Plymouth Pl4s User manual

I

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-

Plymouth

recognizes

the

role

played

by

the

automobile

service

m;,m

who,

since

Pearl

Harbor,

has

shouldered

the

entire

responsibility

of

keeping

the

transportation

system

of

this

country

rolling.

This

manual

is

dedicated

to

the

men

who

service

Plymouth

can>~to

help

them

continue

to

do

the

good

service

work

which

has

resulted

in

keeping

the

millions

of

Plymouth

cars

rendering

satisfactory

service.

' '

r

I

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L_,

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....

PLYMOUTH

SERVICE

MANUAL

lor

PLYMOUTH

PASSENGER

CARS

YEAR

MODELS

1942

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

Pl4S.

Pl4C

1941

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

........

Pll,Pl2

1940

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

P9.Pl0

1939

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

P7.P8

1938

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

P5.P6

1937

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

P3.P4

1936

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

Pl.P2

This

manual

contains

combined

service information

taken

from the following Plymouth

Shop

Manuals:

D-10062-1942

Models-P14S,

Pl4C

D-9298

-1941

Models-Pll.

Pl2

D-8634

-1940

Models-P9.

PIO

D-8096

-1939

Models-P7.

P8

D-4291

-1938

Models-PS.

P6

D-3906

-1937

Models-P3.

P4

D-3496

-1936

Models-PI.

P2

Price-$1.50

Net

Postage

Prepaid

in United

Stales

Order

by

part

number

D-10974

CHRYSLER CORPORATION

PLYMOUTH

DMSION

DETROIT

31.

MICHIGAN

PRINTED

IN

U.S.A.

D-1

097

4-Seeond

Ed

ilion

10·1·4B

(20M)

2 PLYMOUTH

SERVICE

MANUAL

SPECIFICATION CHARTS AND DIAGRAMS

Page

General

data

and

specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Car serial numbers and engine

numbers.

. . . . . . . . . . . . . . . . . . . . . . . . . 12

Table

of

capacities, frequencies and lubricants. . . . . . . . . . . . . . . . . . . . .

16-17

Lubrication

charts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Front

axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rear

axle.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Brakes

Clutch

76

88

Clutch

fixture

spacers

and

feeler gauges

.....

,

...........

,

.......

,

93

Cooling

system

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

96

Engine

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

, . . . . . . 101

Engine

tune-up

.

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

,

104

Frame alignment diagrams.

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

.

Fuel

System

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

.

120-123

126

Generator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Generator

regulator

....

, ,

.........

, . ,

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

,

.....

, . . . 140

Ignition

system

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

144

Lighting

system

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

,

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

, . . . . . . . . . . . . . . . 148

Wiring

diagrams

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

,

........

,

..

,

.....

,

........

, 154-164

Starting

motor

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

..

. . . . . . . . . . . . . . . . . . . . . 165

Shock

absorbers

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

, , ,

......

,

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

, . 171

Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . 178

Transmission

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

, . 192

Wheels

and

tires

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

, . . . . 212

TABLE

OF

CONTENTS

FOF1EWORD

General data and specifications

...........

.

Car :serial numbers

and

engine numbers .

....

.

SJ'C~riON

I-LUBRICATION

AND

•

MAINTENANCE

Table

of

capacities, frequencies

Page

7

11

12

and

lubricants.

. . . . . . . . . 16-17

Lubrication

charts.........

18-19

1.

Importance

of

lubrication

and

maintenance

. . . . . . . . . . . . . . 13

2.

Engine

oil

recommendations.

. . . 13

3. Checking

the

engine oil

level.

. . . 14

4.

When

to

change

engine

oil. . . . . . 14

5.

Cleaning

of

carburetor

air

cleaner

14

6.

Lubrication

of

transmission. . . . 14

7.

Lubrication

of

rear

axle.

. . . . . . .

15

8.

Lubrication

of front wheel

bearings

. . . . . . . . . . . . . . . . . 15

9. Lubrication

of

rear

wheel

bearings

..

. . . . . . . . . . . . . . . . 20

10.

Lubrication

of

steering

gear.

. . . 20

11.

Lubrication

of

water

pump.

. . . . 20

12. Lubrication

of

universal

joints.

.

20

13. Chassis

lubricant

fittings. . . . . . .

20

14.

Lubrication

of

starter.

. . . . . . . . 20

15.

Lubrication

of

generator.

. . . . . . 21

16.

Lubrication

of

distributor.

. . . . . 21

17.

Lubrication

of

hand

brake

linkage

21

18.

Lubrication

of

pedals

and

linkage

(brake

and

clutch)

. . . . . . . . . 21

19.

Lubrication

of springs

with

metal

covers . . . . . . . . . . . . . .

21

20.

Lubrication

of

Powermatic

shift

22

21. Cleaning

and

lubricating

power

cylinder

in air

cleaner.

. . . . . .

22

22. Cleaning and oiling crankcase

oil filler

pipe

air

cleaner.

, . . . . 23

23.

Replacement

of oil filter. . . . . . . 23

24.

Maintenance

of

rubber

parts.

. . . 23

25.

Maintenance

of Oilite

bearings.

23

2

6.

Servicing

batteries

......

, . . . . 24

27.

Recommended

tire pressures. . .

24

SECTION

II-TROUBLE

SHOOTING

1.

Engine

will

not

turn.

. . . . . . . . . 25

2.

Engine

turns

but

will

not

start.

. 25

3.

Engine

does

not

develop

normal

power

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

26

4.

Eng~ne

ru?s unevenly

..

,

..

, . .

27

5.

Engme

notses . . . . . . . . . . . . . . . 27

6.

Low

or

no

oil pressure. . . . . . . .

28

7.

Excessive

oil consumption .

...

,

28

8.

Excessive

fuel consumption . . . .

28

9.

