; ;;,
/ ,_(, I G,,,: ::!: :
(3) The following suggestions are offered as an
,,, ;.>* ! <: ,,:.- *.I
1~,a.. ,j-. ,. , .,_, aid in making the weld :
WOOD a. Do not gas weld.
BLOCKS
b. Use a D.C. welder that is set straight polarity
14) ^=
60x1657
or an A.C. welder if proper electrode is available.
c. Use a % inch diameter welding rod, and a weld-
Fi g. & Removi ng St at i c s Ri ng Gear ing current of 80 to 125 amps.
d. Direct the arc at the intersection of gear and
(3) Support the converter with the four drive lug
front cover from an angle of 45 degrees from
faces resting on blocks of wood. The c onvert er
the rear face of the gear.
must not rest on f r ont c over hub during this
(4) Inspect the gear teeth and remove all nicks
oper at i on. Using a blunt chisel or drift and ham-
where metal is raised, weld metal splatter, etc., in
mer, tap downward on ring gear near welded areas
order to insure quiet starter operation.
to break any remaining weld material (Fig. 8). Tap
around ring gear until it comes off the converter. 4. FRONT OIL PUMP AND TORQUE
(4) Smooth off weld areas on cover with a file. CONVERTER
Installing Ring Gear
The driving lugs of the front pump inner rotor are
Any of the following methods may be used to heat
located in the center of the rotor and both faces of the
and expand the starter ring gear for installation on
lugs are square. The diameter which pilots the rotor
the converter.
on the converter impeller hub is also located at the
center of the rotor (Fig. 9). The converter impeller
Oven: Place ring gear in Oven, C-794 and set hub has two slots to drive the new rotor instead of
temperature at 200 degrees F. Allow ring gear to re- two tangs.
main in oven for 15 to 20 minutes. Servicing operations are the same as outlined in the
Boiling Water: Place the ring gear in a shallow
1960 Plymouth Service Manual except thod there is no
container, add water, and heat for approximately eight
difference between the front and rear side of the rotor.
minutes after the water has come to a boil.
However, dye marks (made during removal) must
Steam: Place the ring gear on a flat surface and
be aligned when reassembling.
direct a steam flow around the gear for approximately
two minutes.
5. REACTION SHAFT SUPPORT TO FRONT
CLUTCH THRUST WASHER
Flame: Place the ring gear on a flat surface.
Using a medium size tip, direct a slow flame evenly
A fibre thrust washer has been added between the
around the inner rim of the gear. Do not apply
reaction shaft support and the front clutch assembly
flame to the gear teeth. Place a few drops of
(Fig. 9). The washer is .043 and .045 inch thick and
water on the face of gear at intervals during the heat-
should be replaced if found damaged or worn beyond
ing process., When the gear is hot enough to just boil
specified limits.
i .
i the water, installation of the gear on the torque con-
L verter can be made.
6. GOVERNOR PRESSURE TEST
j
(1) After ring gear is expanded by heating, place The governor pressure test take-off point has been
i
the gear in position on the converter front cover. Tap relocated on 1961 models, It is located on the left lower
1
the gear on the cover evenly with a plastic or rawhide side of the extension housing just back of the extension
.I mallet until front face of gear is even with the scribed housing mounting flange.
i
TRANSMI SSI ONS 139
DUL, m1.v ..na,LR
(6)
REACTION SHAFT SUPPORT
A
t
0 RING
IANER ROTOR
OliTER ROTOR
7 . CONVERTER AND
FIBER THRUST FIBER THRUST WASHER WASHER
Fig. Q-Front Oil Pump and Reaction Shaft Support
ne or
AL I GNMENT
The torque converter is supported at the f
engine crankshaft and at the rear in a bus1
front oil pump housing. The drive plate corn
crankshaft to the converter is flexible to act
tain amount of misalignment of the transmi
and crankshaft. Excessive misalignment I
premature front pump bushing WE
7 . CONVERTER AND TRANSMI SSI ON
of the block. Drive plate damage will result if a
AL I GNMENT
both dowels are missing or if they are not positioned
The torque converter is supported at the front in the
properly.
