1962 PLYMOUTH SAVOY

Typical onset: 80,000-150,000 mi original, or unknown-history engines

Symptoms: Rattling on cold start from front of engine, disappears when warm, Rough idle, backfiring through carburetor, Loss of power, hard starting especially when hot, Check timing—if it's jumped teeth, you'll be 10+ degrees off

Fix: Replace timing chain, both gears, and tensioner. On slant-six, access is reasonable—4-5 hours. V8s need radiator/fan removal, add another hour. Replace front seal and oil pan gasket while you're there. Critical: these engines are interference on some valve/piston combos if chain breaks.

Estimated cost: $450-800

Typical onset: 70,000+ mi, but often age-related regardless

Symptoms: Drips or puddle of ATF under bellhousing area, Clunking into gear, especially reverse, Tail housing leak at speedometer cable or output shaft, Slipping between 1st-2nd if clutch packs are cooked from low fluid

Fix: Rear seal replacement requires pulling driveshaft, tail housing off—3 hours. If bushing is worn (common), needs machining or replacement housing. Front pump seal less common but check it. If previous owner ran it low on fluid, expect internal rebuild (12-16 hours).

Estimated cost: $350-600 for seals/bushing; $1,800-2,800 for full rebuild

Symptoms: Flooding, fuel smell, black smoke—stuck or sunken float (common with modern ethanol fuel), Hesitation on acceleration, flat spot off idle, Hard starting when hot, vapor lock tendencies, Leaking externally from gaskets or overflow

Fix: Rebuild kit with modern ethanol-resistant components, adjust float level precisely (critical on BBD). Replace accelerator pump diaphragm, check power valve. Budget 2-3 hours for proper bench rebuild and tuning. Consider switching to modern float material (nitrile).

Estimated cost: $180-350

Typical onset: 90,000+ mi, or abused/poorly maintained units

Symptoms: Excessive play at steering wheel—more than 2 inches at rim, Wandering on highway, constant correction needed, Clunking when turning lock-to-lock, Leaking gear oil from sector shaft seal

Fix: Manual steering boxes can often be adjusted (1-2 hours), but worn worm/sector needs rebuild or replacement. Power steering (rare on base Savoy) complicates it. Rebuilt unit swap is 3-4 hours including alignment check. Inspect pitman arm and idler arm simultaneously—they wear together.

Estimated cost: $250-500 for adjustment/seals; $600-900 for rebuilt box swap

Symptoms: Dim lights at idle, brightness varies with RPM, Ammeter shows discharge, battery goes dead overnight, Burning smell from generator, brushes worn to nubs, Voltage regulator chattering or stuck points

Fix: These use 1960s generators (not alternators)—rebuild with new brushes, bearings, test armature (2-3 hours). Voltage regulator is separate, mechanical points-style unit—replace or rebuild. Upgrade to alternator conversion is popular (adds $200-300 but worth it). Generator output is marginal for modern accessories.

Estimated cost: $220-400 for generator rebuild; $150-250 for regulator; $450-650 for alternator conversion

Symptoms: Harsh ride, suspension feels locked up over bumps, Squeaking or groaning from rear on rough roads, Rear axle crabbing or off-center in wheelwells, Visible rust, cracked rubber, or frozen shackles

Fix: Replace all four bushings and both shackles—they're sixty years old. Fronts often require torch to free rusted bolts, rear shackles same. Add spring eye bushings if worn. Budget 4-5 hours, more if fasteners break. Inspect rear spring main leafs for cracks while you're there.

Estimated cost: $300-550

Symptoms: Soft or spongy pedal that goes to floor, Brake fluid leak at master cylinder or under dash at pushrod, Complete brake loss if any wheel cylinder or line fails (single circuit system), Pulling to one side, rear-only or front-only braking

Fix: Replace master cylinder, flush entire system—2-3 hours. Inspect all four wheel cylinders (rears especially leak). Single-circuit means total failure if ANY line ruptures—strongly consider dual master cylinder upgrade (4-5 hours fabrication). Replace all rubber flex hoses, they're original and dangerous.

Estimated cost: $180-350 for master; $600-1,000 for dual-circuit conversion with lines

Symptoms: Front end sags unevenly side-to-side, Seized torsion bar adjusting bolts at rear crossmember, Clunking from front over bumps—upper control arm bushings shot, Rust perforation at torsion bar anchors

Fix: Torsion bar adjusters rust solid—requires penetrant, heat, sometimes cutting/welding new adjuster. Check lower control arm pivot shafts for wear (common). Upper bushings need press, 3-4 hours per side. If torsion bars are original, inspect for surface rust/pitting (they can crack). Full front end refresh: 8-12 hours.

Estimated cost: $400-700 for bushings/adjusters; $800-1,400 for complete front end overhaul