TM 9-2320-272-24-4

ARMY TM 9-2320-272-24-4

AIR FORCE TO 36A12- 1 C- 1155-2-4

This publication supersedes TM 9-2320-272-20- 1, October 1985, and changes 1 through 4; TM 9-2320-272-20-2,

O c t o b e r

1 9 8 5 , a n d c h a n g e s t h r o u g h 3 ; 9 - 2 3 2 0 - 2 7 2 - 3 4 - 1 , 1 9 8 6 , c h a n g e s t h r o u g h

TM 9-2320-272-34-2, June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, October 1992.

TECHNICAL MANUAL

VOLUME 4 OF 4

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT

MAINTENANCE MANUAL

FOR

TRUCK, 5-TON, 6X6, M939, M939A1, M939A2

SERIES TRUCKS (DIESEL)

TRUCK, CARGO: 5-TON, 6X6, DROPSIDE,

M923 (2320-01-050-2084) (EIC: BRY); M923A1 (2320-01-206-4087) (EIC: BSS); M923A2 (2320-01-230-0307) (EIC: B57);

M925 (2320-01-047-8769) (EIC: BRT); M925Al (2320-01-206-4088) (EIC: BST); M925A2 (2320-01-230-0308)(EIC: BS8);

TRUCK, CARGO: 5-TON, 6X6 XLWB,

M927 (2320-01-047-8771) (EIC: BRV); M927Al (2320-01-206-4089) (EIC: BSW); M927A2 (2320-01-230-0309) (EIC: BS9);

M928 (2320-01-047-8770) (UC: BRU); M928Al (2320-01-206-4090) (EIC: BSX); M928A2 (2320-01-230-0310) (EIC: BTM);

TRUCK, DUMP: 5-TON, 6X6,

M929 (2320-01-047-8756) (EIC: BTH); M929Al (2320-01-206-4079) (EIC: BSY); M929A2 (2320-01-230-0305) (EIC: BTN);

M930 (2320-01-047-8755) (EIC: BTG); M930Al (2320-01-206-4080) (EIC: BSZ); M930A2 (2320-0l-230-0306) (EIC: BTO);

TRUCK, TRACTOR: 5-TON, 6X6,

M931 (2320-01-047-8753) (EIC: BTE); M931A1 (2320-01-206-4077) (EK: BS2); M931A2 (2320-01-230-0302) (EIC: BTP);

M932 (2320-01-047-8752) (EIC: BTD); M932Al (2320-01-205-2684) (EIC: 855); M932A2 (2320-01-230-0303) (EIC: BTQ);

TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6,

M934 (2320-01-047-8750) (EIC: BTB); M934A1 (2320-01-205-2682) (EIC: BS4); M934A2 (2320-0l-230-0300) (EIC: BTR);

TRUCK, MEDIUM WRECKER: 5-TON, 6X6,

M936 (2320-01-047-8754) (EIC: BTF); M936Al (2320-0l-206-4078) (EIC: BS6); M936A2 (2320-01-230-0304) (EIC: BTT).

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

JUNE 1998

TM 9-2320-272-24-4

WARNING

EXHAUST GASES CAN KILL

1.

DO NOT operate vehicle engine in enclosed area.

2.

DO NOT idle vehicle engine with windows closed.

3.

DO NOT drive vehicle with inspection plates or cover plates removed.

4.

BE ALERT at all times for odors.

5.

BE ALERT for exhaust poisoning symptoms. They are:

Headache

Dizziness

Sleepiness

Loss of muscular control

6.

IF YOU SEE another person with exhaust poisoning symptoms:

Remove person from area

Expose to open air

Keep person warm

Do not permit person to move

Administer artificial respiration or CPR, if necessary*

* For artificial respiration, refer to FM 21-11.

7.

BE AWARE: The field protective mask for Nuclear, Biological, or Chemical (NBC) protection will not protect you from carbon monoxide poisoning.

THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.

Warning a

TM 9-2320-272-24-4

WARNING SUMMARY

Hearing protection is required for the driver and passenger. Hearing protection is also required for all personnel working in and around this vehicle while the engine is running (AR-40-5 and TB MED

501).

If required to remain inside vehicle during extreme heat, occupants should follow the water intake, work/rest cycle, and other stress preventive measures (FM 21-10, Field Hygiene and Sanitation).

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment. Consult with your unit NBC officer or NBC NCO for appropriate handling or disposal instructions.

This vehicle has been designed to operate safely and efficiently within the limits specified in this

TM. Operation beyond these limits is prohibited by IAW AR 70-1 without written approval from the commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMCPEO-CM-S,

Warren, MI 48397-5000.

Never work under dump body unless safety braces are properly positioned. Failure to do this will result in injury to personnel.

During winching operation, never stand between vehicles. Assistant must remain in secondary vehicle to engage service brake if cable snaps or automatic brake fails while towing vehicle. Failure to do this may result in injury to personnel.

Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to Army POL (para. 1-7) for information concerning storage, use, and disposal of these liquids. Failure to do so may result in injury or death.

Cleaning solvents are flammable and toxic. Do not. use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to do this will result in injury to personnel and/or damage to equipment.

Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed

30 psi (207 kPa). Failure to do so may result in injury to personnel.

Extreme care should be taken when removing surge tank filler cap if temperature gauge reads above 175°F (79°C). Steam or hot coolant under pressure will cause injury.

Alcohol used in the alcohol evaporator is flammable, poisonous, and explosive. Do not smoke when removing alcohol evaporator or adding fluid, and do not drink fluid. Failure to do this will result in injury or death.

Do not perform electrical circuit testing fuel tank with fill cap or sending unit removed. Fuel may ignite, causing injury to personnel.

When performing battery maintenance, ensure batteries are seated and clamped down, all rubber boots are installed, clamps are well down on battery posts, and all battery cables lie flat against the top of the batteries. Failure to do this may result in injury to personnel and/or damage to equipment.

Ensure companion seatbelts are not caught inside battery box. This will cause belts to rot which may lead to injury of personnel.

On M936/Al/A2 model vehicles, remove spare tire prior to changing tire and install tire in spare tire carrier after tire change is complete. Operation of crane and/or vehicle engine while vehicle is on jacks may result in injury to personnel or damage to equipment.

Never assemble or disassemble tire and rim assembly while inflated, use inflation to seat lockring on split rim or tire on two-piece rim, or inflate a tire without a tire inflation cage. Injury to personnel may result.

Do not disconnect air lines or hoses, remove safety valves or CTIS components, or perform brake chamber repairs before draining air reservoirs. Small parts under pressure may shoot out with high velocity, causing injury to personnel.

Warning

b

TM 9-2320-272-24-4

WARNING SUMMARY (Contd)

Remove all jewelry when working on electrical circuits. Jewelry coming in contact with electrical circuits may produce a short circuit, causing extreme heat, explosions, and fling particles of metal.

Failure to do so will result in injury or death and damage to equipment.

Use eyeshields and follow instructions carefully when performing assembling, disassembling, or maintenance on this device. Components of this device are under spring tension and may shoot out at a high velocity. Failure to do so will result in injury to personnel.

Do not remove hoses with engine running or start engine with hoses removed. High-pressure fluids may cause hoses to whip violently and spray randomly. Failure to do so may result in injury to personnel.

Keep hands out from between metal surfaces when removing heavy components. Failure to do so may result in injury to personnel.

Keep personnel out from under equipment and components of equipment when supported by only a lifting device. Sudden loss of lifting power or shift in load may result in injury or death.

Do not drain engine, transmission, or radiator fluids, or remove lines containing these fluids, when hot. Doing so may result in injury to personnel.

Vehicle will become charged with electricity if it contacts or breaks high-voltage wires. Do not leave vehicle while high-voltage lines are in contact with vehicle. Failure to do so may result in injury to personnel.

Wear hand protection when handling lifting and winching cables, hot exhaust components, and parts with sharp edges. Failure to do so may result in injury to personnel.

Do not perform fuel system procedures while smoking or within 50 ft (15.2 m) of sparks or open flame. Diesel fuel is highly flammable and can explode easily, causing injury or death to personnel and/or damage to equipment.

Ensure drainvalve on aftercooler is open when filling cooling system. Failure to do so may result in injury to personnel.

Turbocharger intake fins are extremely sharp and turn at very high rpm. Keep hands and loose items away from intake openings. Failure to do so may result in injury to personnel.

Do not place hands between frame and radiator when removing screws from trunnion or lifting radiator. Sudden changes in support may cause the radiator to shift, causing injury to personnel.

Air pressure may create airborne debris. Use eye protection or injury to personnel may result.

Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components.

Wear safety goggles when using a hammer.

Ether is extremely flammable. Do not perform ether start system procedures near fire. Injury to personnel may result.

Warning c/(Warning d blank)


NO.9-2320-272-24-4

TECHNICAL ORDER

NO. 36A12-1C-1155-2-4

ARMY TM 9-2320-272-24-4

AIR FORCE TO 36A12-1C-1155-2-4

HEADQUARTERS

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

Washington, D.C., 30 JUNE 1998


VOLUME 4 OF 4

UNIT, DIRECT SUPPORT, AND

GENERAL SUPPORT MAINTENANCE MANUAL

FOR

TRUCK, 5-TON, 6X6, M939, M939A1, M939A2 SERIES TRUCKS (DIESEL)

TRUCK

Cargo, Dropside

Cargo, Dropside

Cargo, Dropside

Cargo, Dropside

Cargo, Dropside

Cargo, Dropside

Cargo

Cargo

Cargo

Cargo

Cargo

Cargo

Dump

Dump

Dump

Dump

Dump

Dump

Tractor

Tractor

Tractor

Tractor

Tractor

Tractor

Van, Expansible

Van, Expansible

Van, Expansible

Medium Wrecker

Medium Wrecker

Medium Wrecker

EIC

BTQ

BTB

BS4

BTR

BTF

BS6

BTT

BRU

BSX

BTM

BTH

BSY

BTN

BTG

BSZ

BTO

BTE

BS2

BTP

BTD

BS5

BRY

BSS

BS7

BRT

BST

BS8

BRV

BSW

BS9

MODEL

M923

M923Al

M923A2

M925

M925Al

M925A2

M927

M927Al

M927A2

M928

M928Al

M92842

M929

M929Al

M929A2

M930

M930Al

M930A2

M931

M931Al

M931A2

M932

M932Al

M932A2

M934

M934Al

M934A2

M936

M936Al

M936A2

NSN WITHOUT WINCH

2320-01-050-2084

2320-01-206-4087

2320-01-230-0307

2320-01-047-8771

2320-01-206-4089

2320-01-230-0309

2320-01-047-8756

2320-01-206-4079

2320-01-230-0305

2320-01-047-8753

2320-01-206-4077

2320-01-230-0302

2320-01-047-8750

2320-01-205-2682

2320-01-230-0300

NSN WITH WINCH

2320-01-047-8769

2320-01-206-4088

2320-01-230-0308

2320-01-047-8770

2320-01-206-4090

2320-01-230-0310

2320-01-047-8755

2320-01-206-4080

2320-01-230-0306

2320-01-047-8752

2320-01-205-2684

2320-01-230-0303

2320-01-047-8754

2320-01-206-4078

2320-01-230-0304

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in back of this manual, directly to: Director, Armament and

Chemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630. A reply will be furnished to you. You may also provide DA Form 2028-2 information via datafax or e-mail:

E-mail: [email protected]

Fax: DSN 783-0726 or commercial (309) 782-0726

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

i

TM 9-2320-272-24-4

*This publication supersedes TM 9-2320-272-20-1,24 October 1985, and changes 1 through 4; TM 9-2320-272-20-2,25

October 1985, and changes 1 through 3; TM 9-2320-272-34-1, 10 June 1986, and changes 1 through 2; TM 9-2320-272-34-2,

10 June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, 21 October 1992.

This publication is published in four volumes. TM 9-2320-272-24-1 contains chapters 1,2, and 3 (through section IX). TM 9-2320-272-24-2 contains chapters 3 (sections X through XVI) and 4 (sections I through III).

TM 9-2320-272-24-3 contains chapter 4 (sections IV through XVI). TM 9-2320-272-24-4 contains chapters 5 and

6 and appendices A through H. Volume 1 contains a table of contents for the entire manual. Volumes 1,2, and 3 contain an alphabetical index covering tasks found in their respective volume. Volume 4 contains an alphabetical index covering all tasks found in the entire manual.

TABLE OF CONTENTS ii

CHAPTER 5

Section I.

Section II.

Section III.

Section IV

Section V

Section VI.

Section VII.

VOLUME 4 OF 4

Page

GENERAL SUPPORT (GS) MAINTENANCE INSTRUCTIONS

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

5-1

Engine (M939/Al) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-l

Engine (M939A2) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-157

TransmissionMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-280

Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-398

Front and Rear Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-432

Special Purpose Bodies Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-463

Winch, Hoist, and Power Takeoff (PTO) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-606

CHAPTER 6

Section I.

Section II.

Section III.

SHIPMENT AND LIMITED STORAGE INSTRUCTIONS

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

6-1

General Preparation of Vehicle for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

Loading and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

LimitedStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

APPENDIX A

REFERENCES

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

A-1

APPENDIX B

Section I.

Section II.

Section III.

Section IV.

MAINTENANCE ALLOCATION CHART (MAC)

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

B-l

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-l

Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-4

Tool and Test Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-25

Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-26

APPENDIX C

Section I.

Section II.

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

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

C-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-l

Expendable/Durable Supplies and Materials List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-3

APPENDIX D

MANDATORY REPLACEMENT PARTS

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

D-l

APPENDIX E

APPENDIX F

APPENDIX G

APPENDIX H

COMMON AND SPECIAL TOOL IDENTIFICATION LIST

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

E-l

ILLUSTRATED LIST OF MANUFACTURED ITEMS

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

F-l

TORQUE LIMITS

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

G-l

SCHEMATIC AND WIRING DIAGRAMS

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

H-l

5-1. GENERAL

Section I. ENGINE (M939/A1) MAINTENANCE

5-2. ENGINE (M939/A1) MAINTENANCE INDEX

PARA.

NO.

5-3.

5-4.

5-5.

5-6.

5-7.

5-8.

5-9.

5-10.

5-11

5-12.

5-13.

5-14.

5-15.

5-16.

5-17.

5-18.

5-19.

5-20.

5-21.

5-22.

5-23.

TITLE

Cylinder Head Repair

Intake and Exhaust Valves Refacing

Valve Seat Inserts Maintenance

Fuel Injector Sleeve Maintenance

Cylinder Liners and Block Maintenance

Crankshaft and Main Bearings Maintenance

Camshaft and Gear Maintenance

Piston and Connecting Rod Maintenance

Engine Oil Pump Repair

Mounting Fuel Pump to Holding Fixture

Pressure Gear Pump Removal

Governor Spring Pack Maintenance

Fuel Pump Housing Maintenance

Throttle Cover and Shaft Maintenance

Governor Weight Maintenance

Fuel Pump Setup and Calibration

Fuel Injector Repair

Injector Leak Test

Injector Spray Pattern Test

Injector Test Stand Calibration

Injector Flow Test

TM 9-2320-272-24-4

PAGE

NO.

5-2

5-18

5-22

5-26

5-34

5-48

5-58

5-64

5-78

5-92

5-93

5-94

5-96

5-98

5-102

5-104

5-122

5-136

5-140

5-142

5-148

5-1

TM 9-2320-272-24-4

5-3. CYLINDER HEAD REPAIR

THIS TASK COVERS: a. Disassembly b. Cleaning c. Inspection d. Assembly

INITIAL SETUP:

APPLICABLE MODELS

M939/Al

SPECIAL TOOLS

Head holding future (Appendix E, Item 7)

Cleaning brush (Appendix E, Item 28)

Valve guide arbor (Appendix E, Item 153)

Gauge block (Appendix E, Item 52)

Crosshead guide puller (Appendix E, Item 106)

Crosshead guide spacer (Appendix E, Item 33)

TOOLS

General mechanic’s tool kit (Appendix E, Item 1)

Outside micrometer (Appendix E, Item 80)

Depth micrometer (Appendix E, Item 81)

Torque wrench (Appendix D, Item 145)

Soft-faced hammer

MATERIALS/PARTS

Six freeze plugs (Appendix D, Item 133)

Sixteen half-keepers (Appendix D, Item 253)

Two O-rings (Appendix D, Item 438)

Two screw-assembled lockwashers (Appendix D,

Item 578)

Gasket (Appendix D, Item 94)

Freeze plug (Appendix D, Item 132)

Two freeze plugs (Appendix D, Item 134)

Lubricating oil (Appendix C, Item 50)

Prussian blue (Appendix C, Item 54)

Sealing compound (Appendix C, Item 61)

Antiseize tape (Appendix C, Item 72)

Crocus cloth (Appendix C, Item 20)

PERSONNEL REQUIRED

TWO

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-247

EQUIPMENT CONDlTlON

Cylinder head removed (para. 4-12).

GENERAL SAFETY INSTRUCTIONS

When cleaning with compressed air, wear eyeshields and ensure source pressure does not exceed 30 psi

(207 kPa).

a. Disassembly

1.

Remove sixteen half-keepers (1) from valve springs (3) and cylinder head (7). Discard sixteen halfkeepers (1).

NOTE

Tag springs for installation

2.

Remove eight upper spring guides (2), valve springs (3), and lower spring guides (4) from valve guide (5) and cylinder head (7).

3.

Tap eight valve (6) stems down lightly to loosen and remove from cylinder head (7). Place on numbered valve board and hold for inspection.

5-2

5-3. CYLINDER HEAD REPAIR (Contd)

TM 9-2320-272-24-4

5-3

TM 9-2320-272-24-4


4.

Remove two screw-assembled lockwashers (2), plate (3), and two O-rings (4) from cylinder head (11) and fuel crossover connection (5). Discard O-rings (4) and screw-assembled lockwashers (2).

5.

Remove pipe plugs (10) from front and rear face of cylinder head (11). Hold pipe plugs (10) for installation.

6.

Remove four freeze plugs (8) from exhaust ports (17) on cylinder head (11). Discard freeze plugs (8).

7.

Remove two freeze plugs (6) from front and rear face of cylinder head (11). Discard freeze plugs (6).

8.

Remove two freeze plugs (1) from cylinder head (11). Discard freeze plugs (1).

9.

Remove freeze plug (9) from front of cylinder head (11). Discard freeze plug (9).

5-4


TM 9-2320-272-24-4

5-5

TM 9-2320-272-24-4


2.

3.

4.

5.

6.

b . C l e a n i n g

Clean all cylinder head (1) components (TM 9-247).

c . I n s p e c t i o n

1.

7.

8.

9.

10.

11.

12.

Install four pipe plugs (11) in front and rear face of cylinder head (1).

NOTE

Apply sealing compound to outer diameter of freeze plugs before installation.

Install new freeze plug (10) in front face of cylinder head (1).

Install two new freeze plugs (2) in cylinder head (1).

Install two new freeze plugs (7) in front and rear face of cylinder head (1).

Install four new freeze plugs (9) in exhaust ports (8) on cylinder head (1).

Install two new O-rings (5), plate (4), and two new screw-assembled lockwashers (3) on fuel crossover connection (6) in cylinder head (1).

CAUTION

Do not use sander to polish cylinder heads. Serious damage to gasket sealing surfaces can result.

Clean cylinder head mating surfaces (12) lightly enough to remove all gasket remains and carbon

deposits. Inspect in accordance with instructions in para. 5-25.

NOTE

Instructions for use of portable magnetic tester are included with the tester.

Inspect valve seats (13) and injector ports (14) on cylinder head (1) for cracks. If cracks are found, replace cylinder head (1).

NOTE

The following examples of cylinder head defects are provided to assist in determining causes of failures.

Check cylinder head valve seats (13) and injector ports (14) for hot spots and correct probable causes.

If this condition exists, probable causes are overheating, loss of coolant, coolant flow stoppage, overfueling, tight injector holddowns, incorrect injector sleeve installation, defective casting, hot shutdowns, and incorrect insert fittings. If hot spots are found, replace cylinder head (1).

Check cylinder head (1) and water passage holes (15) for pits and scratches. If pits and scratches are less than .003 in. (0.08 mm), remove with crocus cloth. If pits and scratches are more than 0.003 in.

(0.08 mm) deep in the area 0.-625-0.156 in. (1.59-3.97 mm) from edge of water passage hole (15), replace cylinder head (1).

Check cylinder head surfaces (12) for warped surfaces. If warped surface exceeds 0.002 in. (0.05 mm), replace cylinder head (1).

Check cylinder head (1) for required thickness. Cylinder head (1) must measure 4.340 in. (110.24

mm) thick. If less than 4.340 in. (110.24 mm) thick, replace cylinder head (1).

5-6


TM 9-2320-272-24-4

5-7

TM 9-2320-272-24-4

5-3. HEAD

REPAIR

(Contd)

13.

14.

15.

16.

17.

18.

Check valve seat insert (2) and cylinder head (3) for looseness by tapping surface around valve seat

insert (2). Replace valve seat inserts (2) that bounce when tapped (para. 5-4).

Measure width (6) of valve seat insert (2). If width exceeds 0.125 in. (3.18 mm) at any one point

and cannot be narrowed during regrinding, mark valve seat inserts (2) for replacement (para. 5-4).

NOTE

The following examples of valve seat defects are provided to assist in determining causes of failure.

Inspect valve seat insert (2) and cylinder (3) for cracks (1) and correct probable causes. If cracks exist, probable causes are improperly machined insert bore, improper fitting of insert in bore, foreign particle under insert, faulty installation, and overheating.

Inspect valve seat insert (2) and cylinder head (3) for bums and correct probable causes. If burned, probable causes are carbon or foreign matter that prevents proper seating of valve. If burned,

resurface or replace (para. 5-4).

Inspect injector sleeves (4) and cylinder head (3) in accordance with instructions in para. 5-6. Check

injector sleeves (4) for scratches with bright light. If scratched, mark injector sleeve (4) for

replacement (para. 5-6).

Check injector cup seating area (5).

a. Lightly coat injector cup (11) with Prussian blue.

b. Install injector (9) into sleeve (4) with washer (10), clamp (8), and two screws (7). Tighten alternately in 4 lb-ft (5.4 N.m) steps to 10-12 lb-ft (14-16 N-m).

c. Remove two screws (7), clamp (8), washer (10), and injector (9).

d. Check seat pattern in bottom of sleeve (4) and sleeve seating area (5).

e. Blued band (12) on sleeve (4) in sleeve seating area (5) must be 0.060 in. (1.52 mm) minimum width and be located approximately 0.469 in. (11.91 mm) from bottom of cylinder head (3) surface.

5-8


TM 9-2320-272-24-4

5-9

TM 9-2320-272-24-4


19.

Install injector (18) in cylinder head (3) with washer (19), clamp (10), and two screws (11). Tighten alternately in 4 lb-ft (5.4 N-m) steps to 10-12 lb-ft (14-16 N-m).

20.

Measure protrusion of injector tip (8) with gauge block. Protrusion should be 0.060-0.070 in.

(1.52-1.78 mm). If not, mark sleeve (9) for replacement (para. 5-6).

21.

Air-test fuel inlet passage (4) and fuel outlet passage (5) for leakage and cracks.

a. Install two O-rings (6), plate (2), and two screw-assembled lockwashers (1).

b. Install pipe adapter (151, pipe extension (16), and air pressure gauge (17) into fuel outlet passage (5).

c. Install air hose adapter (121, air pressure control valve (13), and air hose (141 into fuel inlet passage (4).

d. Open air pressure control valve (13) and apply air pressure until air pressure gauge (17) reads

80-100 psi (550-690 pKa), then close valve (13).

e. Observe air pressure gauge (17). If pressure drops before fifteen seconds, replace cylinder head (3).

f. If air pressure holds for fifteen seconds, cylinder head (3) is serviceable.

NOTE

Replace pipe plugs in fuel passages of cylinder head after removal of test adapters.

22.

Remove air pressure gauge (17). pipe extension (16), and pipe adapter (15).

23.

Remove air hose adapter (12), air pressure control valve (13), and air hose (14) from fuel inlet passage (4)

24.

Inspect four crosshead guides (7) in accordance with instructions in para. 2-15.

25.

Check outside diameter of four crosshead guides (7) using micrometer or dial gauge. If outside diameter is less than 0.432 in. (10.97 mm), mark guide (7) for replacement.

26.

Check four crosshead guides (7) for correct height. If height is not 1.860-1.880 in. (47.24-47.75 mm), mark guide (7) for replacement.

27.

Check four crosshead guides (7) for straightness. If guide (7) is not straight, replace guide (7)

(subtask d, step 1).

5-10


TM 9-2320-272-24-4

5-11

TM 9-2320-272-24-4


28.

Inspect valve crossheads (1) in accordance with instructions in para. 2-15. Discard crossheads (1) if defective.

a. Check valve crossheads (1) for damaged adjusting screw threads (5) and excessive wear on rocker lever contact area (2).

b. Using micrometer, set small bore gauge at 0.4402 in. (11.181 mm).

c. Attempt to insert gauge into bore (4). Discard valve crosshead (1) if bore gauge goes into bore (4).

d. Check for out-of-round bore (4) by gauging at several points 90° apart. Discard valve crosshead (1) if bore (4) is out of round.

e. Check valve stem counterbore depth (3). Discard crosshead (1) if depth (3) is not 0.1200-0.1400 in.

(3.048-3.556 mm).

29.

Inspect eight valve guides (9) in accordance with instructions in para. 2-15. If defective, mark valve guides (9) for replacement.

a. Check eight valve guides (9) for chips, cracks, burrs, or broken out sections. If chipped, cracked, broken, or burrs are found, mark for replacement.

b. Check valve guide (9) for protrusion (7). If protrusion (7) is not 1.270-1.280 in. (32.26-32.51 mm) above cylinder head surface (8), mark valve guide (9) for replacement.

c. Set small bore gauge at 0.4552 in. (11.562 mm) and attempt to insert gauge into guide bore (6). If gauge goes into bore (6), mark guide (9) for replacement.

30.

Check valve head (14) and intake and exhaust valves (15) for cracks, warping, pits, burns, or cupping. Discard valve(s) (15) if cracked or warped, pitted, burned, or cupped.

a. Check rim thickness (13) on intake and exhaust valves (15). Discard valve (15) if rim thickness (13) is less than 0.105 in. (2.67 mm).

b. Check intake and exhaust valve keeper grooves (11) for wear. Use new keeper to check grooves (11).

Discard valve(s) (15) if new keepers fit loosely in grooves (11).

c. Check valve stem (12) for cracks, scoring, and galling. If cracked, scored, or galled, discard valve (15).

d. Measure valve stem (10) outside diameter with micrometer. If stem (10) outside diameter is less than 0.449 in. (11.41 mm), discard valve (15).

CAUTION

Use care when selecting replacement valve springs. Intermixing of old and new valve guides in any one cylinder head is permissible only if a specific crosshead has two of the same type or equivalent guides and springs installed under it.

31.

Inspect valve springs (16) in accordance with instructions in para. 2-15. Discard valve springs (16) if defective.

a. Check valve springs (16) for distortions, cracked, or collapsed coils. Discard valve spring (16) if distorted, or if coils are cracked or collapsed.

b. Check valve spring (16) free length. No. 1 valve spring is 2.29 in. (58 mm) in length. No 2. valve spring is 2.69 in. (68 mm) in length.

c. Using spring tester, inspect for serviceability by checking load when spring is compressed.

Discard spring No. 1 if spring does not give load of at least 150 lb (667 N) when compressed to

1.77 in (45 mm). Discard spring No. 2 if spring does not give load of at least 143 lb (636 N) when compressed to 1.72 in. (44 mm).

5-12


TM 9-2320-272-24-4

5-13

TM 9-2320-272-24-4

5-3. CYLINDER HEAD REPAIR (Contd) d . A s s e m b l y

NOTE

Use repaired and inspection-approved cylinder heads only.

1.

Replace worn valve guides (3). Drive valve guides (3) from underside of cylinder head (2) with hammer and punch.

2.

Using arbor press, mandrel, and valve guide arbor, install new valve guides (3).

3.

Using crosshead guide puller, remove defective crosshead guides (6) from cylinder head (2).

4.

Thoroughly clean crosshead guide (9) holes.

5.

Check crosshead guide (6) height. Assembled height must be 1.860-1.880 in. (47.24-47.75 mm).

To install intake and exhaust valves, position cylinder head on intake port face. Use wooden surface, workbench, or protective surface to prevent damage. Bench must be clean.

Be sure to install valves in original locations as numbered in step 3.

Ensure cylinder head is clean

6.

Dip valve stem (4) in clean engine oil.

7.

Install valve stems (4) through valve guides (3) from face side (5) of cylinder head (2). Ensure valve heads are correctly seated on valve seats (1).

8.

Carefully position cylinder head (2) face down on workbench after all valves are installed so valve springs can be installed.

CAUTION

Two differently-designed valve spring guides have been used in

NHC-250 series engines. Part number 128879 spring guide cannot be used with 211999 valve spring. Number 170296 spring guide can be used with either valve spring.

Reground valve heads seat deeper in cylinder head, causing valve stem to protrude farther above valve guide. This allows valve spring to extend beyond length limits of 2.250 in. (57.150

mm), and causes weak spring action. Use spacers up to 0.0625

in. (15.875 mm) to reduce valve spring to proper height.

5-14


TM 9-2320-272-24-4

5-15

TM 9-2320-272-24-4


9.

10.

11.

12.

13.

g.

h.

i.

l.

m.

n.

NOTE

A maximum of two 0.03125 in. (0.794 mm) spacers may be used under lower spring guide when cylinder head has been resurfaced and valve seat insert has been refaced. Do not use spacers to compensate for weak springs.

Place eight lower spring guides (18) over valve guides (16) and seat to cylinder head (1).

NOTE

Do not mix intake and exhaust springs. Intake springs are taller.

Place eight valve springs (15) on lower spring guides (18).

Place eight upper spring guides (14) on top of springs (15) and over stem end of valve (8). Compress spring compressor until keeper grooves (12)on valve (8) are exposed.

Install new keepers (13) into valve grooves (12) and slowly release spring compressor. Repeat this step until all valves (8) are locked by keepers (13).

Using vacuum tester, test intake and exhaust valves (8) for proper seating.

NOTE

Valves and valve seats must be dry.

Grease can be applied to O-ring on vacuum cup for better seal.

a.

b.

C.

d.

Select correct size vacuum cup (9) for size valves (8) being tested.

Hold vacuum cup (9) over head of valve (8) and seat flat on cylinder head surface (2) surrounding valve (8).

Turn tester shutoff valve (6) to open position and hold pushbutton (7) down to operate vacuum pump (4).

Operate tester shutoff valve (6) until indicator hand (5) on vacuum gauge (4) stops climbing between 18-25 in. (457-635 mm) of mercury. Close tester shutoff valve (7) and release pushbutton (8).

e.

f.

j.

k.

Begin timing as soon as hand (5) reaches 18 in. of mercury on gauge (4).

Stop timing as soon as indicator hand (5) reaches 8 in. (20.32 cm) of mercury. If time is less than ten seconds, valve (8) seating is not satisfactory

Tap valve stem end with soft-faced hammer and retest by repeating steps a through f.

If valve seating is unsatisfactory, proceed to step i.

Check for loose connections on tester.

Operate vacuum pump (3) with suction cup (9) against a clear glass window.

Check indicator hand (5) for movement. If indicator hand (5) moves, there is leakage in the tester.

Tighten connections and retest valves (8).

Repeat steps b through 1.

If test fails, regrind valves before retesting (para. 5-4).

5-16


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install injectors (para. 4-32)

Install cylinder head (para. 4-12).

5-17

TM 9-2320-272-24-4

5-4. INTAKE AND EXHAUST VALVES REFACING

THIS TASK COVERS: a. Valve Specifications b. Grinding or Refacing Valves c. Cleaning after Refacing

INITIAL SETUP:


M939/A1

EQUIPMENT CONDITION

Cylinder head disassembled (para. 5-3)

TOOLS

SPECIAL ENVIRONMENTAL CONDlTlONS


Well-ventilated work area.

Valve refacer

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-4910-484-10

a. Valve Specifications

NOTE

Hard-faced exhaust valves are marked by letters “EX” or “HF” in recessed area of valve head. Intake valves are not marked.

Use table 5-l for solid valves

Sodium-filled valves are not used in Cummins engines.

5-18

TM 9-2320-272-24-4

2

3

1

4

5-4. INTAKE AND EXHAUST VALVES REFACING

(Contd)

Ref.

Intake and

Exhaust Valves

Table 5-1. Valve Specifications.

New

Minimum

Stem

0.4500 in.

(11.4300 mm)

Seat angle

30°

Refacing depth

0.0625 in.

(1.59 mm)

Valve head thickness

0.105 in.

(2.67 mm)

New

Maximum

0.4510 in.

(11.4554 mm)

30°

Worn limits

0.4990 in.

(11.4046 mm)

0.0625 in

(1.59 mm)

0.105 in.

(2.67 mm)

5-19

TM 9-2320-272-24-4

5-4. INTAKE AND EXHAUST VALVES REFACING (Contd)

1.

2.

3.

4.

8.

9.

5.

6.

7.

10.

11.

12.

NOTE

Mark on ground face of valve. Mark is used to determine head or stem warpage.

For operating instructions of valve refacer, refer to

TM 9-4910-484-10.

Install valve (3) stem in chuck (2).

Turn switch (5) of valve refacer to ON to start valve grinder electric motor.

NOTE

An out-of-round condition of valve will be marked by a small bright spot on valve seating surface of valve head.

Turn grinder wheel handle (6) and very lightly touch valve (3) face with grinder wheel (4).

Move grinder wheel (4) away from valve head and switch valve grinder electric motor to OFF with valve refacer switch (5).

Indicate location of small bright spot on ground face of valve (3).

Rechuck valve (3) 180° from first position and mark new position on valve (3).

Turn valve refacer switch (5) to ON to start valve refacer electric motor.

Turn grinder wheel (4) handle (6) and very lightly touch valve (3) face with grinder wheel (4).

Move grinder wheel (4) away from valve (3) head and switch grinder electric motor to OFF with switch (5).

If bright spot is in the same position after both chucking operations, the valve (3) is warped. If valve (3) is warped, replace valve (3).

If bright spots occur in different positions, the chuck (2) is out of alignment or the valve (3) is being incorrectly chucked. Run-out should not exceed 0.0001 in. (0.0254 mm).

NOTE

Use valve refacer handle for left and right motion of valve.

Wet grind valves (3) to an exact 30° angle from horizontal and check valve (3) head rim thickness with wheel handle (7) controlling depth of grind (table 5-l).

NOTE

Keep valves in order in a numbered valve stick or board.

NOTE

Do not use cloth to wipe valves clean.

1.

Clean refaced valves (3). For general cleaning instructions, refer to para. 2-14.

5-20

5-4. INTAKE AND EXHAUST VALVES REFACING (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Assemble cylinder heads (para. 5-3).

5-21

TM 9-2320-272-24-4

5-5. VALVE SEAT INSERTS MAINTENANCE

THIS TASK COVERS: a .

Removal b. Gauging c. Counterboring d. Cleaning e. Installation

INITIAL SETUP:

APPLIABLE MODELS

M939/Al

SPECIAL TOOLS

Valve seat insert tool (Appendix E, Item 158)

Cutter seat (Appendix E Item 34)

Valve guide arbor (mandrel set) (Appendix E,

Item 154)

Tool driver (Appendix E, Item 140)

Valve seat insert staking tool (Appendix E,

Item 157)

Valve seat insert extractor (Appendix E,

Item 156)

TOOLS


Inside micrometer (Appendix E, Item 82)


Vernier calipers (Appendix E, Item 159)

Depth gauge (Appendix E, Item 81)

Brush

Electric drill

MATERIALS/PARTS

Valve seat inserts (Appendix D, Item 708)

Drycleaning solvent (Appendix C, Item 71)

REFERENCES (TM)

TM 9-2320-272-24P


Cylinder head disassembled (para. 5-3).


When cleaning with compressed air, wear eyeshields and ensure source pressure does not exceed 30 psi (207 kPa).

Keep fire extinguisher nearby when using drycleaning solvent.

Drycleaning solvent is flammable and toxic. Do not use near an open flame.

1.

Pull valve seat insert (3) from bore (2) on cylinder head (1) with valve seat insert extractor tool.

CAUTION

Each replacement valve seat insert outside diameter and thickness must be measured and compared to relating valve seat insert counterbore in the cylinder head before counterboring.

These measurements will prevent over-boring and damage to the cylinder head.

1.

Measure outside diameter of valve seat insert (3) using micrometer. Record reading and compare

with specifications in table 5-2.

2.

Measure thickness of valve seat insert (3). Record reading and compare with specifications in table

5-2.

3.

Measure valve seat counterbore (4) depth (5) with depth micrometer. Record reading and compare to

specifications in table 5-2.

4.

Measure valve seat insert counterbore (4) inside diameter with inside micrometer. Record reading

and compare to specifications in table 5-2.

5-22

5-5. VALVE SEAT INSERTS MAINTENANCE

(Contd)

TM

9-2320-272-24-4

CYLINDER HEAD

VALVE SEAT

COUNTERBORE DEPTH

Standard

Table 5-2. Valve Seat Specifications.

INSERT

OUTSIDE DIAMETER

2.0025 - 2.0035 in.

(50.864 - 50.889 mm)

CYLINDER HEAD

COUNTERBORE

INSIDE DIAMETER

1.9995 - 2.0005 in.

(50.787 - 50.813 mm)

INSERT

THICKNESS

0.278 - 0.282 in.

(7.0612 -

7.1629 mm)

5-23

TM 9-2320-272-24-4

5-5. VALVE SEAT INSERTS MAINTENANCE (Contd) c. Counterboring

1.

Clamp base (2) of counterbore cutter (7) to cylinder head (3) near valve insert seat bore (4). Ensure counterbore cutter (7) is securely clamped before starting electric drill motor (1).

NOTE

Allow cutter to turn several revolutions at exact moment the proper depth in cylinder head is reached to ensure a perfectly flat bottom of bore for valve seats to seat.

2.

Center counterbore cutter (7) in valve seat insert bore (4) and valve guide mandrel (6).

3.

Cut counterbore (5) 0.006-0.010 in. (0.1524-0.2540 mm) deeper than valve seat insert thickness to allow staking (peening) of cylinder head (3) to secure valve seat insert.

Eyeshields must be worn when cleaning with compressed air.

Compressed air source will not exceed 30 psi (207 kPa). Failure to do so may result in injury to personnel.

1.

Blow cylinder head (3) out with compressed air.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container.

Failure to do this may result in injury or death to personnel and/or damage to equipment.

2.

Clean opening and ports of cylinder head (3) with brush and drycleaning solvent.

3.

Dry cylinder head (3) with compressed air.

e. Installation

CAUTION

Valve seat inserts may be installed one time only. If valve seat insert is not properly installed the first time, a new valve seat insert must be installed.

NOTE

Keep valve seat inserts in cold storage until ready to install in cylinder head. Install valve seat insert very quickly so room temperature does not have a chance to expand insert and make it difficult to install.

1.

Drive valve seat insert (9) into valve seat insert bore (4) with valve seat insert tool until fully seated.

2.

Stake (peen) valve seat insert (10) into cylinder head (3) with valve seat insert tool and valve seat insert staking tool.

5-24

5-5. VALVE SEAT INSERTS MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Grind valve seats (para. 5-2).

5-25

TM 9-2320-272-24-4

5-6. FUEL INJECTOR SLEEVE MAINTENANCE

THIS TASK COVERS: a. Removal b. Bead Cutting c. Installation d. Fitting and Forming e. Check and Test

INITIAL SETUP:


M939lAl

SPECIAL TOOLS

Bead cutting tool (Appendix E, Item 9)

Injector sleeve expander tool (Appendix E,

Item 73)

Injector sleeve cutter (Appendix E, Item 72)

Injector protrusion gauge (Appendix E, Item 53)

Injector sleeve holding tool (Appendix E,

Item 74)

Injector sleeve installation mandrel (Appendix

E, Item 75)

Injection sleeve extractor (Appendix E,

Item 67)

TOOLS


Torque wrench (Appendix E, Item 146)

Dial indicator (Appendix E, Item 36)

Drill press

MATERIALS/PARTS

Injector sleeve (Appendix D, Item 257)

Injector sleeve O-ring (Appendix D, Item 478)

Cutting oil (Appendix C, Item 26)


Prussian blue (Appendix C, Item 54)

REFERENCES (TM)

TM 9-2320-272-24P


Cylinder head disassembled (para. 5-3).

3.

4.

1.

