Dodge CUSTOM ROYAL 1957 User manual

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DODGESERVICEMANUAL
ENGINESERIALNUMBER
F¡g. 1—EngineNumber—(6Cyl.)
Vehicle Engine Number Location
Theenginenumberisstampedona bossontheleft
frontsectionofthecylinderblock(6cylinder)andon
abossatthecenterofthecylinderblockdirectlybe-
hindthewaterpumpandnexttotheoilfillertubeon
theV-8,asshowninFigures1and2.
Vehicle Serial Number Location
Thevehicleserialnumberislocatedona platewhich
isattachedtotheleftfrontdoorhingepillar"A"post,
asshowninFigure3.
PowerF¡ite and TorqueFlite Transmission
Number Location
ThePowerFliteandTorqueFliteTransmissionserial
numberandbuildingdateisstampedona bossdirectly
abovetheoilfillertubeconnectiontothetransmission
oilpan,asshowninFigure4.
Fig. 3—SerialNumber
TRANSMISSIONSERIALNUMBER
OILPAN
Fig. 4—TransmissionNumber54x807
Rear Axle Gear Ratio Number Location
The rearaxlerationumberisstampedona bossdirectly
underthefillerplugonthecarrierhousing,asshown
inFigure5.
Generator, Voltage Regulator and
Distributor Number
Thegenerator,voltageregulatoranddistributornum-
berareshownonplatesattachedtotheunits.Check
beforereplacing.
54x810
Fig. 2—EngineNumber—<V-8)
F¡g. 5—RearAxleRatio
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BRAKES-SERVICE
BRAKESCONTENTSPar. Page
SERVICEBRAKES — 3
POWERBRAKES(PistonType) — 15
SERVICEINFORMATION
AdjustingBrakes 1110
AdjustingHandBrake(ExternalType) 1412
AdjustingHandBrakeCable(ExternalType) 1512
Bleeding the BrakeSystem 9 10
CyclebondBrakeLining 1815
GeneralInformation — 4
GrindingRecommendations 3 6
Inspecting the BrakeShoes 2 6
InspectingSupportPlates 6 9
Installing the BrakeShoes 4 7
InstallingSupportPlates and WheelCylinders 8 9
Removing the BrakeShoes 1 5
RemovingtheSupportPlatesandWheelCylinders 5 8
ServicingHandBrake(ExternalType) 1312
ServicingHandBrake(InternalType) 1614
ServicingHandBrakeCable(InternalType) 1714
ServicingMasterCylinder 1212
ServicingWheelCylinders 7 9
Test for FluidContamination 1010
SERVICE
CONDITIONS m^
POSSIBLECAUSES T,
Improperbrakefluid
Airinsystem
Swollenrubberparts
Brokenorcrackeddrum
Loosewheelbearings
Loosepedalmountingbracketormastercylinder
Incorrectshoeadjustment
Mastercylinderpushrodadjustment
Leaking or brokenlines
Loosecylinderbleedscrews
Drum"out of round"
Hardspots on drum
Improperorglazedlining
Sprungshoes
Water,mud,dirtindrums
Tornorlooselining
Weakpedalreturnspring
Loosesupportplatebolts
Bentmastercylinderpush rod
Spongy-Rubbery
Pedal
•
•
•
•
DIAGNOSIS
Chattering
Squealing
•
•
•
i
•
NoReserve
•
•
•
•
Pressure
Loss
•
•
•
Hard
Pedal
•
•
•
Pumping Necessary
•
•
•
Binding
•
No
Pedal
Return
•
•
Grab
or
Lock
•
•
•
•
Side
Pull
•
•
•
•
•
Overheating
•
•
•
•
Fading
•
•
Dragging
•
•
•
•
•
•
•
•
•
Pulsating
•
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DODGESERVICEMANUAL
SERVICEDIAGNOSIS-(Cont¡nued)
CONDITIONS mþ>
POSSIBLECAUSES X,
Pedallinkage
Pushrods not engaged in brakeshoeslots
Axleshaft or axleshaft to dustshieldrun-out
Loosespring"U"bolts
Brakeshoeguideshaveinsufficienttension
Spongy-Rubbery Pedal
Chattering
Squealing No
Reserve
Pressure
Loss
Hard
Pedal
•
Pumping Necessary
Binding
•
NoPedal
Return
•
Grab
or
Lock
Side
Pull
Overheating
•
Fading
Dragging
Pulsating
•
•
•
•
SERVICEINFORMATION
PROCEDURES
GENERALINFORMATION
A new type of servicebrake is used on thenew Dodge
models and is known asthe CenterPlaneBrake. The
mainfeatures of this new brakeare;lesspedaleffort
fora givenstop;morepedalreserve;less
brakefade; longerlininglife;smootheroper-
ation;lessfrequentadjustmentand,when
needed,simpleservicingoperations.