Engine

overheats

. . . . . . . . . . . . 28

10.

Improper

generator

charging

rate

29

11.

Lights

. . . . . . . . . . . . . . . . . . . . . 29

12.

Improper

clutch

operation.

. . . .

29

13. Difficult

gear

shifting.

. . . . . . . .

30

14. Noise

or

play

in

drive

line.

. . . . .

30

15.

Noisy

rear

axle

........

, . . . . .

30

16.

Brakes

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

30

17.

Steering

. . . . . . . . . . . . . . . . . . . 31

SECTION

Ill-FRONT

AXLE

Data

.and specifications'.

......

.

1.

Front

wheel

alignment

........

.

2. Checking king

inclination

..

.

3. Checking

camber

...........

.

4.

Checking

caster

angle

........

.

5.

Adjusting

camber

and

caster

...

.

6. Measuring toe-in

...........

.

7.

Adjusting toe-in

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

.

8.

Measuring toe-out

on

tw·ns. ,

..

.

9. Location

of

pitman

arm for

proper toe-.out

on

turns.

,

....

10.

Removal

of

steering

knuckles

and

bushings . . . . . . . . . . . .

..

11.

Installation

of

steering

knuckles

and

bushings . . . .

......

, ,

..

12.

Removal

of

upper control arm ..

13. Installation

of

upper

control arm

14. Installation of

upper

control arm

bushings

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

.

15.

Removal

of lower control arm

and front spring ,

.........

.

16.

Installation

of

lower

control arrri

and front spring.

.........

, .

17.

Removal

of

tie

rods

.......

, ,

..

18.

Installation

of

tie

rods

........

.

SECTION

IV-REAR

AXLE

Data

?n~

specifications·,

......

.

1.

Desertptton . . . . . . . . . . . . . . . .

2. AdjustmP.nt of

axle

shaft

end

play

3.

Removal

of axle

drive

shaft

and

oil seal

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

.

4.

Installation

of axle

drive

shaft

and oil

seal

. . . . . . ,

..

,

.....

5.

Removal

of

broken

end

of axle

drive

shaft

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

, ,

..

6.

Replacement

of

drive

pinion

bearing oil s.eal

...........

.

7.

Replacement

of differential

carrier

assembly

. ,

...

,

.....

8.

Disassembly

of differential

carrier

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

.

9. Assembly of differential

carrier.

10.

Removal

of

rear

axle

housing.

..

11. Installation of rear

axle

housingo

12.

Removal

of

rear

axle

assembly.

o

13.

Installation

of

rear

axle

assembly

SECTION

V-BODY

1.

Adjustment

of

door

striker

plate

2.

Removal

of

door

remote

control

handle and

window

regulator

handle

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

.

3.

Removal

of

door outside handle

4. Installation

of

door outside

handle

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

,

..

.

5.

Replacement

of

door

lock

cylinder . , . o

•••••••

,

•••••

6.

Replacement

of luggage

compart-

ment

lock

cylinder

.....

,

...

7.

Removal

of

door

garnish

molding

and ventilator

...

,

.....

,

...

3

Page~

32

33

34

35

36

37

38

39

40

41

51

53

54

56

57

58

59

4 TABLE

OF

CONTENTS-Cont'd

Page

:rage

:8.

Replacement

of

door

trim

panel

59

17.

Adjusting

hand

brake

.........

85

9.

Removal

of

front

door

vertical

18.

Replacement

of

hand

brake

•.••

85

sliding

ghss

...........

,

...

59 19.

Replacement

of

hand

brake

lining

85

10.

Replacement

of

window

lift

regulator . 0

••••

0

••••••

a

•••

61

SECTION

VII-CLUTCH

11.

Removal

of

front

door

latch

and

Data

and

specifications

....•...

88

remote

control

..

~

.........

64

Clutch

fixture

spacers

and

feeler

12.

Replacement

of

front

door

gauges

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

93

ventilator

assembly

........

65

l.

Description

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

87

13.

Removal

of

rear door glass.

....

65

2.

Adjustment

of

clutch

pedal

free

14.

Removal

of

rear door

window

play

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

87

regulator

••

0

••••••••

0

•••

'.

66 3.

Adjustment

of

over-center spring

87

15.

Removal

of rear door latch and

4.

Replacement

of

over~center

remo~e

control • • • • • • 0

•••••

66 spring 0

••••••••••••••••••

87

16.

Replacement

of

rear quarter

5.

Removal

of

clutch

...........

91

window

...........

b

••••••

66

6.

Installation

of

dutch

..........

91

17.

Replacement

of

ventilator

7.

Disassembly

of

clutch

.........

91

window

(rear side

quarter)

..

67

8.

Assembly

of

clutch

...........

92

18.

Removal

of rear quarter

window

9.

Adjustment

of

clutch

release

glass and regulator

assembly

levers

with

fixture C-585

.....

92

(2-door

sedan)

...........

67

10.

Adjustment

of

clutch

levers

with

19.

Replacement

of

rear

window

fixture

C-411

.

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

94

glass

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

67

20.

R~placement

of

rear arm rest

SECTION

VIII-COOLING

SYSTEM

and trim assembly.

.........

68

Data

and specifications .

.......

96

21.

Removal

of

seat

back cushion

1.

Adjustment

of

fan

belt

........

95

(front

or

rear)

............ 68 2.

Replacement

of

fan

belt

........

95

22.

Adjustment

of

front

seat

guide

..

68 3.

Replacement

of

engine

water

23.

Removal

of

windshield

glass

....

68 thermostat

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

95

24.

Installation

of

windshield

glass

..

70

4.

Replacement

of

water

distributor

25.

Adjustment

of hood

striker

plate

tube

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

95

and

lock

•••••

0

•••••••••••

72

5.

Replacement

of

water

pump

....

95

26. Adjustment

of

hood lock control

6.