engine crankshaft and at the rear in a bushing in the
(4) Slide the converter assembly out of the trans-
front oil pump housing. The drive plate connecting the
mission.
crankshaft to the converter is flexible to accept a cer-
(5) Tighten the front (kickdown) band adjusting
tain amount of misalignment of the transmission case
screw to 47-50 inch-pounds torque with torque wrench
and crankshaft. Excessive misalignment can cause
C-3380 and adapter C-3790, to prevent the front and rear
premature front pump bushing wear, converter im-
clutch retainers from moving forward during removal
peller hub wear, oil seal leakage and/ or damage to
of the front pump assembly.
the drive plate.
(6) Remove the front pump housing retaining bolts.
(7) Attach Tool C-3752 to pump housing flange as
peller hub wear, oil seal leakage aria/ or <
~. . . *_
8. CHECKI NG TRANSMI SSI ON ALk NMENT
shown in Figure 10. Thread the sc r ew s of the tool into
the flange holes at 11 and 4 oclock positions.
( 1) Remove transmission and converter assembly as (8) Bump outward evenly on the two knocker
outlined in Paragraph 1. weights to withdraw oil pump and reaction shaft sup
(2) Remove the flexible drive plate. port assembly from the case.
(3) Check the two dowels in rear face of cylinder (9) Install the dial indicator on the crankshaft
block, making sure they extend at least 5/ 16 inch out flange as shown in Figure 11. An indicator post can
TRANSMI SSI ONS
be made by cutting a 7/16-20 thread on the end of a
rod approximately 5% inches long.
(IO) Clean all foreign material from the cylinder
block flange face also from the transmission case
flange face.
(11) Bolt the transmission case to the engine being
careful not to strike the indicator when raising the
transmission into place. Tighten the bolts to 25-30
foot-pounds torque.
(12) Position the dial plunger against the bore diam-
eter which pilots the front pump assembly as shown
in Figure 12. Make sure the plunger does not rest on
the chamfered edge of the bore. To adjust the dial and
plunger, reach into the case from the front below the
engine oil pan. Adjust the dial and plunger so that the
plunger can travel in each direction.
(13) Rotate crankshaft with a 1% inch wrench on (1) After determining the amount and direction of
the bolt in front end of crankshaft. On some cars, this transmission case bore runout, select a pair of offset
bolt (Part No. 2128569, G-16 thread, 1 inch long) will dowels with the offset nearest to % the amount of
have to be installed for purpose of the test. Remove runout.
fan belt to prevent fan from interfering with the wrench. (2) Drive the dowels from the engine block flange
(14) Measure the bore runout by rotating the crank- and install the selected offset dowels with slots parallel
shaft slowly, recording the readings every 45 degrees and the offset in the direction of the runout. The upper
of rotation (12, 3, 16 and 9 oclock positions). Also, re- dowel must be installed with the slotted end into the
cord the points of maximum and minimum readings. block flange (toward the front of the engine). Install
Use a mirror if necessary to see the dial as it is being the lower dowel with slotted end toward the rear as
rotated. shown in Figure 13. Both dowels must be installed
Tot al r unout of t he bor e should not exceed up to the shoulder of the of f set .
.015 inch. (3) Reinstall the transmission case, carefully tighten
the attaching bolts to 25-30 foot-pounds torque. DO not
9. CORRECTI NG TRANSMI SSI ON ALI GNMENT force the bolts as the case might be binding on the
If the total runout of the transmission case bore ex-
dowels. Recheck the bore runout.
(4) Small corrections can be made by turning the
)I!
ceeds .015 inch, it may be reduced to within limits by
the use of offset dowels. The dowels must be used in
dowels with a screw driver bit and wrench (See Fig
I are available m tne rollowing sizes: .007,
ure 14). Support weight of the transmission
!
:014 and 921 inch offset.
and loosen the case bolts slightly. Turn the
dowels to obtain as near zero runout as POS-
sible. The dowel slots must be kept approximately
parallel to maintain the proper center distance be-
pairs, and
. . . . . . , 1.