Thebrakeshoedesign and method of support are the
maindifíerencesbetween the centerplanebrake and
theconventionalbrakes, as shown in Figures1,2, 3, and
4. Additionaldifíerences are: fullfloating,shoes,rather
thanfixedanchorshoes;uniformpressureshoes,that
havebeendesigned to matchdrumdeflection; a center
planesupport of theseshoes,between two steelplates,
and, an increasedwidth of lining.
Thecenterplanebrakeshoeshavecontouredwebs,
(seeFigure 1) whichallowgreaterflexibility ofthe
TOE
shoes, causing the drum and shoes to match in rigidity
togivesimilardeflections atany section.Thiseliminates
highpressures at thetoeand heel of the shoe,when the
drumbecomesmoreovalshapedthan the shoesduring
hard or heavybreakingeffort.Thisactionallows uni-
formpressuredistributionover the fulllength ofthe
shoelining arcand results in lesspedaleffort fora
givenstop.
Thebrakingaction is centralizedbetween thetwo
supportplates, as shown in Figure2.Theseplatesalign
WHEELBRAKE
CYLINDER
WHEELBRAKE
CYLINDER
CONNECTING
TUBE
CONSTANT
WEBDEPTH
CONTOURED
WEBDEPTH
HEEL
CONVENTIONALBRAKECENTER-PLANEBRAKE
55X712
F¡g. i—CenterPlane and ConventionalBrakeShoes
BRAKE
CYLINDER
COOLINGFINS
OUTER
SUPPORT
PLATE
INNER
SUPPORT
PLATE
WHEELSTUD
BRAKESHOE
WEB
BRAKELINING
ADJUSTING
CAM
BRAKE
SHIELD
BRAKE
DRUM
55X713
F¡g. 2—CenterPlaneBrake(SectionalView)
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BRAKES-SERVICE
CYLINDERASSEMBLY
ADJUSTING CAM
SPRINGLOOP
RETURNSPRING
(5COILS)
SPRINGLINK
SEAL
ANCHORS
Fig. 3—CenterPlaneBrakeAssembly(LeftFront)57x47
theshoesandholdtheanchorsandwheelcylinders.The
applyingforcefrom the piston andthe shoereturn
springsareallin a centerplane.Thusƒtheshoesdonot
tend to twist,(resulting in unevencontact) butare
aligned ina single,centrallylocatedplane.
Siderattle ofthe shoes is controlled by guides, as
showninFigures3and4.Theguidesmaintainconstant
pressureagainsttheweb of theshoes.
Thewheelcylindersoperate in thesamemanner as
theconventionalcylinders, but,are mounted onthe
brakesupportplate.
Selfenergizingaction is effective onall frontbrake
shoesandtherearbrakefrontshoe,whenthevehicle
istravelingforward; and selfenergizingaction onthe
rearshoeoftherearbrakes,whenthevehicleistravel-
inginreverse.
1. REMOVING THE BRAKESHOES
Should it becomenecessarytoremovethebrakeshoes
forrelining or completereplacement,refertoFigures 3
or4,thenproceed as follows:
Removing the Front Brake Shoes
(1)Blockthebrakepedal to preventanydownward
movement of thepedal.
(2)Removethefrontwheelanddrumasanassembly,
afterbacking off theadjustingcams.
(3)UsingToolC-3462,removetheshoereturnsprings,
asshowninFigure5.Theend of theToolshouldbein-
sertedbetween the springlink andthe supportplate.
Withthetoolcamslotengaging the springhook,turn
handle ofthe tool to disengage the spring. DO NOT
USE BRAKESPRING PLIERS, OR DAMAGE
TOTHE LININGWILL RESULT.