Disassembly

of

water

pump

....

98

cable

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

73

7.

Assembly

of

water

pump

......

98

27.

Adjusting

Convertible

Coupe

8.

Water temperature indicator.

..

99

top

to

fit

body

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

73

9.

Removal

of

radiator core.

.....

99

28.

Replacement

of

Convertible

10.

Removal

and

installation

of

Coupe

top vacuum

cylinder

..

74

radiator and fender unit.

....

100

29.

Replacement

of

Convertible

Coupe

top vacuum

valve

....

74

SECTION

IX-ENGINE

30.

Removal

of

Convertible

Coupe

Data

and specifications.

.......

101

body

window

and frame .. ,

..

75 Engine

tune-up

charto

••••••••

104

31.

Removal

of

Convertible

Coupe

1.

Description

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

103

body

door

latch

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

75

2.

Engine tests

and

adjustments

.

..

103

32.

Removal

of Convertible

Coupe

3.

Removal

and

installation

of

body

window

regulator

......

75

engine ................... 105

4.

Cy

Iinder

head

installation

......

107

SECTION

VI-BRAKES

5.

Replacement

of

valves

and

Data

and specifications

........

76 oprings .................. 107

1.

Brake

pedal

free

play

.........

77

6.

Adjustment

of

valve

tappet

2.

Foot

brake minor

adjustment

.

..

77

clearance

••••

0

••

0

•••••

0

••

109

3.

Foot

brake

major

adjustment

...

78

7.

Reconditioning

of

exhaust

valve

4.

Bleeding

brake

system

........

79

seat

inserts ............... 110

5.

Removal

of brake shoes .

......

80

8.

Replacement

of

exhaust

valve

6.

Installation

of

brake

shoes

.....

80

seat

inserts ............... 110

7.

Replacement

of

brake

lining

....

80

9.

Replacement

of

valve

stem

8.

Removal

of wheel

cylinder

.....

80 guides

(valves

and

springs

9.

Installation

of

wheel

cylinder

...

Ill

removed)

................ 110

10.

Disassembly

of

wheel

cylinder

..

1!3

10.

Replacement

of

valve

tappets

...

110

11.

Assembly

of

wheel

cylinder

....

1!3

11.

Checldng

valve

timing

,

........

110

12.

Removal

of

master

cylinder

.

...

l!3

12.

Replacement

of

timing

gear

13.

InstalJation

of

master

cylinder,

.

83

case coVer and

oil

seal

.......

llO

14.

Disassembly

of

master

cylinder.

83

13.

Replacement

of

timing

chain

15.

Assembly

of

master

cylinder

....

83

and

sprockets

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

111

16.

Reconditioning brake

cylinders.

83

14.

Replacement

of

camshaft

......

111

~'-··~~-

"_-.

.i

'

r-

TABLE OF CONTENTS--Cont'd 5

Page

15.

Replacement

of

camshaft

bearings

. . .

..

. . . . • . . .

..

. . 112

16.

Replacement

of

connecting

rod

and

piston

assembly.

. • . . . . . 112

17

••

Reconditioning

of

cylinder

walls 112

18.

Fitting

pistons . . . . . . . . . . . • . . 112

19.

Replacement

of

piston

rings. . . . 113

20.

Replacement

of

piston

pins

(pistons

removed).

. . . . . . . . 114

21.

Replacement

of

connecting

rod

bearings

. . .

..

. . . . . . . . . . . . 114

22.

Replacement

of

crankshaft

(main)

bearings

. . . . . . . . . . . 115

23.

Checking

crankshaft

end

play.

. 115

24.

Installation

of

crankshaft

bearing

oil seals . . . . . . . . . . . . . . . . . . 116

25.

Replacement

of flywheel . . . . . . 116

26.

Engine

Oiling

System.

. . . . . . . 116

27.

Removal

and

installation

of oil

pan and strainer. . . . . . . . . . . 116

28.-

Removal

and

installation

of oil

pump

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

117

SECTION

X-EXHAUST

SYSTEM

1.

Disassembly

and

assembly

of

manifold

heat

control.

. . . . . . 118

2.

Replacement

of

exhaust

pipe

and

muffler . . . . . . . . . . . . . . . 118

3.

Replacement

of

intake

and

exhaust

manifold

gaskets.

. . . 118

SECTION

XI-FRAME

1.

Frame

alignment

. . . . . . . . . . . . 119

Frame

alignment

diagrams

..

120-123

SECTION

XII--FUEL

SYSTEM

Data

and

specifications . . . . . . . 126

1.

Description

of

carburetor.

. . . . . 125

2.

Disassembly

of

carburetor.

. . . . 125

3.

Assembly

of

carburetor.

. . . . . . . 125

4.

Adjusting

idle

speed

of

carburetor

125

5. Accelerating

pump

setting.

. . . . 125

6.

Replacement

of

main

metering

jet

125

7.

Adjustment

of

carburetor

float

level

.....

, . . . . . . . . . . . . . . 125

8.

Cleaning carburetor air

cleaner.

127

9.

Description

of fuel

pump...

. . . 127

10.

Disassembly

of fuel

pump.

. . . . . 127

11.

Assembly

of

fuel

pump.

. . . . . . . 127

:2.

Testing

fuel

gauge

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

130

13.

Calibrating

fuel

gauge

(dash

unit)

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

130

SECTION

XIII-GENERATOR

Data

and

specifications. . . . . . . . 132

1.

Description

. . . . . . . . . . . . . . . . . 133

2.

Disassembly

of

generator.

. . . . . 133

3.

Removal

of field coils. . . . . . . . . 136

4.

Installation

of field coils. . . . . . . 136

5.

Assembly

of

generator.

. . . . . . . 136

6.

Testing

generator

on

test

stand

..

137

7.

Testing

generator

on

engine.

