Carburetor (5.9L) R & I: Disassembly

Remove air cleaner anchor screw. Note position of choke control rod and remove from choke valve lever shaft. Remove choke valve lever retaining screw. Slide choke rod out of choke lever. Remove air horn attaching screws, identification tag, air horn, and gasket. See Fig 1 .

Fig 1: Exploded View of Carburetor (5.9L)
Courtesy of CHRYSLER MOTORS.
Remove choke rod seal from air horn. Remove fast idle cam retaining clip and choke shield. Grind off choke cover rivet heads. Remove retainer, cover and coil, and gasket. Remove remaining portion of rivets. Remove fast idle cam rod from fast idle cam lever. Remove choke housing assembly retaining screws, housing, and gasket. Remove fast idle cam.
Remove coil lever retaining screw, coil lever, and fast idle cam lever from choke housing. Using a screwdriver, pry float shaft retainer from fuel inlet seat. Remove float, float shaft retainer, and fuel inlet needle assembly. See Fig 1 .
Remove retainer, float shaft, and float damper spring (if equipped) from float lever. Remove fuel inlet needle seat and gasket. Remove main jets. Remove accelerator pump discharge screw, air distribution plate, booster venturi, and gasket. See Fig 1 . DO NOT attempt to remove tubes from venturi.
Invert main body and catch accelerator pump discharge weight and check ball. Disconnect accelerator pump operating rod from overtravel lever. Remove rod and retainer. Remove inlet check valve by grasping it firmly and pulling out.
NOTE: If tip of inlet check valve breaks off during removal, make sure it is removed from fuel bowl. Inlet check valve must be replaced whenever it is removed.
Invert main body and remove power valve cover screws, cover and gasket. See Fig 1 . Using an 8-point socket, remove power valve. Remove and discard power valve gasket. Remove altitude compensator assembly and gasket.
Remove idle mixture screw caps. Turn idle mixture screws inward, counting turns for reassembly reference, until lightly seated. Remove idle mixture screws and springs. Remove fast idle lever assembly from throttle shaft. Remove throttle solenoid. Remove choke diaphragm.