/
I
tween the dowels.
(5) When the transmission is properly aligned, re-
move the assembly without disturbing the dowels. In-
stall the front pump and reaction shaft support assem-
bly as described on page 106 Transmission Group in
the 1960 Plymouth Service Manual.
(6) Back off front (kickdown) band adjusting screw
2Ya turns and tighten lock nut to 20-25 foot-pounds
torque.
,:
!:!I
> 10. CHECKI NG CONVERTER HUB RUNOUT
0 ,.,.i
Fi g. 12Ahec k i ng Transmi ssi on Case
(Fr ont Pump Bor e) Runout
If the flexible drive plate is cracked or broken, install
u new plate. Do not use lockwashers on retain-
i ng bolts, tighten bolts to 20 foot-Pound torque, then
proceed as follows:
t -4
TRANSMI SSI ONS 141
Fi g. 14-Adj ust i ng Of f set Dowel s
(1) Install converter and tighten bolts to 270 inch- shaft should be .0005 to .OlO inch. A maximum of .003
pounds torque. Do not use l oc k w asher s on bolts. inch is preferred.
(2) Attach dial indicator to engine block flange as (5) After correct alignment has been obtained, in- :
shown in Figure 15. Position dial indicator so dial stall the transmission assembly as outlined in Para-
plunger rests on converter hub (just ahead of pump grcrph 1.
drive slots).
(3) Rotate crankshaft with wrench on bolt at front
end of crankshaft and check the converter hub runout.
~~~LE:~~,
!
Do not rotate converter by hand or with a
;,:(l.:,::,
!I,.,
,.;;
turning tool as flexing of the drive plate will : ,.::
give a false reading.
I
(4) The total runout of the converter hub should not
exceed .015 inch. Runout less than .050 inch may be
corrected by the use of a large C clamp. Attach the
clamp in front of engine block flange and behind starter
ring gear on converter. Draw the ring gear adjacent
to the low runout point of the converter hub toward
the engine. Release the clamp and recheck the runout.
Do not pry t he c onver t er aw ay f r om the
engi ne and be careful to avoid over correc-
tion.
In some cases it may be necessary to check the
crankshaft flange for excessive nmout. The flange
runout should not exceed .002 inch. The clearance be-
tween the converter pilot hub and bore in the crank-
Fi g. 1 S-Chec k i ng Conver t er Hub Runout
,
,. i
142 WHEELS-BEARINGS-TIRES
l G R O U P 2 2
.
WHEELS, BEARI NGS AND TI RES
Servicing procedures for the Wheels, Bearings and Service Manual. There ore some changes in the Speci-
Tires remain the same as outlined in the 1990 Plymouth fications.
SPECIFICATIONS
Station Wagon Passenger Car
MODELS 2 Seats 3 Seats 118 W.B.
WHEELS
Type . . . . . . . . . . . . . . . . . . . Steel Disc Steel Disc
Rim . , . . . . . . . . . . . . . . . * . . . . . . . . . . . Drop Center-Safety Wheel . Drop Center-Safety Wheel
Size . . . . . . . . . _ . . . . . . . . . . 14x5s 14 x 6 14 x 5 14x5s
(with 800-14 tire)
14 x 6 14 x 6
(with 12 brakes) (with 12 brakes)
No. of Wheel Nuts. . . . . . . 5 5
St& Hole Circle. . . . . . . . . . . . . . . . . 41/2 41/2
Stud Size. . . . . . I,$-20 l&-20
65 ft.-lbs. Torque 65 ft.-Rx. Torque
TIRES _
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Super Cushion-Tubeless Super Cushion Tubeless
Size . . . . . . . . . . . . . . . . . . . . . . . . 8CO-14** 750-14 (8 Cyl.) .800-14 (Optional)
700-14 (6 Cyl.) 750-14 (Optionab
Ply. . . . . . . . . . . . . . . . . . . . . . 4 Std. 4 Std.