. . . 138

·page

SECTION

XIV-GENERATOR

REGULATOR

Data

and

specifications. . . . . . . . 140

1.

Testing

and

adjusting

generator

regulator

(1940-42)

........

139

·2.

Testing

and

adjusting

cut-out

relay

(

1936-39)

. . . . . . . . . . . 142

3.

Testing

and

adjusting

circuit

breaker

and

voltage

regulator

(

1936-39)

.

..

.

.. .. ..

.

..

142

SECTION

XV-IGNITION

SYSTEM

Data

and

specifications. . . . . . . . 144

1.

Description

. . . . . . . . . . . . . . . . . 143

2.

Disassembly

of

distributor.

. . . . 143

3.

Assembly

of

distributor.

. . . . . . . 145

4.

Spark

plugs . . . . . . . . . . . . . . . . . 147

SECTION

XVI-LIGHTING

AND

WIRING

SYSTEMS

Data

and

specifications. . . . . . . . 148

1.

Description

of

lights.

. . . . . . . . . 149

2.

Aiming

of headlights.

. . . . . . . . . 149

3.

Replacement

of

light

bulbs . . . . . 151

4.

Description

of wiring

....

, . . . . . 153

Wiring

diagrams

..........

154-164

SECTION

XVII-STARTING

MOTOR

Data

and

specifications

.....

, . . 165

1.

Description

. . . . . . . . . . . . . . . . . 165

2.

Replacement

of

starting motor

brushes

. . . . . . . . . . . . . . . . 165

3.

Disassembly

of

starting

motor.

. 165

4.

Replacement

of starting motor

field coils . . . . . . . . . . . . . . . . 167

5.

Assembly

of

starting

motor.

. . . . 168 .

6.

Testing

starting

motor

. . . . . . . . 169

SECTION

XVIII-SHOCK

ABSORBERS

Data

and

specifications. . . . . . . . 171

1.

Description

..

.

..

.. .. ..

171

2.

Testing

shock

absorber

operation

171

3. Refilling shock

absorbers.

. . . . . 172

4.

Disassembly

of

shock

absorbers.

172

5. Assembly

of

shock

absorbers.

. . . 173

6.

Installation

of shock

absorbers.

. 175

SECTION

XIX-SPRINGS

Data

and

specifications. . . . . . . . 178

1.

Front

spring

height.

. . . . . . . . . . 177

2.

Installation

of

front

spring.

. . . . 177

3.

Adjustment

of

front

spring

shackles

. . . . . . . . . . . . . . . . . 177

4.

Inst~ll~tion

of

steering

shock

ehmmator

. . . . . . . . . . . . . . . . 177

5.

Installation

of

rear

spring.

. . . . . 177

6.

Adjustment

of

rear

spring

shackles

. . . . . . . . . . . . . . . . . . 178

7.

Adjustment

of

rear

spring

bolts..

179

8.

Spring

clip

maintenance

. . . . . . 179

6 TABLE

OF

CONTENTS-Cont'd

Page

SECTION

XX-STEERING

GEAR

1.

Description

. . . . . . . . . . . . . . . . . 180

2.

Adjustment

of

worm

bearings.

. . 180

3.

Adjustment

of

roller

tooth

a:nd

worm

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

180

4."

Removal

of

horn

button

(

wi1th

blowing

ring)

. . . . . . . . . . . . 181

5.

Removal

of

horn

button

(without

blowing

ring)

. . . . . . . . . . . . . 181

6.

Removal

of

steering

wheel.

. . . . 183

7.

Disassembly

of

gearshift

control.

183

8.

Removal

of

steering

gear.

. . . . . . 184

9.

Installation

of

steering

gear.

. . . 189

10.

Alignment

of

steering

gear

in

frame

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

190

11.

Alignment

of

steering

and

front

wheels

. . . . . . . . . . . . . . . . . . 190

12.

Disassembly

of

steering

gear.

. . . 191

13.

Assembly

of

steering

gear

...

, . . 191

SECTION

XXI-TRANSMISSION

Data

and

specifications.

. . . . . . . 192

1.

Description

. . . . . . . . . . . . . . . . . 193

2.

Replacement

of

transmission. . . 193

3:

Di~assembly

of

transmission

(1940-42

models)

.........

196

4. Assembly

of

transmission

( 1940-42

models)

......

, . . . 196

5.

Disassembly

of

transmission

(1936-39

models)

.........

198

6.

Assembly

of

transmission

(

1936-39

models)

. . . . . . . . .

203

7.

Measuring

clutch

housing align-

ment (transmission

removed)

204

Page

8.

Replacement

of

rear

oil

seal.

. . .

204

9.

Disassembly

of

gearshift

lever

housing

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

204

10.

Adjustment

of

gearshift

control

rod

(manual

shift)

. . . . . . . . .

204

11.

Adjustment

of

gear

selector

rod

(manual

shift)

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

205

12.

Adjustment

of

Powermatic

shift.

205

13.

Lubricating

Powermatic

shift.

. .

205

14.

Cleaning

power

cylinder

air

cleaner

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

207

SECTION

XXII-UNIVERSAL

JOINT(S

AND

PROPELLER

SHAFT

1.

Description

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

208

2.

Replacement

of

universal joint

(ball

and

trunnion)

. . . . . . . .

208

3.

Replacement

of

universal

joint

boot

(ball

and

trunnion)

....

208

4.

Replacement

of

universal joint

(cross

a:nd

roller

type)

. . . . . .

211

SECTION

XXIII-WHEELS

AND

TIRES

Data

and

specifications.

. . . . . . .

212

l.

Adjustment

of

front

wheel

bea:rings . . . . . . . . . . . . . . . . .

213

2.

Adjustment

of

rear

wheel

bearings

00

••

00

•

00

......

00

213

3.