2.

7.

8.

5.

6.

Place cylinder head (5) on workbench with exhaust manifold side down.

Insert tapered end of lower puller collar (7) into injector sleeve (6).

Insert upper puller collar (9) on top of collar (7) with threaded end out.

Position support bridge (10) over threaded end of collar (9) with one hand holding support bridge (10) legs against cylinder head (5) and install washer (11) and nut (12). Tighten nut (12) finger tight.

While holding support bridge (10) insert threaded rod (4) through holes in collars (7) and (9).

Install hex nut (1) and extractor tip (3) on threaded rod (4) and tighten. Ensure extractor tip (3) is seated firmly against injector sleeve (6) bottom.

Tighten nut (1) to remove injector sleeve (6). Discard injector sleeve (6).

Remove O-ring (8) from injector sleeve bore (2). Discard O-ring (8).

5-26

5-6. FUEL INJECTOR SLEEVE MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-27

TM 9-2320-272-24-4


1.

Insert cylinder head (5) cutter (3) and cutter pilot (2) into injector sleeve bore (6).

2.

Position holder (1) to cutter (3).

3.

Set cylinder head (5) on table of drill press.

CAUTION

Tool chatter may occur if drill speed is higher than 75 rpm, causing damage to cylinder head.

Do not cut more than 0.010 in. (0.254 mm) deep into cylinder head.

Cutter must be sharp to prevent bead damage.

NOTE

Press may be turned by hand for light cuts or to prevent accidental removal of too much material.

4.

Set drill press speed no higher than 75 rpm.

5.

Lift holder (1), pilot (2), and cutter (3) and apply cutting oil to lubricate cutter (3).

6.

Turn drill press motor on and take a very light cut. When the proper cut depth has been reached, allow cutter (3) to dwell ten seconds to ensure a good seat and to clean the groove.

7.

Remove holder (1), pilot (2), and cutter (3) from injector sleeve bore (6).

8.

Apply Prussian blue to coat seat end of new injector sleeve (7) and insert new injector sleeve (7) in injector sleeve bore (6) until fully seated.

9.

Remove new injector sleeve (7) from injector sleeve bore (6). Ensure blueing shows a complete 360° band on both the injector sleeve (7) and seat (4).

Ensure sleeve seat at bottom of injector bore is free from oil, carbon, or other foreign materials.

1.

Apply lubricating oil to coat new O-ring (10).

2.

Install new O-ring (10) into groove (11) of injector sleeve bore (6).

NOTE

Ensure mandrel is not struck with a hammer during this operation.

3.

Use injector sleeve mandrel to push the new injector sleeve (7) into injector sleeve bore (6) until it bottoms.

4.

Remove mandrel from injector sleeve bore (6).

5.

Install injector sleeve holding tool (8) in cylinder head (5). Tighten nut (9) 35-40 lb-ft

(48-54 N•m)

6.

Insert injector sleeve mandrel into injector sleeve bore (6) and drive injector sleeve (7) in with softfaced hammer until seated.

7.

Retighten nut (9) 35-40 lb-ft (48-54 N•m).

5-28


(Contd)

TM 9-2320-272-24-4

5-29

TM 9-2320-272-24-4


(Contd)

CAUTION

Do not roll lower area of injector sleeve which will cause distortion of total sleeve.

Over-rolling of injector sleeve will cause deformation of sleeve into O-ring groove.

1.

Position injector sleeve expander tool into injector sleeve (2) in cylinder head (1).

2.

Turn thrust nut (4) to adjust depth of expander tool so that roller (3) extends 0.5 in. (12.7 mm) into sleeve (2).

3.

Lock thrust nut (4) in place using an Allen wrench.

4.

Push expander tool down, turn, and adjust until 75 lb-in. (8.5 N-m) maximum is reached.

NOTE

Form cutter per specifications in table 5-3.

Table 5-3. Cutter Specifications.

Item In.

5

6

7

8

15

16

17

18

12

13

14

9

10

11

19

20

21

22

0.080

0.090

0.0015

0.0025

0.0077

0.0097

1.0615

1.0635

15° angle relief

15° angle relief

30° 9’ angle relief

0.375

0.312

0.125

0.375

0.010

0.0937

0.384

0.386

0.226

0.236

0.3425

1.250

0.375

(MM)

(2.0320)

(2.2860)

(0.0381)

(0.0635)

(0.1955)

(0.2463)

(26.9621)

(27.0129)

(9.5250)

(7.9375)

(3.1750)

(9.5250)

(0.2540)

(2.3812)

(9.7536)

(9.8044)

(5.7404)

(5.9944)

(8.6995)

(31.7500)

(9.5250)

5-30


(Contd)

TM 9-2320-272-24-4

I

5-31

TM 9-2320-272-24-4


(Contd)

5.

Size, grind, and inspect injector sleeve seat cutter (5) and ensure it is ground to exact contours

listed in table 5-3.

NOTE

Use a solid stream of clean cutting oil to allow injector sleeve seat cutter to cut freely without grabbing.

Proper seating and protrusion of injector sleeve seat cutter are checked in task e.

6.

Install injector sleeve seat cutter (5) on head (6) and use in drill press with pilot (4) to cut injector sleeve (2) just enough to provide for proper seating of injector and to maintain correct injector tip protrusion.

e. Check and Test

1.

2.

3.

4.

5.

6.

NOTE

Steps 1 through 4 check injector cup seating pattern in injector.

Apply light coat of Prussian blue to injector cup (11) and install injector assembly (9) into cylinder head (1) with washer (10), clamp (8), and two screws (7). Tighten screws (7) alternately in

4lb-ft (5 N•m) steps to l0-12 lb-ft (14-16 N•m).

Remove two screws (7), clamp (8), washer (l0), and injector assembly (9) from cylinder head (1).

Check seat pattern in bottom of injector sleeve (2) cup seating area.

If blued band (3) on injector sleeve (2) seating area is not at least 0.060 in. (1.52 mm) wide and located approximately 0.469 in. (11.91 mm) from bottom of cylinder head (1) surface, regrind injector sleeve (2) seating area as described in steps 5 and 6 of task f.

Install injector assembly (9) in injector sleeve (2) in injector head (1) with clamp (8), washer (10), and two screws (7). Tighten screws (7) alternately in 4 lb-ft (5 N•m) steps to 10-12 lb-ft. (14-16 N•m).

Check protrusion of injector tip (13) using dial indicator (12).

a. If injector tip (13) protrusion exceeds 0.070 in. (1.78 mm), install new injector sleeve (2).

b. If injector tip (13) protrusion is less than 0.060 in. (1.52 mm), regrind injector sleeve (2).

5-32


TM 9-2320-272-24-4

FOLLOW-ON TASK: Assemble cylinder head (para. 5-3).

5-33

TM 9-2320-272-24-4

5-7. CYLINDER LINERS AND BLOCK MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Cleaning and Inspection d. Cylinder Liners Installation

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Liner clamp set (Appendix E, Item 78)

Liner driver (Appendix E, Item 79)

TOOLS


Cylinder liner puller (Appendix E, Item 107)






Telescoping gauge set (Appendix E, Item 136)


Feeler gauge

Hold-down tool

MATERIAL PARTS

Two lockwashers (Appendix, Item 349)

Suction flange gasket (Appendix D, Item 680)

Two O-rings (Appendix D, Item 460)

Crevice seal (Appendix D, Item 88)



Lint-free cloth (Appendix C, Item 21)

Lubricating oil OE/HDO (Appendix C, Item 50)

Detergent (Appendix C, Item 27)

REFERENCES (TM)

TM 9-2320-272-24P


Crankshaft and main bearings removed (para. 5-8).





SPECIAL ENVIRONMENTAL CONDITIONS

Work area clean and free from blowing dirt and dust.

NOTE

Tag all cylinder liners for installation.

Remove six cylinder liners (1) from cylinder liner bores (2) with cylinder liner puller.

5-34

5-7. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-35

TM 9-2320-272-24-4


1.

2.

3.

4.

7.

8.

5.

6.

NOTE

All six cylinder liners are repaired the same way. This procedure covers only one cylinder liner.

Remove upper and lower O-rings (4) and (5) and crevice seal (3) from cylinder liner (1). Discard Orings (4) and (5) and crevice seal (3).

Remove shim pack (2) from cylinder liner (1) and measure thickness with micrometer. Record readings so same shim pack (2) thickness can be installed.

Tape shim pack (2) together and tag with corresponding cylinder liner (1) number. Hold shim pack (2) for reassembly.

Place cylinder liner (1) on numbered rack and hold for cleaning and inspection.

NOTE

Note location of plug removal for installation.

Remove four water passageway pipe plugs (6) from engine block (7).

Remove eight oil passageway pipe plugs (9) from engine block (7).

Remove two water passageway cup plugs (8) from engine block (7).

Remove two screws (11), lockwashers (12), suction flange plate (10), and gasket (13) from engine block (7). Discard lockwashers (12) and gasket (13) and clean gasket remains from mating surfaces.

5-36


TM 9-2320-272-24-4

5-37

TM 9-2320-272-24-4


5.

6.

7.

3.

4.

8.

9.

10.

11.

12.

13.

1.

2.

WARNING



Clean engine block (1). Refer to para. 2-14 for general cleaning instructions.

Run rods (3) with brushes through all oil passages (2) in engine block (1).

WARNING



Blow oil passages (2) of engine block (1) clean with compressed air.

Clean water pump air bleed hole (4) in cylinder bore (5) with compressed air.

Blow all dirt and cleaning solvent from all engine block (1) screw holes (7).

Remove scale from liner counterbore ledge (6).

Clean carbon from lower liner bore (8) of engine block (1).

NOTE

Ensure engine block is on flat surface or workbench for inspection.

Refer to para. 2-15 for general engine block (1) inspection instructions.

Check engine block (1) for worn surfaces, pitting, corrosion, nicks, gouges, burrs, eroded waterholes, damaged threads, distortion, and cracked areas.

Inspect counterbore ledge (6) of cylinder liner counterbore (9) at points (A) and (B) to ensure counterbore ledge (6) is 90° to liner bore.

Check counterbore diameter (A) and depth (B) to insure proper seating of cylinder liner and to determine if machining of counterbore ledge (6) depth is necessary.

NOTE

If counterbore depth varies more than 0.001 in. (0.03 mm) at several areas measured or counterbore slants downward toward center of cylinder liner bore, counterbore ledge will need to be refinished.

Steps 12 and 13 check engine block for possible counter-bore distortion.

Position telescoping gauge in counterbore (9) and set dial to zero.

Move bore gauge around circumference of counterbore (9) and take readings at three intervals of 120°. The difference in the readings will indicate amount of distortion. If specifications in

table 5-4 are exceeded, replace engine block (1).

5-38


(Contd)

TM 9-2320-272-24-4

5 - 3 9

TM 9-2320-272-24-4


Table 5-4. Cylinder Liner Counterbore.

New minimum . . . . . . . . . . . . . . . . . . . . . . . .

6.5615 in.

(166.662 mm)

New maximum . . . . . . . . . . . . . . . . . . . . . . . .

6.5635 in.

(166.713 mm)

Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSlDE DIAMETER DEPTH

0.350 in.

(8.89 mm)

0.352 in.

(8.94 mm)

0.412 in.

(10.56 mm)

14.

Ensure cylinder liners (2) protrude 0.003-0.006 in. (0.08-0.15 mm) above the engine block (1) when they are properly installed.

NOTE

Shims are used to compensate for counterbore depth wear.

Steps 15 through 17 check cylinder liner for proper protrusion without installing a cylinder liner.

15.

Measure cylinder liner (2) outside flange (4) with micrometer. Do not include bead (3) when taking measurements.

16.

Measure counterbore ledge (5) depth with gauge block. Ensure counterbore ledge (5) is smooth and not “cupped” more than 0.0014 in. (.036 mm). Depth must not vary more than 0.001 in. (0.254 mm).

17.

Subtract counterbore depth from cylinder liner (2) outside flange (4) depth to determine amount of shims or depth of counterbore cut to be made to obtain 0.0036-0.006 in. (0.08-0.15 mm) liner protrusion.

18.

Install cylinder liner (2) and clamps in engine block (1) without O-rings or crevice seal. Ensure clamps are installed so there is equal pressure on liner. Tighten clamps 50 lb-ft (68 N•m).

19.

Use feeler gauge to check clearance between lower liner (2) and engine block (1). If clearance is not

within limits specified in table 5-5, check lower O-ring groove inside diameter in engine block (1).

20.

Remove cylinder liner (2) from engine block (1).

21.

Use telescoping gauge to check lower liner bore (6) in engine block (1). Bore (6) should be within

limits set in table 5-5.

Table 5-5. Lower Liner Bore Inside Diameter and Block Clearance.

MINIMUM MAXIMUM

Lower liner bore inside diameter . . . . . . . . . . . . . . .

6.124 in.

(155.55 mm)

Lower liner to block clearance . . . . . . . . . . . . . . . . . 0.002 in.

(0.05 mm)

6.126 in.

(155.60 mm)

0.006 in.

(0.15 mm)

5-40


TM 9-2320-272-24-4

5-41

TM 9-2320-272-24-4


22.

Install main bearing caps (2) in engine block (1) without crank or bearing shells.

23.

Measure main bearing bore diameter (3) horizontally, vertically, and diagonally with telescoping gauge (4). Ensure bore diameter does not exceed 4.75 in. (120-663 mm).

NOTE

Pipe plugs, cup plugs, and suction flange plate are installed at this time to keep passages clean. Wrap pipe plug threads with sealing tape to prevent leakage.

24.

Install two cup plugs (9) in engine block (1).

25.

Install four pipe plugs (8) in block (1) and tighten according to table 5-6.

26.

Install eight pipe plugs (10) in block (1) and tighten according to table 5-6.

27.

Install new gasket (14) and suction flange plate (13) on engine block (1) with two new lockwashers (12) and screws (11). Tighten screws (11) 10-15 lb-ft (14-20 N•m).

Table 5-6. Engine Block Pipe Plug Torque.

PIPE PLUG SIZE

1/8 in.

1/4 in.

3/8 in.

1/2 in.

3/4 in.

1-1/4 in.

1-1/2 in.

LB-FT

MINIMUM

( N M

60

75

90

15

30

35

45

(20)

(41)

(47)

(61)

(81)

(102)

(122)

LB-FT

20

35

45

55

70

85

100

MAXIMUM

(N•M)

(27)

(47)

(61)

(75)

(95)

(115)

(136)

NOTE

Most attempts to hone or deglaze cylinder liners provide worse results than leaving them “as is”. Experience and laboratory results indicate that liners do not need to be honed, rotated, or deglazed to provide proper setting.

It is recommended that cylinder liners be inspected before cleaning so defects can be clearly noted.

Inspect cylinder liners closely for any of the metal conditions illustrated. If one liner has failed, then other liners in the same engine are likely to have early signs of the same type of failure.

28.

Check cylinder liner (5) for scoring or vertical grooving (6) on the inside diameter indicating heavy metal-to-metal contact of piston to cylinder liner (5). If scoring or vertical grooving (6) is present, tag cylinder liner for replacement.

29.

Check cylinder liner (5) for cracks (7) indicated by magnetic detection. If cracks (7) are present, tag cylinder liner (5) for replacement.

5-42


TM 9-2320-272-24-4

5-43

TM 9-2320-272-24-4


30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

Check cylinder liner (2) for a series of pit erosions (3) on the thrust or antithrust side of the cylinder liner (2) outside diameter. If pit erosions (3) are present, tag cylinder liner (2) for replacement.

Check cylinder liner (2) for visible cracks. As a rule, cylinder liners are highly resistant to vertical cracks or breakage. If cracks are present, tag cylinder liner (2) for replacement.

Check cylinder liner (2) for eroded surface (4). Moving coolant contacting the cylinder liner (2) outside diameter erodes the surface away and attacks the crevice seal. If surface is eroded (4), tag cylinder liner (2) for replacement.

Check cylinder liner (2) for fretting of surfaces (6), and/or machined area. Top of cylinder liner bead has worn away on illustrated cylinder liner (2). If surfaces (6) have fretted, tag cylinder liner (2) for replacement.

NOTE

Do not use wire brush on cylinder liners.

Steam, clean, or wash cylinder liner (2) in hot water and detergent. Scrub with bristle brush.

Remove rust, scale, and corrosion from cylinder liner (2). If cylinder liner (2) is excessively rusted, scaled, or corroded, replace.

WARNING



Blow cylinder liner (2) dry with compressed air.

Apply generous coat of lubricating oil to cylinder liner (2) and let stand for five to ten minutes.

Wipe oil from cylinder liner bore (1) with heavy paper towel. Gray and black residue will appear on towels.

Repeat steps 37 and 38 until black or gray residue no longer appears on towel.

Apply lubricating oil lightly to cylinder liners (2) and wrap cylinder liners (2). Store in clean, dry location until installation.

NOTE

Cylinder liners must be checked at 60°-70°F (16°-21°C). New cylinder liners with lubrite finish may be 0.0002-0.0006 in.

(0.005-0.015 mm) smaller than indicated due to lubrite coating.

Check liner bore (1) with telescoping gauge. If measurement exceeds 5.5050 in. (139.830 mm), tag cylinder liner (2) for replacement.

5-44


TM 9-2320-272-24-4

5-45

TM 9-2320-272-24-4

5-7. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) d. Cylinder Liners Installation

1.

Clean cylinder liner flange (2), crevice seal groove (12), and O-ring grooves (3) and (11) with lint-free cloth.

2.

Install new crevice seal (10) in crevice seal groove (12). Ensure crevice seal (10) is straight and not twisted.

3.

Install new black O-ring (9) in top O-ring groove (11) using molding mark as a guide. Ensure new black O-ring (9) is straight and not twisted.

4.

Install new red O-ring (9) in bottom O-ring groove (3). Ensure new red O-ring (9) is straight and not twisted.

5.

Clean cylinder bore (7), counterbore (4), and lower bore (5) and apply lubricating oil.

6.

Apply light coat of clean engine oil to crevice seal (11) and O-rings (8) and (9) and position cylinder liner (1) in engine block (6) by hand. Take care not to dislodge O-rings (8) and (9) and crevice seal (10).

Press cylinder liner (1) in place using hand pressure.

NOTE

Install cylinder liner without shims until liner protrusion is checked in step 8. It may be necessary to remove liners and add shims.

7.

Drive cylinder liner (1) in with liner driver and liner clamp until cylinder liner flange (2) is seated.

Hold down with hold-down tool.

8.

Position dial indicator and gauge block on cylinder liner (1) and measure cylinder liner (1) protrusion.

If protrusion is not 0.003-0.006 in. (0.08-0.15 mm), add or remove shims and repeat task d.

NOTE

When performing step 9, if liner is more than 0.002 in. (0.05 mm) out-of-round in lower bore O-ring area, remove liner and check for cause of distortion. It is permissible to have 0.003 in. (0.08 mm) out-of-round at the top 1 in. (25.4 mm) of liner bore.

9.

Position telescoping gauge in cylinder liner (1) and measure at several points within range travel for out-of-round condition. If out-of-round, remove cylinder liner (1) and reinstall.

of piston

5-46


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install crankshaft and main bearings (para. 5-8).

5-47

TM 9-2320-272-24-4

5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE

THIS TASK COVERS: a. Removal b. Cleaning and Inspection c. Installation d. End Play Clearance

INITIAL SETUP:


M939/A1

TOOLS


Main bearing cap puller (Appendix E, Item 108)


Vernier caliper (Appendix E, Item 159)



Hoist

Rubber-protected hooks

MATERIALS/PARTS

Crankshaft main bearing set

(Appendix D, Item 87)

Thrust ring set (Appendix D, Item 682)

Fourteen lockplates (Appendix D, Item 341)

Woodruff Key (Appendix D, Item 738)

Fourteen dowel rings (Appendix D, Item 100)


GAA grease (Appendix C, Item 28)



REFERENCES (TM)

TM 9-2320-272-24P


Connecting rod and pistons removed (para. 5-10).


l Keep fire extinguisher nearby when using drycleaning solvent.

l


l


a. Removal

1.

Turn engine block (1) upside down.

2.

Bend down lockplate tab (8) and remove two screws (7) from seven main bearing caps (9). Discard lockplates (8).

NOTE

Tag all bearing caps and bearing shells for installation.

3.

Remove main bearing caps (9) from engine block (1) with main bearing cap puller.

4.

Remove lower half bearing shell (10) from main bearing caps (9). Discard lower half bearing shell (10).

5.

Remove lower half of thrust ring (4) from crankshaft near journal (5). Discard thrust ring (4).

6.

Carefully remove crankshaft (6) from engine block (1) using hoist and rubber-protected hooks (11).

Place crankshaft (6) on clean, flat surface.

7.

Remove upper half bearing shells (2) from engine block (6). Discard upper half bearing shells (2).

8.

Remove fourteen dowel rings (3) from engine block (1). Discard dowel rings (3).

9.

Remove upper half of thrust ring (4) from engine block (1). Discard thrust ring (4).

5-48

5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-49

TM 9-2320-272-24-4

5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE (Contd) b. Cleaning and Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near open flame and always have a tire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container.


Clean crankshaft (2) and crankshaft gear (6) with drycleaning solvent. For cleaning instructions, refer to para. 2-14.

Inspect crankshaft gear (6) for breaks, cracks, or chips. If broken, cracked, or chipped, replace crankshaft (2) assembly.

Wipe rear No. 7 main bearing journal thrust flange (1) clean and check stamping (4) on shaft web (5). Stamped numbers show standard or oversize thrust rings both front and rear.

Inspect rear No. 7 main bearing journal thrust flange (1) for scratches or scoring. If scratched or scored, regrind and stamp shaft web (5) accordingly.

CAUTION

If any one bearing shell half is damaged, all bearing shells must be discarded. Not doing so will vary oil clearance limits when installed in engine and cause lubrication problems.

Wipe lower and upper half main bearing shell (7) clean and inspect for pits, chips, and scratches.

If pitted, chipped, or scratched, replace bearing set.

Measure thickness of lower and upper half main bearing shell (7). If thickness is less than 0.1215

in. (3.086 mm), replace bearing set.

Wipe crankshaft main bearing journals (3) clean with lint-free cloth and inspect for out-of-round condition. Measure out-of-round condition with micrometer. If out-of-round more than 0.002 in.

(0.05 mm), replace crankshaft (2).

Measure outer diameter of crankshaft main bearing journals (3) with micrometer. If outer diameter is less than 4.4975 in. (114.237 mm), repair and stamp on front counterweight (8) accordingly.

Wipe lower and upper half rod bearing shell (7) clean and inspect for pits, chips, and scratches. If pitted, chipped, or scratched, replace bearing set.

Measure lower and upper half rod bearing shell (7) thickness with micrometer. If thickness is less than 0.071 in. (1.80 mm), replace bearing set.

Wipe crankshaft rod journals (9) clean with lint-free cloth and measure outer diameter with micrometer. If outer diameter is less than 3.122 in. (79.30 mm), repair and stamp on front counterweight (8) accordingly.

Measure outer diameter of rear counterweight seal flange (10) with micrometer. If outer diameter is under 5.997 in. (152.94 mm), replace crankshaft (2).

5-50


TM 9-2320-272-24-4

5-51

TM 9-2320-272-24-4

5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE (Contd) c. Installation

4.

5.

1.

2.

3.

6.

7.

8.

WARNING



Ensure main bearing bores (3) of engine block (1) are facing up.

Clean all engine block screw holes (2) with compressed air.

Wipe all engine block bearing bores (3) clean with lint-free cloth.

CAUTION

Touching bearing shell wear surface after shells have been cleaned will cause shell corrosion, resulting in engine damage.

NOTE

Count new bearing upper shells from front of engine block.

Wipe new bearing upper shells (4) Nos. 1, 2, 3, 4, 5, and 6 (4) clean with lint-free cloth.

Position new bearing upper shells (4) Nos. 1, 2, 3, 4, 5, and 6 (4) in bearing bores (3) with oil holes

(5) aligned and press in place. Apply coat of lubricating oil. Bearing shell (4) will project slightly above bore (3).

NOTE

Wide portion of upper bearing shell is measured from oil groove to edge.

Install new bearing upper shell No. 7 (7) in bore (10) with wide portion (8) toward flywheel end of block (1).

Align new bearing upper shell No. 7 oil holes (9) and press in place. Apply coat of lubricating oil.

Bearing shell (7) will project slightly above bore (10).

Install fourteen new dowel rings (6) in engine block (1).

5-52


TM 9-2320-272-24-4

5-53

TM 9-2320-272-24-4


9.

10.

11.

12.

13.

14.

15.

16.

17.

Wipe clear surfaces of crankshaft (1) clean with lint-free cloth, and apply lubricating oil.

Position crankshaft (1) in engine block (2) with hooks protected with rubber hose or rope sling at two crank throws and rotate crankshaft (1) until rear crankshaft web is visible.

NOTE

Upper thrust rings are not doweled to block. Lower halves are doweled to No. 7 bearing cap.

Check markings (12) on rear crankshaft web (10) to determine what size upper thrust rings (7) and (8) are to be placed at front or rear of journal (9).

Apply lubricating oil to new upper thrust ring (8) and roll in place. Ensure babbit face or grooved side of new upper thrust ring (8) is next to crankshaft flange (11).

Wipe new lower bearing shells (5) clean with lint-free cloth and apply lubricating oil.

Insert new lower bearing shells (5) over crankshaft (1).

NOTE

Lower thrust ring and No. 7 bearing cap are installed together.

Lower thrust ring must be located over dowel on bearing cap.

Apply lubricating oil to new lower thrust ring (8) and position on No. 7 main bearing cap. Ensure babbit face or grooved side is next to crankshaft flange (11).

Wipe wear surfaces of main bearing caps (6) clean with lint-free cloth, and apply coat of lubricating oil.

Position main bearing caps (6) in engine block (2) over new lower bearing shells (5). Ensure numbers on caps (6) correspond with numbers on engine block (2) on camshaft side.

CAUTION

l

Do not tap main bearing caps to seat. Hammering will jar bearing shells out of position and cause engine damage.

l Main bearing screws must be tightened alternately and slowly to ensure proper seating of bearing caps.

18.

Apply lubricating oil to screw (3) threads and new lockplates (4).

19.

Install new lockplates (4) and fourteen screws (3) through caps (6) in engine block (2).

20.

Tighten each screw (3) in three steps of 100 lb-ft (136 N•m) until 300-310 lb-ft (410-423 N•m) is reached.

21.

Loosen all screws (3) three turns and repeat step 20.

NOTE

Do not bend up tabs on lockplates until after crankshaft end clearance is checked.

5-54


TM 9-2320-272-24-4

5-55

TM 9-2320-272-24-4

5-8. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE (Contd) d. End Play Clearance

1.

Attach dial indicator to rear of engine block (6) with contact point (4) resting on crankshaft end face (3).

2.

Push crankshaft end face (3) toward front of engine block (6) and set dial indicator to zero.

3.

Push crankshaft end face (3) back toward rear of engine block (6) and check dial indicator,

NOTE

Complete steps 4 through 6 only if end clearance of crankshaft is less than 0.007 in. (0.18 mm).

4.

Loosen main bearing screws (1) one turn and push crankshaft (2) first toward front, then toward rear of engine block (6).

5.

Tighten main bearings screws (1) as in task c, steps 18 through 21.

6.

Repeat steps 1 through 3.

NOTE

If end clearance is more than 0.22 in. (0.56 mm), crankshaft must be replaced or oversize thrust rings installed. Ensure markings on rear crankshaft counterbalance are correct. (Refer to task a, steps

11 and 12).

7.

Bend up tabs on fourteen lockplates (7) to hold screws (1).

5-56


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install pistons and connecting rods (para. 5-10).

5-57

TM 9-2320-272-24-4

5-9. CAMSHAFT AND GEAR MAINTENANCE

THIS TASK COVERS: a.

Check Backlash b. Removal c.

Disassembly d. Cleaning and Inspection e. Assembly f.

Installation

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Telescoping gauge (Appendix E, Item 136)

Cam bushing replacement tool (Appendix E,

Item 26)

TOOLS



Puller kit (Appendix E, Item 102)



Brass rod

MATERIALS/PARTS

Seven cam bushings (Appendix D, Item 34)

Camshaft bushing (Appendix D, item 33)



REFERENCES (TM)

TM 9-2320-272-24P


l

Engine oil pan removed (para. 4-22).

l

Piston and connecting rod installed (para. 5-10).


l Keep tire extinguisher nearby when using drycleaning solvent.

l Drycleaning solvent is flammable and toxic. Do not use near an open flame.

a. Check Backlash

1.

Attach dial indicator to engine block (3) and rotate camshaft gear (2) as far as it will freely move and hold it in place. Ensure crankshaft gear (1) does not move.

2.

Position dial indicator arm to camshaft gear (2) tooth and set dial indicator to zero.

3.

Rotate camshaft gear (2) in opposite direction and read backlash measurement as rotation stops. If backlash is not 0.002-0.020 in. (0.05-0.51 mm), replace camshaft gear (2).

NOTE

Normal backlash is 0.0045-0.0105 in. (0.114-0.267 mm) on new gear with a minimum of 0.002 in. (0.05 mm).

b. Removal

Rotate camshaft gear (2) and camshaft (4) slightly and remove from engine block (3).

CAUTION

Use care when removing camshaft to avoid damaging bearings.

5-58

5-9. CAMSHAFT AND GEAR MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-59

TM 9-2320-272-24-4

5-9. CAMSHAFT AND GEAR MAINTENANCE (Contd) c. Disassembly

NOTE

Before disassembling camshaft gear from camshaft, perform task d of this procedure. If, as a result of inspection, camshaft gear must be disassembled from camshaft, perform stops 1 through 4.

1.

Place camshaft (2) between V-blocks. V-blocks should support camshaft (2).

2.

Remove pipe plug (5) from camshaft (2).

3.

Remove camshaft gear (1) from camshaft (2) with puller.

4.

Remove woodruff key (4) and thrust ring (3) from camshaft (2).

NOTE

Before removing camshaft bushings from engine block, perform task d of this procedure. If, as a result of inspection, bushings must be replaced, perform step 5.

5.

Remove seven camshaft bushings (6) from cylinder block (7) with cam bushing replacer.

d. Cleaning and Inspection

1.

2.

3.

4.

5.

WARNING



Clean camshaft (2), camshaft gear (1), and thrust washer (3) with drycleaning solvent and inspect for cracks, breaks, or pits. If cracked, pitted, or broken, discard.

Measure outside diameter of camshaft journals (8) using micrometer. If outside diameter is less than 1.996 in. (50.70 mm), replace camshaft (2).

Measure thickness of thrust ring (3). If thickness is less than 0.083 in. (2.11 mm), discard thrust ring (3).

Clean seven camshaft bushings (6) with drycleaning solvent and inspect for breaks, cracks, or pits.

If broken, cracked, or pitted, discard.

Measure inner diameter of seven camshaft bushings (6) with telescoping gauge. If inner diameter exceeds 2.001 in. (50.83 mm), discard.

5-60


TM 9-2320-272-24-4

5-61

TM 9-2320-272-24-4

5-9. CAMSHAFT AND GEAR MAINTENANCE (Contd) e. Assembly

Install thrust ring (3), woodruff key (4), camshaft gear (1), and pipe plug (5) in camshaft (2).

f. Installation

CAUTION

Positioning of new camshaft bushing in No. 7 bushing bore (rear of cylinder block) is critical. The new bushing must be pressed in, leaving clearance between bushing and rear face of cylinder block to allow oil to drain from hole at rear of camshaft. Hydraulic lock will occur if oil drain passage is blocked.

NOTE

No. 1 cam bushing (gear end) is wider; all others are the same.

1.

Position seven cam bushings (7) on cam bushing replacer (6), aligning oil hole (8) in cam bushing (7) to oil hole in main bearing bore.

2.

Press seven cam bushings (7) into position in cam bore and check oil hole (8) alignment with a brass rod through main bearing bore oil hole and cam bushing oil hole (8). If brass rod does not pass through with ease, reposition cam bushings (7).

Use extreme care when installing camshaft to avoid damage to bearings and camshaft lobes.

NOTE

Assistant will help with steps 3 through 5.

3.

Apply coat of lubricating oil to camshaft lobes (10) on camshaft (2) and camshaft gear (1).

4.

Position camshaft (2) and camshaft gear (1) in engine block (9) by grasping camshaft gear (1) with both hands and gently sliding end into cam bore (11). With aid of assistant, carefully guide lobes (10) through bore (11) as camshaft (2) is installed.

5.

Align index mark on camshaft gear (1) with index mark on crankshaft gear (12).

6.

Repeat task a. to check backlash.

5-62


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l Replace engine oil pan (para. 4-22).

l

Install cylinder heads (para. 5-10).

5-63

TM 9-2320-272-24-4

5-10. PISTON AND CONNECTING ROD MAINTENANCE

THIS TASK COVERS: a. Connecting Rod Side Clearance Check b. Removal c.

Disassembly d. Cleaning and Inspection e. Assembly f.

Installation

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Piston ring groove gauge (Appendix E, Item 97)

TOOLS






Piston ring expander (Appendix E, Item 96)

Arbor press

Feeler gauge

Soft-faced hammer

Vise

Tape-protected tool

MATERIALS/PARTS

Twelve bearing shells (Appendix D, Item 14)

REFERENCES (TM)

TM 9-2320-272-24P


Camshaft and gear removed (para. 5-9).


Gloves must be worn when handling hot pistons.

a. Connecting Rod Side Clearance Check

1.

2.

3.

NOTE

Connecting rod should have free movement at crank journal.

Check with hand pressure first. Tap lightly with soft-faced hammer only if necessary.

Move connecting rod (1) up and down on crank journal (3) and measure clearance with feeler gauge.

Clearance should be 0.0045-0.13 in. (0.11-0.33 mm). Record clearance of all six connecting rods for reassembly.

NOTE

If clearance is not 0.0045-0.13 in. (0.11-0.33 mm) or rod will not move, continue with steps 2 and 3.

Remove cap (2) and check for improper bearing size, dirt, or burrs.

Install cap (2) as outlined in task f.

5-64

5-10. PISTON AND CONNECTING ROD MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-65

TM 9-2320-272-24-4


1.

Place cylinder block (1) in vertical position and remove all carbon from upper inside wall of each cylinder liner. Use ridge reamer as necessary.

NOTE

All six connecting rod and bearing caps are removed the same way.

Steps 2 through 5 are for one connecting rod and bearing cap only.

2.

Rotate crankshaft (3) until connecting rod bearing caps (5) are above edge of cylinder block flange (2).

3.

Loosen two screws (6) on connecting rod bearing cap (5) 3/8 in. (9.5 mm) and tap with soft-faced hammer to free connecting rod bearing cap (5) from connecting rod (7).

NOTE

l

Tag and mark bearing cap for installation.

l Do not mix bearing caps.

4.

Remove two screws (6), bearing cap (5), and lower half bearing shell (4) from connecting rod (7).

Discard lower half bearing shell (4).

CAUTION

Use a tape-protected tool to push piston from block. Failure to do this may result in damage to cylinder liners.

NOTE

l Assistant will help with steps 5 and 6.

l

Mark location and position of all pistons before removal from block. Discard upper half bearing shells.

5.

Push connecting rods (7), pistons (8), and upper bearing shells (9) out of cylinder block (1) with tapeprotected tool. Begin at crankshaft (3) side.

CAUTION

Bearing caps and connecting rods are stamped with same number as the cylinder. Mixing piston assemblies may cause equipment damage.

6.

After each piston (8) and connecting rod (7) is removed, assemble connecting rod bearing cap (5) to connecting rod (7) with two screws (6).

5-66


TM 9-2320-272-24-4

5-67

TM 9-2320-272-24-4

5-10. PISTON AND CONNECTING ROD MAINTENANCE (Contd) c. Disassembly

1.

Remove four piston rings (1) from piston (6).

2.

Remove two snaprings (2) from piston pin bore (5).

WARNING

Pistons must be heated in hot water to remove piston pins. Do not handle hot pistons with bare hands. Use protective gloves to avoid burning hands.

NOTE

Mark piston and connecting rod so it can be reassembly in same manner.

3.

Submerge pistons (6) and connecting rod (4) assemblies in container of hot water for fifteen minutes to allow pistons to expand.

4.

Remove pistons (6) and connecting rod (4) assemblies from hot water with tongs or hook and place in vise. Push piston pin (3) out of piston pin bore (5). Do not drive pins (3) out with hammer.

5.

Place pistons (6), piston pins (3), and connecting rods (4) on a numbered rack and hold for inspection.


NOTE

Ensure bearing caps remain assembled to mating connecting rods at all times to avoid mixing.

1.

Clean connecting rod assemblies (7) (para. 2-14).

2.

Inspect connect rod assemblies (7) (para. 2-15).

3.

Visually check I-beam section (8) of connecting rod (4) for nicks, dents, and gouges. If nicks, dents, or gouges are greater than 0.031 in. (0.787 mm), replace connecting rod (4).

4.

Inspect connecting rod assemblies (7) for cracks (para. 2-16).

NOTE

To accurately measure all connecting rod bearing cap bores, the screws

must be tightened to the operating torque specified in table 5-7.

5.

Install bearing caps (9) on connecting rod (4) with screws (10).

6.

Alternately tighten screws (10) with torque wrench in accordance with the sequence order in

table 5-7.

Table 5-7. Connecting Rod Screw Tightening Sequence.

TIGHTEN SEQUENCE

TORQUE VALUES

Step l-Tighten to

Step 2-Tighten to

Step 3-Loosen to

Step 4-Tighten to

Step 5-Advance to

Step C--Advance to

LB-FT

70-75

140-150

(0)

25-30

70-75

140-150

N•M

(95-102)

(90-203)

(0)

(34-41)

(95-102)

(190-203)

5-68


TM 9-2320-272-24-4

5-69

TM 9-2320-272-24-4


7.

Using telescoping gauge, measure inside diameter of crankshaft. journal bore (2) in connecting rod (1) at points A-A and B-B, up to 30° either side of parting line C. Record readings. If crankshaft journal bore (2) diameter is not 3.2725-3.2730 in. (83.122-83.134 mm), replace connecting rod (1).

8.

Using telescoping gauge, measure inside diameter of crankshaft journal bore (2) in connecting rod at points D-D and E-E. Record readings. If crankshaft journal bore (2) diameter is not 3.2725-3.2730

in. (83.122-83.134 mm), replace connecting rod (1).

NOTE

Check pin bores with bushings installed.

9.

Check inside diameter of piston pin bushing bore (6) in connecting rod (1) with telescoping gauge. If piston pin bushing bore (6) is worn beyond 2.0022 in. (50.856 mm), mark bushings for replacement.

NOTE

l Pistons must be cleaned before inspection.

l Conditions of the pistons and piston rings should be carefully noted, as ‘they indicate borderline conditions leading to engine failures.

l

Pistons should be inspected at ambient temperatures of 70°-

90°F (21°-32°C).

10.

Check piston (5) wear surface for scoring, scuffing, and cracks. If scored, scuffed, or cracked, replace piston (5).

NOTE

Vertical scratching and discoloration of piston ring sealing surface is a major cause of oil consumption and piston and liner scoring.

11.

Check piston rings (3) for vertical scratching and discoloration of piston ring sealing surface. If ring sealing surface is scratched or discolored, replace piston rings (3).

12.

Check for broken piston rings (3). If broken, replace piston ring (3).

13.

Check piston rings (3) for formation of deposits which prevent outward movement of piston rings (3) to seal. If piston ring (3) sticks in piston grooves, replace piston ring (3).

14.

Check piston pin bore (4) on piston (5) for fractures. If piston ring bore (4) is fractured, replace piston (5).

NOTE

l

Pistons must be inspected at ambient temperatures of 70°-90°F

(21°-32°C) to obtain accurate measurement readings.

l

First and second piston ring grooves are checked for depth wear the same way. Step 15 checks for ring groove depth wear on the top ring groove.

15.

Insert ring groove gauge into top ring groove (7) of pistons (5) and note whether shoulders (6) of gauge touch ring groove (7). If shoulders (6) of gauge touch either ring groove (7), pistons (5) are not serviceable and must be discarded.

16.

Repeat step 15 for second ring groove (8).

5-70


TM 9-2320-272-24-4

5-71

TM 9-2320-272-24-4


NOTE

First and second piston ring groove widths are checked for wear the same way. Step 17 checks top ring groove width for wear.

17.

Place and hold new piston ring (2) in top ring groove (3) and try to insert 0.006 in. (0.15 mm) feeler gauge into ring groove (3) at top of piston ring (2). If feeler gauge enters either ring groove (3) without force, piston (1) is not serviceable and must be discarded.