TIRE PRESSURE-COLD
Pounds-Rear. . . . . . . . . . . . . . . . . . . . . . 24* (750-14) 2 2 (800-14) 22
(700-14) 24 (750-14) 22
Front. . . . . >. . . . . . . . . . . . . . . . 2 4 2 4 2 2
/ .
*With Station Wagon fully loaded, increase rear tire COLD pressure to 28 pounds.
**800 x 14 Standard on Convertible.
SPECIAL TOOLS
C-715. Bead Breaker
C-3455 Bead Breaker
C-3446. Constrictor
GROUP 23 -
I
i ,
i
BODY AND SHEET. METAL
i
The 1961 Plymouth body and sheet metal service Models. For complete servicing procedures, refer to the
procedures are essentially the same crs for the 1960 1960 Plymouth Service Manual.
AIR CONDITIONING 143
GROUP 24
AI R CONDI TI ONI NG
The operation, air flow, electrical circuits, and the information contained in this Supplement covers only
procedures for servicing the unit including discharging, the Service Procedures that are different from those
chargi ng, tests, removal and i nstal l ati on of the ex- given in the 1960 Plymouth Service Manual. There are
pansion valve, heater core, evaporator and other com- some changes in the Specifications and Special Tools.
ponents are basically the same for 1961 models. The
COMPRESSOR
SPECIFICATIONS
Location
318 Cu. I n. Engi ne. .
361-383 Cu. I n. Engi ne.
Right Cylinder Block
Left of Center on Cylinder Block
2 Cylinder V Type
2% I nch
11/ 8 I nch
9.45 Cubic Inches
Reed Type
Approximately 1250 rpm at 25 mph
11 Ounces
.
.
Type. . . . . . . . . . .
Bore
Stroke. . . . . . . .
D i s p l a c e m e n t .
Type Valve. . . . . . . . . . . . . . . .
Speed (depends on axle ratio and tire size)
Oil Capacity (Refrigerant Oil) . . . . . . .
Clutch
..................
.............. ...
..................
..................
..................
. .
.
.
.
.
.
318 Cu. In. Engine.. . .
3 6 1 - 3 8 3 C u . I n . E n g i n e .
Muffler . :I., ._ _, .
CONDENSER
Location . .
RECEI VER-DRI ER-STRAI NER
T y p e
.
. . . . . .
Rotating Coil
Stationary Coil
In Compressor Discharge Line
. .
.
........ ........
............
Front of Radiator
Cylindrical Steel Container
In Front of Radiator Location . . . . . . . . . . .
REFRIGERANT
Ref r i ger ant. .
Front Unit Only
Dual Units (all)
EVAPORATOR
L o c a t i o n
BLOWERS
T y p e
L o c a t i o n
C a p a c i t y .
...................... Refrigerant 12
. . . . . . . . . . . . . . . . . . . . . 2s/ 8 to 21/ , lbs.
. . . . . . . . . . . . . . . . . . . . . . 3y8 to 37 lbs.
Dash Panel
. . . . . . . . . . . . . . . . . . . . . . Centrifugal
. . . . . . . . . . . . . . . . . . . . . . . Dash Panel
. . . . . . . . . . .
.c
250 to 265 cubic feet of air
per minute at high speed
. . . . . . . . . . . . . . . . . . . Approximately 14-17 amps at 14 volts
T,
SPECI AL T OOL S
C-3620 . . . . . . . ..Socke t
C3621..........Socke t
C-3622 . . . . . . . Extension
C-3623, . . . . . . . . . Thermometer
C-3644*. . . . . . . .Test Hose
C-3645. . .Test Hose
C-3652. . . . . . . . .Vacuum Pump
C-3663. . . I . . . . . .Condenser Comb
C-3704. . . . . . . . . .Psychrometer
C-3707. . . . . . . . . . Gauge
.
.
.
.
Current Draw
c-590.
c- 744..
C- 804. .
SP-2922*
C - 3 1 2 8 .
c - 3 3 5 5 .
C - 3 3 5 8 .
C3361A.
C - 3 3 6 2 .