Installation

of

front

wheel

bearings

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

213

4.

Removal

of

tires.

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

213

5.

Installation

of

tires.

. . . . . . . . . .

214

6.

Rotation

of

tires

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

214

I

t:!

PI.YMOUTH

SERVICE

MANUAL

FOREWORD

This

manual

contains

maintenance

and

service

information

for

all

Plymouth

cars

built

from

1936

through

1942.

The

mechanical

information

and

repair

instructions

are

intended

for

the

use of service

men

already

familiar

with

the

construction

of

Plymouth

cars.

No

attempt

has

been

made

in

this

manual

to

give

detailed

information

covering

the

function

or

construction

of units.

Data

and

specifications

are

arranged

in

chart

form for service

men

who

already

know

how

to

perform

the

work,

but

wish

to

quickly

obtain

the

necessary

repair

specifications.

The

clearances given for fitting

parts

when

rebuilding

units

of

the

car

are

based on

the

type

of

equipment

usually

available

for service

work.

Manufacturing

tolerances

are

usually

held

to

much

closer

limits

by

the

use of special

machinery

and

tools

designed

specifically for

manufacturing

purposes.

Servicing

instructions

covering

units

originally

installed

on

cars

as

"special

equipment,"

such as

Powermatic

shift, springs

with

metal

covers, directional signals

and

horn

blowing rings,

are

included

in

the

manual.

No

attempt

has

been

made

to

designate

such

units

as

"special

equipment"

in

this

manual.

Special tool

equipment

required

for

the

proper

servicing of

Plymouth

cars

is

referred

to

throughout

the

manual.

The

special tool

number

is

given in

each

instance,

and

the

use

of

the

tool is

illustrated

when

its

application

is of a special

nature:

A

catalog

of

all

Plymouth

special

tool

equipment

may

be

obtained

from

the

Miller

Manufacturing

Company,

1725

16th

Street,

Detroit

16, Michigan.

8 PLYMOUTH SERVICE MANUAL

1942

Plymouth

Four

Door Sedan

1941

Plymouth

Four

Door

Sedan

·'

PLYMOUTH SERVICE MANUAL 9

1940

Plymouth

Four

Door Sedan

1939

Plymouth

Four

Door Sedan

10

PLYMOUTH SERVICE MANUAL

1938

Plymouth

Four

Door Sedan

1937

Plymouth

Four

Door Sedan

PLYMOUTH

SERVICE MANUAL

11

1936

Plymouth

Four

Door

Sedan

GENERAL DATA

AND

SPECIFICATIONS

Year 1942 1941 I 1940 1939 1938 1937 I 1936

1----------~

----~-----

..

·--'-----

----------------------

Bore

and

stroke,

inches

3~x4%

3Ysx4% 3Ysx4%

3Ysx4%

3Ysx4% 3Ysx4%

3Ysx4%

Piston

displace·

ment,

inches

Compression

ratio

217.8 201.3 201.3 201.3 201.3 201.3 201.3

I

-;-l;::~::~::e

___

6.8--~-~6.7

____

6.7

____

6.7

__

1

__

6.7

___

~

____

6.7

__

_

---~~:~-----

2

5.3_5

___

23.4~-

----=-~~~

--=-~4~-1--=-3.4~--

-~-=-3

.4~-

--=-~~~-

Brake

horse 95

@,

87

@,

84

@,

82

@,

!

82

@,

82

@,

82

@,

-~~e~~:

-~40;

1

:pm

~80;