18.

Repeat step 17 for second ring groove (4).

NOTE

Measurements to check piston skirt outside diameters are taken at right angle to piston bore.

19.

Measure piston (1) upper skirt outside diameter (6) approximately 1 in. (25.4 mm) below bottom ring groove (4) with micrometer.

20.

Measure piston (1) bottom skirt outside diameter (7) approximately 1 in. (25.4 mm) above skirt bottom (8).

If outside diameters (6) and (7) measure less than 5.483 in. (139.27 mm), discard piston (1).

21.

Measure piston pin bore (5) inside diameter. If inside diameter exceeds 1.99 in. (50.775 mm) at 70°F

(21°C), discard piston (1). Add .0005 in. (0.13 mm) per each 10°F over 70°F (21°C) up to 90°F (32°C).

22.

Check outside diameter of piston pin (9) with micrometer. If outside diameter is worn out-of-round more than 0.001 in. (0.03 mm), discard piston pin (9). If diameter is smaller than 1.99885 in.

(50.762 mm), discard piston pin (9).

23.

Check all piston (1) parts to be sure they are numbered the same. Number is generally located on the inside of piston (1) skirt.

NOTE

New piston rings must be checked in the cylinder liner in which they will be used to ensure ring gaps are correct.

24.

Insert piston rings (11), (13), (14), and (15) in each mating cylinder liner (10) bore, using head (top) of piston (1) to position piston ring (11) so it seats squarely in piston ring (11) travel area.

25.

Measure ring gap (12) with feeler gauge. Ring gap (12) should meet specifications given in

table 5-8.

NOTE

Add 0.003 in. (0.08 mm) ring gap to new maximum for each 0.001

in. (0.03 mm) wear in cylinder liner wall. Measurement made in ring travel area of liner.

Table 5-8. Ring Gap.

No. 1 compression ring (13) gap

No. 2 and 3 compression ring (11) and (14) gap

No. 4 oil ring (15) gap

0.023-0.033 in.

(0.58-0.85 mm)

0.019-0.029 in.

(0.48-0.74 mm)

0.010-0.025 in.

(0.25-0.64 mm)

26.

Install piston rings (13), (11), (14), and (15) in piston (1) with piston ring expander. Ensure the word

“top” faces toward top of piston (1).

27.

Check connecting rod journals (17) on crankshaft assembly (16) for scores and scratches. If scored or scratched, replace crankshaft.

28.

Check connecting rod journals (17) for out-of round wear with micrometer. If worn more than 0.002

in. (0.05 mm), replace crankshaft.

5-72


TM 9-2320-272-24-4

5-73

TM 9-2320-272-24-4


1.

Remove piston pin bushing (10) from connecting rod (5) with mandrel, removal tool, and arbor press.

2.

Install sleeve (6), new standard size piston pin bushing (10), and guide sleeve (8) on mandrel.

3.

Place connecting rod (5) on block (7) and place in horizontal position.

4.

Line up mark on guide sleeve (8) with middle of boss on connecting rod (5). Ensure oil hole in new piston pin bushing (10) and pin bore (9) are lined up.

5.

Press new piston pin bushing (10) into pin bore (9) with arbor press until guide sleeve (8) contacts side of rod pin boss.

6.

Check inside diameter of new piston rod bushing (10). If inside diameter is not 2.001-2.0015 in.

(50.83-50.838 mm), replace piston pin bushing (10).

WARNING

Do not handle hot pistons with bare hands or injury to personnel may result.

CAUTION

Never drive piston pins into pistons. Driving may cause distortion of piston and cause piston seizure in cylinder liner.

5-74

TM 9-2320-272-24-4


NOTE

l Ensure rod and bearing cap are stamped with the numbers of the cylinders they were removed from. All pistons must have same part number.

l

Ensure pistons and connecting rods are assembled with orientation marks matching.

7.

Install one piston pin snapring (1) in groove of piston pin bore (2).

8.

Heat pistons (3) in hot water.

CAUTION

Do not attempt to install pin after piston has cooled. Pin will not fit.

9.

Install piston pin (4) through piston (3) and connecting rod (5) pin bores (9) before piston (3) cools.

10.

Install second snapring (1) in piston pin (4) groove at opposite end of pin bore (2).

5-75

TM 9-2320-272-24-4

5-10. PISTON AND CONNECTING ROD MAINTENANCE (Contd) f. Installation

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

NOTE

l

Before installation, ensure all pistons have been properly assembled and lubricated.

l If old pistons are being installed, ensure they are installed in same location from which they were removed.

Remove two screws (5) and rod cap (4) from connecting rod (2).

Apply coat of lubricating oil to piston (1), connecting rod (2), and upper bearing shell (3).

Position tang (6) on new bearing (3) to groove (7) in connecting rod (2) and snap into place.

NOTE

Ensure piston ring gaps are staggered so they are not in line with each other or piston pin.

Position ring compressor (10) over piston (1) and tighten with Allen wrench.

CAUTION

Assistant must guide connecting rod through cylinder from oil pan side of block to avoid damaging liner.

NOTE

Ensure numbered side of connecting rod is toward the camshaft side of engine block.

Carefully insert connecting rod (2) in cylinder liner (9) and hold ring compressor (10) right and firmly seated against engine block (8). Ensure crankshaft journal (12) is at bottom dead center.

CAUTION

l

Ring compressor must be held firmly against engine block to prevent compressor from sipping and causing piston ring breakage when pushing piston into cylinder liner.

l

Do not force piston assembly into liner. If piston does not install freely in liner, remove and check for broken rings.

NOTE

Assistant will guide rod onto crankshaft journal to prevent damage to journal and liner.

Push piston (1) through ring compressor (10) until all piston rings are well into cylinder liner (9) in engine block (8).

Drive piston (1) and rod (2) into cylinder liner (9) with rubber or wooden mallet handle until upper rod bearing shell (3) seats on crankshaft journal (12).

Apply lubricating oil to lower connecting rod bearing shell (11).

Position new bearing shell (11) in rod cap (4) and install rod cap (4) so numbered side is matched to numbered side of rod (2). Ensure tang (6) on bearing shell (11) is aligned with groove in rod cap (4).

Apply lubricating oil to screw (5) threads and install screws (5) through rod cap (4) and tighten

(table 5-7).

Check connecting rod clearance by following task a.

5-76


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install camshaft and gear (para. 5-9).

5-77

TM 9-2320-272-24-4

5-11. ENGINE OIL PUMP REPAIR

THIS TASK COVERS: a. Disassembly b. Cleaning and Inspection c. Repair d. Assembly

INITIAL SETUP:


M939/A1

TOOLS



Snap gauge (Appendix E, Item 123)

Boring tool (Appendix E, Item 18)


Soft-faced hammer

Arbor press

MATERIALS/PARTS

Bypass seat (Appendix D, Item 29)

Bypass spring (Appendix D, Item 30)

Bypass disc (Appendix D, Item 28)

Lockplate (Appendix D, Item 339)


Two dowel pins (Appendix D, Item 96)

Two screw-assembled lockwashers


Two gaskets (Appendix D, Item 174)

Seven lockwashers (Appendix D, Item 354)

Spring (Appendix D, Item 668)

Three lockwashers (Appendix D, Item 364)




REFERENCES (TM)

TM 9-2320-272-24P


l

Engine oil filter removed (para. 3-5).

l

Engine front gearcase cover removed (para. 4-18).

l Engine accessory drive removed (para. 4-26).

l Engine oil pump removed (para. 4-21).


l

Keep tire extinguisher nearby when using drycleaning solvent.

l Drycleaning solvent is flammable and toxic. Do not use near an open flame.

l


a. Disassembly

1.

Remove adapter (7), elbow (8), and nipple (6) from oil pump body flange (1).

2.

Remove elbow (9) and nipple (10) from oil pump body flange (1).

3.

Remove pipe plugs (11) and (12) from oil pump body flange (1).

4.

Remove pipe plug (5) from inner body (2).

5.

Remove pipe plug (3) from filter head (4).

5-78

5-11. ENGINE OIL PUMP REPAIR (Contd)

TM 9-2320-272-24-4

5-79

TM 9-2320-272-24-4


6.

Remove two screw-assembled lockwashers (12), flange plate (11), and gasket (10) from inner body (9).

Discard gasket (10) and screw-assembled lockwashers (12).

7.

Hold retainer (14) down and remove screw (1) from oil pump body (13).

8.

Slowly release retainer (14) and remove lockwasher (16), lockplate (15), retainer (14), retainer cap (2), spring (3), and regulator plunger (4) from oil pump body (13). Discard lockwasher (16), lockplate (15), and spring (3).

9.

Remove bypass seat (6), disc (7), and bypass spring (8) from filter head (5). Discard bypass seat (6) and bypass spring (8).

5-80


TM 9-2320-272-24-4

5-81

TM 9-2320-272-24-4


10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Remove two screws (6) and lockwashers (5) from filter head (1). Discard lockwashers (5).

Remove six screws (7) and lockwashers (8) from filter head (1). Discard lockwashers (8).

Tap filter head (1) with soft-faced hammer to separate from dowel pin (4) and inner body (3) and remove filter head (1) and gasket (2) from inner body (3). Discard gasket (2).

Clean gasket remains from mating surfaces of filter head (1) and inner body (3).

Remove idler gear (14) from idler shaft (15) and inner body (3).

Press driveshaft (10) through driven gear (13) with arbor press and remove driven gear (13) from driveshaft (10).

Tap inner body (3) and gasket (12) with soft-faced hammer to separate from dowel pin (11) and remove inner body (3) and gasket (12) from oil pump body (9). Discard gasket (12).

Clean gasket remains from mating surfaces of oil pump body (9), inner body (3), and gasket (12).

Remove idler gear (17) from idler shaft (15).

Press driveshaft (10) through driven gear (15) with arbor press and remove driven gear (15) from driveshaft (10).

Remove drive gear (18) from driveshaft (10) with arbor press.

Remove idler shaft (15) from oil pump body (9) with arbor press.

NOTE

Perform steps 22 and 23 only if dowel pins are damaged.

Remove dowel pin (4) from inner body (3). Discard dowel pin (4).

Remove dowel pin (11) from oil pump body (9). Discard dowel pin (11).

5-82


TM 9-2320-272-24-4

5-83

TM 9-2320-272-24-4

5-11. ENGINE OIL PUMP REPAIR (Contd) b. Cleaning and Inspection

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

13.

14.

15.

16.

17.

18.

WARNING

l Drycleaning solvent is flammable and toxic. Do not use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to do this may result in injury or death to personnel and/or damage to equipment.

l



Wipe pump body (2) clean with drycleaning solvent.

Blow out pump body (2) oil passages with compressed air.

Inspect pump body (2) for breaks and cracks. Replace if broken or cracked.

Check inside bore diameter of front and rear driveshaft bushings (1). Replace front and rear drive shaft bushings (1) if inside diameter exceeds 0.6185 in. (15.710 mm).

Wipe filter head (5) clean with drycleaning solvent.

Blow out filter head (5) oil passages with compressed air.

Inspect filter head (5) for breaks and cracks. Replace filter head (5) if broken or cracked.

Check inside diameter of filter head bushing (4) for wear with dial bore gauge. Replace bushing (4) if inner diameter exceeds 0.6185 in. (15.710 mm).

Wipe inner body (3) clean with drycleaning solvent.

Blow out inner body (3) oil passages with compressed air.

Inspect inner body (3) for breaks and cracks. Replace inner body (3) if broken or cracked.

Clean drive gear (11), two driven gears (9), and two idler gears (8) with drycleaning solvent, and inspect for cracked, chipped, or broken teeth. Replace gears if gears (11), (8), and (9) teeth are cracked, chipped, or broken. Replace gears (11), (8), and (9) if gear teeth show pitting over more than 1/4 width of active tooth area.

Clean two idler gears (8) and four bushings (10) with drycleaning solvent.

Check inside diameter of two idler gears (8) and four bushings (10) with bore gauge. Replace idler gears (8) and bushings (10) if inner diameter exceeds 0.6185 in. (15.71 mm).

Inspect pressure regulator plunger (6) to ensure it does not bind in bore (7) of oil pump body (2).

Replace pressure regulator plunger (6) if bent or binds.

Clean idler shaft (12) and driveshaft (13) with drycleaning solvent.

Inspect idler shaft (12) and driveshaft (13) for breaks, cracks, and galling. Replace if broken, cracked, or galled.

Check idler shaft (12) and driveshaft (13) outside diameters using dial snap gauge. Replace shafts (12) and (13) if outside diameters are less than 0.6145 in. (15.608 mm).

5-84


TM 9-2320-272-24-4

5-85

TM 9-2320-272-24-4


3.

4.

5.

6.

7.

1.

2.

8.

9.

NOTE

l Steps 1 through 9 are performed to replace parts found defective during cleaning and inspection steps 3, 7, 12, and 13.

l

Bushings must be replaced as a pair.

Using arbor press and mandrel, remove old front and rear driveshaft bushings (2) from oil pump body (1).

Install new front and rear driveshaft bushings (2) in oil pump body (1), flush to 0.030 in. (0.78 mm) below surfaces.

Bore new front and rear driveshaft bushings (2) inner diameter to 0.6165-0.6175 in. (15.659-15.684 mm).

Remove old bushing (3) from filter head (4).

Install new bushing (3) in filter head (4) to 0.020 in (0.51 mm) below front surface.

Bore new bushing (3) inner diameter to 0.6165-0.6175 in. (15.659-15.684 mm).

Using arbor press and mandrel, remove four old bushings (6) from two idler gears (5).

NOTE

Idler gear bushings must be replaced as a pair.

Press two new bushings (6) in each idler gear (5) flush to 0.20 in. (0.51 mm) below gear face.

Bore inner diameter of four bushings (6) to 0.6165-0.6175 in. (15.659-15.684 mm).

5-86


TM 9-2320-272-24-4

5-87

TM 9-2320-272-24-4


9.

10.

7.

8.

5.

6.

1.

2.

3.

4.

11.

12.

13.

Press drilled end of idler shaft (3) into gear pocket side of oil pump body (1) with arbor press and mandrel until idler shaft (3) protrudes 2.604-2.620 in. (66.04-66.55 mm) above back of body.

Press drive gear (5) over drilled end of driveshaft (2) with arbor press and mandrel until driveshaft. (2) end protrudes 0.040-0.060 in. (1.02-1.52 mm) above drive gear (5) face.

Apply lubricating oil to driveshaft (2) and insert driveshaft (2) into oil pump body (1).

Position 0.012 in. (0.20 mm) shim (4) between back side of drive gear (5) and front of oil pump body (1) and install drive gear (5) against shim (4) until snug. Remove shim (4).

NOTE

Perform step 5 only if dowel pin was removed during disassembly procedure.

Install new dowel pin (7) in oil pump body (1) to 0.990-1.010 in. (22.15-25.65 mm) above face.

Install idler gear (10) on idler shaft (3).

Press driven gear (6) on driveshaft (2) with arbor press and mandrel.

Position 0.012 in. (0.30 mm) shim (4) on rear surface of driver gear (6) facing inner body (9) and position inner body (9) over shafts (2) and (3) so it rests on the shim. Install inner body (9) to seat driven gear (6) and remove inner body (9) and shim (4).

Apply lubricating oil to gears (6) and (10), shafts (3) and (2), and gear pockets.

Install new gasket (8) and inner body (9) on pump body (1), using soft-faced hammer to seat inner body (9) on dowel pin (7). Ensure screw holes are open.

NOTE

Perform step 11 only if dowel pin was removed during disassembly procedure.

Install new dowel pin (11) in inner body (9) to 0.990-1.010 in. (25.15 to 25.65 mm) above face.

Press driven gear (6) on driveshaft (2) with arbor press and mandrel. Leave 0.002-0.004 in.

(0.05-0.10 mm) clearance between bottom of gear pocket and driver gear (6) surface.

Install idler gear (10) on idler shaft (3).

5-88

TM 9-2320-272-24-4


14.

Apply lubricating oil to gears (6) and (10), shafts (2) and (3), and gear pockets.

NOTE

Screw is an installation screw and cannot be tightened at this time.

15.

Position screw (14) and new lockwasher (15) in inner body (9).

16.

Install new gasket (12) and filter head (13) on inner body (9) with two screws (17), new lockwashers

(16), six screws (18), and new lockwashers (19). Use soft-faced hammer to seat filter head (13). Tighten screws (17) and (18) 30-35 lb-ft (41-47 N•m).

5-89

TM 9-2320-272-24-4


20.

21.

22.

17.

18.

19.

Rotate drive gear (17) back and forth to ensure inner gears are free.

Check driveshaft (18) end play. End play must be 0.004-0.007 in. (0.10-0.18 mm).

Install pressure regulator plunger (15), new spring (5), and retainer cap (4) in pump body (14) with retainer clamp (16), new lockplate (3), new lockwasher (2), and screw (1). Tighten screw (1)

30-35 lb-ft (41-47 N•m).

Bend tabs of lockplate (3) with hammer and drift punch.

Install new bypass spring (7), disc (9), and new bypass seat (8) in filter head assembly (6).

Install new oil pump flange gasket (11) and flange (12) on pump flange (10) with two new lockwashers (14) and screw-assembled washers (13).

5-90


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l Replace engine oil filter (para. 3-5).

l l

Install engine accessory drive (para. 4-26).

Install engine front gearcase cover (para. 4-18).

l

Install engine oil pump (para. 4-21).

5-91

TM 9-2320-272-24-4

5-12. MOUNTING FUEL PUMP TO HOLDING FIXTURE

THIS TASK COVERS: a. Removal b. Installation

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Mounting plate (Appendix E, Item 84)

Ball joint vise (Appendix E, Item 7)

TOOLS

General mechanic’s tool kit (Appendix E. Item 1)

REFERENCES (TM)

TM 9-2320-272-24P


l

Fuel pump removed from engine (para. 4-35).

l

Fuel pump shutoff valve removed (para. 4-36 or

4-37).

1.

Remove two nuts (2), screws (5), and fuel pump (3) from mounting plate (1).

2.

Remove two screws (4) and mounting plate (1) from ball joint vise.

1.

Attach mounting plate (1) to ball joint vise and install two screws (4).

2.

Install fuel pump (3) to mounting plate (1) with two screws (5) and nuts (2).

FOLLOW-ON TASKS: l

Install fuel pump on engine (para. 4-35).

l

Install fuel pump shutoff valve (para. 4-36 or 4-37).

5-92

TM 9-2320-272-24-4

5-13. PRESSURE GEAR PUMP REMOVAL

THIS TASK COVERS:

Removal

INITIAL SETUP:


M939/A1

MATERIALS/PARTS

Two lockwashers (Appendix D, Item 407)

TOOLS

REFERENCES (TM)


TM 9-2320-272-24P

Soft-faced hammer

Removal

1.

2.

3.

4.

5.

6.

Remove two screws (4), lockwashers (3), washers (2), pulsation damper (1), and seal (5) from gear pump (8). Discard lockwashers (3).

Remove four screws (10) and lockwashers (9) connecting gear pump (8) to fuel pump housing (6).

Discard lockwashers (9).

Tap gear pump (8) lightly with soft-faced hammer and remove from fuel pump housing (6).

Remove gasket (7) from gear pump (8). Discard gasket (7).

Clean gasket remains from gear pump (8) mating surfaces.

Install seal (5) and pulsation damper (1) on fuel pump housing (6) with two washers (2), new lockwashers (3), and screws (4).

5-93

TM 9-2320-272-24-4

5-14. GOVERNOR SPRING PACK MAINTENANCE

THIS TASK COVERS: a. Removal b. Inspection c. Installation

INITIAL SETUP:


M939/A1

TOOLS


Spring tester (Appendix E, Item 131)

MATERIALS/PARTS

Retaining ring (Appendix D, Item 538)


Seal (Appendix D, Item 612)

REFERENCES (TM)

TM 9-2320-272-24P


Fuel pump mounted on holding fixture (para. 5-12).

NOTE

Spring packs are maintained basically the same for AFC and

VS fuel pumps. This procedure covers the AFC fuel pump.

a. Removal

1.

Remove seal (12) from governor adjusting screw (13) and throttle leakage adjusting screw (18).

Discard seal (12).

2.

Remove four screws (14), spring pack cover (15), and gasket (16) from fuel pump (1). Discard gasket (16).

3.

Remove retaining ring (11), spring retainer (10), shim(s) (9), spring (8), spring guide (5), washer (4), spring (3), and plunger (2) from spring pack barrel (17). Discard retaining ring (11).

4.

Remove adjusting screw (7) and spring (6) from spring guide (5).

b. Inspection

1.

For general inspection instructions, refer to para. 2-15.

2.

Inspect spring pack cover (15) for cracks, breaks, and stripped threads. Replace spring pack cover (15) if cracked, broken, or threads are stripped.

3.

Using spring tester, inspect tension of spring (8). Replace spring (8) if tension is not within 0.69-0.85 lb

(0.31-0.39 kg) when compressed to 1.0 in. (25.4 mm).

4.

Using spring tester, inspect tension of spring (3). Replace spring (3) if tension is not within 16.02-

17.78 lb (7.27-8.07 kg) when compressed to 1.025 in. (26.0 mm).

5-94

TM 9-2320-272-24-4

5-14. GOVERNOR SPRING PACK MAINTENANCE (Contd) c. Installation

1.

Install spring (6) and adjusting screw (7) on spring guide (5).

2.

Install plunger (2), spring (3), washer (4), spring guide (5), spring (8), shim(s) (9), and spring retainer (10) on spring pack barrel (17) with new retaining ring (11).

3.

Install new gasket (16) and spring pack cover (15) on fuel pump (1) with four screws (14).

NOTE

Seal is not installed until fuel pump calibration (para. 5-18).

FOLLOW-ON TASKS: l

Remove fuel pump from holding fixture (para 5-12).

l

Calibrate fuel pump (para. 5-18).

5-95

TM 9-2320-272-24-4

5-15. FUEL PUMP HOUSING MAINTENANCE

THIS TASK COVERS: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP:


M939/A1

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS EQUIPMENT CONDITION


l

Governor spring pack removed (para. 5-14).

l

Throttle shaft removed (para. 5-16).

MATERIALS/PARTS

Seven lockwashers (Appendix D, Item 412)


Diesel fuel (Appendix C, Item 41)

a. Disassembly

NOTE

Tap edge of hardware lightly with soft-faced hammer to loosen,

1.

Remove screw (7), six screws (1), seven lockwashers (2), and washers (3) connecting front drive cover (6) to fuel pump housing (4). Discard lockwashers (2).

2.

Pull fuel pump housing (4) straight out from front drive cover (6) to clear dowels.

3.

Remove gasket (5) from front drive cover (6). Discard gasket (5).

4.

Clean gasket remains from front drive cover (6) mating surfaces.

5.

Remove governor plunger (9) and torque spring (8) from fuel pump housing (4).

NOTE

Do not use straight pull on governor plunger torque spring. To remove, twist spring off shoulder.

6.

Remove torque spring (8) from governor plunger (9).

b. Inspection

1.

Inspect governor plunger (9) for scoring, nicks, and scratches. If scored, nicked, or scratched, replace governor plunger (9).

2.

Inspect torque spring (8) for broken coils. If coils are broken, replace torque spring (8).

c. Assembly

NOTE

Parts must submerged in diesel fuel and hands wet with diesel fuel before steps 1 and 2 to prevent damage to close-tolerance parts.

1.

Install torque spring (8) on governor plunger (9).

2.

Install torque spring (8) and governor plunger (9) in fuel pump housing (4).

3.

Install new gasket (5) and fuel pump housing (4) on front drive cover (6) with seven washers (3), new lockwashers (2), six screws (1), and screw (7).

5-96

5-15. FUEL PUMP HOUSING MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install throttle cover and shaft (para. 5-16).

l

Install governor spring pack (para. 5-14).

5-97

TM 9-2320-272-24-4

5-16. THROTTLE COVER AND SHAFT MAINTENANCE

THIS TASK COVERS: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP:


M939/A1

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS EQUIPMENT CONDITION


Fuel pump housing disassembled (para. 5-15).

MATERIALS/PARTS

Two drive pins (Appendix D, Item 101)

O-ring (Appendix D, Item 461)



Lockwasher (Appendix D, Item 400)

Throttle shaft soft ball bearing (Appendix D,

Item 666)

a. Disassembly

1.

Center punch and drill out the two drive pins (8) connecting the fuel pump housing (1) to throttle shaft cover (2). Discard drive pins (8).

2.

Remove nut (4), lockwasher (5), washer (6), screw (7), throttle lever (3), and throttle shaft cover (2) from fuel pump housing (1). Discard lockwasher (5).

3.

Remove retaining ring (10) and throttle shaft (9) from fuel pump housing (1).

4.

Drill and remove soft ball bearing (18) from throttle shaft (9). Discard soft ball bearing (18).

5.

Remove two set screws (15) and throttle stop control (14) from throttle shaft (9).

6.

Remove O-rings (13) and (16), fuel-adjust screw (17), valve plug (12), and O-ring (11) from throttle shaft (9). Discard O-rings (13), (16), and (11).

b. Inspection

1.

Inspect throttle shaft (9) for scoring, nicks, and scratches. If scored, nicked, or scratched, replace throttle shaft (9).

5-98

5-16. THROTTLE COVER AND SHAFT MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-99

TM 9-2320-272-24-4

5-16. THROTTLE COVER AND SHAFT MAINTENANCE (Contd) c. Assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

NOTE

Governor weight must be installed before assembling throttle

shaft cover (para. 5-17).

Install new O-ring (11) and valve plug (12) in fuel pump housing (1).

Install fuel-adjusting screw (17), new O-rings (13) and (16), throttle stop control (14) and two setscrews (15) on throttle shaft (9).

Install new throttle shaft ball (18) in end of throttle shaft (9).

Install throttle shaft (9) in fuel pump housing (1) with retaining ring (10).

NOTE

l

Do not install throttle shaft cover until fuel pump has been

calibrated (para. 5-18).

l Do not perform steps 5 through 7 unless pin holes are damaged beyond use.

Position throttle shaft cover (2) on fuel pump housing (1).

CAUTION

Use care when drilling new holes for drive pins. The pump housing is made of cast aluminum and is easily damaged. Do not allow metal particles to enter pump housing.

Center punch location of new holes on throttle shaft cover (2). Ensure holes are opposite one another.

Carefully drill through throttle shaft cover (2) and into throttle shaft cover flange with 1/15 in. drill bit NO MORE than 1/4 in. (6 mm).

Install throttle shaft cover (2) on fuel pump housing (1) by gently tapping two new drive pins (8) through throttle shaft cover (2) into holes.

Install throttle lever (3) on throttle shaft (9) with screw (7), washer (6), new lockwasher (5), and nut (4).

5-100

5-16. THROTTLE COVER AND SHAFT MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Assemble fuel pump housing (para. 5-15).

5-101

TM 9-2320-272-24-4

5-17. GOVERNOR WEIGHT MAINTENANCE

THIS TASK COVERS: a. Removal b. Inspection c. Installation

INITIAL SETUP:


M939/A1

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS



Throttle cover and shaft disassembled (para. 5-16).

a. Removal

1.

Remove governor weight (6) and gear (2) from front drive cover (1).

2.

Remove weight-assist plunger (5), spring (3), and shims (4) from governor weight (6).

b. Inspection

1.

Inspect spring (3) for bent or broken coils. If bent or broken, replace spring (3).

2.

Inspect governor weight gear (2) for cracked, broken, or pitted teeth. If cracked, broken, or pitted, replace governor weight (6).

c. Installation

1.

Install shims (4), spring (3), and weight-assist plunger (5) in governor weight (6).

NOTE

Large end of weight-assist plunger is installed first.

2.

Install governor weight gear (2) and governor weight (6) on front drive cover (1).

5-102

5-17. GOVERNOR WEIGHT MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install front cover (para. 5-15)

l

Install throttle shaft and cover (para. 5-16).

5-103

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION

THIS TASK COVERS: a. Throttle Shaft Cover Removal b. Mounting Pump to Test Stand c. Fuel Pump Run-In d. Testing Pump Seals for Leaks e. Testing Governor Cutoff RPM f.

Testing and Adjusting Throttle Leakage g. Testing and Adjusting Idle Speed h. Checking and Adjusting Throttle Lever

Travel i.

Testing and Adjusting Pump Main Pressure j.

Testing and Adjusting Fuel Pressure k. Testing and Adjusting Governor Fuel

Pressure l.

Checking and Adjusting Governor Weight

Pressure m. Testing and Adjusting Idle Speed

(VS Governor Only) n. Shutdown and Removal from Test Stand

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Fuel injection tester (test stand) (Appendix E,

Item 49)

Spring pack adjusting tool (Appendix E,

Item 130)

Travel template (Appendix E, Item 150)

Level and angle indicator (Appendix E, Item 66)

Shaft installation tool (Appendix E, Item 120)

Gear pump block plate (Appendix E, Item 57)

TOOLS

General mechanic’s tool kit (Appendix E,

Item 1)

Straightedge

MATERIALS/PARTS

Two drive pins (Appendix D, Item 101)


Throttle shaft soft ball bearing (Appendix D,

Item 666)

Grease, GAA (Appendix C, Item 28)

Lubricating oil OE/HDO 30 (Appendix C, Item 50)

45A calibrating fluid (Appendix C, Item 13)

Sealing tape (Appendix C, Item 72)

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-4910-571-12

TM 9-4910-571-12P


l

Fuel pump removed from vehicle (para. 4-35).

l Fuel pump shutoff valve removed (para. 4-36 or

4-37).

a. Throttle Shaft Cover Removal

NOTE

Perform task a. only if throttle shaft cover has not been removed.

1.

Center punch each of the two drive pins (8) connecting throttle shaft cover (2) to fuel pump housing (1).

2.

Drill drive pins (8) out of throttle shaft cover (2). Discard drive pins (8).

3.

Remove nut (4), lockwasher (5), washer (6), screw (7), and throttle lever (3) from throttle shaft cover (2).

Discard lockwasher (5).

4.

Remove throttle shaft cover (2) from fuel pump housing (1).

5.

Install throttle lever (3) on fuel pump housing (1) with washer (6), new lockwasher (5), and nut (4).

5-104

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd)

TM 9-2320-272-24-4

5-105

TM 9-2320-272-24-4


3.

4.

5.

b. Mounting Pump to Test Stand

1.

2.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Install adapter ring (7) on adapter bracket (8) with four washers (9) and screws (6). Ensure the word TOP or part number on adapter ring (7) faces up.

Install ring and adapter bracket (4) on mounting rails (16) of test stand with clamp bar (14).

Tighten clamp bar (14) finger tight.

Mount fuel pump (11) to ring and adapter bracket (4) with four screws (12) and washers (13).

Place pump coupling insert (15) into test stand drive coupling (10).

Loosen clamp bar (14) and slide fuel pump (11) and ring and adapter bracket (4) forward to engage drive coupling (10).

NOTE

Clean all male pipe threads and wrap with sealing tape before installation.

Install inlet adapter (27) on pump elbow (26).

Connect 1/2 in. (12.7 mm) flexible hose (30) from test stand fuel pressure control valve (32) to adapter (27).

Connect 1/4 in. (6.35 mm) manifold hose (24) from manifold vacuum adapter (28) to adapter (21).

Install pump discharge fitting (18) in fuel pump shutoff solenoid valve (19).

Install fuel pressure hose (17) from test stand pressure gauge outlet (38) to pump discharge fitting (18).

Install 1/2 in. (12.7 mm) flexible hose (25) from test stand lube pressure (31) to test stand lube return (22).

Install fuel input hose (37) from test stand fuel input connector (36) to pump discharge fitting (18).

Install fuel outlet hose (33) from test stand fuel outlet connector (34) to test stand fuel return connector (23).

Install leakage accumulator hose (40) to No. 1 accumulator can (41) from test stand leak test connector (39).

Connect 1/4 in. (6.35 mm) flexible hose (29) to check valve fitting (20) on fuel pump (11) and to auxiliary return connector (35).

Install throttle lever position holding spring (1) from top of throttle shaft lever (3) to ring and adapter bracket (4). Spring (1) will hold throttle shaft lever (3) to full fuel position.

Remove governor spring pack housing pipe plug (2) from spring pack housing (5).

Install spring pack adjusting tool into spring pack housing (5).

5-106


TM 9-2320-272-24-4

5-107

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) c. Fuel Pump Run-In

NOTE

Ensure all other test stand valves are in the CLOSED position to prevent leakage. Seat all other test stand valves by opening one quarter turn and reclosing.

1.

Place test stand (1), bypass valve (10), fuel pressure valve (9), and flow control valve (12) in open position.

2.

Open fuel pump (3) by turning fuel shutoff valve manual override knob (13) until seated.

CAUTION

Check tachometer drive for clockwise rotation. If rotation is not clockwise, reverse rotation of drive coupling.

3.

Apply lubricating oil to tachometer drive seal (2).

4.

Place test stand power switch (8) in ON position.

5.

Place test stand fuel heat switch (4) in ON position. Observe that fuel temperature gauge reads between 90 o

-100°F (32 o

- 38°C) for diesel fuel.

6.

Place selector valve (11) in ROTAMETER position.

7.

Turn range crank (5) to HIGH range position.

NOTE

Perform steps 8 and 9 only on Variable Speed (VS) governor.

8.

Back high-adjusting screw (14), low-adjusting screw (15), and throttle lever (16) out of

VS governor (17) four turns.

9.

Fasten VS governor throttle lever (17) in full fuel position.

CAUTION

Pump must pick up fuel at 500 rpm without priming. If no fluid pickup is indicated at ROTAMETER, check fuel filter for improper installation, motor switch for correct rotation, open suction valve and hose, and that gear pump connections are tight.

10.

Start test stand (1) by depressing start button (8) and run up to 500 rpm. To maintain 500 rpm, depress and release FAST (7) rotate SLOW (6) button.

NOTE

l Check ROTAMETER for air in fuel flow. If air bubbles are present, work pump throttle from fuel full-open to idle several times to relieve entrapped air in pump.

l

If air bubbling persists, it is an indication of an air leak in the system. Turn test stand off and check the line for loose connections between tank and test stand pump, mating of gear pump housing, and full fuel supply tank (TM 9-4910-571-12).

l

If pump is new or has been disassembled and reassembled, run pump at 500 rpm for 5 minutes to allow bearings and seals to seat and to purge air from system.

5-108


TM 9-2320-272-24-4

5-109

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) d. Testing Pump Seals for Leaks

CAUTION

l

Check tachometer drive for clockwise rotation. If rotation is not clockwise, reverse rotation of drive coupling.

l

Do not leave fuel pressure valve closed more than five minutes because pump could overheat and be damaged.

NOTE

All steps must be completed before pump is considered calibrated.

1.

With test stand (2) operating at 500 rpm, close fuel pressure valve (7).

2.

Place test stand fuel flow control valve (1) to OPEN position. If 25 in. vacuum is not obtained, check all hose connections.

3.

Place bypass valve (8) in closed position.

4.

Apply a small amount of GM grease over vent of weep hole (12). If grease is pulled into weep hole (12) at 25 in. vacuum, fuel pump (10) oil seal is defective and fuel pump (10) must be replaced

(para. 4-35).

5.

Open fuel pressure valve (7).

e. Testing Governor Cutoff RPM

1.

Open test stand fuel flow control valve (1) completely.

2.

Increase fuel pump (10) speed to 2,100 rpm by depressing and releasing FAST (5) or SLOW (6) button.

3.

Adjust test stand fuel flow control valve (1) to obtain 8 in. Mercury (HG) on vacuum gauge (4).

NOTE

Once 8 in. HG vacuum setting is obtained, do not change setting.

Readings will fluctuate during other tests. Just note the increases or decreases as they occur.

4.

Open the fuel flow control valve (1) and place the selector valve (9) in ROTAMETER position.

5.

Increase pump (10) speed until the fuel pressure drops. Stand tachometer (3) reading should be

2,130-2,150 rpm. Depress and release FAST (5) or SLOW (6) button to increase or decrease rpm.

The VALVES governor automotive governor portion is set 100 rpm higher.

CAUTION

Test stand must be shut off to change shims in spring pack.

NOTE

l

Perform steps 6 and 7 only if spring pack shims are changed.

l

Each .001 in. (0.25 mm) shim thickness will change speed approximately two rpm.

l

Shims are available in 0.005, 0.010, and 0.020 in. (0.13, 0.25, and 0.51 mm) thicknesses.

6.

If cutoff is too low, remove spring pack (11) and add shims. If cutoff is too high, remove shims

(para. 5-14).

7.

With fuel pump (10) at 500 rpm, move throttle lever (13) back and forth until ROTAMETER shows no air and recheck governor cutoff rpm, steps 1 through 6.

5-110


TM 9-2320-272-24-4

5-111

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) f. Testing and Adjusting Throttle Leakage

1.

Increase fuel pump (9) speed to 2,100 rpm with fuel pump throttle lever (13) and place selector valve (7) to ROTAMETER position to see if any air is in system.

NOTE

At 2,100 rpm fuel flow, ROTAMETER FLOAT should read 315 pph on the scale.

2.

Set fuel flow control valve (8) for 315 pph reading.

3.

Place selector valve (7) to LEAKAGE TEST position and place count selector switch (6) to the 1,000 position.

4.

Pull out dumping lever (2) to retain fuel in No. 1 burette (3).

CAUTION

Do not hold throttle lever in idle position any longer than two minutes to complete test. Pump may overheat, since fuel flow is used to cool the pump.

5.

Remove throttle spring (4) and manually position throttle lever (14) to idle position.

6.

Depress pulse counter button (5) to fill No. 1 burette (3).

7.

Push dumping lever (2) inward.

NOTE

l

Ensure burette is cleared of fuel in order to prevent overflow at this time.

l A test cycle is one-half minute duration.

l

For one half minute cycle, fuel delivery is 40-70 cc.

8.

At the end of a cycle, read the amount of fuel in number one burette (3) on the scale.

9.

If throttle leakage is not as specified, back rear throttle screw (12) out to decrease leakage and in to increase leakage.

g. Testing and Adjusting Idle Speed

1.

Place selector valve (7) to IDLE position and increase fuel pump (9) rpm to 500.

2.

Pull fuel pump throttle lever (13) to idle position.

3.

If fuel pressure is not 26 psi (179.27 kPa), adjust idle screw (10) in governor spring pack housing (11) using adjusting tool.

4.

If pressure is low and the adjusting screw bottoms, stop the test stand, add shims to the spring end

of the adjusting screw (para. 5-14), and retest cutoff rpm and throttle leakage, tasks e. and f.

NOTE

Each time governor spring pack housing or adjusting tool is removed, run pump until purged of air.

5.

After proper adjustment is made, stop the test stand (1) and remove adjusting tool.

6.

Install 1/8 in. (3.17 mm) pipe plug (14) removed in steps 17 and 18, task b.

7.

Purge the fuel pump (9) of air.

5-112


TM 9-2320-272-24-4

5-113

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) h. Checking and Adjusting Throttle Lever Travel

1.

2.

3.

4.

5.

6.

7.

8.

NOTE

Travel template or indicator, level, and angle will be used to set pump throttle lever for travel adjustment. Ensure the combination of the first and third or second and fourth holes on the template are used. Any other combination will result in an inaccurate reading. Correct travel is 27-79 o

.

Place template (7) against throttle housing (8) so inside flats are even on top and bottom.

CAUTION

DO NOT adjust rear throttle screw from valve set under throttle linkage. The rear throttle screw has already been set to provide the proper deceleration time for the engine, and any changes at this point will require recalibration of throttle linkage.

Move the throttle lever (6) to idle position.

NOTE

The throttle lever may be repositioned on shaft as required to line up the lever and template holes.

Line up template (7) idle hole and center of throttle lever (6) with straightedge.

Move the throttle lever (6) to full throttle position and align template (7) holes with hole in throttle lever (6).

NOTE

Steps 5 through 8 check throttle lever travel adjustment.

Place level and angle indicator against the bottom of throttle lever (6) and move throttle lever (6) to idle position. Note reading on scale of angle indicator.

Move throttle lever (6) to full throttle position. Note reading on scale of angle indicator.

Add readings taken in steps 5 and 6. If throttle lever (6) travel is not 27-29 o

, adjust front throttle step screw (9) to obtain correct ravel.

After proper adjustment, the throttle lever (6) may be repositioned to accommodate throttle linkage.

i. Testing and Adjusting Pump Main Pressure

1.

With test stand (2) vacuum set at 8 in. HG on vacuum gauge (5) and throttle wide open, adjust speed to 2,100 rpm.

2.