(4) Turn the brakeshoeguideretainer ¼ turn, then
remove the retainer and guide, as shown in Figure 6.
Thelipontheendofguide,isusedforposi-
tioningtheguideontheoutersupportplate.
UPPERCYLINDERASSEMBLY
ADJUSTING CAM
RETURNSPRING,
(4COILS)
RETAINER
GUIDESPRING
ANCHOR
SUPPORTPLATE
/SPRINGLINK
ANCHOR
Fig. 4—CenterPlaneBrakeAssembly(Rear)
RETURNSPRING
(4COILS)
ADJUSTING CAM
LOWERCYLINDERASSEMBLY
SHIELD
57x46
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DODGESERVICEMANUAL
TOOL
57x49
Fig. 5—RemovingBrakeShoeReturnSpring
GUIDESPRING
RETAINER
57x48
Fig. 6—Removing or InstallingShoeGuides
(5)Slidetheshoesfrombetweenthesupportplates,
asshowninFigure7.
Removing the Rear Brake Shoes
Withthebrakepedalblockedtopreventanydownward
movement,proceedasfollows:
(1)Backofftheadjustingcams.
(2)Removetherearwheelasanassembly.Using
puller.ToolC-845,removetherearwheeldrum.
(3)UsingToolC-3462,removetheshoereturnsprings,
asshowninFigure8.Theendofthetoolshouldbein-
sertedbetweenthespringlinkandthesupportplate.
Withthetoolcamslotengagingthespringhook,turn
handleoftooltodisengagethespring.DONOTUSE
BRAKESPRINGPLIERS,ORDAMAGETO
THELININGWILLRESULT.
(4)Turnthebrakeshoeguideretainer¼ turn,then
removetheretainerandguide.(RefertoFigure6).The
lipontheendofguide,isusedforpositioning
theguideontheoutersupportplate.
(5)Slidetheshoesfrombetweenthesupportplates.
(RefertoFigure7.)
2. INSPECTING THE BRAKESHOES
Wipeorbrushclean(dry)themetalportionsofthebrake
shoes. Examinetheliningcontactpatterntodetermine
iftheshoesaretrue.Theliningshouldshowcontact
acrosstheentirewidth,extendingfromheeltotoe.Shoes
showingcontactononlyonesideshouldbediscarded.
Shoeshavingsufficientliningbutlackofcontactattoe
andheel,shouldbecheckedforproperunder-drum
diametergrind.
3. GRINDINGRECOMMENDATIONS
Brakeshoelining—Newliningshouldbechecked
andgroundto.010to.024inchunderthedrumdiameter
(ifnotpre-ground)ona machinehavinga cylindrical
grindingwheel.
57x5057x51
Fig. 7—RemovingShoesfromSupportPlates8—RemovingShoeReturnSpring(RearWheel)
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BRAKES-SERVICE
Drumrefacing—Measurethedruminsidediameter
with an accurategauge.Drumdiameterservicelimit
should not exceed.004inch outof round. Ifthe drum
diameter isin excess of .004inch, the drumshould be
refaced.Donotremovemorethan.030inchof
metalduringtherefacingoperation.Thedrum
diametermeasurementisthentransferredtothegrinder
andtheliningground to therequiredclearance of .010
to.024inch,underdrumdiameter.
Thegrinding of brakeliningsneedonly be done if
thecyclebondprocess is done inthe dealership.
4.INSTALLING THE BRAKESHOES
Installing the Front Brake Shoes
Beforeinstalling the frontbrakeshoes,apply a light
coat of lubriplate on theshoewherever it contacts the
supportplate,thenproceed as follows:
(1)Slide the brakeshoesintopositionbetween the
supportplates. Be sure the ends ofthe cylinder
pushrodsengagethetoeend of theshoesprop-
erly(SeeFigure 7).
(2)Insertthefourcoilreturnsprings in thehole in
thebrakeshoewebs.
(3)Using the tapered endof ToolC-3462, as shown
inFigure 9, attach the returnsprings tothe links. Be
surethatthelongend of thespring is hooked
into thewebofthe shoes to prevent the coil
ofthespringcontactingtheshoe.