1

:p~

~~~

1

0

1

:P'TI_

360;

1

~~-~~~60~~~~

~60;

1

:p~

360;

1

:p~

---------------------

__

,

_____

[_~----

-----,----

Overall

length

(with

bumpers),

I I

inches

195%

194%' 194)/2

194)-:j'

1 194;{,

1----------L--~~----~-------L_----~----~----~-----

193%

189%*

*De Luxe, Model

P2-190Ys

inches.

12

PLYMOUTH SERVICE MANUAL

CAR SERIAL NUMBERS

AND

ENGINE NUMBERS

SERIAL

NUMBERS*

.

Year

and

Model

ENGINE

Detroit

Los

Angeles

Evansville

NUMBERS**

Plant

1942

De

Luxe

Six

Pl4S

15135501

to

3134501

to

22037001

to

Pl4"1001

to

15153935 3136266 22041356

Pl4-149161

Special

DeLuxe

Six

P14C

11399501

to

3297001

to

20148001

to

P14-1001

to

11494048 3306756 20164436

P14-149161

---

---------

1941 Six

and

DeLuxe

Six

Pll

15000101

to

3121501

to

22001001

to

Pll-1001

to

15135030 3133962 22036667

Pllo535085

Special

DeLuxe

Six

P12

11123001

to

3269301

to

20105101

to

Pl2-1001

to

11399250 3296572 20147921

Pl2o535085

--~-~-------------

-------

1940

Road

King

Six

P9

1378001

to

3114801

to

9062201

to

P9"1001

to

1454303 3121385 9081375

P9-415461

DeLuxe

Six

P10

10883001

to

3242501

to

20063001

to

Pl0-1001

to

11122538 3269066 20104165

Pl0-415461

----------------

-------

--

---

1939

Road

King

Six

P7

1298001

to

3110001

to

9150401

to

P8"1001

to

1377475 3114680 9164593 PB-411923

DeLuxe

Six

P8

10630001

to

3222001

to

20027001

to

P8-1001

to

10879874 3242203 20062199

PS-411923

--------------------

--------

1938

Road

King

Six

P5

1240001

to

3105301

to

9097601

to

P6-1001

to

1296615 3109407 9107725

P6-286619

DeLuxe

Six

P6

10470001

to

3206001

to

20001001

to

P6-1001

to

10625650 3220997 20025900

P6-286619

-------

1937 Six

P3

1184001

to

3101401

to

9085551

to

P4-1001

to

1237460 3105159 9097493

P4-571569

DeLuxe

Six

P4

10101001

to

3162501

to

9950001

to

P4-1001

to

10468044 3205879 9999021

P4-571569

9190000

to

9199074

----------------

-------

--

-------

1936 Six

PI

1111701

to

3157151

to

9000101

to

P2-1001

to

1183569 3162365 9012724

P2-532087

DeLuxe

Six

P2

2641401

to

3040601

to

9025101

to

P2-1001

to

2987635 3077397 9062168

P2-532087

•Located on right front body hinge post. •-x..ocated on left front side

of

cylinder block between numbers 1 and 2 cylinders.

;;_;,__.,.

13

SecUon I

LUBRICATIC>N

Al'lD

MAINTENANCE

1.

IMPORTANCE

OF

LUBRICATION

AND

MAINTENANCE.

Under

extreme

conditions

of

heat,

cold

and

dust,

the

Plymouth

car

has

proven

itself

to

be

dependable

and

worthy

of

the

slogan

"Plymouth

Builds

Great

Cars."

Much

of

the

credit

for

Plymouth's

de-

pendability

goes

to

the

men

who

do

the

lubrication

and

maintenance

work

neces-

sary

to

keep

Plymouth

cars

in

good

operat-

ing condition. Periodical

lubrication

and

maintenance

combat

the

effects

of

heat,

water

and

abrasive

dirt

which

destroy

the

smooth

bearing

surfaces

of

moving

parts.

The

use of

the

right

type

and

quantity

of

lubricant

is

an

important

factor in

extending

the

useful life

of

a car.

All

Plymouth

cars

are

equipped

with

adequate

lubrication

facilities designed

to

protect

vital

parts.

To

keep

the

car

in

con-

dition

to

render

uninterrupted

service,

each

point

of lubrication requires

attention

at

the

frequencies

recommended

in

this

manual.

Neglect

and

the

use of

improper

lubricants

result

in wear, noisy

operation

and

ultimate

failure

of

parts. Good

care

and

periodical

lubrication

result

in quiet,

trouble-free

serv-

ice

and

thousands

of

extra

miles

of

good

service.

2.

ENGINE OIL RECOMMENDATIONS.

193642

( 1)

The

recommendations

shown

on

the

"Table

of

Capacities,

Frequencies

and

Lubricants"

are

based

upon

the

principle

that

the

lower viscosity oils

circulate

more

rapidly

and

lubricate

parts

with

closer clear-

ances

more

readily

than

heavier

oils. Com-

plete

satisfaction, however,

depends

upon

the

use of

only

well refined,

high

quality

products.

IMPORTANT

The

frequencies

recommended

on

the

following pages for lubrica-

tion services are

intended

for nor-

mal

service.

If

the

car

is

operated

under

extreme

conditions

of

heat,

water, dust, sand,

mud

or

snow

or

over

rough gravel or

dirt

roads,

lubricate

at

more

frequent

inter-

vals

than

recommended.

Such

conditions

may

warrant

lubrica-

tion

attention

as

often

as

once

a

day,

and

the

frequency

should

be

governed

by

conditions

encoun-

tered.

(

2)

For

cars of

comparatively

low

mileage,

SAE

20

or

No.

20-W

Engine

Oil is

recommended

as a

general

summer

oil.

Either

grade

may

be

used

in

tropical

cli-

mates

during

the

winter

months

or

No.

20-

W ·

Engine

Oil

may

be

used

in localities

where

only

very

mild

winter

conditions

prevail,

such

as territories

where

temperatures

never

go below

lOoF

above

zero. If, however,

as

a

result

of contit:ued high

speed

driving

or

other

causes, oil

consumption

becomes a

factor,

SAE

30

Engine

Oil

may

be

used

for

temperatures

above

32°F

above

zero.

(3)

No.

10-W

Engine

Oil is recom-

mended

as a

general

winter

oil for

tempera-

tures

as low as

10°F

below

zero,

but

not

lower. However,

should

atmospheric

tem-

peratures

rise

above

+32°F

during