Place selector valve (4) to ROTAMETER position.

3.

Set fuel flow to 3.15 pph with fuel flow control valve (1).

4.

If fuel pressure reading on pressure gauge (3) is not 172-178 psi (1186-1227 kPa), adjust fuel pressure.

5-114


TM 9-2320-272-24-4

5-115

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) j. Testing and Adjusting Fuel Pressure

NOTE

Throttle shaft internal adjusting screw is covered by a throttle shaft ball in the end of throttle shaft.

CAUTION

Be careful not to damage bore of throttle shaft when drilling out ball.

1.

Center punch and drill ball (6) out of fuel pump throttle shaft (7) with 1/4 in. drill bit.

2.

Screw internal fuel adjusting screw located in fuel pump throttle shaft (7) inward to increase fuel pressure and outward to decrease fuel pressure until it is set to 172-178 psi (1186-1227 kPa).

3.

After fuel pressure is adjusted, insert new throttle shaft ball (6) with throttle shaft installation tool.

k. Testing and Adjusting Governor Fuel Pressure

1.

Adjust fuel pump (3) speed to 1,500 rpm.

2.

Place selector valve (4) on test stand (2) in ROTAMETER position.

3.

Place fuel throttle lever (5) to wide-open position.

4.

Set fuel flow to 2.30 pph with the fuel control valve (1).

5.

If fuel pressure is not 100-106 psi (689-730 kPa), check governor cutoff rpm (task e).

l. Checking and Adjusting Governor Weight Pressure

1.

Adjust fuel pump (3) speed to 1,000 rpm.

2.

Place throttle lever (5) to wide-open position.

3.

Place selector valve (4) in ROTAMETER position.

4.

Set fuel flow to 150 pph with fuel flow control valve (1).

NOTE

Shims are available in 0.005 and 0.010 in. (0.13 and 0.25 mm) thickness. Do not change setting more than 0.020 in. (0.508 mm) from specification.

5.

If fuel pressure is greater than 58 psi (399 kPa), decrease pressure by removing shims from behind weight plunger.

6.

If fuel pressure is less than 50 psi (335 kPa), increase pressure by adding shims (para. 5-17).

5-116


TM 9-2320-272-24-4

5-117

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) m. Testing and Adjusting Idle Speed (VS Governor Only)

NOTE

To calibrate fuel pump equipped with Variable Speed (VS) governor, the preceding steps are followed. In addition, task c, steps 8 and 9 are to adjust VS governor only.

1.

On test stand (2), place throttle lever (8) of fuel pump with VS governor (3) and VS governor lever (7) to full-fuel position.

2.

Increase fuel pump (3) speed to 2,140 rpm.

3.

Loosen locknut (5), turn HI-IDLE (top) screw (4) in until fuel pressure starts to drop. Tighten locknut (5).

4.

Decrease fuel pump (3) speed to 2,100 rpm, and gradually increase until pressure starts to drop.

5.

If fuel pump (3) speed is not 2,120-2,140 rpm, adjust VS governor HI-IDLE screw (4) until rpm is

2,120-2,140 rpm.

NOTE

The automotive governor cutoff must be set 100 rpm higher.

6.

Decrease fuel pump (3) speed to 500 rpm.

7.

Place VS governor lever (7) and stand selector valve (1) to IDLE position.

8.

Adjust governor LO-IDLE screw (bottom) (6) to obtain 26 psi (179 kPa).

5-118

TM 9-2320-272-24-4

5-18. FUEL PUMP SETUP AND CALIBRATION (Contd) n. Shutdown and Removal from Test Stand

1.

Depress test stand stop button (11).

2.

Place test stand fuel heat switch (10) in OFF position.

3.

Close test stand fuel pressure control valve (12) and fuel flow control valve (17).

4.

Remove 1/4 in. (6.35 mm) flexible hose (13) from small fitting (9) on fuel pump (3) and auxiliary return fitting (16) on test stand (2).

5.

Remove leakage accumulator hose (15) from No. 1 accumulator can (14) and stand leak test connector (17).

5-119

TM 9-2320-272-24-4


6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Remove fuel outlet hose (10) from test stand fuel input connector (11) and fuel return connector (5).

Remove 1/2 in. (12.7 mm) flexible hose (8) from test stand lube pressure (9) and test stand lube return (6).

Remove fuel pressure hose (14) from test stand pressure gauge outlet (13) and pump discharge fitting (2).

Remove pump discharge fitting assembly (3) from pump fuel shutoff valve (4) and test stand fuel input connector (12).

Remove throttle lever spring (15) from fuel pump (7).

Remove 1/4 in. (6.35 mm) manifold hose (17) from test stand manifold vacuum gauge (16) and

1/4 in. (6.35 mm) adapter on inlet adapter assembly (18).

Remove 1/2 in. (12.7 mm) inner diameter flexible hose (22) from fuel pressure control valve (23) and adapter elbow on inlet adapter assembly (21).

Remove pump inlet adapter assembly (20) from pump inlet port (19).

Remove pump coupling insert (35) from test stand drive coupling (30).

Loosen bar clamp (34) and slide fuel pump (7) and ring and adapter bracket (31) back from test stand drive coupling (30).

Remove fuel pump (7) from ring and adapter bracket (31) by removing four screws (32) and washers (33).

Remove nut (26), lockwasher (27), washer (28), screw (29), and throttle lever (25) from throttle lever shaft (24).

5-120


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install throttle shaft cover (para. 5-16).

l Install fuel pump shutoff valve (para. 4-36 or 4-37).

l

Install fuel pump on vehicle (para. 4-35).

5-121

TM 9-2320-272-24-4

5-19. FUEL INJECTOR REPAIR

THIS TASK COVERS: a. Non-Top Stop Injector Disassembly b. Top Stop Injector Disassembly c. Inspection d. Non-Top Stop Injector Assembly e. Top Stop Injector Assembly

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Cup retainer wrench (Appendix E, Item 162)

Crowfoot injector wrench-(Appendix E,

Item 164)

Adjusting wrench (Appendix E, Item 3)

Locknut wrench (Appendix E, Item 165)

Injector body wrench (Appendix E, Item 70)

TOOLS



Magnifying glass

MATERIALS/PARTS

Injector overhaul kit (Appendix D, Item 255)



REFERENCES (TM)

TM 9-2320-272-24P


Fuel injectors removed (para. 4-32).


l Keep fire extinguisher nearby when using drycleaning solvent.

l


a. Non-Top Stop Injector Disassembly

1.

Remove injector link (1) from injector (8). Set injector link (1) aside to prevent damage.

WARNING



CAUTION

Improper cleaning methods and use of unauthorized cleaning solvents can damage equipment.

2.

Clean exterior of injector (8) with drycleaning solvent (para. 2-14).

CAUTION

l

Injector barrel and plunger are a matched pair (class fit). Do not interchange.

l

Do not touch internal parts unless hands are clean and moistened with diesel fuel. Failure to do so may result in damage to internal parts.

3.

Remove plunger (2) and spring (3) from injector (8). Store plunger (2) by standing on end.

4.

Remove small O-ring (4) and two large O-rings (5) from injector (8). Discard O-rings (4) and (5).

5.

Remove screen retaining ring (6) and screen (7) from injector (8). Discard retaining ring (6) and screen (7).

5-122

5-19. FUEL INJECTOR REPAIR (Contd)

TM 9-2320-272-24-4

5-123

TM 9-2320-272-24-4


6.

Install injector body wrench in vise.

7. Slide flat machined areas of injector (6) into body wrench.

8.

Loosen cup retainer (1) with cup retainer wrench.

9. Remove injector (6) and body wrench from vise.

CAUTION

When handling injector, use care not to drop or lose parts.

10.

Set injector adapter (3) upright on flat surface and remove cup retainer (1) by lifting straight up.

11.

Remove injector cup (2) from injector (6). Discard injector cup (2).

CAUTION

l


l


12.

Hold injector barrel (5) and adapter (3) together and set injector barrel (5) end upright on clean cloth. Lift adaptor (3) straight out of injector barrel (5) while holding injector barrel (5).

13.

Lift injector barrel (5) up and tilt over hand until check ball (4) falls out.

5-124


TM 9-2320-272-24-4

5-125

TM 9-2320-272-24-4


12.

13.

14.

3.

4.

5.

6.

1.

2.

7.

8.

9.

10.

b. Top Stop Injector Disassembly

11.

WARNING



CAUTION

l

When handling injector, use care not to drop or lose parts.

l


Clean exterior of injector (6) with drycleaning solvent (para. 2-14).

Install injector body wrench in vise.

Slide flat machined areas of injector (6) into injector body wrench.

Loosen locknut (4) with locknut wrench.

Loosen adjusting screw (3) with adjusting wrench.

Remove adjusting screw (3), locknut (4), plunger (2), spring retainer (1), and plunger spring (7) from injector (6).

Loosen cup retainer (5) using cup retainer wrench.

Remove injector (6) and body wrench from vise.

Set injector adapter (9) upright on flat surface and remove cup retainer (5) by lifting straight up.

Remove injector cup (8) from injector (6). Discard injector cup (8).

CAUTION

l


l


Hold injector barrel (11) and adapter (9) together and set injector barrel (11) end upright on clean cloth. Lift adapter (9) straight up out of injector barrel (11) while holding injector barrel (11).

Lift injector barrel (11) up and tilt over hand until check ball (10) falls out. Discard check ball (10).

Remove small O-ring (13) and two large O-rings (12) from injector (6). Discard O-rings (13) and (12).

Remove screen retaining ring (14) and screen (15) from injector (6). Discard screen retaining ring (14) and screen (15).

5-126


TM 9-2320-272-24-4

5-127

TM 9-2320-272-24-4

5-19. FUEL INJECTOR REPAIR (Contd) c. Inspection

1.

2.

3.

4.

NOTE

l Bright spots or surface disruption at top of plunger-machined area, on opposite side at bottom or midpoint, are normal results of rocker lever action.

l

This task pertains to the non-top stop and top stop injectors.

Inspect machined surfaces of plunger (1) for pitting, wear, cracks, and looseness. Narrow streaks running length of plunger (1) are normal. Plunger (1) should be one solid part. If plunger (1) is pitted or worn, or if cracks or looseness exist, replace plunger (1) and injector barrel (4).

Inspect injector barrel plunger bore (2) for scoring with strong magnifying glass. If scoring exists, replace injector barrel (4) and plunger (1).

Inspect injector barrel (4) surface at each end for burrs or scratches. If burrs or scratches exist, replace injector barrel (4) and plunger (1).

Inspect injector barrel check ball seat (3) for nicks or burrs. If nicks or burrs exists, replace injector barrel (4) and plunger (1).

5-128

TM 9-2320-272-24-4

5-19. FUEL INJECTOR REPAIR (Contd) d. Non-Top Stop Injector Assembly

CAUTION

l


l Do not touch internal parts unless hands are clean and moistened with diesel fuel. Failure to do so may result in damage to internal parts.

1.

Place new check ball (6) in palm of hand and scoop up into injector barrel (4).

2.

Place injector barrel (4) flat on clean cloth so mating surface faces upward and align spiral pins (7) with holes in adapter (5)

3.

Place adapter (5) on injector barrel (4) and hold together. Set adapter (5) upright on clean cloth.

4.

Position new injector cup (9) on top of injector barrel (4) and screw cup retainer (8) onto adapter (5).

Finger tighten cup retainer (8), and back off 1/4 turn.

5-129

TM 9-2320-272-24-4


17.

18.

19.

20.

21.

5.

Place injector cup retainer wrench over cup retainer (3).

CAUTION

l Injector barrel and plunger are a matched pair (class fit). Do not interchange.


Apply clean diesel fuel to coat plunger (2) and insert plunger (2) into adapter (1).

6.

7.

8.

9.

10.

11.

12.

Remove loading fixture stud (6) from loading fixture (4) and slide body wrench over injector (5) flats.

Position cup retainer wrench on cup retainer (3).

Install loading fixture stud (6) in loading fixture (4) and tighten 110 lb-in. (12 N

Tighten cup retainer (3) 50 lb-ft (68 N

Remove plunger (2) from adapter (1).

l l m).

m) with torque wrench and crowfoot wrench.

Remove loading fixture stud (6) from loading fixture (4) and lift injector (5) out of loading fixture (4).

13.

14.

Apply clean diesel fuel to coat plunger (2).

Insert plunger (2) into injector (5) barrel so plunger (2) remains 0.5 in. (12.7 mm) from edge of adapter (1).

15.

Press plunger (2) into cup retainer (3) with palm of hand.

CAUTION

16.

Do not allow plunger to fall out during step 16.

Turn cup retainer (3) and adapter (1) with one hand so cup retainer (3) faces upward. Plunger (2) should slide out immediately. If plunger (2) does not slide out immediately, the injector (5) is not aligned and must be reassembled as outlined in task b., steps 5 through 14.

Slide two new large O-rings (10) over end of injector (5) and into two upper grooves (15) on adapter.

Slide new small O-ring (9) over end of injector (5) onto lowest groove (13) on adapter (1).

Place new inlet fuel screen (11) over adapter orifice (14) and install with new retainer ring (12).

Place spring (8) on plunger (2) and slide plunger (2) into injector (5).

Install injector link (7) in plunger (2).

5-130


TM 9-2320-272-24-4

5-131

TM 9-2320-272-24-4

5-19. FUEL INJECTOR REPAIR (Contd) e. Top Stop Injector Assembly

3.

4.

1.

2.

5.

6.

CAUTION

l

Lubricate parts only with clean diesel fuel before assembly. Do not use lubricating oil. Oil can crystallize under excessive heat, causing damage to injector components.


Place new check ball (3) in injector barrel (4).

Place injector barrel (4) flat on clean lint-free cloth so mating surface faces upward.

Place adapter (2) on injector barrel (4).

Hold injector barrel (4) and adapter (2) together and set adapter (2) upright on clean lint-free cloth.

Position new injector cup (6) on top of injector barrel (4).

Screw cup retainer (5) onto adapter (2), finger tighten, and back off 1/4 turn.

CAUTION

l


l


7.


8.

Insert plunger (1) into adapter (2).

9.

Remove loading fixture stud (7) from loading fixture (8) and insert injector (9) into loading fixture (8).

10.

Slide body wrench over flats on injector adapter (2).

11.

Position cup retainer wrench on cup retainer (5).

12.

Install loading fixture stud (7) in loading fixture (8) and tighten 75 lb-ft (8 N l m).

13.

Tighten cup retainer (5) 50 lb-ft (68 N l m) with torque wrench and crowfoot wrench.

5-132


TM 9-2320-272-24-4

5-133

TM 9-2320-272-24-4


14.

15.

16.

17.

18.

Remove injector (4) and body wrench from loading fixture.

Remove plunger (2) from injector (4).


Insert plunger (2) into injector (4) so plunger (2) remains 0.5 in. (12.7 mm) from edge of adapter (1).

Press plunger (2) into cup retainer (3) with palm of hand.

CAUTION

20.

21.

22.

23.

24.

19.

Do not allow plunger to fall out. Damage to plunger may result.

Turn cup retainer (3) and adapter (1) with one hand so cup retainer (3) faces upward. Plunger (2) should slide out immediately. If plunger (2) does not slide out immediately, the injector (4) is not aligned and must be reassembled as outlined in steps 1 through 18.

Install body wrench in vise.

Slide injector (4) into body wrench.

Place spring (9) and spring retainer (5) in injector (4).

Slide plunger (2) into injector (4).

Thread locknut (8) and adjusting screw (7) into injector (4) with locknut wrench and top-stop adjusting wrench (6) until locknut (8) contacts adapter (10). Tighten locknut (8) 55 lb-ft

(75 N l m).

25.

26.

Remove injector (4) from body wrench.

Slide two new large O-rings (15) over end of injector (4) and into two upper grooves (11) and (12) of adapter (10).

27.

Slide new small O-ring (14) over end of injector (4) into lowest groove (13) on adapter (10).

28.

Place new inlet fuel screen (17) over adapter orifice (18) and install with new retainer ring (16).

5-134


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install fuel injectors (para. 4-32).

5-135

TM 9-2320-272-24-4

5-20. INJECTOR LEAK TEST

THIS TASK COVERS: a. Setting Up Injector Leakage Detector b. Testing Injector Plunger and Seat

INITIAL SETUP:


M939/A1

REFERENCES (TM)

TM 9-2320-272-24P

SPECIAL TOOLS


Injector leakage detector (Appendix E, Item 68)


TOOLS


Feeler gauge

3.

4.

5.

a . Setting Up Injector Leakage Detector

1.

2.

6.

7.

Set pressure regulator on leakage tester at 60 psi (414 kPa). Read pressure setting on pressure regulator gauge (1).

Operate retraction lever (3) on leakage tester three times, and reset pressure regulator gauge (1) at

60 psi (414 kPa).

NOTE

Air pressure must be held at 60 psi (414 kPa) during all tests.

Place leakage tester retraction lever (3) in position A.

Position load cell (2) on leakage tester.

Adjust knurled knob (4) on load cell (2) until load cell (2) reads 200 psi (1,379 kPa).

NOTE

Do not adjust locknut unless load cell is in use.

Place feeler gauge between knurled knob (4) and locknut (5) and adjust locknut (5).

Remove load cell (2) from leakage tester.

5-136

5-20. INJECTOR LEAK TEST (Contd)

TM 9-2320-272-24-4

5-137

TM 9-2320-272-24-4

5-20. INJECTOR LEAK TEST (Contd) b. Testing Injector Plunger and Seat

17.

18.

19.

20.

21.

22.

23.

24.

12.

13.

14.

15.

9.

10.

11.

1.

Remove plunger (2) and spring (3) from injector (4).

2.

Install injector link (1) in plunger (2) and place in injector (4).

3.

Remove screen retaining ring (6) and inlet fuel screen (7) from injector (4).

6.

7.

8.

4.

Align injector delivery orifice (5) with burnishing tool hole (11) on burnishing tool adapter (10).

5.

Insert locating screw (8) in locating screw hole (9) on burnishing tool adapter (10) and tighten.

NOTE

Support plate may be tilted.

Position injector (4) on support plate (14) and install in leakage tester.

Place feeler gauge between knurled knob (17) and locknut (18). Do not adjust locknut (18).

Install transfer line (20) and tighten in injector adapter (13) drain port.

Tighten T-handle clamp (15).

Shift retraction lever (16) from position A to position B. Ensure plunger (2) retracts.

16.

Rotate plunger (2) in clockwise direction a little at a time while reading air flow meter (12).

Stop rotating plunger (2) when highest reading is obtained.

If air flow meter (12) reading is over 4.5, overhaul injector (4) (para. 5-19).

Shift retraction lever (16) from position B to position A.

Loosen T-handle clamp (15). This will apply 200 lbs (91 kg) load to plunger (2).

While observing checker (21), see if any bubbles appear during the first ten seconds of testing.

No bubbles should appear.

If a bubble does appear, observe the time it takes for the next one to appear. No more than

one bubble can appear every five seconds. If bubbling is too high, overhaul injector (4) (para. 5-19).

Remove transfer line (20) from injector adapter (13) drain port.

Release air pressure from pressure regulator (19).

Remove injector adapter (13) from leakage tester.

Remove locating screw (8) and transfer line (20) from burnishing tool adapter (10).

Remove injector (4) from burnishing tool adapter (10).

Place inlet fuel screen (7) over injector orifice (5), and install with retainer ring (6).

Remove plunger (2) and injector link (1) from injector (4).

Place plunger (2) and spring (3) in injector (4).

5-138

5-20. INJECTOR LEAK TEST (Contd)

TM 9-2320-272-24-4


5-139

TM 9-2320-272-24-4

5-21. INJECTOR SPRAY PATTERN TEST

THIS TASK COVERS: a. Setting Up Spray Pattern Tester b. Testing Spray Pattern

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Fuel injection tester (Appendix E, Item 49)

Spray angle tester (Appendix E, Item 138)

TOOLS


REFERENCES (TM)

TM 9-2320-272-24P




Whenever fuel is forced from injector spray holes, keep hands away from spray stream.

a. Setting Up Spray Pattern Tester

NOTE

Any source of 22 psi (152 kPa) constant fuel pressure will operate spray pattern tester.

1.

Locate spray pattern tester near or on injector test stand.

2.

Attach inlet hose (2) to adapter (8) from injector test stand.

3.

Attach drain hose (4) to adapter base (5) and place loose end in test stand drain area.

4.

Remove plunger (10) and spring (11) from injector (12) and store in safe place.

5.

Remove screen retaining ring (15) and inlet fuel screen (14) from injector test stand.

6.

Place injector (12) in adapter (8).

7.

Install knurled plug (6) in adapter (8) drain opening.

8.

Place injector (12) in spray pattern tester and tighten inlet hose connector (3).

9.

Install injector (12) in spray patter tester holddown bracket (9) with knurled knob (1).

10.

Install target ring (7) marked 8-.007 x 17 o

on spray pattern tester.

b. Testing Spray Pattern

WARNING

Keep hands away from spray stream when fuel is forced from injector spray holes. Failure to do this may result in injury to personnel.

1.

Apply 22 psi (152 kPa) pressure to injector test stand.

NOTE

Each spray stream must hit a window in the target ring.

2.

Shift target ring (7) so one spray stream hits on No. 1 or index window. If spray stream is off 2 o

of

window, replace cup (para. 5-19).

3.

Loosen knurled knob (1) on holddown bracket (9).

4.

Remove injector (12) from spray pattern tester.

5.

Remove knurled plug (6) and injector (12) from adapter (8).

6.

Install spring (11) and plunger (10) in injector (12).

7.

Install inlet fuel screen (14) over injector orifice (13) with screen retaining ring (15).

5-140

5-21. INJECTOR SPRAY PATTERN TEST (Contd)

TM 9-2320-272-24-4


5-141

TM 9-2320-272-24-4

5-22. INJECTOR TEST STAND CALIBRATION

THIS TASK COVERS: a. Setting Up Injection Tester b. Test Stand Calibration

INITIAL SETUP:


M939/A1

SPECIAL TOOLS

Fuel injection tester (Appendix E, Item 49)

TOOLS


REFERENCES (TM)

TM 9-2320-272-24P

a. Setting Up Injection Tester

3.

4.

5.

6.

1.

Rotate counter wheel (2) on injection tester until wheel marks and pointer are aligned.

2.

Open hydraulic valve (3).

CAUTION

Never operate test stand with load cell in position.

Position load cell tester on injection tester and secure by opening air valve (4).

Adjust air regulator (5) by turning knurled knob (7) until load cell tester registers within coded range markings. Record air gauge (1) pressure reading.

Lock air regulator (5) in place with locknut (6).

Place air valve (4) to center position and remove load cell tester from injection tester.

5-142

5-22. INJECTOR TEST STAND CALIBRATION (Contd)

TM 9-2320-272-24-4

5-143

TM 9-2320-272-24-4


7.

When cylinder (11) is down, hydraulic fluid should show in sight bulb. Open air valve (13) when cylinder (11) is at the top of its travel; no air should show in sight glass (14). If air is indicated, tighten all line connections.

NOTE

The master injector is precalibrated and must never be tampered with.

8.

Place adapter (20) on master injector (17). Ensure wheel marks and pointer are aligned (step 1).

NOTE

Ensure injector seat contains 0.20 in. (0.51 mm) restrictor orifice.

9.

Position test stand link (15) over injector link (9) and place master injector (10) in injector seat (18).

10.

Tip back until test stand link (15) is below test stand push rod (8) and not rubbing.

11.

Open air valve (13) to clamp master injector (10) in place. Ensure test stand link (15) is aligned.

12.

Close hydraulic valve (12) to lock master injector (10) in place.

13.

Connect test stand fuel drain connector (19) to adapter (20).

14.

Connect test stand fuel inlet connector (16) to adapter (20).

CAUTION

If temperature exceeds 135°F (57°C), drain and replace with new test oil.

15.

Place injector test stand motor switch (6) in START position. Ensure temperature gauge (7) reads

90°-95°F (32-35°C).

16.

Shift the silver colored counter (1) wheels (3) to the right, rotate counter (1) to indicate 1,020 strokes and release.

17.

Clear counter (1) by rotating thumbscrew (4) one complete revolution. Ensure all white-colored counter wheels (2) read zero.

5 - 1 4 4


TM 9-2320-272-24-4

5-145

TM 9-2320-272-24-4

5-22. INJECTOR TEST STAND CALIBRATION (Contd) b. Test Stand Calibration

1.

Adjust regulator knob (5) on injector test stand by turning until pressure gauge (1) reads 120 psi

(827 kPa). Ensure pressure is maintained at 120 psi (827 kPa) during calibration.

2.

Press red flow start switch (3) in and out until counter (4) reads 1,020 count strokes.

3.

Look directly into vial (2) and observe reading.

NOTE

Reading of 132 counterclockwise at 120 psi (827 kPa) indicates test stand is in calibration. If reading is more than 132 cc, the test stand is not set up properly. Repeat setup steps. If reading is below 132 cc, continue.

4.

Reset counter (4) on injector test stand to zero (task a., steps 16 and 17).

5.

Set counter (4) up seven strokes for each cc less than 132 cc.

6.

Dump fuel from vial (2).

NOTE

If counter is set beyond 1,050 strokes to obtain 132 cc, the test stand is not set up properly. Repeat setup steps. If counter reads

1,050 or below, the test stand is in calibration.

7.

Press red flow start switch (3) in and out until counter (4) sets strokes to obtain 132 cc.

8.

Place motor switch (6) in STOP position.

9.

Remove test stand fuel drain connector (14) from adapter (15).

5-146


10.

Open hydraulic valve (9).

11.

Close air valve (10).

12.

Remove master injector (8) from injector seat (13).

13.

Slide test stand link (11) off injector plunger link (7).

14.

Remove test stand fuel inlet connector (12) from adapter (15).

15. Remove adapter (15) from master injector (8).

TM 9-2320-272-24-4

5-147

TM 9-2320-272-24-4

5-23. INJECTOR FLOW TEST

THIS TASK COVERS: a. Setting Up Test Stand b. Testing Check Ball Seating c. Adjusting and Measuring Fuel Delivery

INlTIAL SETUP:


M939/Al

SPECIAL TOOLS

Injection tester (Appendix E, Item 49)

TOOLS


Burnishing tool adapter

Adjusting tool adapter

MATERIALS/PARTS



REFERENCES (TM)

TM 9-2320-272-24P


• Fuel injector removed (para. 4-32).

• Injector test stand calibrated (para. 5-22).



a. Setting Up Test Stand

1.

Remove screen retainer ring (5) and inlet fuel screen (4) from injector (3).

2.

Remove plunger (1) and spring (2) from injector (3) and separate plunger (1) from spring (2).

3.

Place plunger (1) in injector (3) without spring (2).

4.

Apply diesel fuel to lubricate inside of burnishing tool adapter.

CAUTION

Injector inlet port and burnishing tool adapter inlet hole must be aligned to prevent damage to the burnishing tool points when installed later.

5.

Position injector (3) in burnishing tool adapter so injector (3) inlet port and burnishing adapter inlet holes align. Tighten locating screw (12) on burnishing tool adapter to install injector (3).

6.

Connect test stand inlet pressure line adapter (11) to burnishing tool adapter.

b. Testing Check Ball Seating

NOTE

Hold injector in hand; do not place in test stand holding device,

1.

Hold plunger (1) down in injector (3).

2.

Place motor switch (7) on injection tester in START position. Ensure temperature gauge (9) reads

90-95°F (32-35°C).

CAUTION

If temperature exceeds 135°F (57°C), drain and replace with new test oil.

3.

Adjust regulator knob (9) by turning until pressure gauge (6) reads 150 psi (1,034 kPa).

4.

Check burnishing tool adapter installation hole (10) for leaks. A slight seepage is not harmful. If

leakage is found, replace check ball (para. 5-19).

5.

Place motor switch (7) in STOP position.

6.

Disconnect test stand inlet pressure line adapter (11) from burnishing tool adapter.

5-148

5-23. INJECTOR FLOW TEST (Contd)

TM 9-2320-272-24-4

5-149

TM 9-2320-272-24-4


9.

10.

11.

12.

c. Adjusting and Measuring Fuel Delivery

3.

4.

1.

2.

5.

6.

7.

8.

Remove plunger (11) from injector (9).

Slide spring (12) on plunger (11) and place in injector (9).

Place retainer plate (14) on burnishing tool adapter and secure with pins (13).

Place test stand link (1) in burnishing tool adapter. Test stand link (1) should be 6.5 in. (17 cm) long.

Place injector (9) in injector test stand (7) so injector (9) is in injector seat (8). Tip injector (9) back until test stand link (1) is below test stand push rod (16) and is not rubbing.

Install burnishing tool (2) in test stand inlet pressure line adapter (9).

Retract burnishing tool needle (4) by pulling small knob (3) out.

NOTE

With needle retracted, burnishing tool may be left in adapter during all test operations.

Connect test stand inlet pressure line adapter (6) to burnishing tool adapter inlet hole by screwing in large knob (5).

Install drain connector (10) in burnishing tool adapter.

Clamp injector (9) in place by opening air valve (18). Ensure test stand link (1) is aligned.

Lock injector (9) in place by closing hydraulic valve (17).

Place motor switch (15) in START position. Ensure temperature reads 90°-95° F (32°-35°C).

CAUTION

If temperature exceeds 135 °F (57°C), drain and replace with new test oil.

5-150


TM 9-2320-272-24-4

5-151

TM 9-2320-272-24-4


13.

Adjust injector test stand regulator knob (6) by turning until pressure gauge (1) reads 120 psi

(827 kPa).

14.

Press flow start switch (4) in until counter (5) reads the same as master injector counter strokes.

15.

Observe vial (2) reading, If reading is higher than 122 cc at 120 psi (827 kPa), perform steps 17 through 19 to install new orifice plug (16). If reading is lower than 121 cc at 120 psi (827 kPa), perform steps 20 through 24 to set fuel flow.

16.

Remove test stand inlet pressure line adapter (11) and burnishing tool from burnishing tool adapter (13) by turning large knob (9) out until assembly is free.

17.

Remove orifice plug (16) and gasket (15) from injector (10). Discard gasket (15).

NOTE

New orifice plug size .018-.019 in. (0.48-0.49 mm) is small enough so burnishing will increase fuel efficiency.

18.

Install new gasket (15) and orifice plug (16) in injector orifice (14) and tighten orifice plug (16)

8-10 lb-in. (0.9-1.1N• m).

19.

Install test stand inlet pressure line adapter (11) and burnishing tool on burnishing tool adapter (13) by screwing large knob (9) into burnishing tool adapter (13) inlet hole until tight.

CAUTION

20.

21.

22.

23.

When seating burnishing tool, use care not to push small knob in too hard or overtighten indicator knob. When slight contact is made, stop. Damage can be caused to injector. Test stand must be running while burnishing.

Turn burnishing tool indicator knob (8) until spaced 3/8 in. (9.5 mm) from large knob (9).

Slowly push small burnishing tool knob (7) in until slight contact is made with injector (10).

Turn small burnishing tool knob (7) counterclockwise to lock large knob (9) and indicator knob (8).

Slowly turn indicator knob (8) in until slightly seated in injector (10). Index indicator knob (8) with mark on large knob (9).

24.

25.

Advance indicator knob (8) one mark, and back off until spaced 3/8 in. (9.5 mm).

NOTE

Perform steps 12 through 15 and recheck fuel delivery. If delivery is lower than 121-122 cc, repeat steps 20 through 24. If reading is higher, install new orifice plug (steps 17 through 19), and recheck fuel delivery.

Place injector test stand motor switch (3) in STOP position.

Remove drain connector (12) from burnishing tool adapter (13).

26.

27.

Screw out large knob (9) on burnishing tool and remove test stand inlet pressure line adapter (11) from burnishing tool adapter (13).

28.

Remove burnishing tool from burnishing tool adapter (13). Store burnishing tool in clean place.

5-152


TM 9-2320-272-24-4

5-153

TM 9-2320-272-24-4


29.

Open hydraulic valve (2) on injector test stand.

30.

Close air valve (3) on injector test stand.

31.

Remove injector (1) from injector test stand.

32.

Slide test stand link (7) out of burnishing tool adapter.

33.

Remove two pins (4) and retainer plate (5) from burnishing tool adapter.

34.

Remove burnishing tool adapter from injector (6).

35.

Remove plunger (8) and spring (9) from injector (1).

36.

Install screen (10) in injector orifice (12) with screen retainer (11).

37.

Place spring (9) in plunger (8) and slide in injector (1).

NOTE

Store injectors in a clean place.

5-154


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install fuel injector (para. 4-32).

5-155 (5-156 blank)

Section II. ENGINE (M939A2) MAINTENANCE

5-24. ENGINE (M939A2) MAINTENANCE INDEX

PARA.

NO.

5-25.

5-26.

5-27.

5-28.

5-29.

5-30.

5-31.

5-32.

5-33.

5-34.

5-35.

5-36.

5-37.

TITLE

Cylinder Head Repair

Piston and Connecting Rod Maintenance

Camshaft and Gear Maintenance

Cylinder Liners and Block Maintenance

Crankshaft and Gear Maintenance

Rocker Levers and Push Rods Maintenance

Mounting Fuel Injection Pump to Test Stand

Fuel Injection Pump Pretest

Manifold Pressure Compensator Maintenance

R.Q.V. Governor Cover Maintenance

R.Q.V. Governor Housing Maintenance

Fuel Injection Pump Maintenance

Fuel Injection Pump Calibration

TM 9-2320-272-24-4

PAGE

NO.

5-158

5-166

5-174

5-184

5-196

5-206

5-210

5-214

5-224

5-228

5-232

5-240

5-262

5-157

TM 9-2320-272-24-4

5-25. CYLINDER HEAD REPAIR

THIS TASK COVERS: a. Disassembly b. Cleaning c. Inspection

INITIAL SETUP:


M939A2

TOOLS


Spring compressor (Appendix E, Item 135)


Spring tester (Appendix E, Item 131))



Feeler gauge

Valve refacing machine

d. Repair e. Assembly

MATERIALS/PARTS

Twenty-four collets (Appendix D, Item 253)

Twelve seals (Appendix D, Item 613)

Eight expansion plugs (Appendix D, Item 105)

Expansion plug (Appendix D, Item 106)

Two expansion plugs (Appendix D, Item 107)


Lapping compound (Appendix C, Item 37)


Pigment (Appendix C, Item 54)


REFERENCES (TM)

TM 9-247

TM 9-2320-272-24P


Cylinder head removed (para. 4-41).


Eyeshields must be worn when removing valves.

WARNING

Valve springs are under compression. Eyeshields must be worn when removing valves. Failure to do so may cause injury to personnel.

CAUTION

To remove intake and exhaust valves, position cylinder head on exhaust port face. Use wooden or protective surface work bench to prevent damage to cylinder head.

NOTE

• Mark location and position of valves for installation.

• All intake and exhaust valves are removed the same.

1.

Using spring compressor, compress valve spring (3) and remove two collets (1) from valve (10) and cylinder head (9). Discard collets (1).

2.

Release spring compressor and remove two spring retainers (2), valve spring (3), seal (4), and valve (10) from cylinder head (9). Discard seal (4).

3.

Remove five expansion plugs (5) from top face of cylinder head (9). Discard expansion plugs (5).

4.

Remove expansion plug (6) from rear face of cylinder head (9). Discard expansion plug (6).

5.

Remove two expansion plugs (8) from front and rear faces of cylinder head (9). Discard expansion plugs (8).

6.

Remove plug (7) from rear face of cylinder head (9).

5-158


TM 9-2320-272-24-4

5-159

TM 9-2320-272-24-4

5-25. CYLINDER HEAD REPAIR (Contd) b. Cleaning

Clean all cylinder head components (TM 9-247).

c. Inspection

1.

Inspect cylinder head (1) for cracks, pits, and scratches.

a. If pitted or scratched, remove with crocus cloth.

b. If cracked, excessively pitted or scratched, replace cylinder head (1).

2.

Inspect cylinder head (1) for warping.

a. Using straight edge and feeler gauge, inspect gasket surface of cylinder head (1) from front to rear. Warping should not exceed 0.008 in. (0.20 mm).

b. Inspect gasket surface of cylinder head (1) from side to side. Warping should not exceed 0.003 in.

(0.076 mm).

c. Using 2-in. (51-mm) straight edge and feeler gauge, inspect for warping across valve ports (2) and coolant passages (5). Warping should not exceed 0.001 in. (0.025 mm).

CAUTION

Machining of cylinder head surface is not to exceed 0.040 in.

(1.02 mm) or damage to equipment will result.

d. Replace or resurface cylinder head (1) if warping exceeds limits. Notify your supervisor.

NOTE

Perform steps 3 and 4 if cylinder head was resurfaced.

3.

Install valves (3) in their respective valve ports (2).

4.

Using gauge block, measure depth of valves (3). Mark valve seat(s) (6) for resurfacing if depth is less than 0.043 in. (1.09 mm).

5.

Remove valves (3) from cylinder head (1).

6.

Inspect valve springs (4) for distortion, cracks, and collapsed coils. Refer to table 5-9, Cylinder Head

Wear Limits, for measurements. Replace valve springs (4) if damaged or worn.

7.

Using spring tester, compress valve springs (4) to 2 in. (51 mm). Load measured should be

101.2-115 lb (45.9-52.2 kg). Replace valve spring(s) (4) if not within limits.

8.

Inspect valve spring retainers (8) for wear and distortion. Replace valve spring retainer(s) (8) if worn or distorted.

Table 5-9. Cylinder Head Wear Limits.

ITEM NO.

ITEM/POINT OF MEASUREMENT

WEAR LIMITS/TOLERANCES

INCHES MILLIMETERS

3

14

15

4

Intake and exhaust valves

Rim thickness

Valve stem diameter

Exhaust valve guide

Valve guide length

Valve guide bore, inner

Intake valve guide

Valve guide length

Valve guide bore, inner

Valve springs

Free length

0.060

0.373

0.896

0.376

0.893

0.376

2.585

1.52

9.47

22.76

9.55

22.68

9.55

65.66

5-160

TM 9-2320-272-24-4


9.

10.

11.

12.

13.

14.

15.

Inspect valve seats (6) for wear, burrs, pits, and cracks. Replace cylinder head (1) if worn, pitted, cracked, or burred. Mark valve seat (6) for resurfacing.

Inspect exhaust (14) and intake (15) valve guides for chips, cracks, burrs, breaks, and wear. Replace cylinder head (1) if chipped, cracked, burred, broken, or worn.

Measure valve guide length (12) and inside diameter of valve guide bore (13). Refer to table 5-9,

Cylinder Head Wear Limits, for measurements. Replace cylinder head (1) if not within limits.

Inspect valves (3) for cracks, bends, and wear. Replace valve(s) (3) if cracked, bent, or worn.

Measure outside diameter of valve stem (9). Refer to table 5-9, Cylinder Head Wear Limits, for

measurements. Replace valve(s) (3) if not within limits.

Measure rim (10) thickness of valves (3). Refer to table 5-9, Cylinder Head Wear Limits, for

measurement. Replace valve(s) (3) if not within limits.

Inspect collet grooves (11) for wear.

a. Install new collets (7) in collet grooves (11).

b. If collets (7) fit loosely, replace valve(s) (3).

5-161

TM 9-2320-272-24-4


1.

Apply light coat of lapping compound to valve (2) and lap valve (2) to valve seat insert (1).

2.

Clean lapping compound from valve (2) and valve seat insert (1).

3.

Measure width of valve seat insert (1). Limits are 0.060-0.080 in. (1.52-2.03 mm). If beyond limits, replace cylinder head (4).

4.

Check contact surface between valve (2) and valve seat insert (1) as follows: a. Apply light coat of pigment to valve face (3).

b. Lower valve (2) into valve guide (5) and let valve (2) drop against valve seat insert (1).

NOTE

Do not rotate valve when pushing valve against valve seat insert.

c. Push up on valve stem (6) until valve face (3) is about 1 in. (25.4 cm) above valve seat insert (1).

d. While releasing valve stem (6), apply pressure to valve (2) until valve face (3) makes contact with valve seat insert (1). Repeat several times to get good imprint on pigment.

NOTE

Do not smear pigment from valve.

e. Remove valve (2).

f. Imprint on pigment should have an even contact surface all around center of valve face (3). If pigment imprint is uneven, mark valve (2) and valve seat insert (1) for grinding.

NOTE

Repeat step 4 for all valves to check contact surface between valve and valve seat insert.

5.

Grind valve (2) and valve seat insert (1) if valve (2) is new or has an uneven contact surface.

a. Use a 30° grinding wheel on valve seat insert (1) for intake port (7).

b. Use a 45° grinding wheel on valve seat insert (1) for exhaust port (8).

