DODGE Coronet, Royal, Custom Royal, D-500 1957 Shop Manual | PDF Download

DODGE Coronet, Royal, Custom Royal 1957 Shop Manual | PDF Download covering servicing, maintenance, repairs, and fault finding for the full range of 1957 Dodge passenger cars.

• Step-by-step servicing and repair procedures – making it easy to carry out repairs
• Detailed illustrations and diagrams – making repair procedures easier to understand
• Specifications – including torque settings, capacities, clearances, and adjustment information
• Repair procedures and remedies – covering everything from simple routine maintenance to complete overhauls
• PDF format – for easy viewing on your computer, tablet, or smartphone
• Bookmarked – so you can quickly find the section you need
• Over 525 pages

Models Covered:

• Dodge Coronet (All Series)

• Dodge Royal

• Dodge Custom Royal

• Dodge Suburban Station Wagons

• Dodge D-500 & D-501 High-Performance Models

Engine Coverage:

• 230 CID L-Head Inline 6-Cylinder

• 325 CID V8 (Red Ram & Super Red Ram - Poly and Hemispherical Heads)

• 354 CID V8 & 392 CID V8 (D-501 Models)

What’s Included in This Manual:

General Information and Lubrication

• General vehicle identification, engine serial numbers, body style codes, and chassis serial numbers

• Recommended lubricants, fluid viscosity charts, lubrication points, and service intervals

• Engine oil recommendations, filter servicing, crankcase capacities, and fluid drain procedures

• Service specifications, tune-up settings, and primary torque specifications

Front Suspension & Torsion-Aire Ride

• Torsion-Aire front suspension system removal, installation, and overhaul

• Front torsion bar removal, height adjustment, and anchor housing servicing

• Upper and lower control arms, ball joints, control arm bushings, and rebound bumpers

• Steering knuckles, front wheel hubs, bearings, grease seals, and brake drum assemblies

• Front wheel alignment specifications: Camber, caster, toe-in, and steering axis inclination

• Shock absorber removal, inspection, replacement, and mounting bracket servicing

• Fault finding for front-end noise, uneven tyre wear, bottoming out, and suspension lean

Rear Axle & Differential

• Rear axle assembly removal, axle tube housing, and installation procedures

• Axle shafts, shaft bearings, retaining rings, and outer axle shaft oil seals

• Differential carrier assembly removal, teardown, inspection, and reassembly

• Drive pinion, ring gear, pinion depth shims, and differential carrier bearings

• Bearing preload adjustment, pinion depth setting, and ring gear backlash adjustment

• Ring-and-pinion tooth contact pattern inspection and shim adjustments

• Sure-Grip (limited-slip) differential operation, clutch pack overhaul, and maintenance

• Fault finding and remedies for rear axle gear whine, bearing noise, backlash, and leaks

Brakes (Service, Power & Parking Brakes)

• Hydraulic brake system servicing, brake pedal free play, and push rod adjustments

• Total-Contact service brake assemblies, shoe adjustment, and lining replacement

• Hydraulic wheel cylinder disassembly, honing, piston cups, and return springs

• Master cylinder overhaul, fluid reservoir, residual pressure valves, and push rod setting

• Brake line pressure loss checks, system bleeding procedures, and brake fluid specifications

• Power brake booster unit removal, internal valve assembly, diaphragm, and vacuum testing

• Transmission-mounted parking brake (internal expanding type), cable linkage, and band adjustment

• Fault finding for spongy brake pedal, brake pull, dragging shoes, power loss, and fluid leaks

Clutch & Manual Transmission

• Single dry-plate clutch removal, disc inspection, pressure plate overhaul, and alignment

• Clutch release bearing (throwout bearing), release fork, pivot ball, and torque shaft linkage

• Clutch pedal free-play adjustment and return spring settings

• 3-speed manual transmission removal, teardown, case inspection, and gear replacement

• Input shaft, cluster gear, countershaft, synchronizer rings, and gear shift linkage adjustments

• 3-speed manual with Overdrive transmission servicing, governor, solenoid, and kickdown switch setup

• Fault finding for clutch slip, chatter, hard gear engagement, and transmission noise

Automatic Transmissions (PowerFlite & TorqueFlite)

• 2-speed PowerFlite automatic transmission maintenance, band adjustment, and linkage setup

• 3-speed TorqueFlite automatic transmission teardown, planetary gear sets, clutches, and bands

• Push-button gear selector control cables, mechanical shift linkage, and neutral safety switch setup

• Hydraulic control valve body overhaul, pressure regulator springs, and valve spool servicing

• Transmission oil cooler, cooler lines, torque converter inspection, and fluid flush

• Transmission throttle valve (TV) rod alignment, stall speed testing, and hydraulic pressure tests

• Fault finding for slipping shifts, delayed engagement, harsh push-button selection, and leaks

Engine Mechanics & Rebuild Specs

• Engine removal and installation for Inline-6 and V8 engine families

• Cylinder head removal, gasket replacement, valve grinding, valve seat angles, and guides

• Hydraulic and mechanical valve lifters, pushrods, rocker arms, and valve lash adjustments

• Cylinder block inspection, cylinder wall honing, ridge reaming, and main bearing line boring

• Pistons, wrist pins, piston ring end gap specs, connecting rods, and rod bearing fit

• Crankshaft removal, journal specs, thrust washer play, and rear main seal replacement

• Camshaft, timing chain, chain sprockets, and valve timing alignment marks

• Engine lubrication system: Oil pump overhaul, oil relief valve, strainer, and oil pan gasket setup