winter,

No.

10-W

Engine

Oil is satisfactory,

and

a

change

is

not

necessary

until

the

age

period. No.

10-W

Engine

Oil

may

also

be

used

during

summer,

if desired,

provided

driving

habits

are

moderate.

14

PLYMOUTH SERVICE MANUAL

(

4)

For

sub-zero

winter

conditions,

such

as

in

temperatures

below

-lOoF,

No.

10-W

Engine

Oil should

be

diluted

with

about

10%

colorless, refined kerosene,

which

should

be

thoroughly

mixed

with

the

oil before

it

is

added

to

the

engine.

3.

CHECKING THE ENGINE OIL

LEVEL.

193642-The

engine oil level

should

be

checked

each

time

a

car

is refueled.

The

oil

level indicator is

marked

at

"full"

and

"1

/2

."

A

third

marking

between

these

two

marks

indicates

the

proper

running

level (fig.

1).

Figure I

--Engine

Oil Level lntlicator

(1936-42 Models)

35x

31

The

"full"

mark

shows

the

proper

level for

the

oil

after

the

engine

has

not

been

run

for

a few hours.

When

the

engine is

started,

the

oil level will

drop

due

to

the

filling of

the

oil

passages

and

filter. Oil

should

not

be

added

until

the

level is

below

the

mark

indicating

the

running

level,

but

the

oil level

should

never

be

allowed

to

drop

below

the

"1f2

"

mark.

4.

WHEN TO CHANGE ENGINE OIL.

1936-42-0il

changes should

be

made,

under

normal

conditions,

every

1500

to

2000

miles during

winter

and

every

2500

to

3000

miles

during

summer.

It

is

always

advisable

to

drain

the

oil while

the

engine is

at

normal

operating

temperature,

because

the

oil will drain

more

completely

when

hot,

'

. '

carrying

more

of

the

foreign !material

and

dirt

with

it. 1

(2 )

During

winter, ·

the

engine

oil

should

have

a

pour

point

m·

cold

'test

below

the

lowest

temperature

that

will

be

encoun-

tered

during

its

use.

If

the

car

is

driven

for

short

distances of

only

a few miles

at

a time,

moisture in

the

crankcase

will

condense

and

form a sludge which

may

freeze

and

clog

the

oil

inlet

screen.

This

condition is

greatly

aggravated

by

extremely

low temperatm:es

extending for a long

period

of

time.

Under

driving conditions of

this

type,

the

engine

does

not

become sufficiently

warm

to

expel

the

moisture

through

the

crankcase

ven-

tilator. Therefore,

under

these

conditions,

the

oil

should

be

changed

every

500

miles

to

eliminate sludge.

(

3)

An

alternative

to

this

frequent

change period

during

winter

is

an

occasional

drive of

30

miles

or

more

which

will

help

to

eliminate

water

accumulation

through

the

crankcase

ventilation

system.

If

the

car

is

driven in

this

manner

frequently,

the

oil

may

be

changed

at

·the

normally

recom-

mended

winter

change

period

of

1500

to

2000

miles.

5.

CLEANING

OF

CARBURETOR

AIR

CLEANER.

193642-The

carburetor

air

cleaner

(figs. 2

and

3)

should

be

cleaned

at

least

every

2000

miles

(or

more

often

if ex-

tremely

dusty

conditions

are

encountered)

or

whenever

the

oil sump,

on

oil

bath

type,

becomes

half

filled

with

a semi-solid mix-

ture

of oil

and

dirt.

6.

LUBRICATION

OF

TRANSMISSION.

1936-42-Every

1000

miles, check

the

transmission

lubricant

level

to

see

that

it

is

up

to

the

filler hole

in

the

side of

the

trans-

mission case.

The

transmission

should

be

drained

and

refilled

yearly

or

every

15,000

miles.

The

capacity

is

2%

pints.

LUBRICATION AND MAINTENANCE

15

figure

.2--Cieanlng

Carburetor

.4ir

Cleaner

(Oiled

Mesh Type)--Wash Filler Elem,ent

In

Kerosene,

tet

Dry

and

Reoil

with

SAE

.50

Engine

Oil

1-Wing

nut

4-0il

reservoir

2-Filter

element

5-Air

cleaner to car-

3-Gosket

buretor

clamp screw

Figure

3-Cieanlng

Carburetor

Air

Cleaner

(Oil

Both Type)--Rinse Filter Element in Kerosene.

Wash Reservoir

and

Refill to

Indicated

Level

with

SAE

50

Engine Oil for

Temperatures

Above

+32°F;

Use No. 20-W for

Temperatures

Below

+32°F

7.

LUBRICATION

OF

REAR AXLE.

193642

( 1)

The

hypoid

type

rear

axle

gear

requires.

Extreme

Pressure

Hypoid

Gear

Lubricant

especially designed for

hypoid

gear

lubrication.

The

gear

lubricant

should

always

be

fluid

at

the

temperature

in

which

the

vehicle is

to

be

operated.

Lubricants

con-

taining

solid

materials

are

undesirable

for

roller

bearing

lubrication.

Every

1000

miles,

inspect

the

differential

lubricant

level

to

see

that

it is

up

to

the

filler hole.

NOTE

Never

mix

one

brand

of

Extreme

Pressure

Hypoid

Gear

Lubricant

with

another

brand.

(2)

Drain

and

refill

the

rear

axle

every

15,000

miles

with

the

proper

viscosity of

Extreme

Pressure

Hypoid

Gear

Lubricant.

The

rear

axle

may

be

drained

with

a suction

gun

through

the

filler hole,

or

by

removing

two

of

the

lower

cap

screws which hold

the

differential

carrier

in

the

housing

and

allow-

ing it

to

drain.

The

capacity

is

3'-/4

pints.

8.

LUBRICATION

OF

FRONT

WHEEL

BEARINGS.

193642

(

1)

Lubricate

the

front

wheel bearings

every

6000

miles

with

Short

Fibre

Wheel

Bearing

Grease,

Medium.

(2 )

Remove

the

front

wheels,

remove

the

old grease from

the

hubs

and

bearings

and

pack

new

grease

into

them.

(

3)

Do

not

put

too

much

grease

in

the

hub