C - 3 3 6 3
Studs
Li ght
Tool
.Test Cap
Pl i ers
Goggl es
Wrench Set
.Ratchet
Bender Set
Wrench Set
144
SPECI AL TOOLS (Contd)
C-3420. Adapter C-3740. .Tester
C-3429. Scale
C-3741. Adapter Kit
C-3478. Cutter C-3787..........Puller
SP- 3496. Suppor t f or C- 3825 C-3788. . Tool
C-3499. . . . Tester
C-3807 S l e e v e
C3569..........Torch C-3822..........Tool
C-3616. .Ratchet C-3825. T o o l
*These Numbers for ordering service repair or replacement parts for C-3740 Tester.
TORQUE REFERENCE
Compressor Bearing Housing Bolt . . . . . . . . . . . . . . . . .
Compressor to Bracket Bolt. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Connecting Red Screw. . . . . . . . . . . . . . . . .
Compressor Cylinder Head Cover Bolt. . . . . . . . . . . . . .
Compressor Cylinder Head Cover (nameplate bolt) . . .
Compressor Discharge Adapter Bolt. . . . . . . . . . . . . . . .
Compressor to Engine Bolt . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Pump Cover Bolt. . . . . . . . . . . . .
Compressor Oil Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor to Strut Bolt. . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Suction Adapter Bolt, . . . . . . . . . . . . . . .
Magnetic Clutch to Compressor Bolt . . . . . . . . . . . . . . .
.......
.......
......
. .......
.......
. .......
.......
. . .......
.......
. . .......
FLARE NUT TORQUES
Flare Size Foot-Pounds Flare Size
l/ 4 SAE . . . . . . . . . . . . . . . . . . . . 12-14 y2sAE . . . . . .
3/8 SAE . . . . . . . . . . . . . . . . . . . . . . . . 20-25 Sj8SAE . . . . . .
.
.......
.......
4
TO TERMINAL BLOCK
20 AMP. FUSE
RESISTOR
10-13
50
52-56
23-27
20-24
14-18
30
10-13
15-19
30
10-14
20
Foot-Pounds
. . . 30-35
. . . . . . . . . . 55-65
I
I-BLACK
INPUT TERMINAL
HOT
T
CLUTCH FEED
OWER TERMINAL
0TALL BUTTONS
EXCEPT OFF
CLUTCH TERMINAL
MAX. COOL
FRESH COOL
PUSH BUTTON ASSEMBLY
+TO COMPRESSOR CLUTCH
Fig. l-Electrical Control Circuits
145
BLOWER
MOTOR
.
BL OWE R MOT OR
SWI TCH
MO WE R
60X1186 MOTOR
?!!t
Fi g. P-Roof Uni t Wi ri ng Di agram
1 . GENERAL I NFORMATI ON
The electrical circuit is the snma BYPA-* I.,* l I.- on -___ -_--__._-- -.__-.. _- .--- --___- --AqJL ULUL Ulci LV
amuere in line fuse is to the terminal bin-L A ==mm,te
Fig. 3-EPR Val ve and Oi l Ret ur n Passage
EVAPORATOR SUCTION GAUGE
-DISCHARGE PRESSURE GAUGE
COMPRESSOR INLETGAUGE
- SUCTION GAUGE VALVE
CENTER MANIFOLD OUTLET
DISCHARGE GAUGE VALVE
- NEEDLE VA1
DISCHARGE LINE
SUCTION LINE y
~. _-.__ ._- . _...
SERVICE PORTADAPTER y
COMPRESSOR INLETSERVlr= war/
Fi g. 4-Gauge Set Mani f ol d Connec t i ons
146 AI R CONDI TI ONI NG
60 T O 70 PSI THERMAL BULB /
\ ,,,)
SP-2622
clutch power feed jumper wire is also used instead the 318 cubic inch~ installations, the discharge service
of being incorporated in the air conditioning control port is located in the muffler body. A revision was
wiring harness. Refer to Figures 1 and 2. also made in the valve plate assemblies. Refer to
The tests remain the same except a change was made Servicing the Compressor.