NOTE

If contact surface is at bottom of valve face, valve seat insert will require more grinding with 15° wheel.

c. To center contact surface on valve face (3), grind area (11) of valve seat insert (1) with a 60° wheel, and area (12) of valve seat insert (1) with a 15° wheel.

d. Using valve refacing machine, grind face of intake valve (2) to a 30° angle or a 45° angle for exhaust valve.

6.

If valve stem tip (10) is not flat, dress tip for flatness on grinding wheel.

7.

Measure valve (2) depth from bottom of cylinder head (4) to surface when valve (2) is seated against valve seat insert (1).

a. Position gauge block flat on surface of cylinder head (4) with plunger extended to cylinder head (4) surface. Adjust dial indicator to zero.

b. Position gauge block flat on surface of cylinder head (4) with plunger extended to valve (2).

c. Valve (2) depth must measure 0.035-0.056 in. (0.89-1.42 mm) below bottom surface of cylinder head (4).

d. If measurement is not within limits, use new valve (2) and repeat steps a through c.

e. If measure is beyond limit, replace cylinder head (4).

8.

Using pigment, check contact surface (9) between face of valve (2) and valve seat insert (1) (step 4d.).

9.

Clean cylinder head (4) and valves (2) after valves (2) and valve seat inserts (1) have been ground

(para. 2-14).

5-162


TM 9-2320-272-24-4

5-163

TM 9-2320-272-24-4


1.

2.

3.

4.

NOTE

• Wrap male pipe threads with antiseize tape before installation.

• Apply sealing compound to mating surfaces of expansion plugs before installation.

Install plug (8) on rear face of cylinder head (10).

Install two new expansion plugs (9) on front and rear faces of cylinder head (10).

Install new expansion plug (7) on rear face of cylinder head (10).

Install five new expansion plugs (6) on top face of cylinder head (10).

CAUTION

Position cylinder head on exhaust port face to install intake and exhaust valves. Use wooden or protective surface work bench to prevent damage to cylinder head. Bench must be clean.

5.

NOTE

Ensure intake and exhaust valves are installed in original locations as previously noted.

Dip valve (11) stems in clean engine oil and install in valve guides (5) from face side of cylinder head (10).

Carefully position cylinder head (10) face down on bench.

Install twelve new seals (4), valve springs (3), and spring retainers (2) on valves (11).

6.

7.

8.

Using spring compressor, compress valve springs (3) until collet grooves (12) on valves (11) are exposed.

NOTE

Ensure all valves are locked by collets.

9.

Install twenty-four new collets (1) in collet grooves (12) and slowly release spring compressor.

5-164


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install cylinder head (para. 4-41).

5-165

TM 9-2320-272-24-4

5-26. PISTON AND CONNECTING ROD MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Cleaning and Inspection d. Assembly e. Installation

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Engine barring tool (Appendix E, Item 43)

Ring compressor (Appendix E, Item 32)

TOOLS


Keystone gauge (Appendix E, Item 54)






Feeler gauge

Soft-headed hammer

MATERIALS/PARTS

Piston rings (Appendix D, Item 518)

Two retaining rings (Appendix D, Item 539)

Connecting rod bearing (Appendix D, Item 40)


Plastigage (Appendix C, Item 55)

REFERENCES (TM)

TM 9-2320-272-24P

EQUIPMENT CONDITlON

• Cylinder head removed (para. 4-41).

• Oil pan and suction tube removed (para. 4-47).

NOTE

All piston assemblies are replaced the same way. This procedure covers replacement of one piston assembly.

a. Removal

1.

Using engine barring tool, rotate crankshaft (6) to lower pistons (1) enough to remove all carbon from upper inside wall of each cylinder (3).

2.

Remove two nuts (8) from screws (5) and connecting rod cap (7).

3.

Using soft-headed hammer, tap screws (5) and remove connecting rod cap (7) from crankshaft (6).

CAUTION

Use a tape-protected tool to push piston from cylinder block.

Failure to do so may cause damage to cylinder liners.

NOTE

Assistant will help with step 4.

4.

Using tape-protected tool, push connecting rod (2) and piston (1) from engine block (4).

b. Disassembly

CAUTION

Pistons, connecting rods, and connecting rod caps must be kept together as an assembly. Missing parts may cause damage to equipment.

1.

Remove two retaining rings (12) from bore of piston (1). Discard retaining rings (12).

2.

Remove piston pin (13) and connecting rod (2) from piston (1).

3.

Remove ring (9), compression ring (10), and oil ring (11) from piston (1). Discard rings (9), (10), and (11).

5-166

TM 9-2320-272-24-4


4.

Remove two screws (5) from connecting rod (2).

5.

Remove upper half bearing shell (14) from connecting rod (2). Discard upper half bearing shell (14).

6.

Remove lower half bearing shell (15) from connecting rod cap (7). Discard lower half bearing shell (15).

5-167

TM 9-2320-272-24-4

5-26. PISTON AND CONNECTING ROD MAINTENANCE (Contd) c. Cleaning and Inspection

1.

For general cleaning instructions, refer to para. 2-14.

2.


3.

Replace all parts failing inspection.

NOTE

Measurements to check piston skirt outside diameters are taken at right angle to piston pin bore.

4.

5.

Measure outside diameter of piston skirt (3) at several places. If diameter is less than 4.479 in.

(113.8 mm), replace piston (4).

Check piston ring groove (5) for wear.

a. Insert keystone gauge into ring groove (5).

b. If shoulders of keystone gauge touch either end of ring groove (5), replace piston (4).

6.

Check compression ring (6) and oil ring (7) grooves for wear.

a. Insert new compression ring (1) into compression ring groove (6).

b. Try to insert 0.006 in. (0.152 mm) feeler gauge between compression ring (1) and compression ring groove (6).

c. If feeler gauge enters compression ring groove (6) without force, replace piston (4).

7.

8.

9.

10.

11.

12.

13.

14.

15.

d. Repeat steps a through c using new oil ring (2) and 0.005 in. (0.127 mm) feeler gauge to check oil ring groove (7) for wear.

Measure inside diameter of piston pin bore (9). If inside diameter exceeds 1.773 in. (45.03 mm), replace piston (4).

Measure outside diameter of piston pin (8). If outside diameter exceeds 1.771 in. (44.98 mm), replace piston pin (8).

Inspect I-beam section (15) of connecting rod (11) for nicks, dents, and gouges. If nicked, dented, or gouged, replace connecting rod (11).

Install two connecting rod screws (12) in connecting rod (11).

Install connecting rod cap (14) on connecting rod (11) with two nuts (13). Tighten nuts (13) to

73 lb-ft (99 N•m).

Check crankshaft journal bore (10) of connecting rod (11) for wear: a. Measure inside diameter of crankshaft journal bore (10) at several points 30° from each other.

b. If inside diameter measurement exceeds 2.9926 in. (76.012 mm), replace connecting rod (11).

Measure inside diameter of piston pin bore (16). If inside diameter exceeds 1.773 in. (45.03 mm), replace connecting rod (11).

Remove two nuts (13) and connecting rod cap (14) from connecting rod (11).

Check connecting rod journals (18) on crankshaft (17) for wear.

a. Measure outside diameter of six connecting rod journals (18) at A-A and B-B. If difference

exceeds 0.0005 in. (0.013), replace crankshaft (17) (para. 5-29).

b. Measure outside diameter of six connecting rod journals (18) at C-C and D-D. If difference

exceeds 0.002 in. (0.05 mm), replace crankshaft (17) (para. 5-29).

5-168


TM 9-2320-272-24-4

5-169

TM 9-2320-272-24-4


d. Assembly

1.

• Ensure numbers on pistons, connecting rods, and connecting rod caps match numbers on the mating cylinders.

• Perform step 1 if assembling with new connecting rod.

Install two connecting rod screws (8) on connecting rod (2). Ensure heads of screws (8) are on flat of connecting rod (2).

2.

3.

4.

5.

6.

Install retaining ring (13) in pin groove of piston (1).

Position connecting rod (2) in piston (1). Ensure connecting rod (2) matches FRONT mark on piston (1).

Apply clean engine oil to lubricate piston pin (7) and piston pin bore (12).

Install piston pin (7) through piston (1) and connecting rod (2).

Install retaining ring (6) in pin groove of piston (1).

NOTE

Piston rings must be installed on piston with the word TOP or supplier’s mark facing upward.

Install new oil ring (5) in oil ring groove (14).

Using piston ring expander, install new compression ring (4) and new ring (3) on piston (1).

7.

8.

NOTE

Align bearing shell tabs with connecting rod and connecting rod cap slots when installing.

9.

Install new upper half bearing shell (9) in connecting rod (2).

10.

Install new lower half bearing shell (10) in connecting rod cap (11).

5-170


TM 9-2320-272-24-4

5-171

TM 9-2320-272-24-4

5-26. PISTON AND CONNECTING ROD MAINTENANCE (Contd) e. Installation

1.

Apply clean engine oil to lubricate piston (3) and cylinder bore (5).

NOTE

Ensure piston rings are staggered properly so they are not in line with each other or piston pin.

2.

Lubricate ring compressor and install over piston rings (4) and piston (3).

3.

Using engine barring tool, rotate crankshaft (91 until connecting rod journal (11) is at bottom dead center.

CAUTION

• Ensure piston assembly number matches that of mating cylinder. Failure to do so will cause poor engine performance.

• Ring compressor must be held firmly against engine block to prevent compressor from slipping and causing piston ring breakage when pushing piston into cylinder liner.

• Do not force piston assembly into liner. If piston does not install freely in liner, remove and check for broken rings.

NOTE

Ensure piston assemblies are installed with FRONT mark facing front of engine.

4.

Insert connecting rod (7) in cylinder bore (5) and hold ring compressor tight and firmly seated against engine block (6).

5.

Using rubber or wooden mallet handle, push piston (3) from ring compressor and into cylinder bore (5) until upper half bearing (8) seats against connecting rod journal (11).

6.

Place a piece of plastic strip across lower half bearing shell (2).

7.

Install connecting rod cap (1) on connecting rod (7) with two nuts (10). Ensure numbers on connecting rod cap (1) and connecting rod (7) are aligned.

8.

Tighten two nuts (10) as follows: a. Tighten two nuts (10130 lb-ft (41 N•m).

b. Tighten two nuts (10) 60 lb-ft (81 N•m).

c. Tighten two nuts (10) 90 lb-ft (122 N•m).

9.

Remove two nuts (10) and connecting rod cap (1) from connecting rod (9).

10.

Using plastigage, measure width of plastic strip. Width should be 0.0013-0.0046 in. (0.033-0.117

mm). If width is not within limits, inspect connecting rod journal (11) (task c.).

11.

Clean connecting rod cap (1) and install on connecting rod (7) with two nuts (10). Ensure numbers on connecting rod (7) and connecting rod cap (1) are aligned.

12.

Tighten nuts (10) as follows: a. Tighten two nuts (10) 30 lb-ft (41 N•m).

b. Tighten two nuts (10) 60 lb-ft (81 N•m).

c. Tighten two nuts (10) 90 lb-ft (122 N•m).

13, Check connecting rod side clearance.

a. Move connecting rod (7) back and forth on connecting rod journal (11).

b. Using feeler gauge, measure connecting rod (7) side clearance. Clearance should be 0.004-0.012 in.

(0.1-0.030 mm). If not within limits, remove connecting rod cap (1) and inspect for proper size and seating of lower half bearing shell (2), and for dirt or burrs.

c. Repeat steps 12 and 13 to install connecting rod cap (1).

5-172


TM 9-2320-272-24-4

FOLLOW-ON TASKS: • Install cylinder head (para. 4-41).

• Install oil pan and suction tube (para. 4-47).

5-173

TM 9-2320-272-24-4

5-27. CAMSHAFT AND GEAR MAINTENANCE

THIS TASK COVERS: a. Check Backlash and End Play b. Removal c. Disassembly

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Cam bushing replacement tool

(Appendix E, Item 26)

TOOLS


Gear puller (Appendix E, Item 102)






Arbor press

Prybar

d. Cleaning and Inspection e. Assembly f. Installation

MATERIALS/PARTS

Dowel pin (Appendix D, Item 98)



Adhesive sealant (Appendix C, Item 4)

Rags (Appendix C, Item 58)


REFERENCES (TM)

TM 9-2320-272-24P


• Engine mounted on repair stand (para. 4-9).

• Rocker levers and push rods removed (para. 4-41).

• Flywheel housing removed (para. 4-43).

• Oil pan and suction tube removed (para. 4-47).

• Front gearcase cover removed (para. 4-48).


• Keep fire extinguisher nearby when using drycleaning solvent.

• Drycleaning solvent is flammable and toxic. Do not use near open flame.

a. Check Backlash and End Play

1.

Rotate engine block (2) so bottom is facing upward.

2.

Install dial indicator on engine block (2) and crankshaft gear (1).

NOTE

Prevent crankshaft from rotating when checking backlash.

Reading will be the total of both gears.

3.

Rotate camshaft gear (3) clockwise until teeth contact teeth of crankshaft gear (1).

4.

Set dial indicator to zero.

5.

Rotate camshaft gear (3) counterclockwise until teeth contact crankshaft gear (1) teeth. Ensure crankshaft gear (1) does not turn.

6.

Backlash of camshaft gear (3) should read 0.005-0.013 in. (0.13-0.33 mm). If reading is not within limits, replace camshaft (tasks b through f.).

7.

Position dial indicator on face of camshaft gear (3). Press camshaft gear (3) towards rear of engine block (1).

8.


9.

Pull camshaft gear (3) to front of engine block (1).

10.

End play of camshaft gear (3) should read 0.006-0.010 in. (0.152-0.254 mm). If reading is not within limits, replace camshaft support (tasks b through f).

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TM 9-2320-272-24-4

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TM 9-2320-272-24-4

5-27. CAMSHAFT AND GEAR MAINTENANCE (Contd) b. Removal

1.

Install two vibration damper screws (1) on crankshaft (3).

2.

Using prybar, prevent crankshaft (3) from rotating.

3.

Remove nut (6) and lockwasher (7) from drive gear (8). Discard lockwasher (7).

4.

Using gear puller, remove drive gear (8) from fuel injection pump shaft (5).

5.

Rotate crankshaft (3) and align timing marks (14) on crankshaft gear (2) and camshaft gear (4).

6.

Remove two screws (12) from camshaft support (11) and engine block (9).

CAUTION

Use care when removing camshaft. Damage to camshaft and bushings may result.

7.

Remove camshaft (13) and camshaft support (11) from engine block (9).

NOTE

Tag all valve tappets for installation.

8.

Rotate crankshaft (3) as necessary to remove twelve valve tappets (10) from engine block (9).

c. Disassembly

NOTE

Before removing camshaft gear from camshaft, perform task d of this procedure. If, as a result of inspection, the camshaft or camshaft gear requires replacement, perform steps 1 and 2.

1.

Using arbor press, press camshaft gear (4) from camshaft (13).

2.

Remove dowel pin (15) from camshaft (13). Discard dowel pin (15).

5-176


TM 9-2320-272-24-4

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TM 9-2320-272-24-4

5-27. CAMSHAFT AND GEAR MAINTENANCE (Contd) d. Cleaning and Inspection

3.

4.

1.

2.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

WARNING



Clean all camshaft (6) components with drycleaning solvent and dry with clean rag.

Inspect camshaft support (1) for wear. Replace camshaft support (1) if excessively worn.

Inspect camshaft (6) for cracks, pits, and breaks. Replace camshaft (6) if cracked, pitted, or broken.

Inspect exhaust (4) and intake (2) camshaft lobes for wear.

a. Measure outside diameter of exhaust camshaft lobe (4) at several positions. Replace camshaft (6) if outside diameter is less than 2.0313 in. (1.5950 mm).

b. Measure outside diameter of intake camshaft lobe (2) at several positions. Replace camshaft (6) if outside diameter is less than 2.0383 in. (51.7728 mm).

c. Measure outside diameter of lift pump lobe (5) at several positions. Replace camshaft (6) if outside diameter is less than 1.626 in. (59.9618 mm).

Inspect camshaft journals (3) for wear. Measure outside diameter of camshaft journals (3) at several positions. Replace camshaft (6) if outside diameter is less than 2.3067 in. (59.9618 mm).

Inspect camshaft gear (7) for cracks, pits, and breaks. Replace camshaft gear (7) if cracked, pitted, or broken.

Inspect camshaft gear teeth (8) for pitting and cracks at root of teeth (8). Replace camshaft gear (7) if pitted or cracked.

Inspect camshaft bushings (9) for wear. Measure inside diameter of camshaft bushing (9) at several positions. If inside diameter exceeds 2.367 in. (60.122 mm), mark camshaft bushing (9) for replacement.

NOTE

Perform steps 9 through 14 for replacing camshaft bushings.

Remove expansion plug (11) from rear of engine block (10). Discard expansion plug (11).

Using cam bushing replacement tool, remove camshaft bushing (9) from bushing bore (14). Discard camshaft bushing (9).

Measure inside diameter of camshaft bores (14). Replace engine block (10) if inside diameter exceeds 2.520 in. (64.008 mm).

CAUTION

When installing camshaft bushing, ensure oil hole and oil hole passages are aligned. Failure to do so will result in premature failure and damage to engine.

Mark engine block (10) and new camshaft bushing (9) to ensure oil holes (12) and (13) are aligned.

Using cam bushing replacement tool, install new camshaft bushing (9) in camshaft bushing bore (14).

NOTE

Perform step 14 if rear camshaft bushing was removed.

Apply adhesive sealant to mating surfaces of new expansion plug (11) and install on engine block (10).

5-178


TM 9-2320-272-24-4

5-179

TM 9-2320-272-24-4


15.

Inspect valve tappets (2) for nicks, burrs, and wear. Replace tappet(s) (2) if nicked, burred, or worn.

1 6 . Measure outside diameter of tappet stem (1). Replace tappet(s) (2) if outside diameter is less than

0.628 in. (15.95 mm).

17.

Inspect tappet bores (8) for scoring and wear. Replace engine block (7) if excessively scored or worn.

18.

Measure inside diameter of tappet bore (8). Replace engine block (7) if inside diameter exceeds

0.632 in. (16.05 mm).

NOTE

Perform steps 1 through 3 if camshaft gear was removed.

1.

Install new dowel pin (3) in camshaft (4).

2.

Apply GM grease to coat camshaft lobe (5).

3.

Using arbor press, press camshaft gear (6) on camshaft (4).

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TM 9-2320-272-24-4

5-27. CAMSHAFT AND GEAR MAINTENANCE (Contd) f. Installation

NOTE

• Used valve must be installed in mating tappet bores. If valve tappet position was not noted during removal, replace all valve tappets.

• Do not reuse old valve tappets if installing new camshaft.

1.

Rotate crankshaft (10) as necessary to access tappet bores (8).

2.

Coat twelve tappets (2) with GAA grease and install in tappet bores (8).

CAUTION

Use care when installing camshaft. Camshaft and bushings are easily damaged.

3.

Apply coat of GM grease to camshaft (4) and install in engine block (7). Ensure timing marks (13) of camshaft gear (6) and crankshaft gear (9) are aligned.

4.

Install camshaft support (11) on engine block (7) with two screws (12). Tighten screws (12) 18 lb-ft

(24 N•m).

5.

Check backlash and end play of camshaft (4) for proper seating (task a).

5 - 1 8 1

TM 9-2320-272-24-4


6.

7.

8.

Using prybar between two vibration damper screws (1), rotate crankshaft (2).

Press in timing pin (15), while rotating crankshaft (2), until timing pin (15) engages camshaft gear (3).

Remove access plug (9), copper washer (8), and fuel injection pump timing pin (10) from fuel injection pump (11).

9.

Install nut (4) on fuel injection pump shaft (12) and rotate until timing tooth (14) is visible in timing pin hole (13).

10.

Install fuel injection pump timing pin (10) in hole (13). Ensure slot (7) of fuel injection pump timing pin (10) is positioned over timing tooth (14).

11.

12.

Install copper washer (8) and access plug (9) on fuel injection pump (11).

Remove nut (4) from fuel injection pump shaft (12).

NOTE

Do not exceed torque limit for fuel injection pump drive gear nut.

Torque is not the final limit.

13.

Install drive gear (6) on fuel injection pump shaft (12) with new lockwasher (5) and nut (4). Tighten nut (4) 7-11 lb-ft (10-15 N•m).

14.

15.

16.

Disengage timing pin (15) from camshaft gear (3).

Remove access plug (9), copper washer (8), and timing pin (10) from fuel injection pump (11).

Install timing pin (10) in fuel injection pump (11) with slot (7) facing outward from fuel injection pump (11).

17.

Install copper washer (8) and access plug (9) on fuel injection pump (11).

18.

Using prybar between two vibration damper screws (1), tighten nut (4) 80 lb-ft (109 N•m).

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TM 9-2320-272-24-4

FOLLOW-ON TASKS: • Install oil pan and suction tube (para. 4-47).

• Install front gearcase cover (para. 4-48).

• Install flywheel housing (para. 4-43)

• Install rocker levers and push rods tpara. 4-41)

• Remove engine from repair stand (para. 4-9).

5-183

TM 9-2320-272-24-4


THIS TASK COVERS: a. Cylinder Liner Inspection b. Cylinder Liner Removal c. Engine Block Disassembly d. Cylinder Liner and Engine Block Cleaning and Inspection e. Engine Block Assembly f. Cylinder Liner Installation

INITIAL SETUP:


M939A2

REFERENCES (TM)

TM 9-2320-272-24P

SPECIAL TOOLS EQUIPMENT CONDITION

Cylinder liner puller (Appendix E, Item 107)

Cylinder liner driver (Appendix E, Item 79)

• Connecting rods and pistons removed (para. 5-26).

• Camshaft removed (para. 5-27).

Two cylinder liner clamps (Appendix E, Item 35)

• Crankshaft removed (para. 5-29).

TOOLS GENERAL SAFETY INSTRUCTIONS


• Keep fire extinguisher nearby when using


drycleaning solvent.



• Drycleaning solvent is flammable and toxic.



Feeler gauge

• Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa).

MATERIALS/PARTS

Cylinder block kit (Appendix D, Item 93)

Cylinder liner seal (Appendix D, Item 95)


Rags (Appendix C, Item 58)


Detergent (Appendix C, Item 27)




a. Cylinder Liner Inspection

CAUTION

Do not hone or deglaze cylinder liners. Honing or deglazing will prevent oil ring from sealing properly.

NOTE

Inspect all cylinder liners to determine need for replacement.

1.

Inspect cylinder liner (1) for vertical scratches, grooves, pits, scuffing, scoring, and cracks. Tag cylinder liner (1) for replacement if scratched, grooved, pitted, scuffed, scored, or cracked.

2.

Inspect for dirt or debris embedded in walls of cylinder liner (1). Tag cylinder liner (1) for replacement if debris is present.

3.

Inspect walls of cylinder liner (1) for heavy polishing and wear. Heavy polishing exists when wall has a bright mirrored finish. Tag cylinder liner (1) for replacement if heavy polishing exists.

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TM 9-2320-272-24-4


4 . Check cylinder liner (1) for wear: a. Measure inside diameter of cylinder liner (1) in two places offset 90° at top of piston travel.

b. Record inside diameter measurements A and B.

c. Measure inside diameter of cylinder liner (1) in two places offset 90° at bottom of piston travel.

d. Record inside diameter measurements C and D.

e. Compare inside diameter measurements A with B and C with D. Tag cylinder liner (1) for replacement if difference exceeds 0.0016 in. (0.041 mm).

f. Compare inside diameter measurements A with D and B with C. Tag cylinder liner (1) for replacement if difference exceeds 0.0016 in. (0.041 mm).

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TM 9-2320-272-24-4

5-28. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) b. Cylinder Liner Removal

NOTE

All cylinder liners are removed the same way. This procedure covers the removal of one cylinder liner.

1.

Scribe a mark (3) across cylinder liner (2) and engine block (4) for installation.

CAUTION

Do not install cylinder liner puller on lower block ledges. Failure to comply may cause damage to engine block.

NOTE

Tag all cylinder liners with mating cylinder bore number for installation.

2.

Install cylinder liner puller on engine block (4) and cylinder liner (2). Ensure cylinder liner puller does not catch on lower block ledges (5).

3.

Remove cylinder liner (2) from engine block (4).

4.

Remove cylinder liner seal (1) from cylinder liner (2). Discard cylinder liner seal (1).

5-186


TM 9-2320-272-24-4

5-187

TM 9-2320-272-24-4

5-28. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) c. Engine Block Disassembly

NOTE

Mark position and location of pipe and expansion plugs for installation.

1.

Remove expansion plug (1) from engine block (2). Discard expansion plug (1).

2.

Remove three expansion plugs (12) from engine block (2). Discard expansion plugs (12).

3.

Remove two expansion plugs (11) from engine block (2). Discard expansion plugs (11).

4.

Remove drainvalve (10) from engine block (2).

5.


6.

Remove pipe plugs (5) and (9) from engine block (2).

7.


8.


9.


NOTE

Perform step 10 if dowel pins are damaged.

10.

Remove four dowel pins (3) from engine block (2). Discard dowel pins (3).

11.

Remove three pipe plugs (16) from engine block (2).

12.

Remove expansion plugs (13) and (17) from engine block (2). Discard expansion plugs (13) and (17).

13.


5-188


NOTE

Perform step 14 if dowel pins are damaged.

14.

Remove two dowel pins (14) from engine block (2). Discard dowel pins (14).

15.

Remove six piston cooling nozzles (18) from engine block (2).

NOTE

Perform step 16 for late model engine.

16.

Remove twelve piston cooling nozzles (18) from engine block (2).

TM 9-2320-272-24-4

5-189

TM 9-2320-272-24-4

5-28. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) d. Cylinder Liner and Engine Block Cleaning and Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

WARNING

• Drycleaning solvent is flammable and toxic. Do not use near an open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to do this may result in injury or death to personnel and/or damage to equipment.

• Eyeshields must be worn when cleaning with compressed air.


CAUTION

• Do not allow debris to fall into crankshaft oil holes. Damage to crankshaft bearings could result.

• Do not remove stock material from cylinder liner seating surface when cleaning. Machined tolerances are critical and premature engine failure will result if material is removed.

Cover crankshaft oil holes (6) with clean rags.

Clean all expansion plug holes of engine block (2) with drycleaning solvent. Dry with compressed air.

Clean sealing surfaces (3), (4), and (5) of engine block (2) with crocus cloth and drycleaning solvent.

Inspect sealing surfaces (3), (4), and (5) for cracks, pits, scores, and excessive wear. Replace engine block (2) if cracked, pitted, scored, or excessively worn.

Measure inside diameter of sealing surface (4). Replace engine block (2) if inside diameter exceeds

5.2342 in. (132.949 mm).

Clean all oil draining and water cooling passage bores with brush and drycleaning solvent. Dry with compressed air.

CAUTION

Engine block deck can be resurfaced twice in increments of

0.010 in. (0.254 mm). Do not exceed 0.020 in. (0.508 mm) when resurfacing or damage to equipment will result.

Using straight edge and feeler gauge, inspect engine block (2) deck for warping. Replace engine block (2) if warping exceeds 0.008 in. (0.203 mm). Notify your supervisor.

Install seven main bearing caps (8) on engine block (2) with fourteen screws (9). Tighten screws (9) 130 lb-ft (176 N•m).

Using bore gauge, measure inside diameter of main bearing bore (10). Record measurement.

Replace main bearing (7) if inside diameter exceeds 3.8632 in. (98.125 mm).

Using bore gauge, measure inside diameter of camshaft bore (12). Replace bushing (13) if inside diameter exceeds 2.367 in. (60.12 mm).

Measure inside diameter of tappet bore (11). Replace engine block (2) if inside diameter exceeds

0.632 in. (16.05 mm).

NOTE

Cylinder liners should be inspected before cleaning so defects can be clearly noted.

Check cylinder liner (1) for cracks, scoring, or vertical grooves. Replace cylinder liner (1) if cracked, scored, or vertical grooves are present.

Check cylinder liner (1) for pits and eroded surfaces. Replace cylinder liner (1) if pitted or eroded.

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TM 9-2320-272-24-4


14.

Check cylinder liner (1) for fretting and breaks in machined areas. Replace cylinder liner (1) if fretted or broken.

15.

Check cylinder liner (1) for rust, scaling, and corrosion.

a. Clean with steam or hot water and detergent.

b. Replace if excessively rusted, scaled, or corroded.

5 - 1 9 1

TM 9-2320-272-24-4

5-28. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) e. Engine Block Assembly

CAUTION

Ensure all engine block oil passages are free of obstructions.

Failure to do so may result in damage to engine.

NOTE

• Perform step 1 for late model engines, serial number 44487830 and after.

• Perform step 2 if dowel pins were removed.

1.

Install twelve piston cooling nozzles (7) in engine block (2).

2.

Install two new dowel pins (3) in engine block (2).

3.

Install six piston cooling nozzles (7) in engine block (2).

NOTE

• Apply adhesive sealant to mating surfaces of all expansion plugs before installation.

• Wrap male pipe threads with antiseize tape before installation.

4.

Install new expansion plug (4) in engine block (2).

5.

Install new expansion plugs (6) and (1) on engine block (2).

6.

Install three pipe plugs (5) on engine block (2). Tighten pipe plugs (5) 6 lb-ft (8 N•m).

NOTE

Perform step 7 if dowel pins were removed.

7.

Install four new dowel pins (8) on engine block (2).

8.

Install new expansion plug (13) on engine block (2).

9.


10.


11.

Install pipe plugs (10) and (14) on engine block (2). Tighten pipe plug (14) 6 lb-ft (8 N•m). Tighten pipe plug (10) 27 lb-ft (37 N•m).

12.


13.

Install new drainvalve (15) on engine block (2).

14.

Install two new expansion plugs (16) on engine block (2).

15.

Install three new expansion plugs (17) on engine block (2).

16.


5-192


TM 9-2320-272-24-4

5-193

TM 9-2320-272-24-4

5-28. CYLINDER LINERS AND BLOCK MAINTENANCE (Contd) f. Cylinder Liner Installation

NOTE

All cylinder liners are installed the same. This procedure covers installation of one cylinder liner.

1.

Apply clean engine oil to lubricate cylinder liner bore (4).

2.

Install new cylinder liner seal (2) on cylinder liner (1).

3.

Apply clean engine oil to lubricate sealing surfaces (5), (6), and (7), cylinder liner (1), and cylinder liner seal (2).

4.

Install cylinder liner (1) in mating cylinder liner bore (4).

NOTE

Perform step 5 if installing old cylinder liner.

5.

Rotate cylinder liner (1) 1/8 turn from position noted in removal. Using cylinder liner driver, drive cylinder liner (1) until it bottoms in cylinder liner bore (4).

6.

Install two cylinder liner clamps on engine block (3) with two washers and screws. Tighten screws

50 lb-ft (68 N·m).

7.

Remove two screws, washers, and cylinder liner clamps from engine block (3).

8.

Using gauge block, measure cylinder liner protrusion: a. Position gauge block on engine block (3).

b. Place plunger on engine block (2) and set dial indicator to zero.

c. Position gauge block on engine block (3) and place plunger on cylinder liner (1).

d. Cylinder liner protrusion should be 0.005-0.0043 in. (0.0127-0.1092 mm).

e. Check cylinder liner (1) for proper installation if cylinder liner protrusion is not within limits.

f. If installed correctly, counterbore of engine block (3) will require cutting. Notify your supervisor.

9.

Check clearance between cylinder liner (1) and lower block ledges (8) using 0.009 in. (0.229 mm) feeler gauge. If feeler gauge does not pass between cylinder liner (1) and lower bottom ledges (8), remove cylinder liner (1) and reinstall.

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TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install connecting rods and pistons (para. 5-26).

Install crankshaft (para. 5-29).

Install camshaft (para. 5-27).

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TM 9-2320-272-24-4

5-29. CRANKSHAFT AND GEAR MAINTENANCE


Check End Play b. Removal c . Disassembly

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Torque angle gauge (Appendix E, Item 141)

TOOLS


Heavy duty gear puller (Appendix E, Item 102)



Feeler gauge

Prybar

Soft-head hammer

Nylon brush

MATERIALS/PARTS

Dowel pin (Appendix D, Item 99)

Crankshaft main bearing set





Plastigage (Appendix C, Item 55)


d.

Cleaning and Inspection e. Assembly f .

Installation

REFERENCES (TM)

TM 9-2320-272-24P



Oil pan and suction tube removed (para. 4-47).

Front gearcase housing removed (para. 4-46).

Flexplate and flywheel housing removed

(para. 4-43).

Rear cover and oil seal removed (para. 4-44).


Drycleaning solvent is flammable and toxic. Do not use near open flame.


Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa).

a. Check End Play

1.

Position engine block (2) so crankshaft (1) is facing upward.

2.

Install dial indicator on engine block (2) with plunger on face of crankshaft gear (3).

3.

Move crankshaft (1) towards rear of engine block (2) using prybar.

4.


5.

Move crankshaft (1) toward front of engine block (2) using prybar. Record dial indicator reading.

6.

Replace thrust bearing in subtasks b and f if crankshaft (1) end play is not between 0.006-0.013 in.

(0.152-0.330 mm).

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TM 9-2320-272-24-4

5-29. CRANKSHAFT AND GEAR MAINTENANCE (Contd) b. Removal

NOTE

Tag all connecting rod caps, main bearing caps, mating cylinders, and bearings for installation.

All connecting rod caps and main bearing caps are removed the same.

1.

Remove twelve nuts (5) from six connecting rod caps (4).

2.

Using soft-head hammer, tap screws (6) and remove connecting rod caps (4) from crankshaft (1).

3.

Remove fourteen screws (8) from seven main bearing caps (9).

4.

Loosen main bearing caps (9) and remove from crankshaft (1) using screws (8).

5.

Remove seven lower main bearings (7) from main bearing caps (9). Discard bearings (7).

6.

Remove crankshaft (1) from engine block (2).

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TM 9-2320-272-24-4

5-29. CRANKSHAFT AND GEAR MAINTENANCE (Contd)

7.

Remove six upper main bearings (5) and thrust bearing (6) from engine block (4). Discard bearings (5) and (6).

NOTE

Perform step 8 for late model engines, serial number 44487830 and after.

8.

Remove twelve piston cooling nozzles (7) from engine block (4).

9.

Remove six piston cooling nozzles (7) from engine block (4).

c. Disassembly

NOTE

Before removing crankshaft gear from crankshaft, perform subtask d of this procedure. If, as a result of inspection, the crankshaft gear must be removed, perform steps 1 and 2.

1.

Using gear puller, remove crankshaft gear (3) from crankshaft (1).

2.

Remove dowel pin (2) from crankshaft (1). Discard dowel pin (2).

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TM 9-2320-272-24-4

5-29. CRANKSHAFT AND GEAR MAINTENANCE (Contd) d. Cleaning and Inspection

1.

2.

3.

4.

WARNING

Drycleaning solvent is flammable and toxic. Do not use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to do this may result in injury or death to personnel and/or damage to equipment.



Clean all parts with drycleaning solvent and dry with compressed air. Use nylon brush to clean all oil passages.

Inspect crankshaft (1) for cracks, gouges, pits, burrs, nicks, and scratches. Remove minor damage with fine mill file or crocus cloth. If excessively cracked, gouged, pitted, burred, nicked, or scratched, replace crankshaft (1).

Inspect crankshaft gear (3) for cracks, breaks, and damaged teeth. If cracked, broken, or teeth are damaged, replace crankshaft gear (3).

Inspect connecting rod journals (9) and main bearing journals (8) for scratches, grooves, excessive wear, and discoloring caused by overheating. Replace crankshaft (1) if scratched, grooved, worn, or discolored.

5-199

TM 9-2320-272-24-4


5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Inspect connecting rod caps (14) for cracks, breaks, and pits. Replace connecting rod caps (14) if cracked, broken, or pitted.

Inspect main bearing caps (7) for cracks, breaks, and pits. Replace main bearing caps (7) if cracked, broken, or pitted.

Inspect engine block (9) for scratches, grooves, wear, and stripped threads. Replace or repair if engine block (9) is scratched, grooved, worn, or threads are stripped.

Measure outside diameter of main bearing journals (2) for out-of-roundness across points A and B.

Replace crankshaft (1) if difference of measurements exceeds 0.002 in. (0.0051 mm).

Measure outside diameter of main bearing journals (2) for taper at points C and D. Replace crankshaft (1) if difference of measurements exceeds 0.0005 in. (0.013 mm).

Measure outside diameter of connecting rod journals (3) for out-of-roundness across points A and B.

Replace crankshaft (1) if difference of measurements exceeds 0.002 in. (0.0050 mm).

Measure outside diameter of connecting rod journals (3) for taper at points C and D. Replace crankshaft (1) if difference of measurements exceeds 0.0005 in. (0.0127 mm).

Inspect front (4) and rear (5) crankshaft seal wear surfaces for scratches and grooves. Replace crankshaft (1) if scratched or grooved.

CAUTION

Ensure main bearings are installed in proper mating seats.

Failure to do so will cause engine to fail.

Install new thrust bearing (8) in No. 4 main bearing seat (11).

Install six new upper main bearings (7) in main bearing seats (10). Ensure tangs (12) of upper main bearings (7) are aligned with slots (13) of main bearings seats (10).

Install crankshaft (1) in engine block (9).

Install seven new lower main bearings (6) in main bearing caps (7).

Place plastic strips across width of seven main bearing journals (2).

5-200


TM 9-2320-272-24-4

5-201

TM 9-2320-272-24-4


NOTE

Ensure main bearing caps are installed with mating cylinders.

Number on main bearing caps should face camshaft.

18.

Apply clean engine oil to coat threads of fourteen screws (2).

19.

Position seven main bearing caps (3) on engine block (14) and crankshaft (7) and tap main bearing caps (3) using soft-head hammer until seated on main bearing journals (6).

20.

Install main bearing caps (3) on engine block (14) with fourteen screws (2). Tighten screws (2)

125 lb-ft (170 N·m) in sequence shown.

21.

Remove fourteen screws (2) and seven main bearing caps (3) from engine block (14).

22.

Measure width of plastic strip at widest point using plastigage. If plastic strip does not measure

0.0026-0.0053 in. (0.660-0.1346 mm), replace all upper (10), lower (1), and thrust (11) bearings.

e. Assembly

NOTE

Perform steps 1 through 3 if gear was removed.

1.

Install new dowel pin (5) in crankshaft (7).

2.

Apply GAA grease to lobe (8) of crankshaft (7).

3.

Press crankshaft gear (9) on crankshaft (7).

f. Installation

CAUTION

Late and early model engine main bearings and main bearing caps and components are not interchangeable. Mixing components will cause damage to engine.

NOTE

Perform step 1 if inspection did not require replacement of main bearings.

Perform step 3 for late model engines, serial number 44487830 and after.

Piston cooling nozzles are located in all upper chain bearing seats, except for No. 3 cylinder.

1.

Remove six upper main bearings (10) and thrust bearing (11) from engine block (14).

2.

Install six piston cooling nozzles (15) in upper main bearing seats (12). Ensure piston cooling nozzles (15) seat below main bearing surface.

3.

Install twelve piston cooling nozzles (15) in upper main bearing seats (12). Ensure piston cooling nozzles (15) seat below main bearing surface.

NOTE

Apply lubricating oil to all main bearings and bearing surfaces.

4.

Align tangs (16) of six upper main bearings (10) with slots (17) of main bearing seats (12) and install on engine block (14).

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TM 9-2320-272-24-4


5 .

Install thrust bearing (11) in No. 4 main bearing seat (13).

6.

Install crankshaft (7) in engine block (14).

NOTE

Perform step 7 if inspection required replacement of lower main bearings.

7.

8.

9.

10.

Align tangs (4) of seven lower main bearings (1) with slots of main bearing caps (3) and install seven lower main bearings (1) in main bearing caps (3).

Apply clean engine oil to main bearing journals (6) and install seven main bearing caps (3) on engine block (14).

Using soft-head hammer, tap main bearing caps (3) until seated against main bearing journals (6).

Apply clean engine oil to threads of fourteen screws (2) and install on main bearing caps (3).

11.

Tighten screws (2) as follows:

12.

13.

a.

Tighten screws (2) 125 lb-ft (170 N·m) in sequence shown. Loosen screws (2).

b.

Tighten screws (2) to 70 lb-ft (95 N·m) in sequence shown.

c.

Using torque angle gauge, tighten screws (2) an additional 45-75°.

Rotate crankshaft (7) and check for freedom of movement.