because

it

may

be

forced

out

past

the

grease seals

and

get

on

the

brake

lining.

(4)

The

lubricant

capacity

of

each

wheel

is 2

¥2

ounces.

16

PLYMOUTH

SERVICE

MANUAL

TABLE

OF

CAPACITIES

Normal

Paragraphs

Frequency

of

Containing

·Unit*

•

Models

Capacity

·

LubYication

Additional

**

Information

2500-3000

miles-Summer

Engine

1936-42 5

qt.

1500-2000

miles-Winter

2, 3

and

4

Inspect

level

when

refueling

---~--------------------

------

--------------

Carburetor air cleaner 1936-42

To

oil

level

2000

miles

s.

------

--------------

----------

Transmission 1936-42 2%'

pts.

1000

miles-Inspect

level

6

15,000

miles-Drain

and

refill

----------------

------

------------

Rear

axle 1936-42 3~

pts.

1000

miles-Inspect

level

7

15,000

miles-Drain

and

refill

------

Front

wheel

bearings

1936-42 6000

miles

8

---------------

------

1~----

Rear

wheel

bearings

1936-42 15,000

miles

9

------

--

Steering gear 1936-42 8 oz. 1000

miles-Inspect

level

10

-------r-

-------

Water

pump

1936-42 2000

miles

11

------

Universal

joints

1936-42

1~

oz. 1'5,000

miles

12

----------------

-------

-----------

Chassis

lubricant

fittings

1936-42 1000

miles

13

------

-~-------------

Starter

1936-42 6000

miles

14

-----------------

------

---

Generator 1936-42 6000

miles

15

-------------------

------

----------~---

-~--~-----

1936-40 1000

miles-Grease

cup

16

6000

miles-Wick

Distributor

-------

-·-

1941-42 2000

miles-Oil

cup

16

6000

miles-Wick

-~---------------

------

~----

--

Hand

brake

linkage

1936-42 1000

miles

17

------

Brake

and

clutch

pedals

and

1936-42 1000

miles

18

shifting

linkage

-----

------

Springs

(with

metal

covers)

1936-42 15,000

miles

19

Powermatic

shift

cylinder

1941-42 15,000

miles

20

---------------

----------

Powermatic

shift

cylinder

air

1941-42 10,000

miles

21

cleaner

---~----

---------

------

Oil filler

pipe

air

cleaner

1936-42 2000

miles

22

Engine

oil filter 1936-42 8000

miles

23

*See Lubrication Charts (Figures 4 and 5).

••under

extremely

sandy

or

dusty

conditions,

lubric_ate

more frquently.

See

page 13.

,I

~

I

~.

LUBRICATION AND MAINTENANCE

17

FREQUENCIES AND LUBRICANTS

.

Lowest

Expected

Temperature

.

Above

+32'

F.

Above

+10'

F.

Above

-10'

F.

Below

-10'

F.

SAE

20

or 20-W No. 20-W No. 10-W

No.

10-W

ENGINE

OIL+lO%

colorless

ENGINE

OIL

ENGINE

OIL

ENGINE

OIL

refined kerosene

SAE

50 No. 20-W

ENGINE

OIL

No. 20-W

ENGINE

OIL

ENGINE

OIL

SAE

90

FLUID

GEAR

LUBRICANT

SAE

80

FLUID

(LOW

COLD

TEST)

GEAR

LUBRICANT

SAE

90

EXTREME

PRESSURE

HYPOID

GEAR

LUBRICANT

SAE

80

EXTREME

PRESSURE

HYPOID

(LOW

COLD

TEST)

GEAR

LUBRICANT

SHORT

FIBRE

WHEEL

BEARING

GREASE-MEDIUM

---

SHORT

FIBRE

WHEEL

BEARING

GREAsE-MEDIUM

-------

SAE

90

FLUID

GEAR

LUBRICANT,

LOW

COLD

TEST

WATER

PUMP

GREASE

--

HEAVY

SHORT

FIBRE

GREASE-MEDIUM

SEMI-FLUID

CHASSIS

LUBRICANT

--------·------

SAE

10

ENGINE

OIL

-----------------------------

SAE

10

ENGINE

OIL

------------------------------------------------------

SHORT

FIBRE

GREASE-MEDIUM-IN

GREASE

CUP

SAE

10

ENGINE

OIL

ON

WICK

SAE

10

ENGINE

OIL

IN

OIL

CUP

AND

ON

WICK

-----~--------------------------------------------------

SAE

10

ENGINE

OIL

·----------

SEMI-FLUID

CHASSIS

LUBRICANT

'

SAE

10

ENGINE

OIL

SPECIAL

SPRING

LUBRICANT

-

--------

ICE

MACHINE

OR

TRANSFORMER

OIL

-----------------

SAE

50

ENGINE

OIL

--

SAE

50

ENGINE

OIL

-

INSTALL

NEW

FILTER

OR

REPLACE

CARTRIDGE

-

18

3 (4.1939 model)

Ch~ssis

lubricant

fittings-Lower

---~

control arm bushing5

3 Chassis lubricant

fit-

tings-

Tie rod ball

jt>ints

PLYMOUTH

SERVICE:

MANUAL

Generator-Oil

cup

(front)-Covered

oil

hole

-----------!l;~~

(rear)

3 Chassis lubricant

fit-

tings-Upper

control arm

bushings

Front wheel

bearings-

Disassemble

2 Chassis lubricant

fit-

tings-Steering

kn,odJe·-_/

bushings

Steering

gear-Threaded

plug

Distributor-Oil

cup

or

grease

cup,

and

wick

Brake

and

clutch

pedals

and

shifting

linkoge-4

Lubricant fittings

(3

Lubri-

cant

fittings, 1939-41

models)

and

friction

points

Powermatic shift cylinder

and

air

cleaner

[special

equipment)

Hand brake

11;

nk<'o'e-·--J

Friction points

Propeller

Shaft

center

bearing-

I

lubricant

fit-

ting

(7

pass.

sedons

only}

Rear·

Wheel

bearings~

Threaded

plug

Spring (with

-----·-_./

metal )

3 {4·1939 model) Chossts

lubricant

fittings-l.ower

control

arm

bushings

1 Chassis lubricant

fit-

ting-

Tie

rod

ball

ioint

3 Chassis lubricant

fit~

tings-Upper

control

arm

bushings

2 Chassis lubricant fit-

tings-

Steering

knuckle

bushings

Front wheel

bearings-

Disassemble

Water

pump-1

Lubri-

cant

fitting

Carburetor

air

cleaner-

Disassemble

Engine oil

Crankcase

oil filler

pipe

air

cleaner-

Remove

Oil

filter-

Replace

Starter-1

Otl cup

Transmission-

Threaded

plug

Universal

joints-

Disassemble

Rear

wheel

bearings--

Threaded

plug

Rear

axle-

Threaded

plug

Spring (with

metal

covers)

4 Chassis lubricant

fit-

tings

(2

each

side)-

Spring shackles (1939-40

models)

42

X

24

Figure

4--Lubricalion

Chari

(1942

Model,

Typical

of

1939-41 Models)

Plymouth Pl4S User manual

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