(4)Checkthetensionofthebrakeshoereturnsprings.
Thespringtensioncan be checked by hooking a scale
atthetoe of theshoeandpulling in thedirection of pis-
tonmovement. The scaleshouldreadfrom 35to45
pounds at theinstantthetoe of thebrakeshoemoves.
Adialindicatormay be used to indicatemovement in
place ofa scale.
(5)Lubricate the brakeshoeguidecontactingareas
ontheshoeswithlubriplate,theninstallguidesandre-
tainers(Refer to Figure6.) Be sure the positioning
lipofthe guideslidesinto the hole in support
plate.
(6)Install the drum, and wheel and tireassembly,
afterbacking offthe adjustingcams.Adjust the front
wheelbearings, as described inthe FrontSuspension
Section.
(7)Adjustthebrakes, as described in Paragraph 11
ofthisSection.
Installing the Rear Brake Shoes
Beforeinstallingtherearbrakeshoes,apply a lightcoat
oflubriplate on theshoewherever it contacts the sup-
portplate,thenproceed as follows:
(1)Slide the brakeshoesintopositionbetween the
supportplates. Be sure the ends ofthe cylinderpush
rodsengage thetoeendofthe shoesproperly. (See
Figure7.)
(2)Insertthefivecoilreturnsprings in theloop of
thetable of theshoes, as shown in Figure10.
(3)Usingthetaperedend of ToolC-3462, as shown in
Figure10,throughthespringlink,attachthesprings to
thelink.
(4)Lubricate the brakeshoeguidecontactingareas
ontheshoeswithlubriplate,theninstallguidesandre-
tainers. (Refer to Figure6.) Be surethepositioning
lip ofthe guideslidesinto the hole in support
plate.
(5)Checkthetensionofthebrakeshoereturnsprings.
Thespringtensioncan be checked by hooking a scale
atthetoe of theshoeandpulling in thedirection of pis-
tonmovement. The scaleshouldreadfrom 35to45
pounds at theinstantthetoe of theshoemoves. A dial
indicatormaybeusedtoindicatemovementinplaceof
ascale.
(6)Install the drum,wheel and tireassembly,after
backing off theadjustingcams.
LOOPTOOL
57x53
57x52
Fig. 9—AttachingShoeReturnSpring to SpringLink
Fig. 10—AttachingShoeReturnSpring to SpringLink
(RearWheel)
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8
DODGESERVICEMANUAL
57x54
Fig. 11—RemovingBrakeSupportPlates
andWheelCylinders(FrontWheel)
SEALING
COMPOUND
57x55
Fig. 12—RemovingWheelCylinderMountingBolt
(FrontWheel)
DUSTSEALS
57x56
Fig. 13—RemovingSupportPlatefromDustShield
(FrontWheel)
(7)Adjustthebrakes,asdescribedinParagraph11
ofthisSection.
5.REMOVINGTHESUPPORTPLATES
ANDWHEELCYLINDERS
Shoulditbecomenecessarytoremovethesupportplates
andwheelcylindersduetodamageorwear,proceedas
follows:
Removing the Front Support Plates
and Wheel Cylinders
(1)Removethewheelandtire,thenthebrakedrum.
(2)Removethefourretainingnutsthatattachthe
centerplanesupportplatesanddustshieldtothesteer-
ingknuckle.
(3)Disconnecttheflexiblebrakehosefromtheframe
bracket.
(4)Removethefourboltsthatholdthebrakeassembly
tothesteeringknuckle.(RefertoFigure11and
notethelocationandsizeofbolts.Threedif-
ferentlengthsareused.)
(5)Removethebrakeassembly(withdustshield),as
showninFigure11.Donotallowthedustshield
tostrikethebearingsurfaceofknuckleas
damagemayresult.
(6)RemovethebrakeshoesasdescribedinPara-
graph1.
(7)Removetheconnectingtubebetweenthewheel
cylinders.Donotdistorttube.
(8)Removeeachwheelcylindermountingboltafter
removingsealer(ifpresent),asshowninFigure12.
Now,removethesupportplateassemblyfromthedust
shield,asshowninFigure13.
(9)Removethewheelcylinders.Ifitisnecessaryto
servicethewheelcylinders,refertoParagraph7,Serv-
icingTheWheelCylinders.