Check crankshaft (7) end play (task a).

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TM 9-2320-272-24-4


19.

20.

21.

22.

23.

14.

15.

16.

17.

18.

NOTE

All connecting rod caps are installed the same. This procedure covers the installation of one connecting rod cap.

Rotate crankshaft as necessary to access connecting rod journals.

Place a piece of plastic strip across width of connecting rod cap (1).

Install connecting rod cap (1) on crankshaft (2) and connecting rod (3) with two nuts (4).

Tighten nuts (4) 30 lb-ft (41 N·m), then 60 lb-ft (81 N·m), then 90 lb-ft (122 N·m).

Remove two nuts (4) and connecting rod cap (1) from connecting rod (3) and crankshaft (2).

Using plastigage, measure width of plastic strip. If width is not 0.0013-0.0046 in.

(0.033-0.117 mm), replace all connecting rod bearings (5) and (6).

Apply clean engine oil to lubricate connecting rod cap (1).

Install connecting rod cap (1) on crankshaft (2) and connecting rod (3) with two nuts (4).

Tighten nuts (4) 30 lb-ft (41 N·m), then 60 lb-ft (81 N·m), then 90 lb-ft (122 N·m).

Move connecting rod (3) back and forth on crankshaft (2).

Measure connecting rod (3) side clearance using feeler gauge. If clearance is not 0004-0.012 in.

(0.1-0.30 mm), remove connecting rod cap (1) and inspect for proper size and seating of bearings (5) and (6).

5-204


TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install rear cover and oil seal (para. 4-44).

Install flexplate and flywheel housing (para. 4-43).

Install front gearcase housing (para. 4-46).

Install oil pan and suction tube (para. 4-47).

Install fuel injectors (para. 4-55).

5-205

TM 9-2320-272-24-4

5-30. ROCKER LEVERS AND PUSH RODS MAINTENANCE

THIS TASK COVERS: a. Disassembly b.

Cleaning and Inspection c. Assembly

INITIAL SETUP:


M939A2

TOOLS





MATERIALS/PARTS

Twelve locknuts (Appendix D, Item 326)



REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


Parking brake set (TM 9-2320-272-10).

Rocker-levers and push rods removed (para. 4-41).



Drycleaning solvent is flammable and toxic.

Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa).

a. Disassembly

NOTE

All rocker levers are disassembled the same way. This procedure covers one rocker lever assembly.

1.

Remove two retaining rings (2), washers (3), spring washers (4), and rocker levers (1) from rocker shaft (7).

2.

Remove locknut (5) and adjusting screw (6) from each rocker lever (1). Discard locknut (5).

b. Cleaning and Inspection

1.

For general cleaning instructions, refer to para. 2-14

2.


3.

Replace all parts failing inspection.

4.

Measure inside diameter of rocker lever bore (8) at several points, If inside diameter exceeds

0.878 in. (22.3 mm), replace rocker lever (1).

5.

Measure outside diameter of rocker shaft (7) at several points. If outside diameter is less than 0.874

in. (22.2 mm), replace rocker shaft (7).

5-206

5-30. ROCKER LEVERS AND PUSH RODS MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-207

TM 9-2320-272-24-4





6.

Inspect oil manifold (2) for bends, cracks, and breaks. If bent, cracked, or broken, replace oil manifold (2).

CAUTION

Oil manifold screws are self-tapping and must be reinstalled in their proper positions to ensure proper alignment of screw flats or damage may occur to oil manifold.

7.

Inspect oil manifold (2) for clogged oil ports. If oil ports are clogged, remove two screws (1), flush oil manifold (2) with drycleaning solvent. Dry with compressed air and replace two screws (1) in oil manifold (2).

d. Assembly

All rocker levers are assembled the same way. This procedure is for one rocker lever assembly.

Lightly oil all parts before assembling.

Perform step 1 if assembling with new rocker shaft.

1.

Install two plugs (8) on rocker shaft (13).

2.

Install adjusting screw (12) and new locknut (7) on each rocker lever (6).

3.

Install spring washer (5), washer (4), and retaining ring (3) on one side of rocker shaft (13).

4.

Install two rocker levers (6) on rocker shaft (13).

5.

Install spring washer (11), washer (10), and retaining ring (9) on rocker shaft (13).

5-208


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install rocker levers and push rods (para. 4-41).

5-209

TM 9-2320-272-24-4

5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND

THIS TASK COVERS: a. Mounting Fuel Injection Pump to

Test Stand b. Removing Fuel Injection Pump from

Test Stand

INITIAL SETUP:


M939A2

TOOLS


Fuel injection pump test stand (Appendix E,

Item 50)

MATERIALS/PARTS


Two copper washers (Appendix D, Item 42)

Copper washer (Appendix D, Item 45)


REFERENCES (TM)

TM 9-2320-272-24P


Fuel injection pump removed (para. 4-57).

a. Mounting Fuel Injection Pump to Test Stand

1.

Remove screw plug (11) and copper washer (12) from drive end of fuel pump (14). Discard copper washer (12).

2.

Install adapter ring (23) on adapter bracket (6) with three washers (9) and screws (10).

3.

Install adapter bracket (6) on test stand (20) with washer (7), screw (8), and clamp bar (25).

4.

Install fuel pump (14) on adapter bracket (6) with four washers (26), screws (27), washers (22), and nuts (21).

5.

Install woodruff key (13) and drive hub (3) on fuel pump (14) with lockwasher (2) and nut (1).

6.

Slide fuel pump (14) forward so drive hub (3) engages with drive coupling (28) and secure fuel pump (14) in place with four lockwashers (4) and nuts (5).

7.

Install rear support bracket (19) on rear of fuel pump (14) with two washers (17) and screws (18).

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TM 9-2320-272-24-4

5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND (Contd)

8.

Install rear support bracket (19) and clamp bar (24) on test stand (20) with two washers (16) and screws (15).

9.

Connect six test stand fuel lines (30) to delivery valve holders (29) and test stand injectors.

10.

Connect air line (32) to manifold pressure compensator (31).

11.

Remove plug (36), two copper washers (35), and adapter (37) from fuel pump (14). Discard copper washers (35).

12.

Install outlet elbow (34) on fuel pump (14).

13.

Connect test stand supply line (33) to outlet elbow (34).

14.

Remove plug (38) and copper washer (39) from side of fuel pump (14) for access to number one cylinder. Discard copper washer (39).

15.

Refer to table 5-10, Test Stand Requirements, for further preliminary requirements.

Calibration Fluid Temperature

Inlet Pressure

Opening Pressure

Firing Order

Select Drive Rotation

Direction of Drive Rotation

Number of Injection Cylinders

ITEM

Table 5-10. Test Stand Requirements.

REQUIREMENTS

100°-108°F (38°-42°C)

22 psi (152 kPa)

3,000-3,046 psi (20,684-21,001 kPa)

1-5-3-6-2-4

1:2

Clockwise

Six

5-211

TM 9-2320-272-24-4

5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND (Contd) b. Removing Fuel Injection Pump from Test Stand

1.

Install new copper washer (10) and plug (9) on fuel pump (11).

2.

Disconnect test stand supply line (4) from outlet elbow (5).

3.

Remove outlet elbow (5) from fuel pump (11).

4.

Install two new copper washers (6), adapter (8), and plug (7) on fuel pump (11).

5.

Disconnect air line (3) from manifold pressure compensator (2).

6.

Disconnect six test stand fuel lines (1) from delivery valve holders (12).

7.

Remove two screws (29) and washers (28) from rear support bracket (30).

8.

Remove four nuts (17) and lockwashers (16) from drive coupling (39). Discard lockwashers (16).

5-212

TM 9-2320-272-24-4

12.

13.

14.

15.

16.

9.

10.

11.

5-31. MOUNTING FUEL INJECTION PUMP TO TEST STAND (Contd)

Remove four nuts (32), washers (33), screws (38), and washers (37) from adapter bracket (18).

Loosen screw (20) and slide fuel pump (11) from drive coupling (39).

Remove nut (13), lockwasher (14), drive hub (15), and woodruff key (25) from fuel pump (11).


Remove fuel pump (11) from adapter bracket (18) and test stand (31).

Install new copper washer (22) and screw plug (21) on fuel pump (11).

Remove three screws (24), washers (23), and adapter ring (34) from adapter bracket (18).

Remove screw (20), washer (19), adapter bracket (18), and clamp bar (36) from test stand (31).

Remove two screws (26), washers (27), rear support bracket (30), and clamp bar (35) from test stand (31).

FOLLOW-ON TASK: Install fuel injection pump (para. 4-57).

5-213

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST

THIS TASK COVERS: a. Prestroke and Rack Travel b. Cylinder Phasing (Timing) c. High-speed Fuel Delivery Test d. Low-speed Fuel Delivery Test e. Rated Speed Test f. Full Load Delivery g. Manifold Pressure Compensator Test h. Start Cut Out Test

I. Fuel Delivery Test j. Fuel Breakaway Test k. Starting Fuel Delivery Test l. Low Idle Fuel Delivery Test

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Rack extension (Appendix E, Item 112)

Plunger lift device (Appendix E, Item 98)

TOOLS


Dial Indicator (Appendix E, Item 36)

MATERIALS/PARTS


REFERENCES (TM)

TM 9-2320-272-24P

TM 9-4910-778-14&P


Fuel injection pump mounted to test stand (para. 5-31).

NOTE

Refer to TM 9-4910-778-14&P for operation of fuel injection pump test stand, DFP 156.

If readings taken during pretest deviate from specifications listed below, fuel pump must be repaired.

a. Prestroke and Rack Travel

1.

2.

3.

Mount dial indicator (10) and rack travel indicator holder (9) on drive end of fuel pump (13).

Install rack extension (11) on control rack (12).

Pull control lever (2) to full load position and, using rack extension (11), push control rack (12) all the way back.

Preload dial indicator (10) giving control rack (12) 0.004 in. (0.1 mm) of preload travel.

4.

5.

Install plug (3) in return line access hole (14).

NOTE

Cylinder number one is located at drive end of fuel pump.

6.

Rotate test stand driveshaft until tappet reaches bottom dead center.

Install plunger lift device (5) on fuel pump (13) with finger of plunger lift device (5) resting on top of tappet located in cylinder number one.

7.

Mount dial indicator (4) on plunger lift device (5) and zero dial indicator (4).

8.

Manually rotate test stand driveshaft (8) until a reading is observed on dial indicator (4).

9.

Manually reverse rotation test stand driveshaft (8) until dial indicator (4) reads zero.

10.

Apply 435-464 psi (2,999-3,190 kPa) of calibration fluid pressure.

5-214

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST (Contd)

NOTE

Ensure a steady stream of calibration fluid flows from all bleed-off valves. If not, increase calibration fluid pressure until a steady stream of calibration fluid is obtained.

11.

Manually rotate test stand driveshaft (8) in correct fuel pump rotation until calibration fluid stops flowing from bleed-off valve (1).

12.

Check prestroke measurement. Measurement should be 0.360-0.480 in. (9.14-12.19 mm).

13.

Remove plunger lift device (5) and dial indicator (4) from fuel pump (13).

14.

Install copper washer (7) and plug (6) on fuel pump (13).

5-215

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST (Contd) b. Cylinder Phasing (Timing)

3.

4.

1.

2.

5.

6.

7.

10.

11.

8.

9.

In order to perform this task, correct prestroke measurement must be obtained for cylinder number one (task a).

Set protractor (1) on drive end of test stand (6) to zero.

Remove plug (7) from fuel pump (4).

Install two new copper washers (5), plug (7), and adapter (8) on fuel pump (4).

Connect test stand return line (2) to fuel pump adapter (8).

Apply 435-464 psi (2,999-3,199 kPa) of calibration fluid pressure to fuel pump (4).

Manually rotate test stand driveshaft (3) in correct rotation of fuel pump (4) until calibration fluid stops flowing from number five bleed-off valve.

Observe reading on protractor (1). Correct reading should be 60°.

NOTE

Following fuel pump firing order 1-5-3-6-2-4, repeat steps 6 and 7 until remaining cylinders are phased (timed).

For each cylinder phased, test stand protractor will increase in

60° intervals.

Perform steps 8 through 11 if 60° interval is not obtained.

Perform steps 8 through 11 to adjust one cylinder. Adjustment of remaining five cylinders is performed basically the same way.

Remove fuel test line (9) from delivery valve holder (10).

Loosen three nuts (11) and remove two shims (12) between barrel (13) and fuel pump (4). Discard shims (12).

CAUTION

Shims of the same thickness must be used on both sides of barrel.

Failure to do so will result in inaccurate prestroke measurement.

NOTE

Refer to TM 9-2320-272-24P to select shims.

Install two new shims (12) between barrel (13) and fuel pump (4).

Tighten three nuts (11) and install fuel test line (9) on delivery valve holder (10).

5-216


TM 9-2320-272-24-4

5-217

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST (Contd) c. High-speed Fuel Delivery Test

NOTE

Maintain 21 psi (145 kPa) calibration fluid pressure throughout this task.

1.

Set test stand (4) to measure fuel delivery at 1,000 strokes.

2.

Set fuel pump (1) to 1,050 rpm.

NOTE

If needed, increase aneroid air pressure to obtain correct rack travel.

3.

Move control lever (3) to obtain rack travel of 0.360-0.480 in. (9.14-12.19 mm).

4.

Take fuel draw and check fuel delivery. Correct fuel delivery is 0.891-0.928 in.

3

(14.6-15.2 cm

3

).

5.

Allowable reading spread is 0.037 in.

3

(0.6 cm

3

).

d. Low-speed Fuel Delivery Test

NOTE


1.

Reduce fuel pump (1) to 300 rpm.

2.

Set control rack travel between 0.308-0.316 in. (7.8-8.0 mm).

3.

Take fuel draw and check fuel delivery. Correct fuel delivery 0.079-0.134 in.

3

(1.3-2.2 cm

3

)

4.

Allowable reading spread is 0.030 in

3

(0.5 cm

3

).

e. Rated Speed Test

1.

Install protractor (2) on control lever (3).

2.

Position control lever (3) between 42-50°

3.

Increase rpm of fuel pump (1) until control rack travel of 0.464 in. (11.78 mm) is obtained.

4.

Fuel pump (1) rpm should be between 1,090-1,100.

5.

Increase rpm of fuel pump (1) to 1,185-1,215.

6.

Check control rack travel. Correct control rack travel should be 0.016 in (0.40 mm).

7.

Position control lever (3) between 10-18°.

8.

Adjust fuel pump (1) to 300 rpm.

9.

Check control rack travel. Correct control rack travel should be 0.312 in. (7.9 mm).

10.

Decrease fuel pump (1) to 100 rpm.

11.

Check control rack travel. Correct control rack travel should be 0.372 in. (9.45 mm).

12.

Increase rpm of fuel pump (1) to 300. Check control rack travel. Correct control rack travel should be 0.308-0.316 in. (7.82-8.03 mm).

5-218


TM 9-2320-272-24-4

5-219

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST (Contd) f. Full Load Delivery

1.

Apply 131 psi (903 kPa) of air pressure to manifold pressure compensator (2).

2.

Adjust fuel pump (1) to 1,050 rpm.

3.

Position control lever (3) in full load position.

4.

Take fuel draw and check delivery quantity. Correct fuel delivery quantity should be 8.90-9.28 in.

3

(145.8-152.1 cm

3

).

5.

Allowable reading spread is 0.366 in.

3

(5.998 cm

3

).

6.

Close air supply source to manifold pressure compensator (2).

g. Manifold Pressure Compensator Test

1.

Set fuel pump (1) to 500 rpm and position control rack (5) at 0.038-0.039 in. (0.97-0.99 mm) control rack travel.

2.

Apply 44 psi (303 kPa) of air pressure to manifold pressure compensator (2) and observe control rack travel. Correct control rack travel is 0.432-0.436 in. (10.97-11.07 mm).

3.

Increased air pressure to 75 psi (517 kPa) and observe control rack travel. Correct control rack travel is 0.476-0.488 in. (12.09-12.39 mm).

4.

Increase air pressure to 131 psi (903 kPa) and observe control rack travel. Correct control rack travel is 0.504-0.508 in. (12.80-12.90 mm).

5.


h. Start Cut Out Test

1.

Set fuel pump (1) to 240 rpm and run fuel pump (1) at this speed for approximately one minute.

2.

Move throttle lever (4) to full load position and measure control rack travel. Control rack travel should be no more than 0.084 in. (2.13 mm).

6.

7.

8.

1.

2.

3.

4.

5.

i. Fuel Delivery Test

Apply 131 psi (903 kPa) of air pressure to manifold compensator (2).


Set test stand to measure fuel delivery at 1,000 strokes.

Check fuel delivery quantity. Correct fuel delivery quantity should be 8.73-9.21 in.

3

(143-150.9 cm

3

).

Check fuel spread. Correct fuel spread should be 0.427 in. (6.99 cm).

Decrease fuel pump rpm to 500.

Check fuel delivery quantity. Correct fuel delivery quantity is 4.64-5.00 in.

3

(76.0-81.9 cm

3

).


I

5-220


TM 9-2320-272-24-4

5-221

TM 9-2320-272-24-4

5-32. FUEL INJECTION PUMP PRETEST (Contd) j. Fuel Breakaway Test

1.

Move control lever (3) to full load position.

2.

Gradually increase rpm of fuel pump (1) until control rack (6) moves 0.004 in. (0.1 mm) towards shut off.

3.

Adjust fuel pump (1) to 1,090-1,100 rpm.

4.

Move control lever (3) to full load position and observe control rack travel. Correct control rack travel should be 0.464 in. (11.79 mm).

k. Starting Fuel Delivery Test

1.

Set fuel pump (1) to 100 rpm.

2.

Set test stand (5) to measure calibration fluid at 1,000 strokes.

3.

Position throttle lever (4) to full load position and observe control rack (6) travel. Correct control rack travel should be 0.076-0.084 in. (1.93-2.13 mm).

4.


3

(212-227.9 cm

3

).

l. Low Idle Fuel Delivery Test

1.


2.

Position control lever (3) against low idle stopscrew (2) and take a fuel draw.

3.

Observe control rack travel. Correct control rack travel is 0.308-0.316 in. (7.82-8.03 mm).

4.

With test stand (5) set at 1,000 strokes, check fuel delivery quantity. Correct fuel delivery quantity should be 0.824-1.373 in.

3

(13.5-22.5 cm

3

).

5.

Check fuel spread. Correct fuel spread should be 0.305 in.

3

(4.90 cm

3

).

5-222


TM 9-2320-272-24-4

FOLLOW-ON TASK: Remove fuel injection pump from test stand (para. 5-31).

5-223

TM 9-2320-272-24-4

5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE


INITIAL SETUP:


M939A2

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS



Fuel injection pump pretest performed (para. 5-32).

MATERIALS/PARTS

Manifold pressure compensator maintenance

kit (Appendix D, Item 423)

Silicone adhesive (Appendix C, Item 3)

a. Removal

3.

4.

5.

6.

1.

Remove safety wire (1) from screw (24) and protective cap (2). Discard safety wire (1).

NOTE

It may be necessary to cut a slot on breakoff screws for removal.

2.

Remove breakoff screw (22), screw (24), lockwashers (21) and (23), protective cap (2), and pullstop (3) from pull-stop cover (16). Discard breakoff screw (22) and lockwashers (21) and (23).

Remove O-ring (4) from pull-stop (3). Discard O-ring (4).

Remove nuts (20) and (19) from stop bolt (12).

Remove three screws (18) and lockwashers (17) from pull-stop cover (16). Discard lockwashers (17).

Remove breakoff screw (5), lockwasher (6), and pull-stop cover (16) from manifold pressure compensator (7). Discard breakoff screw (5) and lockwasher (6).

7.

8.

Remove three screws (8), lockwashers (9), and washers (10) from manifold pressure compensator (7).


Remove breakoff screw (15), lockwasher (14), washer (13), and manifold pressure compensator (7) from governor cover (11). Discard breakoff screw (15) and lockwasher (14).

b. Disassembly

1.

Remove cotter pin (28), washer (27), and lever (26) from stop bolt (12). Discard cotter pin (28).

2.

Remove stop bolt (12) and spring (29) from manifold pressure compensator (7).

3.

Remove round nut (34), washer (33), washer plate (32), diaphragm (31), and washer plate (30) from stop bolt (12). Discard diaphragm (31).

4.

Remove O-ring (25) from manifold pressure compensator (7). Discard O-ring (25).

5-224

5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-225

TM 9-2320-272-24-4

5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE (Contd) c. Cleaning and Inspection

NOTE

Remove gasket sealant from mating surfaces.

1.


2.


d. Assembly

1.

Install new O-ring (2) on manifold pressure compensator (1).

2.

Install washer plate (8), new diaphragm (9), washer plate (10), and washer (11) on stop bolt (7) with round nut (12).

3.

Install spring (6) and stop bolt (7) in manifold pressure compensator (1).

4.

Install lever (3) on stop bolt (7) with washer (4) and new cotter pin (5).

e. Installation

NOTE

Perform step 1 to ensure manifold pressure compensator lever is engaged to rocker arm in governor cover.

1.

Remove plug (24) from governor housing (23).

2.

Install manifold pressure compensator (1) on governor cover (22) with three washers (21), new lockwashers (20), and screws (19).

3.

Install washer (25), new lockwasher (26), and new breakoff screw (27) on manifold pressure compensator (1).

5-226

TM 9-2320-272-24-4

5-33. MANIFOLD PRESSURE COMPENSATOR MAINTENANCE (Contd)

NOTE

Apply silicone adhesive to mating surfaces of pull-stop cover and manifold pressure compensator.

4.

Install pull-stop cover (28) on manifold pressure compensator (1) with three new lockwashers (29) and screws (30).

5.

Install new lockwasher (18) and new breakoff screw (17) on pull-stop cover (28).

6.

Install nuts (31) and (32) on stop bolt (7).

7.

Install new O-ring (16) on pull-stop (15).

8.

Place pull-stop (15) in pull-stop cover (28).

9.

Install protective cap (33) on pull-stop cover (28) with new lockwashers (14) and (34), screw (13), and new breakoff screw (35).

10.

Install plug (24) on governor housing (23).

NOTE

Safety wire will not be installed at this time. Safety wire will be

installed after fuel pump is calibrated (para. 5-37).

FOLLOW-ON TASK: Calibrate fuel injection pump (para. 5-37).

5-227

TM 9-2320-272-24-4

5-34. R.Q.V. GOVERNOR COVER MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Cleaning and Inspection d. Assembly e. Adjustment f. Installation

INITIAL SETUP:


M939A2

TOOLS



MATERIALS/PARTS

R.Q.V. governor cover maintenance kit



REFERENCES (TM)

TM 9-2320-272-24P


Manifold pressure compensator removed (para. 5-33).

a. Removal

1.

Remove guide pin (8) and gasket (9) from governor cover (5). Discard gasket (9).

2.

Remove five screws (10) from governor cover (5).

3.

Remove two screws (12), lockwashers (13), governor stop (3), and two spacers (4) from governor cover (5). Discard lockwashers (13).

NOTE

When removing governor cover, move governor lever back and forth.

4.

Remove safety wire (6) from screws (7) and (11). Discard safety wire (6).

5.

Remove screw (7), governor cover (5), and gasket (2) from governor housing (1). Discard gasket (2).

b. Disassembly

1.

Remove two drive pins (25) from linkage lever (23) and shaft (19). Discard drive pins (25).

2.

Remove shaft (19) from governor cover (5).

3.

Remove screw (14), lockwasher (15), shim (16), template (17), and shim (18) from governor cover (5).


4.

Remove linkage lever (23) and intermediate plates (22) and (24) from governor cover (5).

5.

Remove rocker arm (21) and spring (20) from governor cover (5).

c. Cleaning and Inspection

1.


2.


5-228

5-34. R.Q.V. GOVERNOR COVER MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-229

TM 9-2320-272-24-4

5-34. R.Q.V. GOVERNOR COVER MAINTENANCE (Contd) d. Assembly

1.

Install spring (12)and rocker arm (13) in governor cover (3).

2.

Install intermediate plates (14) and (16) and linkage lever (15) in governor cover (3).

3.

Install shaft (11) in governor cover (3).

4.

Install shim (10), template (9), and shim (8) on governor cover (3) with new lockwasher (7) and screw (6).

5.

Install two new drive pins (17) in linkage lever (15) and shaft (11).

e. Adjustment

1.

Position control lever (4) in full load position so pilot (5) contacts bottom end of template slot (1).

2.

Position new gasket (2) on governor cover (3).

3.

Place straightedge on governor cover (3). Using depth gauge, measure from straightedge to pilot (5).

Distance should be 0.098 in. (2.49 mm).

NOTE

Perform steps 4 through 7 if measurement is incorrect.

4.

Remove screw (6), lockwasher (7), shim (8), template (9), and shim (10) from governor cover (3).

5.

If distance is less than 0.098 in. (2.49 mm), use smaller shim (10).

6.

If distance is more than 0.098 in. (2.49 mm), use larger shim (10).

7.

Install shim (10), template (9), and shim (8) on governor cover (3) with lockwasher (7) and screw (6).

f. Installation

NOTE

Safety wire will not be installed at this time. Safety wire will be

installed after fuel pump is calibrated (para. 5-37).

Linkage lever piston must fit into cylinder on lever located in governor housing.

1.

Install new gasket (2) and governor cover (3) on governor housing (18) with five screws (24) and screw (21).

2.

Install governor stop (19) on governor cover (3) with two spacers (20), new lockwashers (25), and screws (26).

NOTE

Apply sealing compound to male threads.

3.

Install new gasket (23) and guide pin (22) in governor cover (3).

5-230

5-34. R.Q.V. GOVERNOR COVER MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install manifold pressure compensator (para. 5-33).

5-231

TM 9-2320-272-24-4

5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Cleaning and Inspection d. Assembly e. Installation f. Adjustment

INITIAL SETUP:


M939A2

TOOLS




MATERIALS/PARTS

R.Q.V. governor housing maintenance kit


REFERENCES (TM)

TM 9-2320-272-24P


R.Q.V. governor cover removed (para. 5-34).

GENERAL SAFETY INSTRUCTIONS

Wear eye protection when removing or installing springs under tension.

6.

7.

8.

13.

14.

15.

9.

10.

11.

12.

a. Removal

1.

2.

3.

4.

5.

Remove retaining pin (12) from link pin (10). Discard retaining pin (12).

Remove link pin (10), slider (15), and lever (11) from link fork (9).

Remove retaining pin (5) and link fork (9) from connection plate (3). Discard retaining pin (5).

Bend tab washer (19) away from two nuts (20).

Remove nut (20). tab washer (19), nut (20), coupling pin (8), and washer (7) from flyweight assembly (6). Discard tab washer (19).

Remove bearing pin (16) from guide bushing (17).

Bend two tab washers (13) away from screws (14).

Remove two screws (14), tab washers (13), and guide bushing (17) from flyweight assembly (6).

Discard tab washers (13).

Remove round nut (18) from camshaft (4) and governor flyweight assembly (6).

Remove governor flyweight assembly (6) from camshaft (4).

Remove capsule (21) and four rubber buffers (22) from driver (24). Discard rubber buffers (22).

Remove shim (23) and driver (24) from camshaft (4).

NOTE

Screws in steps 13 and 14 are torx head.

Remove four screws (28) and holding brackets (27) from governor housing (2).

Remove two screws (26) from governor housing (2).

Remove two screws (25), governor housing (2), and gasket (29) from fuel pump housing (1). Discard gasket (29).

5-232

5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-233

TM 9-2320-272-24-4

5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE (Contd) b. Disassembly

NOTE

Relieve governor flyweight spring tension when performing step 1.

1.

Press down on outer spring seat (3) and remove round nut (2) from threaded pin (9).

WARNING

Eye protection must be worn when removing springs under tension. Failure to do so may result in injury to personnel.

2.

Remove outer spring seat (3), springs (4), (5), and (6), shim (7), and lower spring seat (8) from governor flyweight assembly (12).

3.

Remove shims (1) and (13) from governor flyweight assembly (12).


1.


2.


3.

Inspect two governor flyweights (11) for nicks and scratches. If either flyweight (11) is nicked or scratched, replace governor flyweight assembly (12).

4.

Inspect bell crank levers (10) for noticeable wear. Replace governor flyweight assembly (12) if either bell crank lever (10) is worn.

5.

Inspect bearing pin (14) for scratches, scoring, nicks, and wear. Replace bearing pin (14) if scratched, scored, nicked, or worn.

6.

Inspect guide bushing (15) for wear, scratches, or scores. Replace guide bushing (15) if worn, scratched, or scored.

d. Assembly

1.

Install shims (13) and (1) in governor flyweight assembly (12).

WARNING

Eye protection must be worn when installing springs. Failure to do so may result in injury to personnel.

2.

Install lower spring seat (8), shim (7), and springs (6), (5), and (4) in governor flyweight assembly (12).

3.

Install outer spring seat (3) on spring (4).

4.

Install round nut (2) on threaded pin (9).

5-234


TM 9-2320-272-24-4

5-235

TM 9-2320-272-24-4


11.

12.

13.

14.

e. Installation

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Install new gasket (6) and governor housing (5) on fuel pump housing (7) with two screws (1) and screws (2).

Install four holding brackets (3) and screws (4) on governor housing (5).

Place shim (28) in driver (29) and install driver (29) on camshaft (9).

Install capsule (26) and four new rubber buffers (27) in back side of governor flyweight assembly (11).

Install governor flyweight assembly (11) on driver (29).

Install round nut (23) on camshaft (9). Tighten round nut (23) 30-35 lb-ft (41-47 N·m).

CAUTION

Failure to obtain proper axial play may cause damage to fuel pump.

Check governor flyweight assembly (11) for axial play: a. Normal range is 0.002-0.004 in. (0.05-0.1 mm).

b. If axial play is less than 0.002 in. (0.05 mm), replace shim (28) with larger shim (28).

c. If axial play is more than 0.004 in. (0.1 mm), replace shim (28) with smaller shim (28).

d. When axial play is correctly adjusted, it is possible to turn governor flyweight assembly (11) without governor flyweight assembly (11) sticking.

NOTE

Do not bend tab washer until fuel pump is calibrated (para. 5-37).

Install guide bushing (22) on flyweight assembly (11) with two new tab washers (18) and screws (19).

Tighten screws (19) 53-71 lb-in. (6-8 N·m).

Place bearing pin (21) in guide bushing (22).

NOTE

Adjust nuts to allow end play of 0.04-0.12 in. (1.0-3.0 mm).

Insert coupling pin (13) through washer (12), governor flyweight assembly (11), and bearing pin (21) and install nut (25), new tab washer (24), and nut (25) on coupling pin (13). Tighten nuts (25)

53-71 lb-in. (6-8 N·m).

Install slider (20) on bearing pin (21).

Install lever (16) on slider (20).

Install link fork (14) on connection plate (8) with new retaining pin (10).

Install lever (16) on link fork (14) with link pin (15) and new retaining pin (17).

5-236


TM 9-2320-272-24-4

5-237

TM 9-2320-272-24-4

5-35. R.Q.V. GOVERNOR HOUSING MAINTENANCE (Contd) f. Adjustment

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

NOTE

Distance is obtained by the measured distance plus the thickness of straightedge minus half the thickness of slider.

Place straightedge on governor housing (1). Using depth gauge, measure distance between slider (2) and straightedge. Distance should be 1.39-1.40 in. (35.3-35.6 mm).

NOTE

Perform steps 2 through 15 if measurement is incorrect.

Remove retaining pin (7) from link pin (6).

Remove link pin (6). slider (2), and lever (8) from link fork (5) and bearing pin (11).

Remove retaining pin (4) and link fork (5) from connection plate (3).

Remove nut (14), tab washer (15), nut (14), coupling pin (9), and washer (10) from governor flyweight assembly (16).

Remove bearing pin (11) from guide bushing (13).

If slider measurement was less than 1.39 in. (35.3 mm), turn adjusting screw (12) in bearing pin (11) clockwise.

If slider measurement was more than 1.40 in. (35.6 mm), turn adjusting screw (12) in bearing pin (11) counterclockwise.

Place bearing pin (11) in guide bushing (13).

Install washer (10) on coupling pin (9) and insert coupling pin (9) through governor flyweight assembly (16) and bearing pin (11) and secure with nut (14), tab washer (15), and nut (14) on coupling pin (9). Tighten nuts (14) 53-71 lb-in. (6-8 N·m).

Bend tab washer (15) on nuts (14).

Install slider (2) on bearing pin (11).

Install lever (8) on slider (2).

Install link fork (5) on connection plate (3) with retaining pin (4).

Install lever (8) on link fork (5) with link pin (6) and retaining pin (7).

Check distance between slider (2) and straightedge (step 1).

5-238


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install R.Q.V. governor cover (5-34).

5-239

TM 9-2320-272-24-4

5-36. FUEL INJECTION PUMP MAINTENANCE

THIS TASK COVERS: a. Camshaft Removal b. Tappet and Plunger Removal c. Barrel and Control Rack Removal d. Cleaning and Inspection e. Leakage Test f.

Delivery Valve and Barrel Installation g. Plunger and Control Rack Installation h. Tappet and Spring Installation i. Camshaft Installation

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Two separation tubes (Appendix E, Item 119)

Side plug puller (Appendix E, Item 111)

Three tappet holders (Appendix E, Item 134)

Tappet spring compressor (Appendix E, Item 135)

TOOLS



Arbor press

MATERIALS/PARTS

Fuel injection pump repair kit (Appendix D,

Item 137)

Fuel injection pump maintenance kit


MATERIALS/PARTS (Contd)





REFERENCES (TM)

TM 9-2320-272-24P


R.Q.V. governor housing removed (para. 5-35).


Diesel fuel is flammable. Do not perform this task near open flames.


Drycleaning solvent is flammable and toxic. Do not use near open flame.

a. Camshaft Removal

WARNING

Diesel fuel is flammable. Do not perform fuel system procedure near open flame. Injury to personnel may result.


CAUTION


1.

Clean exterior of fuel pump housing (10) with drycleaning solvent.

2.

Using side plug puller, remove three side plugs (7) from fuel pump housing (10). Discard side plugs (7).

3.

Remove three spacer blocks (8) from side holes (9).

CAUTION

Keep cylinder parts together for replacement in their original cylinder. Failure to do so may result in damage to fuel pump.

4.

Remove six nuts (4), lockwashers (3), spacer rings (2), and locking tabs (1) from studs (5) and delivery valve holders (13). Discard lockwashers (3).

5-240

TM 9-2320-272-24-4

5-36. FUEL INJECTION PUMP MAINTENANCE (Contd)

NOTE

Perform step 5 to aid in insertion of tappet holder.

5.

Loosen twelve barrel flange nuts (12) and remove twelve shims (6) from between barrel (11) and fuel pump housing (10).

5-241

TM 9-2320-272-24-4


6.

7.

8.

9.

10.

11.

12.

13.

Reverse position of fuel pump housing (1) and mount in vise.

Remove six screws (9), holding brackets (19), cover (18), and seal ring (17) from fuel pump housing (1). Discard seal ring (17).

NOTE


Rotate camshaft (16) until cylinder number one is at Top Dead Center (TDC).

Turn knurled handle (14) on tappet holder (15) fully counterclockwise.

Apply GM grease to ramp (12) and guide (11) on tappet holder (15).

NOTE

Tappet holder will insert only part way in when lifting tappet number one off camshaft.

Hold tappet holder (15) with ramp (12) up and insert tappet holder (15) into side hole (10) of fuel pump housing (1).

NOTE

Pressure must be maintained on handle of tappet holder to prevent tappet holder from popping out.

When all six tappets are lifted off the camshaft, camshaft will rotate with little resistance.

Rotate camshaft (16) until cylinder number two is at TDC and push tappet holder (15) until tapered edge (13) on tappet holder (15) contacts fuel pump housing (1).

NOTE

Repeat steps 8 through 12 to install remaining two tappet holders.

Remove two screws (21) and seal rings (22) from fuel pump housing (1). Discard seal rings (22).

CAUTION

If arbor press is used, care should be taken to prevent damage to control rack guide pin.

14.

Remove camshaft (16), with bearing (23) and bearing shell (20), from governor end of fuel pump housing (1).

15.

Remove four screws (5), lockwashers (4), end plate (3), and gasket (2) from fuel pump housing (1).

Discard gasket (2) and lockwashers (4).

16.

Remove O-ring (6) and oil seal (7) from end plate (3). Discard O-ring (6) and oil seal (7).

17.

Remove O-ring (8) from fuel pump housing (1). Discard O-ring (8).

5-242


TM 9-2320-272-24-4

5-243

TM 9-2320-272-24-4


3.

4.

5.

6.

7.

b. Tappet and Plunger Removal

1.

2.

8.

9.

10.

11.

12.

NOTE

Camshaft must be removed to perform this task.

Position fuel pump housing (14) bottom side up in vise.

NOTE l


l

Step 2 covers the removal of tappet holder from cylinders one and two. Remaining tappet holders are removed the same.

Install spring compressor clamp (1) on governor side of fuel pump hosing (14) with two washers (2) and screws (3).

Place spring compressor adapter (6) on shaft (5).

Position shaft (5) and adapter (6) on the first two tappets (7).

Position lever (4) on spring compressor clamp (1) and shaft (5).

Depress lever (4), compressing both tappets (7).

Turn knurled knob (11) on tappet holder (10) fully clockwise and apply GAA grease to ramp (12) and guide (9) on tappet holder (10).

While both tappets (7) are compressed, remove tappet holder (10) from side hole (8) of cylinders one and two.

NOTE

Repeat steps 2 through 8 until all tappet holders are removed.

Remove two screws (3), washers (2), spring compressor clamp (1), lever (4), shaft (5), and adapter (6) from fuel pump housing (14).

CAUTION

Keep cylinder parts together for replacement in their original cylinder. Failure to do so may result in damage to fuel pump.

Remove six tappets (7), lower spring seats (15), plungers (16), and springs (20) from fuel pump housing (14).

Position control rack (13) to align control sleeve ball (17) with notch (21) on fuel pump housing (14).

Remove six upper control sleeves (18) and upper spring seats (19) from fuel pump housing (14).

5-244


TM 9-2320-272-24-4

5-245

TM 9-2320-272-24-4

5-36. FUEL INJECTION PUMP MAINTENANCE (Contd) c . Barrel and Control Rack Removal

1.

Position fuel pump housing (5) top side up in vise.

2.

Loosen six delivery valve holders (1) from barrels (9).

3.

Remove twelve barrel flange nuts (2), lockwashers (3), and spacer rings (4) from fuel pump housing (5). Discard lockwashers (3).

4.

Remove six barrels (9) from fuel pump housing (5).

5.

Remove six O-rings (8) from barrels (9). Discard O-rings (8).

6.

Remove six retainers (6) and capsules (7) from barrels (9). Discard retainers (6).

7.

Remove six delivery valve holders (1), washers (12), springs (11), and delivery valves (10) from barrels (9).

8.

Remove six O-rings (13) from delivery valve holders (1). Discard O-rings (13).

5-246

TM 9-2320-272-24-4


9.

10.

11.

12.

Remove two screws (19) and retaining plate (20) from control rack (18) and fuel pump housing (5).

Remove control rack (18), spring retainer (17), spring (16), and washer (15) from fuel pump housing (5).

NOTE

Perform step 11 if control rod is damaged.

Remove control rod (14) from fuel pump housing (5).

Remove fuel pump housing (5) from vise.

5-247

TM 9-2320-272-24-4


10.

11.

12.

13.

7.

8.

9.

5.

6.


1.

2.

3.

4.


Inspect plunger (1) for scratches and scoring. Replace plunger (1) and barrel (5) if plunger (1) is scratched or scored.

Inspect delivery valve (4) for wear and scoring. If worn or scored, replace delivery valve (4).

NOTE

Replace all camshaft bearings if camshaft requires replacement.

Inspect camshaft (7) for scratches and gouged lobes (6). If lobes (6) are scratched or gouged, replace camshaft (7).

NOTE

Perform steps 5 through 7 if camshaft and endplate bearings require replacement.

Press roller bearing (2) from end plate (3).

Remove nut (10) and lockwasher (9) from camshaft (7). Discard lockwasher (9).

Press bearing (8) from camshaft (7).

Inspect tappets (11) for wear or scratches. If worn or scratched, replace tappets (11).

Inspect six spacers (14) in fuel pump housing (13) for burrs, scratches, and nicks. If burred, scratched or nicked, replace spacer (14).

NOTE

Perform steps 10 through 12 if spacer requires replacement.

Bend edges of spacers (14) in towards center of port (12).