in the suction and discharge gauge pressures of the Two types of magnetic clutches are used on the
expansion valve test. Refer to Testing the Expansion 1961 models. One type has the electromagnet incorpo-
Valve for further details. rated in the pulley assembly, and is identified as the
Also, a new modified compressor is used, which rotating field type. The electrical circuit to the electro-
has the Evaporator Pressure Regulator (EPR) Valve magnet is through collector rings and brushes. This
installed internally. It also incorporates an internal
type will be used on all 318 cubic inch engine in-
oil return passage. Refer to Figure 3. The EPR Valve stallations. The service procedures for the rotating field
is calibrated at the factory to provide maximum cooling type are the same as outlined in the 1960 Plymouth
and is not adjustable. However, the functioning is the
Service Manual. The other type uses a stationary
same as the external valve, described in the 1960 electromagnet attached to the compressor, and is
Plymouth Service Manual, except that the service port identified as the stationary field type. Since the electro-
valves are in different locations. Refer to Figure 4. magnet does not rotate, collector rings and brushes are
On all 361 or 383 cubic inch engine installations, eliminated. This type will be used on all 361-383 cubic
the discharge service port is located in the discharge inch engine installations. The servicing of the station-
I
line as it connects to the compressor. However, on ary field type magnetic clutch will be explained in
AI R CONDI TI ONI NG 147. ;
- B O L T
PLATE
GASKET
ISTON
LOCK
SEAL
VALVE
I
/ FITTING
ROD
FiTT::=T\ -
R&NC:-&. HObSING \ \ RoToR
-3rlMP
BOLT
61 x324
Fig. &Compressor (Disassembled)
1
further detuil under Servicing the Magnetic Clutch. The minimum flow test suction pressure remains the
/
same 21-24 psi.
!
2. TESTI NG THE EXPANSI ON VALVE
3. SERVI CI NG THE COMPRESSOR
A few changes have been made in connecting the i
suction and discharge hoses of the gauge manifold to
Figure 6 is a disassembled view of the compressor.
the compressor in the expansion valve test. There is
With the exception of the Cylinder Head and Valve !
also a change in the maximum and minimum flow
Plate .Assembly, also the EPR Valve, the disassembly
1
test pressure gauge readings. With the exceptions of
and reassembly of the compressor is the same as de-
i
these changes, the expansion valve test procedures
scribed in the 1960 Plymouth Service Manual. Refer to
/
are the same as described in the 1960 Plymouth Service
Figure 7.
Manual. The changes are as follows:
However, the removal and installation of the Cyl -
i
Before connecting the suction or discharge hose to
inder Head and Valve Plate Assemblies are the same
the compressor, remove the Dill Valve Fittings from
except that there is no external oil return tube. Also,
the service ports. Also, remove the special adapters
the valve plate and reed valve are different, as shown
,
from both hoses. The suction and discharge hoses are
in Figure 8.
I - B O L T
%(\ \ \ -~C~VER
CRANKSHAFT
,v.m-- -
\
..v..-
GASKET
k SCREEN
then connected directly to the service ports.
EPR Valve Removal
The pressure readings on the right hand (discharge) (1) Remove the EPR Valve suction line fitting bolts,
gauge change from 70 psi to 75 psi for both the maxi- the fitting which also contains the compressor suction ;
mum and minimum flow test. Refer to Figure 5. The screen, spring, and the gasket. i
suction gauge pressure for the maximum flow test (2) Remove the EPR Valve and 0 ring from the
changes from 43-53 psi to 60-70 psi for the front unit. compressor using Tool C-3822 by rotating the valve i
However, the roof unit readings should be 65-75 psi. slightly, as shown in Figure 9.
148
0 RING
OL (PILOT STUDS)
A
\ EPR VALVE\
Fi g. 7-I nst al l i ng Val ve Pl at e and Cyl i nder Hea
Id
type. The servicing of the rotating field type is the
same as outlined in the 1960 Plvmouth Service Manual.
The servicing of the stationary field type (Figure
I nst al l i ng t he EPR Val ve
lo), is as follows:
(1) Install the 0 ring on the EPR Valve.