Removing the Rear Support Plates
and Wheel Cylinders
Shoulditbecomenecessarytoremovethesupportplates
andwheelcylindersduetodamageorwear,proceedas
follows:
(1)Removetherearbrakeshoes,asdescribedinPara-
graph1,steps1 through5.
(2)Disconnectthebraketubeatthewheelcylinder.
Removethenutsandlockwashersthatholdthesupport
platesandwheelcylinderstothedustshieldandaxle
flange.
(3)Slidethesupportplatesoutandawayfromthe
axle, asshowninFigure14.Whenremovingthedust
shield,itisadvisabletoinstallthesealprotectorC-745,
thenslidedustshieldandsealoffaxle.
(4)Removetheboltsthatholdthewheelcylinderto
thesupportplates.Liftwheelcylinderawayfromthe
plates. Inspectandcleanthesupportplatesasdescribed
below.Ifreconditioningthewheelcylinders,referto
Paragraph7,ServicingtheWheelCylinders.
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BRAKES-SERVICE
57x57
Fig. 14—RemovingSupportPlates and
WheelCylinder(RearWheel)
6.INSPECTING THE SUPPORTPLATES
Clean the supportplates ina suitablesolvent,thenblow
drywithcompressedair,theninspect as follows:Check
thefreeness ofthe adjustingcams and returnspring
links. The adjustingcamsshouldturnwithoutbinding.
Check the condition ofthe adjusting cam dustwashers.
If the washers are cracked or deteriorated, new ones
should be installed at assembly. Ifany visualdistortion
of the supportplates is apparent, new platesshould be
installed.Thesupportplatesmust be flat and true.Coat
thecontactsurfaces ofthe cams and anchorswithlubri-
plate at reassembly.
7.SERVICING THE WHEELCYLINDERS
Wheelcylinderpistonsthat are badlyscored orcor-
BLEEDERSCREW
PISTON CUPJ^ EXPANDER
PISTONSPRING
PUSH ROD
CYLINDER
RETURNSPRING
CUPEXPANDER
PISTON CUP
PUSH ROD
CYLINDERBOOTPISTON
56x48
56x69
Fig. 15—FrontWheelBrakeCylinder(SectionalView)
Fig. 16—RearWheelBrakeCylinder(SectionalView)
rodedshould be replaced. Theold pistoncupsshould
bediscardedwhenreconditioningthehydraulicsystem.
Cylinderwallsthathavelightscratches,orshowsigns
ofcorrosion, can usually be cleaned up withcrocus
cloth,using a circularmotion.However,cylindersthat
havedeepscratches or scoring maybe honed,using
ToolC-3080,providing the diameter ofthe cylinderbore
isnotincreasedmorethan .002 inch.Acylinderthatdoes
notclean upat .002inchshould be discarded anda new
cylinderinstalled.(Blackstains onthe cylinderwalls
arecaused bythe pistoncups and will dono harm.)
Beforeassembling the pistons andnew cups inthe
wheelcylinder, dip them in superbrakefluid.Refer to
Figures 15or16 thenassemble the brakecylinders. If
theboots are deteriorated, ordonotfit tightly onthe
brakeshoe pin,as well asthe wheelcylindercasting,
newbootsshould be installed.
8.INSTALLING THE SUPPORTPLATES
ANDWHEELCYLINDERS
Installing the Front Support Plates
and Wheel Cylinders
(1)Installthebrakecylindersonthesupportplates,
thenpositionthesupportplatesonthedustshield.(Be
surethedustwashersareinplace.(SeeFigure13.)Now,
installthewheelcylinderattachingboltsandtighten
withthefingersuntilsnug.
(2)Lubricatethebrakeshoesaspreviouslydescribed,
thenslideintothesupportplates.
(3)Installthefourcoilspringendsintheholein
theshoewebsatthetable.Usingthetaperedendof
ToolC-3462,insertedthroughthespringandlink,slide
theendofspringintolink.(RefertoFigure9.)
(4)Installthebrakeshoeguidesandretainersafter
lubricatingthecontactareaofguidewithlubriplate.
(5)Installthewheelcylinderconnectingtube,being
carefulnottobendordistort.
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