Drive six spacers (14) out through top of fuel pump housing (13). Discard spacers (14).

Remove six O-rings (15) from fuel pump housing (13). Discard O-rings (15).


5-248


TM 9-2320-272-24-4

5-249

TM 9-2320-272-24-4


6.

7.

3.

4.

5.

9.

10.

11.

12.

13.

14.

e. Leakage Test

1.

2.

8.

CAUTION

Plungers and barrels are matched sets. Do not interchange parts or damage to fuel pump may result.

NOTE

Barrels must be installed (subtask f) to perform this task.


Install six plungers (4) in mating barrels (7). Position plunger (4) so groove (5) on plunger (4) points away from rack.

Install plunger retainer tubes (2) on fuel pump housing (1) with two bottom cover screws (3).


Install screw plug (8) in fuel gallery outlet (9).

Connect air hose to fuel gallery inlet (6).

Submerge fuel pump housing (1) in clean test oil bath and pressurize fuel pump housing (1) to

75 psi (517 kPa).

Check for bubbles at top and bottom of fuel pump housing (1). Any bubbles, other than small bubbles from inside of plunger retainer tubes (2), indicate a leak.

If leaks are present, replace fuel pump housing (1).

Disconnect air hose from gallery inlet (6).

Remove screw plug (8) from gallery outlet (9).

Remove two bottom cover screws (3) and plunger retainer tubes (2) from fuel pump housing (1).

Remove six plungers (4) from barrels (7).


5-250


TM 9-2320-272-24-4

5-251

TM 9-2320-272-24-4


9.

10.

11.

12.

3.

4.

5.

1.

2.

f. Delivery Valve and Barrel Installation

6.

7.

8.

13.

NOTE

l

The following subtask covers installation of one barrel. Remaining barrels are installed the same.

l

Coat all parts with oil before installation.

l Coat all O-rings with GAA grease.

NOTE

Perform steps 1 and 2 if spacer was removed.

Install new O-ring (13) in fuel pump housing (11).

Using arbor press, press new spacer (14) through top of fuel pump housing (11).

Position fuel pump housing (11) top side up in vise.

Install new O-ring (22) on delivery valve holder (1).

Install delivery valve (191, spring (20), washer (21), and delivery valve holder (1) in corresponding barrel (18).

Install new O-ring (17) on barrel (18).

Install capsule (16) on barrel (18) with new retainer (15).

Position barrel (18) in corresponding cylinder (12) and install with two spacer rings (8), new lockwashers (7), and barrel flange nuts (6). Tighten nuts (6) finger tight.

Place two shims (9) between barrel (18) and fuel pump housing (11).

Tighten nuts (6) 15-20 lb-ft (20-27 N•m).

Tighten delivery valve holder (1) 35-45 lb-ft (47-61 N•m).

Install locking tab (5), spacer ring (4), new lockwasher (2), and nut (3) on stud (10) and delivery valve holder (1). Tighten nut (3) 15-20 lb-ft (20-27 N•m).


5-252


TM 9-2320-272-24-4

5-253

TM 9-2320-272-24-4

5-36. FUEL INJECTION PUMP MAINTENANCE (Contd) g. Plunger and Control Rack Installation

NOTE

Perform step 1 if control rod was removed.

1.

Install new control rod (1) on fuel pump housing (9).

2.

Install washer (2), spring (3), and cap (4) on control rod (1).

3.

Install control rack (5) and retaining plate (6) on fuel pump housing (9) with two screws (7).

4.

Mount fuel pump housing (9) bottom side up in vise.

5.

Position control rack (5) so guide slits (8) align with notch (18) on fuel pump housing (9).

NOTE

Control sleeve balls engage guide slit on control rack.

6.

Install six upper control sleeves (15) into mating barrels (16).

7.

After all control sleeves (15) are installed, move control rack (5) back and forth to ensure control sleeves (14) move freely.

CAUTION

Once correct alignment is obtained, secure control rack in this position until tappets are installed. Failure to do so may result in damage to control sleeves.

8.

Position control rack (5) so guide slits (8) face adjusting groove (17) on barrel (16).

9.

Coat six upper spring seats (14) with GAA grease and position on control sleeves (15).

10.

Install six springs (13) on mating control sleeves (15).

CAUTION

Notch on plungers must align exactly with groove on barrel. If alignment is not obtained, damage to fuel pump may result.

11.

Install six plungers (12) into mating barrels (16) so notched mark (11) on plunger base points toward adjusting groove (17) on barrel (16).

12.

Install six lower spring seats (10) on plungers (12) and rotate lower spring seats (10) 90°.

5-254


TM 9-2320-272-24-4

5-255

TM 9-2320-272-24-4


3.

4.

5.

6.

7.

h. Tappet and Spring Installation

1.

2.

8.

9.

10.

CAUTION

When performing step 1, ensure flats on tappet align with recess on the lower spring seat. Failure to do so may result in damage to fuel pump housing.

NOTE

This task covers installation of two tappets for cylinders number one and two. Remaining tappets are installed the same.

Install two tappets (1) in mating cylinders.

Install spring compressor clamp (3) on governor side of fuel pump housing (2) with two washers (4) and screws (5).

Place spring compressor adapter (8) on shaft (7).

Position shaft (7) and adapter (8) on the first two tappets (1).

Position lever (6) on spring compressor clamp (3) and shaft (7).

Depress lever (6), compressing both tappets (1).

Turn knurled knob (12) on tappet holder (13) fully counterclockwise and apply GM grease to ramp (11) and guide (10) on tappet holder (13).

While both tappets (1) are compressed, insert tappet holder (13) into side hole (9) of cylinders one and two.

NOTE

Repeat steps 1 through 8 until all tappets and tappet holders are installed.

Remove two screws (5), washers, (4), spring compressor clamp (3), lever (6), shaft (7), and compressor adapter (8) from fuel pump housing (2).


5-256


TM 9-2320-272-24-4

5-257

TM 9-2320-272-24-4


2.

3.

4.

i. Camshaft Installation

1.

5.

6.

7.

8.

9.


NOTE

Perform step 2 if roller bearing was removed.

Press roller bearing (8) on end plate (3).

Install new O-ring (6) and oil seal (7) on end plate (3).

Position new gasket (2) and end plate (3) on fuel pump housing (1). Ensure oil return holes are located at top of fuel pump housing (1).

Install end plate (3) on fuel pump housing (1) with four new lockwashers (4) and screws (5).

If bearing (16) was removed, press bearing (16) on camshaft (10) and secure bearing (16) on camshaft (10) with new lockwasher (15) and nut (14).

Install new O-ring (9) on fuel pump housing (1).

CAUTION

When installing camshaft into fuel pump housing, tap only on camshaft outer nut. Failure to do so may result in damage to fuel pump.

Insert camshaft (10) and bearing shell (13) into fuel pump housing (1) through governor end of fuel pump housing (1).

Install bearing shell (13) on fuel pump housing (1) with two new seal rings (12) and screws (11).

5-258


TM 9-2320-272-24-4

5-259

TM 9-2320-272-24-4


NOTE

Steps 10 through 12 cover removal of one tappet holder. Remaining tappet holders are removed the same.

10.

Turn knurled handle (7) on tappet holder (8) fully clockwise.

NOTE

Cylinder number one is located at drive end of fuel injection pump.

11.

Hold tappet holder (8) and rotate camshaft (9) until cylinder number one is at TDC and pull tappet holder (8) from side hole (6).

12.

Rotate camshaft (9) until cylinder number two is at TDC and remove tappet holder (8) from side hole (6).

13.

Install new seal ring (4) and bottom cover (3) on fuel pump housing (5) with six holding brackets (1) and screws (2).

5-260

TM 9-2320-272-24-4


14.

Install three spacer blocks (11) in fuel pump housing (5) through side holes (12).

15.

Apply sealing compound to new side plugs (10) and install side plugs (10) in fuel pump housing (5).

16.


FOLLOW-ON TASK: Install R.Q.V. governor housing (para. 5-35).

5-261

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION


Prestroke and Back Travel b.

Cylinder Phasing (Timing) c.

Lock Timing d. High-speed Fuel Delivery Test e. Low-speed Fuel Delivery Test f.

Bated Speed Test g.

Full Load Delivery h. Manifold Pressure Compensator Test i.

Fuel Delivery Test j.

Fuel Breakaway Test k. Starting Fuel Delivery Test l.

Low Idle Fuel Delivery Test m. External Stop Setting

INITIAL SETUP:


M939A2

SPECIAL TOOLS

Plunger lift device (Appendix E, Item 98)

Rack extension (Appendix E, Item 112)

TOOLS



MATERIALS/PARTS


Two break off screws (Appendix D, Item 19)



Two breakoff screws (Appendix D, Item 20)

Four lockwashers (Appendix D, Item 398)


Safety wire (Appendix C, Item 79)

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-4910-778-14&P


l

Fuel injection pump repaired (para. 5-36).

l

Fuel injection pump mounted to test stand

(para. 5-31).

NOTE

Refer to TM 9-4910-778-14&P for operation of fuel injection pump test stand, DFP 156.

1.

2.

3.

4.

7.

8.

5.

6.

9.

Mount dial indicator (2) and rack travel indicator holder (1) on drive end of fuel pump (5).

NOTE

Cylinder number one is located at drive end of fuel injection pump.

Install plunger lift device (8) on fuel pump (5) with finger of lifting device (8) resting on top of tappet located in cylinder number one.

Mount dial indicator (7) on lifting device (8) and zero dial indicator (7).

Pull control lever (6) to full load position and using dial indicator shaft (3), push control rack (4) all the way back.

Preload dial indicator (2) giving control rack (4) 0.004 in. (0.1 mm) of preload travel.

Manually rotate test stand driveshaft (9) until a reading is observed on dial indicator (7).

Manually reverse rotation test stand driveshaft (9) until dial indicator (7) reads zero.

Manually rotate test stand driveshaft (9) clockwise and take prestroke measurement from dial indicator (7). Correct prestroke measurement should be 0.120-0.128 in. (3.05-3.25 mm).

If correct prestroke measurement is not obtained, perform steps 10 through 13.

5-262

5-37. FUEL INJECTION PUMP CALIBRATION (Contd)

TM 9-2320-272-24-4

5-263

TM 9-2320-272-24-4


10.

11.

NOTE

Steps 10 through 13 pertain to adjusting one cylinder. Remaining five cylinders are adjusted the same.

Remove fuel test line (12) from delivery valve holder (11).

Loosen three nuts (10) and remove two shims (2) between barrel (9) and fuel pump (8). Discard shims (2).

CAUTION

12.

13.

Adjusting shims of the same thickness must be used on both sides of barrel. Failure to do so may result in inaccurate prestroke measurement.

NOTE

Refer to TM 9-2320-272-24P to select shims.

Install two new shims (2) between barrel (9) and fuel pump (8).

Tighten three nuts (10) and install fuel test line (12) on delivery valve holder (11).

NOTE


14.

15.

16.

Close all bleedoff valves (1) except for cylinder number one.

Apply 435-464 psi (2,999-3,199 kPa) of calibration fluid pressure.

NOTE

Ensure a steady stream of calibration fluid flows from number one bleedoff valve. If not, increase calibration fluid pressure until a steady stream of calibration fluid is obtained.

Manually rotate test stand driveshaft (7) in correct fuel pump (8) rotation, until calibration fluid starts to drip from bleedoff valve (1).

17.

Check prestroke measurement. Correct measurement should be 0.360-0.480 in. (9.14-12.19 mm).

18.

Remove dial indicator (3) and plunger lift device (4) from fuel pump (8).

19.

Install new copper washer (6) and plug (5) on fuel pump (8).

5-264


TM 9-2320-272-24-4

5-265

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION (Contd) b. Cylinder Phasing (Timing)

NOTE

l

When phasing (timing) cylinders, test stand calibration fluid pressure must be set at 435-464 psi (2,999-3,199 kPa).

l

When performing this task, correct prestroke measurement must be obtained for cylinder number one. Refer to task a.

1.

Zero test stand protractor (6) on drive end of test stand (5).

2.

Close all bleedoff valves (2) except for cylinder number five.

NOTE

When bleedoff valve is opened, a stream of calibration fluid will flow from bleedoff valve. If not, increase fluid pressure until a stream of calibration fluid is obtained.

3.

Open bleedoff valve (2) on test nozzle (3) for cylinder number five.

4.

Manually rotate test stand driveshaft (7) in correct rotation of fuel pump (4) until calibration fluid starts to drip from number five bleedoff valve (2).

5.

Observe reading on test stand protractor (6). Correct reading is 60°.

NOTE

l

Following fuel pump firing order 1-5-3-6-2-4, repeat steps 2 through 5 until remaining cylinders are phased (timed).

l

For each cylinder phased (timed), test stand protractor should increase in 60° intervals.

6.

If 60° intervals are not obtained, adjust shims under barrel (1) (task a).

7.

If any adjustments are made to bring the remaining cylinders to specification, repeat steps 1 through 6 to ensure all cylinders are phased (timed) to specifications.

5-266


TM 9-2320-272-24-4

5-267

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION (Contd) c. Lock Timing

NOTE

Fuel pump must be phased (timed) before performing this task.

Refer to task b.

1.

Remove access plug (7), washer (8), and timing pin (3) from timing plate (2).

2.

Rotate test stand drive (9) until number one cylinder is at port closure.

3.

Rotate test stand drive (9) in correct pump rotation 8° from cylinder one port closure.

4.

Timing tooth (11) should be aligned with timing pin access hole (10).

NOTE

Perform steps 5 through 11 if drive pointer is not aligned with timing pin access hole.

5.

Remove governor cover from governor housing (para. 5-34).

6.

Remove two breakoff screws (6), lockwashers (5), washers (4), and timing plate (2) from governor housing (1). Discard lockwashers (5) and breakoff screws (6).

7.

Remove governor flyweight and driver from fuel pump (para. 5-35).

8.

Install timing plate (2) on governor housing (1) with two washers (4), new lockwashers (5), and new breakoff screws (6).

NOTE

l

Align driver so timing tooth aligns with timing pin access hole.

l

Timing plate can be adjusted up or down for final alignment.

9.

Install governor flyweight and driver on fuel pump (para. 5-35).

10.

Install timing pin (3) in timing plate (2) with slot of timing pin (3) facing timing tooth (11).

11.

Install washer (8) and access plug (7) on timing plate (2).

12.

Tighten breakoff screws (6).

13.

Install governor cover on governor housing (para. 5-34).

5-268


TM 9-2320-272-24-4

5-269

TM 9-2320-272-24-4


3.

4.

5.

6.

10.

11.

12.

d. High-speed Fuel Delivery Test

1.

2.

7.

8.

9.

13.

14.

15.

16.

NOTE

l


l

Close all bleedoff valves.

Set test stand (12) to measure fuel delivery at 1,000 strokes.

Remove plug (4) from top of governor housing (5) and pour two pints of lubricating oil in governor housing (5).

Remove plug (13) and washer (10) from fuel pump (9).

Install new copper washer (10), adapter (11), new copper washer (10), and plug (13) on fuel pump (9).

Connect return line (1) to adapter (11).


NOTE

Adjust aneroid air pressure to help obtain correct rack travel.

Adjust control lever (8) to obtain rack travel of 0.360-0.480 in. (9.14-12.19 mm).

NOTE

Perform steps 8 and 9 if correct rack travel is not obtained.

Remove breakoff screw (19), screw (21), two lockwashers (18), protective cap (17), and stop (16) from manifold pressure compensator (6). Discard breakoff screw (19) and two lockwashers (18).

Turn nuts (15) and (14) counterclockwise to increase rack travel; or clockwise to decrease rack travel.

Position control lever (8) to full load and take fuel draw.

Check fuel delivery. Correct fuel delivery should be 0.891-0.928 in.

3

(14.6-15.2 cm

3

).

Allowable spread reading is 0.037 in.

3

(0.6 cm

3

).

NOTE

l Perform step 13 if fuel delivery deviates from specifications.

l Step 13 pertains to one cylinder only.

Loosen three nuts (2) and rotate barrel (3) clockwise to increase fuel delivery; counterclockwise to decrease fuel delivery.

Repeat step 13 for remaining cylinders.

Install stop (16) and protective cap (17) on manifold pressure compensator (6) with two new lockwashers (18), screw (21), and new breakoff screw (20).

Install new safety wire (22) on screw (21) and protective cap (17).

e. Low-speed Fuel Delivery Test

NOTE


1.


2.

Set control rack travel at 0.308-0.316 in. (7.8-8.0 mm).

3.

Check fuel delivery. Correct fuel delivery should be 0.079-0.134 in.

3

(1.3-2.2 cm

3

).

4.

Allowable spread reading is 0.030 in.

3

(0.5 cm

3

).

5.

If low-speed fuel delivery deviates from specifications given, adjust low idle stopscrew (7) until correct fuel delivery is obtained.

5-270

5-37 FUEL INJECTION PUMP CALIBRATION (Contd)

TM 9-2320-272-24-4

5-271

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION (Contd) f. Rated Speed Test

1.

2.

3.

Loosen nut (7) on low idle stopscrew (5) and turn low idle stopscrew (5) until flush with governor cover (6).

Position control level (4) until dial indicator (1) on drive end of fuel pump (2) reads zero.

Slowly move control lever (4) towards full load, until dial indicator (1) receives reading.

4.

Set protractor (3) at zero.

5.

Position control lever (4) to read 42-50° on protractor (3) by adjusting low idle stopscrew (5).

6.

Increase rpm of fuel pump (2) until a rack travel of 0.464 in. (11.79 mm) is obtained.

7.

Rpm of fuel pump (2) should be at 1,090-1,100 rpm.

8.

Adjust rpm of fuel pump (2) until rack travel of 0.312 in. (7.9 mm) is obtained.

9.

Rpm of fuel pump (2) should be at 300 rpm.

10.

Decrease rpm of fuel pump (2) to 100 rpm. Rack travel should be 0.372 in. (9.45 mm).

5-272

TM 9-2320-272-24-4


NOTE

Perform steps 11 through 17 if proper control rack travel was not obtained.

11.

Remove safety wire (10) from governor housing (8).

12.

Remove plug (9) from governor housing (8), giving access to governor springs.

NOTE

Repeat steps 13 and 14 until both governor springs are adjusted.

13.

If control rack travel reading is too low at a given speed, increase flyweight spring tension by turning round nut (11) clockwise.

14.

If control rack travel reading is too high at a given speed, decrease flyweight spring tension by turning round nut (11) counterclockwise.

15.

Recheck control rack travel. If control rack travel is incorrect, repeat step 13 or 14. If rack travel is correct, proceed to step 16.

16.

Install plug (9) on governor housing (5).

17.

Install new safety wire (10) on governor housing (8).

5-273

TM 9-2320-272-24-4


3.

4.

1.

2.

5.

6.

9.

10.

11.

7.

8.

g. Full Load Delivery

12.

13.

14.

15.

Apply 13.05 psi (90 kPa) of air to manifold pressure compensator (6).


Set fuel test stand to measure fuel delivery at 1,000 strokes.


Position control lever (8) to full load position.

Take fuel draw and observe delivery quantity. Correct delivery quantity should be 9.1-9.2 in.

3

(149.1-150.8 cm

3

).

Check spread reading. Correct spread reading is 0.366 in.

3

(6.00 cm

3

).



Position control lever (8) to full load position.

Take fuel draw and observe delivery quantity. Correct delivery quantity is 4.8-4.9 in.

3

(78.7-80.3 cm

3

).

NOTE

Perform steps 12 through 14 if fuel delivery quantity deviates from specifications.

Remove breakoff screw (10), screw (1), two lockwashers (3), protective cap (4), and stop (5) from manifold pressure compensator (6). Discard two lockwashers (3) and breakoff screw (10).

Turn nut (9) clockwise to increase fuel delivery; counterclockwise to decrease fuel delivery.

Install stop (5) and protective cap (4) on manifold pressure compensator (6) with two new lockwashers (3), new breakoff screw (11), and screw (1).

Install new safety wire (2) on screw (1) and protective cap (4).

5-274

TM` 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION (Contd) h. Manifold Pressure Compensator Test

1.

Set fuel pump (7) to 500 rpm and position control rack (12) between 0.041-0.042 in.

(1.040-1.060 mm) rack travel.

2.

Apply 3.26 psi (22.5 kPa) of air pressure to manifold pressure compensator (6) and observe control rack (12) travel. Correct control rack (12) travel is 0.429-04.36 in. (11.90-12.30 mm).

3.

Increase air pressure of manifold pressure compensator (6) to 6.53 psi (45.0 kPa) and observe control rack (12) travel. Correct control rack (12) travel is 0.468-0.484 in. (11.90-12.30 mm).

NOTE

Perform steps 5 through 8 if control rack travel deviates from specifications.

4.

Remove plug (14) from top of governor housing (13).

5.

If control rack (12) travel is less than required specifications, turn screw (15) clockwise.

6.

If control rack (12) travel is more than required specifications, turn screw (15) counterclockwise.

7 .

Recheck control rack (12) travel. If control rack (12) travel is incorrect, repeat step 6 or 7. If control rack (12) travel is correct, proceed to step 9.

8 . Install plug (14) on governor housing (13).

5-275

TM 9-2320-272-24-4


6.

7.

8.

9.

i. Fuel Delivery Test

1.

2.

3.

4.

5.

Apply 13.1 psi (90.3 kPa) to manifold pressure compensator (2).


Set test stand to measure fuel delivery at 1,000 strokes.

Set control lever (3) to full load position.

Check fuel delivery quantity. Correct fuel delivery quantity should be 8.73-9.21 in.

3

(143.0-151.0 cm

3

).

Check fuel spread. Fuel spread should be 0.427 in.

3

(7.0 cm

3

).

Decrease fuel pump speed (1) to 500 rpm.


3

(92.0-94.0 cm

3

).

Adjust fuel delivery quantity by turning each barrel assembly (4) counterclockwise or clockwise until correct fuel delivery quantity is obtained.

5-276

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION. (Contd) j. Fuel Breakaway Test

1.

Move control lever (3) to full load position.

2.

Gradually increase rpm of fuel pump (1) rpm until control rack (5) moves 0.004 in. (0.1 mm) towards shutoff.

3.

Rpm of fuel pump (1) should be 1,090-1,100 rpm. Perform step 5 if correct rpm is not obtained.

4.

Move control lever (3) to full load position and observe travel of control rack. Correct control rack travel should be 0.464 in. (11.79 mm).

5.

If breakaway is not as specified rpm, adjust high-speed stopscrew (7) until correct breakaway is obtained.

k. Starting Fuel Delivery Test

1.


2.

Set test stand to measure calibration fluid at 1,000 strokes.

3.

Position throttle lever (6) so control rack (5) is at full load 0.827 in. (21 mm).

4.

Take fuel draw and check delivery quantity. Correct delivery quantity is 12.94-13.91 in.

3

(212.0-228.0 cm

3

).

5-277

TM 9-2320-272-24-4

5-37. FUEL INJECTION PUMP CALIBRATION (Contd) l. Low Idle Fuel Delivery Test

1.


2.

Position control lever (6) against idle stopscrew (5) and take a fuel draw.

3.

Observe control rack travel. Correct control rack travel should be 0.308-0.316 in. (7.80-8.03 mm).

4.

With test stand set at 1,000 strokes, take fuel draw and check delivery quantity. Correct delivery quantity is 0.824-1.373 in.

3

(13.5-22.5 cm

3

).

5.

If fuel delivery deviates from specifications, adjust idle stopscrew (5) until correct fuel delivery is obtained.

m. External Stop Setting

Perform this task so control rack has a 0.039 in. (1 mm) preload.

Failure to do so may result in damage to fuel pump.

1.

Loosen adjusting nut (3) on throttle stopscrew (4).

2.

Position throttle lever (2) against throttle stopscrew (4).

3.

Adjust throttle stopscrew (4) until 0.039 in. (1 mm) preload is observed on dial indicator (7) and tighten adjusting nut (3).

5-278


TM 9-2320-272-24-4

FOLLOW-ON TASK: Remove fuel injection pump from test stand (para. 5-31).

5-279

TM 9-2320-272-24-4

Section III. TRANSMISSION MAINTENANCE

5-38. TRANSMISSION MAINTENANCE INDEX

5-44.

5-45.

5-46.

5-47.

5-48.

5-49.

5-50.

5-51.

5-52.

5-53.

5-54.

5-55.

5-56.

5-57.

5-58.

5-59.

5-60.

5-61.

5-62.

PARA.

NO.

5-39.

5-40.

5-41.

5-42.

5-43.

TITLE

General Maintenance Instructions

Transmission Mounting to Holding Fixture

Transmission Torque Converter Maintenance

Transmission Oil Pan and Filter Maintenance

Modulate Lockup Valve, Low Trimmer Valve, and Low Shift

Valve Replacement

Transmission Control Valve Replacement

Transmission Manual Selector Shaft Replacement

Transmission Oil Pump and Front Support Maintenance

Forward Clutch Maintenance

Fourth Clutch Maintenance

Third Clutch Maintenance

Center Support Maintenance

Gear Unit and Main Shaft Maintenance

Second Clutch Maintenance

First Clutch Maintenance

Transmission Governor Replacement

Rear Cover and Low Planetary Carrier Maintenance

Low Clutch Removal and Clearance

Adapter Housing and First Clutch Piston Maintenance

Adapter Housing, Low Clutch, Low Planetary Carrier, and Rear

Cover Installation

Transmission Housing Maintenance

Transmission Oil Pressure Testing

Transmission Modulator Maintenance

Transmission Converter Stall Test

5-354

5-358

5-362

5-364

5-374

5-378

5-304

5-306

5-308

5-310

5-322

5-332

5-338

5-340

5-348

5-382

5-384

5-386

5-394

5-396

PAGE

NO.

5-281

5-282

5-286

5-300

5-280

5-39. GENERAL MAINTENANCE INSTRUCTIONS

WARNING

l

Drycleaning solvent is flammable and will not be used near open flame. Use only in well-ventilated places. Failure to do so may result in injury to personnel.

l

Compressed air source will not exceed 30 psi (20 kPa). When cleaning with compressed air, eyeshields must be worn. Failure to wear eyeshields may result in injury to personnel.

l

When converter pump hub, front support (including ground sleeve), or oil pump is defective, install wide oil pump kit. This kit converts an early model transmission (P/N 6885292) into a late model transmission (P/N 23040127). Failure to simultaneously install all parts of kit may cause damage to transmission during assembly or may cause transmission malfunction.

NOTE

l

Refer to para. 2-14 for cleaning all transmission components.

l

Make sure location markings are not removed when cleaning.

l

All transmission parts must be lubricated with clean

OE/HDO-10 lubricating oil before assembly.

TM 9-2320-272-24-4

5-281

TM 9-2320-272-24-4

5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE

THIS TASK COVERS a. Installation b. Removal

INITIAL SETUP:


All

SPECIAL TOOLS

Holding fixture adapter set (Appendix E,

Item 64)

Holding fixture (Appendix E, Item 63)

Holding fixture base (Appendix E, Item 65)

TOOLS


Lifting device

Chain

MATERIALS/PARTS


REFERENCES (TM)

TM 9-2320-272-24P


Transmission removed from vehicle (para. 4-71) or transmission removed from engine (para. 4-72).




l All personnel must stand clear during lifting operations.

l

Do not remove hoist chain from transmission until transmission is stable. Injury to personnel may result.

a. Installation

1.

Remove six screws (4), power takeoff cover (3), and gasket (2) from transmission (1). Discard gasket (2).

2.

Install holding plate (6) and holding fixture (5) on right side of transmission (1) with six washers (7) and screws (8).

NOTE

Transmission may be mounted on any overhaul stand or holding fixture. However, the front, rear, and bottom of transmission must be freely accessible for removal and installation of components.

3.

Install holding fixture base (10) on overhaul stand (11) with four screws (14), washers (13), and nuts (12).

WARNING

l All personnel must stand clear during lifting operations.

A snapped cable, or swinging or shifting load, may cause injury to personnel.

l

Do not remove hoist chain from transmission until transmission is stable on holding fixture base, or injury to personnel may result.

4.

Using lifting device and chain, lift transmission (1) and holding fixture (5) into position and install in holding fixture base (10) with pin (15) and setscrew (9).

5.

Remove chain and lifting device from transmission (1)

5-282

5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE (Contd)

TM 9-2320-272-24-4

5-283

TM 9-2320-272-24-4

5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE (Contd) b. Removal

WARNING

All personnel must stand clear during lifting operations.

A snapped cable, or swinging or shifting load, may cause injury to personnel.

1.

2.

3.

4.

NOTE


Attach lifting device and chain to transmission (1).

Remove pin (7) from holding fixture base (6) and loosen setscrew (5).

Support transmission (1) with chain and lifting device and remove transmission (1) and holding fixture (8) from holding fixture base (6).

Remove six screws (4), washers (3), holding fixture (8), and holding plate (2) from transmission (1) and holding fixture (8).

5.

Install new gasket (9) and power takeoff cover (10) on transmission (1) with six screws (11).

6.

Remove lifting device and chain from transmission (1).

5-284

5-40. TRANSMISSION MOUNTING TO HOLDING FIXTURE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install transmission on engine (para. 4-72) or install transmission in vehicle

(para. 4-71).

5-285

TM 9-2320-272-24-4

5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE

THIS TASK COVERS a. Removal b. Disassembly c. Cleaning and Inspection d. Assembly e. Installation

INITIAL SETUP:


All

SPECIAL TOOLS

Bearing puller set (Appendix E. Item 105)

Drive handle (Appendix E, Item 38)

Bearing replacer (Appendix E, Item 15)

Bushing replacer (Appendix E, Item 25)

TOOLS

Arbor press




MATERIALS/PARTS

Converter pump seal ring (Appendix D, Item 636)

Flywheel seal ring (Appendix D, Item 638)

Hook-type seal (Appendix D, Item 637)

Piston seal ring (Appendix D, Item 520)

Pump hub gasket (Appendix D, Item 225)

Six lockstraps (Appendix D, Item 342)

Thirty self-locking screws (Appendix D, Item 648)


Oil-soluble grease (Appendix C, Item 53)

REFERENCES (TM)

TM 9-2320-272-24P


Transmission mounted to holding fixture (para. 5-40).



a. Removal

NOTE

Assistant will help with steps 1 and 2.

1.

Remove four nuts (1), washers (2), and screws (4) from converter retaining strap (3) and transmission (7).

CAUTION

Torque converter must be pulled straight out of transmission and not moved from side to side. Side movement will damage hooktype seal ring on torque converter pump hub.

2.

Pull converter retaining strap (3) with torque converter (5) straight out of transmission (7).

3.

Remove two screws (6) and converter retaining strap (3) from torque converter (5).

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5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-287

TM 9-2320-272-24-4


9.

10.

11.

12.

b. Disassembly

1.

2.

3.

4.

5.

6.

7.

8.

13.

14.

15.

16.

17.

18.

NOTE

Hook-type seal ring used on early models.

Remove hook-type seal ring (12) from torque converter pump hub (11). Discard hook-type seal ring (12).

NOTE

l

Have drainage container ready to catch transmission oil.

l Assistant will help with step 2.

Remove thirty self-locking screws (13) and washers (14) from converter pump (7) and converter flywheel (1), and drain transmission oil. Discard self-locking screws (13).

Separate converter pump (7) from converter flywheel (1).

Remove seal ring (6) from converter pump (7). Discard seal ring (6).

Remove roller thrust bearing (2) and bearing race (3) from converter flywheel (1) or converter pump (7).

Bend corners of six lockstraps (5) away from twelve screws (4) and remove twelve screws (4), six lockstraps (5), and retainer (15) from converter pump (7). Discard lockstraps (5).

Remove torque converter pump hub (11) and gasket (10) from converter pump (7). Discard gasket (10).

NOTE

l

Early model transmission converter pump has a snapring and roller bearing inside front bore. Late model converter pump hub has no snapring or roller bearing, but does have a nose with flats.

l Perform step 8 for early model transmission.

Using bearing puller set, remove snapring (8) and roller bearing (9) from torque converter pump hub (11).

Remove stator (26) from converter turbine (25).

Turn roller race (31) clockwise and lift off stator (26).

Remove ten rollers (27) and springs (28) from stator (26).

Remove thrust bearing (30) and race (29) from stator (26).

NOTE

Converter turbine must be pulled straight off flywheel, or it will bind.

Remove converter turbine (25) from converter flywheel (1).

Using bearing puller, remove ball bearing (22) and spacer (23) from turbine hub (24).

Remove lockup clutch plate (19), backplate (20), and two backplate keys (21) from converter flywheel (1).

NOTE

Scribe mark on converter flywheel and lockup clutch piston for installation.

Place converter flywheel (1) upright and remove lockup clutch piston (17). If lockup clutch piston (17) sticks, tap flywheel (1) lightly with soft-faced hammer.

Remove piston seal ring (18) from piston (17). Discard piston seal ring (18).

Remove flywheel seal ring (16) from converter flywheel (1). Discard flywheel seal ring (16).

5-288


TM 9-2320-272-24-4

5-289

TM 9-2320-272-24-4

5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE (Contd) c. Cleaning and Inspection

1.


2.


3.

Inspect lockup clutch disc (1) for burned surfaces. If burned, discard lockup clutch disc (1).

4.

Measure thickness of lockup clutch disk (1). If thickness is less than 0.190 in. (4.32 mm), discard lockup clutch disc (1).

5.

Measure thickness of thrust bearing race (2). If thickness is less than 0.029 in. (0.74 mm), discard thrust bearing race (2).

6.

Inspect roller race (4) for scoring. If scored, discard roller race (4).

NOTE

Step 7 refers to early model pump hub.

7.

Inspect pump hub (3) for cracks, breaks, burred flats, and scored seal surface and bearing bore. If damage is more than minor scoring, discard pump hub (3).

NOTE

Step 8 refers to late model pump hub.

8.

Inspect pump hub (3) for cracks, breaks, burred flats, and scored seal surface and bushing journal.

If damage is more than minor scoring, discard pump hub (3).

5-290

TM 9-2320-272-24-4

5-41. TRANSMISSION TORQUE CONVERTER MAINTENANCE (Contd) d. Assembly

NOTE

l

Steps 2 and 14 obtain measurements to select proper spacer thickness. These measuring steps are treated as assembly steps.

l

Steps 2 and 3 are performed only if new bearing is being installed.

1.

Install ball bearing (5) in flywheel bore (7). Ensure ball bearing (5) seats against shoulder of flywheel bore (7).

2.

Place straightedge (6) across flywheel bore (7) and measure the distance from inner race of ball bearing (5) to straightedge (6). Record this measurement for use in step 14d.

5-291

TM 9-2320-272-24-4

3.

4.

5.

6.


7.

8.

9.

Remove ball bearing (8) from flywheel (1).

Apply lubricating oil to new flywheel seal ring (2) and install on flywheel (1).

Apply lubricating oil to new piston seal ring (4) and install on lockup clutch piston (3).

Align previously scribed marks on lockup clutch piston (3) and install, cupped side first, on flywheel (1).

Soak lockup clutch plate (5) in clean lubricating oil for at least two minutes. Install lockup clutch plate (5) on clutch piston (3).

Position two backplate keys (7) in flywheel (1) recesses.

NOTE

Backplate and backplate keys must be level for the next step.

Install lockup clutch backplate (6).

a. Position lockup clutch backplate (6) in flywheel (1), engaging notch in lockup clutch backplate (6) with two backplate keys (7).

CAUTION

If backplate is not approximately level with the key, the lockup clutch piston is not properly engaged with the drive pins in the flywheel. Rotate the piston until it drops into place on the pins.

Damage to backplate will result if piston is not engaged properly.

NOTE

Perform step b only if backplate is not level with the keys.

b. Rotate piston (3) until pin holes and flywheel (1) pins are aligned.

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5-293

TM 9-2320-272-24-4


10.

11.

12.

13.

14.

NOTE

Late model transmission does not have roller bearing or snapring in front bore of torque converter pump hub.

Perform step 10 if bearing is to be installed in early model transmission.

Using an arbor press and bearing remover/installer, press roller bearing (16) in torque converter pump hub (18) and install with snapring (15).

CAUTION

Identify transmission model. Late model converter pump hub has longer nose and has 1 in. (25.4 mm) long flats that fit into oil

pump (para. 5-39). Do not intermix parts from early and late

model transmissions. Damage to transmission will result.

Install new gasket (17) and torque converter pump hub (18) on converter pump (14) with retainer (13), six new lockstraps (12), and twelve screws (11). Tighten screws (11) 33-40 lb-ft

(45-54 N•m). Bend comers of lockstraps (12) against head of each screw (11).

Install bearing race (10) and roller thrust bearing (9) in converter pump (14).

Install bearing race (25), thrust bearing (26), and freewheel roller race (27) in stator (24) and place stator (24) and converter turbine (21) in converter pump (14). Center stator (24) and converter turbine (21) carefully.

NOTE

Step 14 is performed only if new bearing was installed in step 1.

Select spacer (23) size: a. Place gauge blocks (22) of equal height on edge of converter pump (14) as shown b. Place straightedge (19) across gauge blocks (22) and measure distance from straightedge (19) to shoulder (20) adjacent to hub of turbine (21). Record this measurement.

c. Subtract measurement obtained in step 14b. from gauge block height. Record this measurement.

d. Subtract measurement obtained in step 14c. from measurement obtained in step 2. Using this

measurement, refer to table 5-11 to select correct size spacer (23).

Table 5-11. Torque Converter Spacer Sizes.

Measurements

0.018-0.032 in. (0.457-0.813 mm)

0.032-0.044 in. (0.813-1.117 mm)

0.044-0.062 in. (1.117-1.575 mm)

0.062-0.077 in. (1.575-1.956 mm)

0.077-0.096 in. (1.956-2.438 mm)

Spacer

Gold

Silver

Plain

Black

Copper

15.

Remove converter turbine (21) from converter pump (14).

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TM 9-2320-272-24-4

5-295

TM 9-2320-272-24-4


16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Install spacer (3) on converter turbine hub (4).

Install ball bearing (2) on converter turbine hub (4) until seated against spacer (3).

Install converter turbine (5) in flywheel (1).

Remove stator (6) from converter pump (12).

Remove freewheel roller race (10) and thrust bearing (9) from stator (6).

NOTE

One of three different types of roller springs will be present in early stators as shown. Either the later or latest type should be used, but all springs must be of the same type.

The latest type roller springs are installed in a different manner. The old tab may be either up or down.

Oil-soluble grease will hold springs and rollers in place.

Pack stator cam pockets (17) with oil-soluble grease and install springs (8) and rollers (7) in stator cam pockets (17).

Apply a small amount of oil-soluble grease to thrust bearing (9) and position thrust bearing (9) to freewheel roller race (10).

Position freewheel roller race (10) and thrust bearing (9) in stator (6) and turn clockwise until seated in stator (6).

Position stator (6) on converter turbine (5).

Apply lubricating oil to new seal ring (11) and install on converter pump (12).

Install converter pump (12) on flywheel (1) with thirty new self-locking washers (16) and new selflocking screws (15). Tighten screws (15) 41-49 lb-ft (56-66 N•m).

NOTE

Hook-type seal ring used on early models.

Install new hook-type seal ring (13) on torque converter pump hub (14).

Install converter retaining strap (19) on torque converter (18) with two screws (20).

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1.

Tilt transmission (7) to horizontal position, with oil pan (6) facing downward.

CAUTION

Torque converter must be installed straight on transmission and not moved from side to side. Side movement will damage hooktype seal ring on turbine shaft.

NOTE


2.

Install torque converter (5) in transmission (7). Ensure seal ring is properly positioned. Torque converter (5) may be rotated until flat sides of pump hub engage flats in oil pump drive gear.

3.

Install converter retaining strap (3) on transmission (7) with four screws (4), washers (2), and nuts (1).

5-298


TM 9-2320-272-24-4

FOLLOW-ON TASK: Remove transmission from holding fixture (para. 5-40).

5-299

TM 9-2320-272-24-4

5-42. TRANSMISSION OIL PAN AND FILTER MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b. Cleaning and Inspection c . I n s t a l l a t i o n

INITIAL SETUP:


All

TOOLS



MATERIALS/PARTS


Transmission oil filter (Appendix D, Item 699)


REFERENCES (TM)

TM 9-2320-272-24P


Transmission torque converter removed (para. 5-41).



1.

Remove twenty-one screws (l), oil pan (2), and gasket (3) from transmission (4). Discard gasket (3).

2.

Rotate transmission (4) in stand until oil pan (2) mounting surface is horizontal and facing upward.

3.

Remove oil filter screw (6), oil filter (7), and filter suction tube (8) from transmission (4).