• Engine assembly bolt torque sequences and cylinder head tightening specs

• Fault finding for low engine oil pressure, valve clatter, rod knock, and blown head gaskets

Engine Cooling & Heating

• Radiator core removal, chemical flushing, flow testing, and expansion tank pressure cap specs

• Water pump overhaul, bearing/seal replacement, impeller clearances, and housing gaskets

• Thermostat testing, thermostat housing elbow replacement, and bypass hose operation

• Fan blade assembly, drive belt alignment, and belt tension adjustments

• Car heater core removal, heater control valves, ducting, and defroster blower motor setup

• Water temperature sending units and dashboard gauge circuit testing

• Fault finding for engine overheating, heater core leaks, and coolant contamination

Fuel, Exhaust & Induction Systems

• Fuel tank removal, tank fuel sender unit, pick-up tube, and inline fuel filters

• Mechanical fuel pump overhaul, diaphragm replacement, fuel pressure, and vacuum tests

• Single-barrel, 2-barrel, and 4-barrel Carter and Stromberg carburettor overhauls

• Dual 4-barrel carburettor setups (D-500 / D-501 models) linkage synchronization and choke setup

• Automatic choke assembly, heat stove tube, fast idle cam, and float level settings

• Intake manifold, exhaust manifolds, heat riser valve operation, and gasket replacement

• Exhaust pipes, dual exhaust system routing, mufflers, resonators, and pipe hangers

• Fault finding for vapor lock, engine hesitation, carburettor flooding, and poor fuel economy

Electrical & Wiring Diagrams

• 12-volt electrical system circuit schematics, chassis wiring harness, and color codes

• Battery specifications, ground cables, starter relay, and charging system components

• Generator overhaul, armature testing, field coils, brushes, and voltage regulator calibration

• Starter motor disassembly, starter drive engagement mechanism, solenoid, and starter switch

• Ignition system: Ignition coil, distributor rebuild, contact breaker points, condenser, and ignition timing

• Headlight switch, dual headlights, tail lights, turn signal switch, and dash panel instrument lighting

• Electric windshield wiper motor, linkage, horn relay, and accessory circuits

• Fault finding for starting trouble, discharge conditions, short circuits, and blown fuses

Air Conditioning (Airtemp Refrigeration System)

• Airtemp factory air conditioning component layout, system controls, and operation

• Compressor removal, servicing, magnetic clutch assembly, shaft seal replacement, and oil level checks

• Condenser, receiver-drier, expansion valve, and evaporator core servicing and ductwork

• Refrigerant system evacuation, leak testing, charging procedures, and pressure gauge diagnostics

• Thermostatic control switch, vacuum actuator controls, electrical relays, and blower motor circuits

• Belt alignment, belt tensioner pulley adjustment, and compressor mounting brackets

• Fault finding for inadequate cooling, system pressure drops, compressor noise, and refrigerant leaks

Steering System

• Manual steering gear box overhaul, sector shaft, worm gear, and backlash adjustment

• Coaxial Power Steering system overhaul, power cylinder, control valve, and hydraulic pump

• Power steering hydraulic hoses, fluid reservoir, system bleeding, and pressure testing

• Steering column tube, flexible coupling, horn ring assembly, and steering wheel removal

• Drag link, tie rod ends, idler arm, and pitman arm linkage servicing

• Fault finding for power steering noise, fluid leaks, hard steering, and steering wheel play

Wheels, Tyres & Hubs

• Steel wheels, trim rings, wheel lug bolt torque, and wheel balance procedures

• Front and rear wheel bearing repacking, hub oil seals, and bearing preload adjustment

• Tyre pressure specs, inflation recommendations, and tyre rotation patterns

Body, Frame & Glass

• All-steel unitized and body-on-frame chassis alignment specifications and crossmember mounting

• Hood, trunk lid, and fender alignment and hinge adjustments

• Front and rear door assembly, door latch mechanisms, door locks, and glass window regulators

• Windshield glass, rear window glass, rubber weatherstripping, and cowl ventilator setup

• Dashboard instrument cluster removal, speedometer cable lubrication, and trim installation

Technical Specifications Data

• Comprehensive engine specs: Bore, stroke, displacement, compression ratio, horsepower, and torque ratings

• Valve train specifications: Seat angles, stem clearances, spring pressure, and valve timing

• Engine tightening specifications: Cylinder head, main bearing caps, connecting rod bolts, and manifold torques

• Chassis torque settings: Suspension U-bolts, wheel nuts, steering linkages, and crossmembers

• Fluid capacities: Crankcase, cooling system, PowerFlite/TorqueFlite transmissions, rear axle, and fuel tank

• Electrical specifications: Generator output, voltage regulator settings, ignition distributor advance curves, and spark plug gaps

• Front-end alignment geometry: Caster, camber, toe-in, and kingpin inclination tolerances

Special Tools & Equipment

• Factory Miller-type special service tools reference list and usage instructions

• Torsion bar gauge fixtures, anchor adjusting tools, and suspension height gauges

• Differential carrier bearing pullers, pinion depth gauge blocks, and backlash dial indicators

• Transmission clutch spring compressors, front/rear pump alignment pins, and band adjusting wrenches

• Steering wheel pullers, pitman arm removers, and ball joint separator tools

• Engine overhaul fixtures, valve guide drivers, main bearing seal installers, and ridge reamers

• Power steering pressure testing gauges and air conditioning manifold gauge sets

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Language: English
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