Disassembly

1. To avoid damaging throttle plates and to facilitate working on carburetor, install bolts approximately 21/4 inches long of correct diameter through carburetor retaining bolt holes with a nut above and below the flange.
2. Remove the fuel bowl and gasket and the metering block and gasket, discarding gaskets.
3. Remove the pump transfer tube from the main housing or metering block and discard O-ring seals.
4. Remove fuel line tube and discard O-ring seal.
5. Remove main jets using suitable tool.
6. Using suitable tool, remove power valve and gasket.
7. Remove fuel level adjustment lock screw and gasket, turn adjusting nut counter-clockwise and remove adjusting nut and gasket, then remove fuel inlet needle and seat assembly. Do not disassemble fuel inlet needle and seat. They are matched assemblies and are replaced as an assembly.
8. Using suitable pliers, remove float shaft retainer clip, slide float off shaft and remove spring from float.
9. Remove baffle plate from fuel bowl.
10. Remove fuel level sight plug and gasket.
11. Remove fuel inlet fitting, gasket and filter screen.
12. Invert fuel bowl and remove accelerating pump cover, diaphragm and spring. The accelerating pump inlet ball check is not serviced separately and should not be removed.
13. Remove secondary fuel bowl and, using suitable tool, the metering body, plate and gaskets, discarding the gaskets.
14. Disassemble secondary fuel bowl.
15. Remove air cleaner anchor stud and the secondary diaphragm link E-clip.
16. Invert carburetor and remove throttle body retaining screws and lock washers, then lift off throttle body and discard the throttle body gasket.
17. On 1982 - 84 models, proceed as follows:
a. Remove choke rod cotter pin from choke housing shaft and lever assembly.
b. Remove thermostatic spring housing and gasket, then the choke housing and gaskets from the main body.
18. On 1982 - 83 models, proceed as follows:
a. Remove choke housing shaft nut, lock or star washer and the spacer, then the shaft and fast idle cam.
b. Remove choke piston and lever assembly.
19. On 1984 models with V8-460 engine, proceed as follows:
a. Remove choke housing shaft nut, star washer, and spacer, then the shaft and fast idle cam.
b. Remove choke piston and lever assembly.
20. On 1984 models with V8-351 heavy duty engine, proceed as follows:
a. Remove choke housing shaft nut, star washer and spacer, then the choke housing lever and fast idle cam.
b. Remove over-center spring and choke housing shaft, then the choke piston assembly.
21. On 1985 - 86 models with V8-460 engine or 1985 - 87 models with V8-351 engine over 8500 GVW applications, proceed as follows:
a. Using hacksaw, carefully cut slots in heads of choke cap breakaway screws, remove breakaway screws and standard screw with screwdriver and remove retaining ring, choke cap and gasket.
b. Remove three choke housing screws, then separate choke housing from main body, pushing choke rod out of retainer on choke housing shaft lever.
c. Remove choke housing shaft nut, star washer, spacer, lever, fast idle cam spring, spring perch and fast idle cam.
d. Remove over-center spring and choke housing shaft.
e. Remove choke diaphragm cover screws, then separate the diaphragm cover from the diaphragm and remove the choke diaphragm spring.
f. Slide diaphragm and shaft assembly out as far as possible, then remove choke modulator spring retaining clip.
g. Remove choke modulator spring, spring seat, and spring perch, then slide choke diaphragm assembly out of choke housing.
h. Remove nylon choke modulator bushing from choke housing.
22. On 1985 - 86 models with V8-351 engine under 8500 GVW applications, proceed as follows:
a. Remove choke rod cotter pin from choke housing shaft and lever assembly.
b. Using hacksaw, carefully cut slots in heads of choke cap breakaway screws, remove breakaway screws and standard screw with screwdriver and remove retaining ring, choke cap and gasket.
c. Remove choke housing assembly from main body.
d. Remove choke housing shaft nut, star washer and spacer.
e. Remove choke housing lever and fast idle cam.
f. Remove over-center spring, thermostat lever and choke housing shaft assembly, then the split link and piston assembly.
23. On all models, remove choke rod and seal from main body.
24. Remove choke plate from choke shaft and slide shaft and lever out of air horn. The retaining screws are staked to the choke shaft. If the tips of the screws are flared excessively, file off flared portion to avoid damage to threads in choke shaft. Be careful not to damage choke shaft or venturi while filing screws.
25. Remove three screws and the secondary diaphragm housing and gasket from main body. The housing must be removed before the cover can be removed.
26. Remove diaphragm housing cover, then the spring and diaphragm, and the vacuum ball check from the housing.
27. Remove accelerating pump discharge nozzle screw, then lift pump discharge nozzle and gaskets out of main body.
28. Invert main body and let accelerating pump discharge ball or needle fall into hand. Do not disassemble throttle body. Parts are matched to meet emission control standards and must be serviced as an assembly.