(2) Lubricate the 0 ring with refrigerant oil and
Test i ng El ec t romagnet Current Draw
install the EPR Valve in the compressor with Tool C
To test the coil for a short or open circuit, connect an
3822 and rotating the.valve. .
ammeter (O-10) ampere scale, in series with a fully
(3) Install the compressor suction screen in the EPR
charged l2-volt battery in the field coil circuit. The
Valve suction line fitting.
current draw at 12 volts should be 2.5 to 2.9 amperes.
(4) Install the suction line fitting gasket, spring,
If the current draw is not within these limits, install a
fitting, and attaching bolts.
new field

coil a
s s e mb
l y
I x95
Re mo v a l
4, SERVICING THE MAGNETIC CLUTCH
(1) Disconnect the field coil lead wire and remove
Two types of clutches are available on the 1961 drive belts.
Models: the rotating field type and the stationary field (2) Remove special locking bolt and washer from
compressor crankshaft at front center of clutch.
(3) I nsert a. 5/ 8 - 11 x 2% cap screw into the
threaded portion of the hub and shoe assembly.
LEAD WIRE
HUB AND SHOE ASSEMBLY
/ CLUTCH BEARING
61 x94
PULLEY ASSEMBLY
61x32
Fi g: a--Val ve Pl at e-I nst al l ed Posi t i on
Fi g. I O-Magnet i c Cl ut ch-St at i onary Fi el d Type
-.t ..
* .. I i l ~~
;h ,.u
.,,. ,:-
AIR CONDITIONING 1 4 9
(4) With the pulley assembly side down and the
bearing hub centered on Tool C-3825, place Tool SP-
3496 on the inner race of bearing, then push bearing out
of pulley assembly with an arbor press. Refer to Fig-
ure 12.
NOTE: A new bear i ng must be installed
every time the magnetic clutch is disassem-
bled.
Assembl y
( 1) Place the pulley assembly with pulley side up
on an arbor press and insert a new bearing into the
pulley assembly bore. Place Tool C-3807 against the
bearing and press into position. Refer to Figure 13.
(2) Place pulley assembly with pulley side facing
down on Tool C-3807.
(3) Start drive hub into inner bearing race, then
press hub into position with an arbor press.
(4) Install bearing snap ring and hub snap ring.
,:,_ :, ,:::-.. > ,..
~::;?.:~:i,:,~:i : / ,:, >.2 ,;.f:r , (
CAUTION: The pulley assembly and hub
. (
assembly ar e mated parts. They ar e bur-
Fi g. 1 l -Removi ng Hub and Shoe Assembl y nished at the factory before shipment. It is rec-
ommended they be replaced in matched
(4) Support clutch with one hand, then tighten cap pairs. Replacement of either unit separately
screw until clutch is removed. will reduce the initial torque of the clutch.
(5) Remove the three hex field coil assembly mount-
ing screws and lift off the assembly.
lnstcdlation
(1) Place the field assembly on the boss of the
Disassembly
compressor bearing housing. Make sure field assem-
( 1) Remove the small snap ring from the drive hub bly is positioned so that the lead wire points up SO
with Tool C-3128 or equivalent. that it can be routed between the compressor cylinder
(2) Install drive hub puller Tool C-3787 aligning the heads. Install the three hex head mounting screws and
three pins of the Tool in the three holes in the hub and tighten to 17 inch pounds torque.
shoe assembly. Refer to Figure 11. (2) Insert woodruff key in crankshaft.
Tighten the 5/ 8 - 11 hex head bolts down until the (3) Install clutch assemblyonto crankshaft.
drive hub is removed from the bearing. (4) Install washer and new ,self-locking bolt, and
(3) Remove the bearing snap ring from the pulley tighten to 20 foot-pounds torque..
assembly. (5) Install belts, and tighten to specified tension.
TOOL (REMOVER
TO O L
(SUPPORT)
61 x63
Fi g. 12-Removi ng Beari ng f rom Pul l ey Assembl y Fi g. 134nst al l i ng New Beari ng i n Pul l ey Assembl y
i
F :
.
a#&&.. *
i
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