4.

Remove filter suction tube (8) from oil filter (7). Discard oil filter (7).

5.

Remove O-ring (9) from filter suction tube (8). Discard O-ring (9).

1.


2.


3.

Inspect oil pan (2) for cracks. If cracked, replace oil pan (2).

NOTE

New oil pan has a plug in left side fill port.

If oil pan is defective, remove plug if present.

4.

Remove oil plug (5). Retain for installation in new oil pan (2).

5-300

5-42. TRANSMISSION OIL PAN AND FILTER MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-301

TM 9-2320-272-24-4


1.

2.

3.

4.

5.

6.

7.

NOTE

Keep oil pan mounting surface in horizontal position and facing upward.

Filter suction tube ends are interchangeable.

Insert one end of filter suction tube (3) into new transmission oil filter assembly (2).

Install new O-ring (4) onto opposite end of filter suction tube (3).

Position new transmission oil filter assembly (2) on transmission (6). Ensure filter suction tube (3) is inserted into oil input port (5).

Install new transmission oil filter assembly (2) on transmission (6) with screw (1). Tighten screw (1) 10-15 lb-ft (14-20 N•m).

CAUTION

Do not use silicone-type gasket sealing compound when installing gasket, because oil leakage may result. Oil or light grease coating may be used to hold gasket in position during installation.

Position new oil pan gasket (10) against housing of transmission (6) and align with holes of transmission (6).

Position transmission oil pan (7) against oil pan gasket (10) and install with twenty-one screws (9).

Tighten screws (9) finger-tight.

Tighten twenty-one screws (9) 10-15 lb-ft (14-20 N•m) following torque sequence shown.

5-302

TM 9-2320-272-24-4


NOTE

Due to gasket compression, torque values will be lost and screws must be retightened.

8.

Tighten twenty-one screws (9) 15-20 lb-ft (20-27 N•m) following torque sequence shown to achieve final torque.

NOTE

Perform step 9 only if new oil pan was installed.

9.

Install plug (8) in oil pan (7). Ensure plug (8) is installed opposite hole for dipstick.

FOLLOW-ON TASK: Install transmission torque converter (para. 5-41).

5-303

TM 9-2320-272-24-4

5-43. MODULATE LOCKUP VALVE, LOW TRIMMER VALVE, AND LOW SHIFT VALVE

REPLACEMENT

THIS TASK COVERS: a . R e m o v a l b . I n s t a l l a t i o n

INITIAL SETUP:


All

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS



Transmission oil pan and filter removed (para. 5-42).




1.

Remove three screws (5) and modulated lockup valve (6) from oil transfer plate (4).

2.

Remove six screws (1) and low trimmer valve (2) from low shift valve (3).

3.

Remove two screws (7) and low shift valve (3) from oil transfer plate (4).

NOTE

Keep oil pan mounting surface in horizontal position and facing upward.

1.

Install low shift valve (3) on oil transfer plate (4) with two screws (7). Finger-tighten screws (7).

2.

Install low trimmer valve (2) on low shift valve (3) with six screws (1). Tighten screws (1) and (7)

9-11 lb-ft (12-15 N•m) in sequence shown.

3.

Install modulated lockup valve (6) on oil transfer plate (4) with three screws (5). Tighten screws (5)

9-11 lb-ft (12-15 N•m) in sequence shown.

5-304

TM 9-2320-272-24-4

5-43. MODULATE LOCKUP VALVE, LOW TRIMMER VALVE, AND LOW SHIFT VALVE

REPLACEMENT (Contd)

FOLLOW-ON TASK: Install transmission oil pan and filter (para. 5-42).

5-305

TM 9-2320-272-24-4

5-44. TRANSMISSION CONTROL VALVE REPLACEMENT


INITIAL SETUP:


All

TOOLS



REFERENCES (TM)

TM 9-2320-272-24P


Low shift valve, low trimmer valve, and modulate

lockup valve removed (para. 5-43).



NOTE

Separate and tag screws for installation.

1.

Remove screw (4) and detent spring and roller (5) from control valve (2).

2.

Remove three screws (3) from control valve (2).

3.

Remove screw (1) from control valve (2).

4.

Remove fifteen screws (6) from control valve (2).

CAUTION

Do not tilt control valve to allow selector valve to drop out.

Selector valve may be damaged.

Remove items as an assembly and do not separate. Loose parts inside will fall free, resulting in damage to control valve.

5.

Remove control valve (2), separator plate (7), and oil transfer plate (8) from transmission (11).

b. Installation

CAUTION

Do not tilt control valve to allow selector valve to drop out.

Damage to selector valve may result.

1.

Position oil transfer plate (8), separator plate (7), and control valve (2) on transmission (11) so pin on detent lever (10) aligns with slot on selector valve (9).

2.

Install control valve (2) on transmission (11) with fifteen screws (6). Finger-tighten screws (6).

3.

Install control valve (2) with three screws (3). Finger-tighten screws (3).

4.

Install control valve (2) with screw (1). Finger-tighten screw (1).

5.

Position detent spring and roller (5) on control valve (2) with roller in notch of detent lever (10), and install with screw (4).

6.

Tighten twenty screws (1), (3), (4), and (6) 9-11 lb-ft (12-15 N•m) in sequence shown.

5-306

5-44. TRANSMISSION CONTROL VALVE REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install low shift valve, low trimmer valve, and modulate lockup valve (para. 5-43).

5-307

TM 9-2320-272-24-4

5-45. TRANSMISSION MANUAL SELECTOR SHAFT REPLACEMENT


INITIAL SETUP:


All

TOOLS



REFERENCES (TM)

TM 9-2320-272-24P


Transmission selector shaft oil seal removed

(para. 4-76).

Transmission control valve removed (para. 5-44).



1.

Remove shaft retainer pin (3) from transmission housing (4).

2.

Remove nut (2) and detent lever (1) from transmission manual selector shaft (5).

3.

Remove transmission manual selector shaft (5) from transmission housing (4).

1.

Tilt transmission housing (4) to horizontal position with the bottom facing upward.

2.

Install manual selector shaft (5) and detent lever (1) on transmission housing (4) with nut (2).

Tighten nut 15-20 lb-ft (20-27 N•m).

3.

Secure manual selector shaft (5) in transmission housing (4) with shaft retainer pin (3).

5-308

TM 9-2320-272-24-4

5-45. TRANSMISSION MANUAL SELECTOR SHAFT REPLACEMENT (Contd)

FOLLOW-ON TASK: Install transmission selector shaft oil seal (para. 4-76).

Install transmission control valve (para. 5-44).

5-309

TM 9-2320-272-24-4

5-46. TRANSMISSION OIL PUMP AND FRONT SUPPORT MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b. Disassembly c. Cleaning and Inspection d. Assembly e . I n s t a l l a t i o n

INITIAL SETUP:


All

SPECIAL TOOLS

Two guide pins (Appendix E, Item 60)

Front support lifter (Appendix E, Item 48)

Bearing installer (Appendix E, Item 11)

Driver handle (Appendix E, Item 38)

Valve pin remover (Appendix E, Item 155)

Slide hammer (Appendix E, Item 122)

Main regulator and lockup spring compressor


Adapters (Appendix E, Item 2)

Centering band (Appendix E, Item 90)

Bushing replacer (Appendix E, Item 25)

TOOLS




Arbor press

MATERIALS/PARTS

Oil seal (Appendix D, Item 502)

Two self-locking screws (Appendix D, Item 649)

Twelve self-locking screws (Appendix D, Item 650)

Two hook-type seal rings (Appendix D, Item 638)

Twelve washers (Appendix D, Item 713)

Oil pump seal ring (Appendix D, Item 226)

Oil pump gasket (Appendix D, Item 227)

Valve guide pin (Appendix D, Item 705)




REFERENCES (TM)

TM 9-2320-272-24P

EQUIPMENT CONDITION

Transmission manual selector shaft removed

(para. 5-45).




Use care when removing snaprings and retaining rings.

1.

Position transmission (5) front upward.

2.

Remove twelve screws (2) and washers (1) connecting oil pump and front support (4) to transmission (5). Discard washers (1).

3.

Attach front support lifter to converter ground sleeve (3) on oil pump and front support (4).

NOTE


4.

Remove oil pump and front support (4) from transmission (5) by lifting straight up. Assistant may tap surface with a rubber hammer to ease removal.

5.

Remove oil pump gasket (6). Discard oil pump gasket (6).

5-310

TM 9-2320-272-24-4

5-46. TRANSMISSION OIL PUMP AND FRONT SUPPORT MAINTENANCE (Contd)

5-311

TM 9-2350-272-24-4


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remove two hook-type seal rings (8) from oil pump (19) and front support (5). Discard seal rings (8).

Remove bearing and race (7) from oil pump (19) and front support (5) or transmission.

Remove oil pump seal ring (1) from oil pump (19) and front support (5). Discard oil pump seal ring (1).

If replacement is necessary, remove needle bearing (6) from front support hub ground sleeve (9).

Install valve pin remover tool on slide hammer on oil pump (19) and front support (5).

Attach valve pin remover tool between coils of valve spring (3) and valve guide pin (2).

NOTE


Remove valve guide pin (2), valve spring (3), and converter pressure regulator valve (4). Discard valve guide pin (2). Tag valve spring (3) for installation.

WARNING

Regulator valve spring is under approximately 65 lb (29 kg) compression. Do not remove retaining snapring until compressor is in place, or regulator valve spring may fly out causing injury.

NOTE

For transmissions with serial numbers 21628 and higher, use two adapters with spring compressor.

Attach main regulator and lockup spring compressor to front support (5) and tighten two screws (23) to relieve spring compression.

NOTE

Perform steps 9 and 10 for transmissions with serial numbers

21628 and higher.

Remove twelve self-locking screws (25) and two self-locking screws (24) and separate oil pump (19) from front support (5). Mark location for installation. Discard self-locking screws (24) and (25).

Remove two cross pins (26) from front support (5).

NOTE

Perform step 11 for transmissions with serial numbers prior to

21628.

Remove snaprings (10) and (11) from oil pump (19) and front support (5).

Carefully remove and detach main regulator lockup spring compressor, valve stops (12) and (17), valve springs (13) and (16), regulator valve (15), and lockup valve (14) from front support (5). Mark locations for installation. Tag valve springs (13) and (16) for installation.

NOTE


21628.

13.

Remove twelve self-locking screws (25) and two self-locking screws (24) connecting oil pump (19) to front support (5). Separate oil pump (19) from front support (5). Mark location for installation and discard self-locking screws (25) and (24).

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TM 9-2320-272-24-4


NOTE

Do not perform steps 14 and 15 unless relative movement is apparent between ground sleeve and front support.

14.

If plug (22) is loose or damaged, remove plug (22) from front support (5).

15.

Remove oil pump gears (20) and (21) and oil pump body oil seal (18) from oil pump (19).

Discard body oil seal (18).

5-313

TM 9-2320-272-24-4


5.

6.

1.

2.

3.

4.

7.

8.

9.

10.

11.

12.

CAUTION

Early model and late model converter pump hub, Front support seals, and oil pump are not interchangeable. Do not intermix parts from early and late transmissions. Damage to transmission will result.



Inspect oil pump gears (3) and (4) for broken teeth. Discard gears if broken.

Install oil pump gears (3) and (4) in pump body (2).

Place straightedge (1) across face of oil pump (2).

Measure clearance between straightedge (1) and gear (4). If clearance is more than 0.0020 in.

(0.051 mm), replace with thicker gear (4). Repeat steps 4 through 6.

NOTE

Perform step 7 for late model transmissions only. Early model transmissions do not have bushing.

Measure inside diameter of bushing (5) on oil pump (2) at 5 o’clock position when viewed from the front. Maximum wear limit is 2.257 in. (57.33 mm). Brass backing showing through is acceptable if wear limit is not exceeded.

Inspect bushing (5) on oil pump (2) for scoring. Replace bushing (5) if scoring can be felt. Use installer/remover tool and arbor press.

Inspect bushing (5) on oil pump (2) for discoloration due to overheating. Replace if discolored.

Inspect all springs for discoloration due to overheating. Discard if discolored.

Inspect all springs for broken coils or coils distorted due to wear. Discard if broken or distorted.

Using spring tester, inspect for serviceability by checking load when spring is compressed to the

correct length. Discard spring if spring does not give the correct load (table 5-12).

SPRING

Main pressure regulator valve spring

Converter pressure regulator valve spring

Lockup valve spring

COLOR

Green

Blue

Yellow

Table 5-12. Spring Data.

FREE LENGTH COMPRESSED LENGTH

3.57 in.

(90.7 mm)

2.01 in.

(51.0 mm)

1.24 in.

(31.5 mm)

2.84 in.

(72.1 mm)

1.05 in.

(26.7 mm)

1.46 in.

(37.1 mm)

UNDER LOAD

70.6-76.6 lb

(314-341 N)

33.1-40.5 lb

(147-180 N)

26.1-28.9 lb

(116-129 N)

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5-315

TM 9-2320-272-24-4


CAUTION

Oil seals for early and late model oil pumps are not

interchangeable (para. 5-39).

NOTE

Coat all internal parts, except oil pump, with lubricating oil

OE/HDO-10 prior to assembly.

Perform steps 1 through 3 only if gears and oil seal were removed.

1.

Using oil-soluble grease, coat outside diameter of new oil pump seal ring (1)

2.

Install new oil pump seal ring (1) in oil pump body (2) 0.030-0.050 in. (1.76-1.27 mm) below outer edge of bore. Install spring-loaded lip first. Use depth micrometer for measurement.

3.

Using oil-soluble grease, coat oil pump body seal (1) lip.

4.

Install oil pump gears (3) and (4).

NOTE

For transmissions with serial numbers 21628 and higher, use two adapters with spring compressor.

5.

Install regulator valve (11), lockup valve (9), valve springs (12) and (8), and valve stops (13) and (7) in front support (10) at location marked during disassembly.

6.

Attach main regulator and lockup spring compressor to front support (10) and tighten screws (14) until snapring grooves or crosspin holes are visible in front of valve stops.

NOTE


21628.

7.

Install snaprings (5) and (6) over valve stops (13) and (7). Tighten screws (14) until snapring grooves are visible in front of valve stops (7) and (13).

5-316

TM 9-2320-272-24-4


5-317

TM 9-2320-272-24-4


8.

9.

10.

11.

12.

13.

14.

NOTE

Perform step 8 for transmissions with serial numbers 21628 and higher.

Install two cross pins (2) in pin holes of front support (1).

Detach and remove main regulator and spring compressor from front support (1).

NOTE

Perform step 10 only if plug was previously removed.

Install plug (3) in front support (1).

Position oil pump (6) to front support (1) and align holes for screws (4) and (5). Install oil pump (6) to front support (1) with two new self-locking screws (4) positioned 180° apart. Finger-tighten screws (4).

Install centering band around oil pump (6).

Install oil pump (6) on front support (1) with remaining ten new self-locking screws (4) and two new self-locking screws (5). Tighten screws (4) 17-20 lb-ft (23-27 N•m). Tighten screws (5) 36-42 lb-ft

(23-27 N•m).

Remove centering band from oil pump (6) to front support (1) and check separation line between oil pump (6) and front support (1). If mating point between oil pump (6) and front support (1) is not perfectly smooth by touch, loosen screws (4) and (5). Repeat steps 12 through 14.

5-318

TM 9-2320-272-24-4


NOTE

Perform step 15 only if needle bearing was previously removed.

15.

Position needle bearing (8) on converter ground sleeve (9). Ensure numbered end of needle bearing (8) faces outward.

16.

Using bearing installer and driver handle, press needle bearing (8) into converter ground sleeve (9) 1.240-1.260 in. (31.50-32.00 mm) below outer edge of bore.

NOTE

Perform steps 17 and 18 only if converter pressure regulator valve was previously removed.

17.

Place valve spring (11) and converter pressure valve (10) on new valve guide pin (7).

18.

Press new valve guide pin (7) into front support (1) until new value guide pin (7) extends

1.16-1.20 in. (29.46-30.48 mm) above finished surface.

NOTE

Two seal rings for front support hub are installed when oil pump and front support are installed in transmission.

5-319

TM 9-2320-272-24-4


7.

8.

1.

2.

3.

4.

5.

6.

CAUTION

Identify transmission model before assembly of oil pump and front support. If early model converter hub was replaced with late model converter hub, a late model oil pump and front support must be installed, or transmission may be damaged during

assembly (para. 5-39).

NOTE

Late model oil pump is thicker than early model oil pump.

Late model front support has a bushing and a thicker seal in oil pump hub. Early model oil pump hub has a thin seal and the torque converter hub has a roller bearing.

Install bearing and race (2) on turbine shaft (3).

NOTE

Guide pins maintain gasket alignment.

Install two guide pins (5) and new oil pump gasket (1) into transmission (4).

Apply oil-soluble grease sparingly to two new seal rings (10) to hold in place, and install seal rings (10) on hub (9) of oil pump (7) and front support (8).

Apply oil-soluble grease to new oil pump and ring coil, and install new oil pump seal ring (6) on oil pump (7) and front support (8).

Attach front support lifter to converter ground sleeve (12).

Align front support holes (13) with corresponding holes in transmission (4), and carefully install front support (8) in transmission (4) over guide pins (5).

Remove two guide pins (5) and front support lifter from transmission (4).

Install front support (8) on transmission (4) with twelve new rubber-covered washers (14) and screws (11). Tighten screws (11) as follows: a.

Tighten alternately 180° apart. Tighten screws (11) 15 lb-ft (20 N•m).

b.

Repeat tightening sequence 180° apart to achieve final torque. Tighten screws (11) 24-32 lb-ft

(33-43 N•m).

5-320

TM 9-2320-272-24-4


FOLLOW-ON TASK: Install transmission manual selector shaft (para. 5-45).

5-321

TM 9-2320-272-24-4

5-47. FORWARD CLUTCH MAINTENANCE


INITIAL SETUP:


All

SPECIAL TOOLS


Forward clutch clearance gauge (Appendix E,

Item 46)

TOOLS






Arbor press

MATERIALS/PARTS

Two turbine shaft seal rings (Appendix D,

Item 640)

Turbine shaft seal ring (Appendix D, Item 639)

Piston inner seal ring (Appendix D, Item 515)

Piston outer seal ring (Appendix D, Item 516)



REFERENCES (TM)

TM 9-2320-272-24P


Transmission oil pump and front support removed

(para. 5-46).



1.

Lift forward clutch housing (9) and turbine shaft (1) straight out from transmission (5).

NOTE

Perform step 2 for transmissions with three-piece bearing.

2.

Remove bearing race (2), roller bearing (3), and bearing race (4) from turbine shaft (1).

NOTE

Perform step 3 for transmissions with single-piece bearing assembly.

3.

Remove bearing assembly (6) from turbine shaft (1).

1.

Remove seal ring (10) and two seal rings (11) from turbine shaft (1). Discard seal ring (10) and two seal rings (11).

NOTE

Support Power Takeoff (PTO) drive gear on arbor press for steps 2 through 6.

5-322

TM 9-2320-272-24-4

5-47. FORWARD CLUTCH MAINTENANCE (Contd)

2.

Locate opening (missing spline) in forward clutch housing (9) nearest snapring (12) gap.

3.

Press snapring (12) into groove in clutch housing (9) and insert one piece of shim stock (8) through opening between snapring (12), Power Takeoff (PTO) gear (7), and teeth of clutch housing (9).

4.

Repeat step 3, inserting remaining pieces of shim stock (8) into PTO gear approximately 5 in.

(127 mm) apart.

5.

Lift PTO gear (7) off clutch housing (9).

6.

Remove snapring (12) and shim stock (8) from clutch housing (9).

5-323

TM 9-2320-272-24-4


7.

8.

Remove snapring (6) from forward clutch housing (16).

Remove fourth clutch drive hub (5) and forward clutch hub (4) from forward clutch housing (16).

NOTE

Perform step 9 for transmission with three-piece bearing.

9.

Remove bearing race (7), bearing (8), and bearing race (9) from forward clutch housing (16) or fourth clutch hub (5).

NOTE


10.

Remove bearing assembly (3) from forward clutch housing (16).

CAUTION

13.

14.

15.

Keep all parts together. Intermixing forward clutch parts with any other clutch pack will cause transmission damage.

NOTE

Tag all clutch parts for reassembly.

11.

Remove six clutch plates (1) and six clutch discs (2) from forward clutch housing (16).

NOTE

Use arbor press with compression tool for step 12.

12.

Position compressor tool on spring retainer (11) and place on arbor press.

Apply pressure on spring retainer (11) and remove snapring (10) from forward clutch housing (16).

Remove compressor tool from spring retainer (11) and arbor press.

16.

17.

Remove spring retainer (11), piston return spring (12), piston (13), and piston inner seal ring (15) from forward clutch housing (16). Discard piston inner seal ring (15).

Remove piston outer seal ring (14) from piston (13). Discard piston outer seal ring (14).

Remove retainer pin (20), valve plug (19), valve spring (18), and centrifugal valve (17) from forward clutch housing (16).

5-324


TM 9-2320-272-24-4

5-325

TM 9-2320-272-24-4


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.



Inspect turbine shaft and forward clutch housing (1) for scoring in area where seals contact turbine shaft (1). If scored, discard turbine shaft and forward clutch housing (1).

Inspect clutch plates (2) for burned surfaces. If burned, discard clutch plates (2).

Inspect clutch discs (3) for burned surfaces. If burned, discard clutch discs (3).

Measure thickness of fourth clutch drive hub (4) at clutch disc (3) contact area. If thickness is less than 0.248 in. (6.30 mm), discard fourth clutch drive hub (4).

Inspect valve spring (5) and piston return spring (6) for discoloration due to overheating. If discolored, discard.

Inspect valve spring (5) and piston return spring (6) for broken coils or coils distorted due to wear. If broken or distorted, discard.

Using spring tester, inspect valve spring (5) for serviceability.

a. Compress valve spring (5) to 0.61 in. (15.5 mm) and check load (table 5-13).

b. If valve spring (5) does not give load of 5.7-6.3 lb (25.3-28 N), discard.

Using spring tester, inspect piston return spring (6) for serviceability.

a. Compress piston return spring (6) to 1.28 in. (32.5 mm) (table 5-13).

b. If piston return spring (6) does not give load of 158-178 lb (707-791 N), discard.


SPRING

Valve spring

Piston return spring

COLOR

Green

None

FREE LENGTH

0.76 in.

(19.3 mm)

3.22 in.

(81.8 mm)

COMPRESSED

LENGTH

0.61 in.

(15.5 mm)

1.28 in.

(32.5 mm)

UNDER LOAD

5.7-6.3 lb

(25.3-28 N)

158-178 lb

(702-791 N)

5-326


TM 9-2320-272-24-4

5-327

TM 9-2320-272-24-4


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

NOTE

If new centrifugal valve is being installed, all components must have same color code as old valve.

Install centrifugal valve (3) and valve spring (2) in forward clutch housing (16). Ensure pointed end of centrifugal valve (3) is installed first.

Push valve plug (1) into forward clutch housing (16) and install with retainer pin (17). Retainer pin (17) must protrude 0.080-0.100 in. (2.03-2.54 mm) above front surface of forward clutch housing (16).

Apply oil-soluble grease to new piston outer seal ring (12) and install new piston outer seal ring (12) on piston (10). Ensure piston outer seal ring (12) lips face toward oil pressure side of piston (10).

Apply oil-soluble grease to new piston inner seal ring (15) and install new piston inner seal ring (15) on forward clutch housing (16) hub. Ensure piston inner seal ring (15) lips face toward oil pressure side of piston (10).

Install piston (10) in forward clutch housing (16).

NOTE

Steps 6 through 12 obtain clutch running clearance.

Starting with clutch plate (5), alternately install six clutch plates (5) and six clutch discs (4) in forward clutch housing (16).

Position fourth clutch drive hub (6) in forward clutch housing (16) and install with snapring (7).

Measure clearance between fourth clutch drive hub (6) and clutch disc (4) with forward clutch clearance gauge.

Clutch running clearance should be 0.094-0.148 in. (2.387-3.759 mm).

NOTE

Perform steps 10 through 12 only if clutch running clearance is incorrect.

If clearance exceeds 0.148 in. (3.759 mm), replace clutch plates (5) and clutch discs (4) with new, thicker clutch plates (5) and clutch discs (4).

If clearance still exceeds 0.148 in. (3.759 mm) after completing step 10, replace piston (10) with new, thicker piston (10).

If clearance is less than 0.094 in. (2.387 mm), replace piston (10) with a new, thinner piston (10).

Remove snapring (7), fourth clutch drive hub (6), six clutch discs (4), and six clutch plates (5) from forward clutch housing (16).

Place piston return spring (14) and spring retainer (13) in forward clutch housing (16).

Place compressor tool on spring retainer (13) and arbor press.

Compress piston return spring (14) with compressor tool and arbor press and install spring retainer (13) with snapring (11).

Remove compressor tool from spring retainer (13).

NOTE

Use oil-soluble grease to hold bearing race and bearing in place.

Soak six clutch discs in clean OE/HDO-10 lubricating transmission oil for at least two minutes before installing in forward clutch housing.


Install bearing assembly (9) in forward clutch housing (16). Ensure lube scallops of bearing assembly (9) face down.

5-328

TM 9-2320-272-24-4


NOTE

Perform steps 19 through 21 for transmission with three-piece bearing.

19.

Install bearing race (8) in forward clutch housing (16). Ensure outer lip of bearing race (8) is installed first.

5-329

TM 9-2320-272-24-4


20.

Install bearing race (3) on forward clutch hub (4). Ensure flat side of bearing race (3) is installed first.

21.

Apply liberal amount of oil-soluble grease on bearing (2) and install bearing (2) on forward clutch hub (4).

22.

Install forward clutch hub (4) in forward clutch housing (1). Ensure splined edge is installed first.

23.

Starting with clutch plate (5), alternately install six clutch plates (5) and six clutch discs (6) in forward clutch housing (1).

24.

Install fourth clutch drive hub (7) in forward clutch housing (1) with snapring (8).

5-330

TM 9-2320-272-24-4


25.

Install PTO gear snapring (12) on forward clutch housing (1).

26.

Slide PTO gear (13), chamfered end first, over PTO gear snapring (12) on forward clutch housing (1).

Ensure PTO gear snapring (12) springs outward into internal groove of PTO gear (13).

NOTE


27.

Install roller bearing (17) on forward clutch hub (4).

NOTE

Perform steps 28 and 29 for transmission with three-piece bearing.

Use oil-soluble grease to hold bearing race, bearing, and seal rings in place.

28.

Install bearing race (14), flat side first, on forward clutch hub (4).

29.

Install bearing (15) and bearing race (16) on forward clutch hub (4).

30.

Install two new seal rings (10) on turbine shaft (11).

31.

Install new seal ring (9) on turbine shaft (11).

Install forward clutch housing (1) and turbine shaft (11) in transmission housing while engaging fourth clutch drive hub (7) with internal-splined clutch discs of fourth clutch. Ensure the fourth clutch housing (1) is properly seated.

FOLLOW-ON TASK: Install transmission oil pump and front support (para. 5-46).

5-331

TM 9-2320-272-24-4

5-48. FOURTH CLUTCH MAINTENANCE


INITIAL SETUP:


All

SPECIAL TOOLS


Fourth clutch clearance gauge (Appendix E,

Item 47)

TOOLS





Arbor press

MATERIALS/PARTS

Piston inner seal ring (Appendix D, Item 515)

Piston outer seal ring (Appendix D, Item 516)



REFERENCES (TM)

TM 9-2320-272-24P


Forward clutch removed (para. 5-47).




Use care when removing piston return spring.

Spring is under great compression.

1.

Lift fourth clutch (1) straight out of transmission (4).

NOTE

Perform step 2 for transmissions with two-piece bearing.

2.

Remove bearing race (2) and bearing assembly (3) from fourth clutch (1) or transmission (4).

NOTE


3.

Remove bearing assembly (3) from fourth clutch (1) or transmission (4).

1.

Position piston return spring compressor on spring retainer (5) and place on arbor press.

WARNING

Piston return spring is under great compression. Do not remove snapring until pressure is applied to spring retainer. If not, piston return spring may fly out, causing injury to personnel.

2.

Apply pressure to spring retainer (5) and remove snapring (6) from fourth clutch (1).

3.

Carefully remove piston return spring compressor.

4.

Remove spring retainer (5), piston return spring (7), and optional spacer (8) from fourth clutch housing (1).

5-332

5-48. FOURTH CLUTCH MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-333

TM 9-2320-272-24-4


5.

Remove backplate snapring (1) from fourth clutch housing (5).

CAUTION

The fourth clutch consists of a backplate, five clutch plates, and five clutch discs. Keep all clutch parts together. Intermixing fourth clutch parts with any other clutch part will cause transmission damage.

NOTE

Tag all fourth clutch parts for reassembly.

6.

Remove backplate (2), five clutch plates (4), five clutch discs (3), and piston (8) from fourth clutch housing (5).

7.

Remove piston outer seal ring (7) from piston (8). Discard seal ring (7).

8.

Remove piston inner seal ring (6) from fourth clutch housing (5). Discard seal ring (6).

1.


2.


3.

Inspect five clutch plates (4) for burned surfaces. If burned, discard clutch plates (4).

4.

Inspect five clutch discs (3) for burned surfaces. If surface of clutch disc (3) is burned, discard clutch disc (3).

5.

Inspect piston return spring (9) for discoloration due to overheating. If discolored, discard piston return spring (9).

6.

Inspect piston return spring (9) for broken coils or coils distorted due to wear. If coils are broken or distorted, discard piston return spring (9).

NOTE

Free length of piston return spring is 3.22 in. (81.8 mm).

7.

Using spring tester, inspect piston return spring (9) for serviceability.

a. Compress piston return spring (9) to 1.28 in. (32.5 mm).

b. If piston return spring (9) does not give load of 158-178 lb (703-791 N), discard.

8.

Measure backplate (2) thickness. If backplate (2) thickness is less than .248 in. (6.30 mm), discard.

5-334


TM 9-2320-272-24-4

5-335

TM 9-2320-272-24-4


NOTE

Ensure new seal ring lips face toward oil pressure side of piston.

1.

Apply oil-soluble grease to new piston outer seal ring (11) and install new piston outer seal ring (12) on piston (10).

2.

Apply oil-soluble grease to new piston inner seal ring (12) and install new piston inner seal ring (12) in fourth clutch housing (5).

3.

Install piston (10) in fourth clutch housing (5).

NOTE

Steps 4 through 9 obtain clutch running clearance.

4.

Starting with clutch plate (9), alternately install five clutch plates (9) and five clutch discs (8) in fourth clutch housing (5).

5.

Position backplate (7) in fourth clutch housing (5) and install with snapring (6).

6.

Measure clearance between backplate (7) and clutch disc (8). Clearance should be 0.68-0.127 in.

(17.27-3.226 mm).

7.

If clearance exceeds 0.127 in. (3.226 mm), replace clutch discs (8) and clutch plates (9) with new, thicker clutch discs (8) and plates (9).

8.

If clearance still exceeds 0.127 in. (3.226 mm) after completing step 7, replace piston (10) with new, thicker piston (10).

9.

If clearance is less than 0.68 in. (17.27 mm), replace piston (10) with new, thinner piston (10).

10.

Remove snapring (6), backplate (7), five clutch discs (8), and five clutch plates (9) from fourth clutch housing (5).

NOTE

Soak five clutch discs in clean OE/HDO-10 lubricating oil for at least two minutes before installing in fourth clutch housing.

11.

Starting with clutch plate (9), alternately install five clutch plates (9) and clutch discs (8) in fourth clutch housing (5).

12.

Place optional spacer (4), piston return spring (3), and spring retainer (2) in fourth clutch housing (5).

13.

Position piston return spring compressor on spring retainer (2) and arbor press, and compress piston return spring (3).

14.

Install spring retainer (2) in fourth clutch housing (5) with snapring (1).

15.

Remove piston return spring compressor from spring retainer (2).

NOTE

Perform step 1 for transmission with single-piece bearing assembly.

1.

Placing race section of bearing assembly (14) into transmission housing (15) first, install bearing assembly (14) in transmission housing (15).

NOTE

Perform step 2 for transmission with two-piece bearing.

Use oil-soluble grease to hold bearing race in place.

2.

Install bearing race (13) and bearing assembly (14) on fourth clutch housing (5). Ensure bearing race (13) is installed outer lip first.

3.

Install fourth clutch housing (5) in transmission housing (15).

5-336


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install forward clutch. (para. 5-47).

5-337

TM 9-2320-272-24-4

5-49. THIRD CLUTCH MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b. Cleaning and Inspection c . I n s t a l l a t i o n

INITIAL SETUP:


All

SPECIAL TOOLS

Third clutch clearance gauge (Appendix E,

Item 139)

TOOLS




REFERENCES (TM)

TM 9-2320-272-24P


Fourth clutch removed (para. 5-48).



CAUTION

Keep all clutch parts together. Intermixing third clutch parts with any other clutch pack will cause transmission damage.

NOTE

Tag all clutch parts for reassembly.

Mark position of all clutch plates in transmission housing for reassembly.

1.

Remove snapring (1), backplate (2), three clutch discs (3), and clutch plates (5) from transmission housing (4).

1.


2.


3.


4. Inspect clutch plates (5) for burned surfaces. If burned, discard clutch plates (5).

5.

Measure backplate (2) thickness.

a. If thickness of backplate (2) marked No. 7 is less than 0.476 in. (12.09 mm), discard backplate (2).

b. If thickness of backplate (2) marked No. 8 is less than 0.450 in. (11.43 mm), discard backplate (2).

c. If thickness of backplate (2) marked No. 9 is less than 0.463 in. (11.76 mm), discard backplate (2).

5-338

TM 9-2320-272-24-4

5-49. THIRD CLUTCH MAINTENANCE (Contd)

1.

Starting with clutch plate (5), alternately install three clutch plates (5) and three clutch discs (3) in transmission housing (4).

2.

Install backplate (2) and snapring (1) in transmission housing (4).

3.

Measure clearance between backplate (2) and snapring (1) with third clutch clearance gauge. Third clutch clearance should be 0.050-0.114 in. (1.270-2.896 mm).

4.

If third clutch clearance exceeds 0.114 in. (2.896 mm), replace clutch discs (3) with new, thicker discs (3).

5.

If third clutch clearance still exceeds 0.114 in. (2.896 mm) after completing step 4, replace backplate (2) with new, thicker backplate (2).

6.

If third clutch clearance is less than 0.050 in. (1.270 mm), replace backplate (2) with new, thinner backplate (2).

FOLLOW-ON TASK: Install fourth clutch (para. 5-48).

5-339

TM 9-2320-272-24-4

5-50. CENTER SUPPORT MAINTENANCE


INITIAL SETUP:


All

SPECIAL TOOLS

Bushing installer (Appendix E, Item 24)

Retainer ring depth tool (Appendix E, Item 114)

Center support lifter (Appendix E, Item 27)

Compressor bar and screw (Appendix E,

Item 29)

Compressor base (Appendix E, Item 30)

Snapring gauge (Appendix E, Item 124)

TOOLS

General mechanic’s tool kit (Appendix E,

Item 1)



Torque wrench (Appendix D, Item 144)

Arbor press

Hoist

MATERIALS/PARTS

Seal ring (Appendix D, Item 641)

Bushing (Appendix D, Item 27)

Eight self-locking retainers (Appendix D, Item 647)

Filter screen (Appendix D, Item 126)

Two piston inner seal rings (Appendix D, Item 258)

Two piston outer seal rings (Appendix D, Item 509)

Checkball (Appendix D, Item 37)

Two step-joint seal rings (Appendix D, Item 638)

Chamfered washer (Appendix D, Item 35)

Anchor bolt (Appendix D, Item 5)


REFERENCES (TM)

TM 9-2320-272-24P


Third clutch removed (para. 5-49).



1.

Remove center support anchor bolt (3) or (4) and washer (5) or (2) from transmission housing (1). Discard anchor bolt (3) or (4) and washer (5) or (2).

NOTE

If old style hex-head bolt and washer were present, center support must be rethreaded. Refer to task c.

2.

Remove snapring (6) from transmission housing (1).

3.

Attach center support lifter to center support (7) and remove center support (7) from transmission housing (1).

NOTE

Record location of any shims present.

5-340

5-50. CENTER SUPPORT MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-341

TM 9-2320-272-24-4


2.

3.

5.

6.

1.

4.

7.

8.

Remove filter screen (14) and seal ring (13) from center support (10). Discard filter screen (14) and seal ring (13).

NOTE

The second and third clutch pistons are disassembled the same way. This procedure covers the second clutch piston.

Remove second clutch piston (11) from center support (10).

Remove inner seal ring (5) and outer seal ring (6) from second clutch piston (11). Discard seal rings (5) and (6).

Remove four self-locking retainers (1) from pins (12) on second clutch piston (11). Discard self-locking retainers (1).

Remove retainer (2) and twenty springs (3) from second clutch piston (11).

Remove two step-joint seal rings (7) from center support (10). Discard step-joint seal rings (7).

NOTE

Bushing is removed only if it fails inspection (task c).

Mark location of bushing notch on center support for reassembly.

Replace checkball if bushing is replaced.

Press bushing (8) out of center support (10) with arbor press and mandrel. Discard bushing (8).

Remove checkball (9) from center support (10). Discard checkball (9).

1.

2.

3.

4.

5.

6.



Inspect center support (10) cavities for obstruction or foreign material. Remove obstruction or foreign material.

Measure depth of anchor bolt hole in center support (10). If hole is not 1.610 in. (40.89 mm) deep, rework center support (10) as follows: a. Drill 1.610 in. (40.89 mm) hole in center support (10).

b. Counterbore 0.469 in. (11.91 mm) diameter 0.66-0.70 in. (16.8-17.8 mm) deep.

c. Tap hole using 3/8 in. (9.53 mm) tap UNC2B min. Full thread to depth of dim. A.

Inspect four pins (12) on each piston (4) and (11) for bends and breaks. If any pin (12) is damaged, replace piston (4) or (11).

Inspect all springs (3) for discoloration due to overheating. If discoloration is present, discard springs (3).

5-342


TM 9-2320-272-24-4

5-343

TM 9-2320-272-24-4


7.

Inspect all springs (6) for broken coils or coils distorted due to wear. If spring (6) is broken or distorted, discard.

8.

Using spring tester, inspect all springs (6) for serviceability.

a. Compress spring (6) to 0.81 in. (20.7 mm) and check load.

b. If spring (6) does not give load of 4.30-5.70 lb (19.1.-25.4 N), discard.

d . A s s e m b l y

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

NOTE

Perform steps 1 and 2 only if bushing was removed.

Checkball will be installed when new bushing is pressed in.

Position checkball (2) in center support (3) and align notch on new bushing (1) with marked location on center support (3).

Press new bushing (1) in center support (3) with bushing installer and arbor press until flush.

NOTE

The second and third clutch pistons are assembled the same way.

This procedure covers the second clutch piston.

Place second clutch piston (10) in center support (3).

Place twenty springs (6) in pockets on piston (11).

Align spring retainer (5) with pins (11) on piston (10) with retainer ring depth tool and install four new self-locking retainer rings (4)

Remove second clutch piston (10) from center support (3).

Apply oil-soluble grease to new inner seal ring (8) and new outer seal ring (9).

Install new inner seal ring (8) and new outer seal ring (9) on second clutch piston (10). Ensure lips of seal rings (8) and (9) face toward center support (3) when second clutch piston (10) is installed.

Repeat steps 3 through 8 to assemble third clutch piston (7).

NOTE

Do not install third clutch piston in center support at this time.

Install second clutch piston (11) in center support (3).

NOTE

Install new filter screen (13) and new seal ring (12) on center support (3).

5-344


TM 9-2320-272-24-4

5-345

TM 9-2320-272-24-4

5-50. CENTER SUPPORT MAINTENANCE (Contd) e. Installation

NOTE

Tilt front end of transmission housing upward before beginning installation.

1.

Attach center support lifter to center support (4).

NOTE

Ensure center support is seated firmly against second clutch snapring.

Do not use old-style washer or hex-head anchor bolt.

2.

Carefully position center support (4) in transmission housing (5) with the anchor bolt hole (6) on center support (4) and transmission housing center support hole (14) aligned.

3.

Install center support (4) in transmission housing (5) with new chamfered washer (13) and anchor bolt (12). Tighten anchor bolt (13) finger-tight.

4.

Remove center support lifter from center support (4).

5.

Position compressor base (9) on center support (4).

6.

Install compressor bar (10) and screw (8) on transmission housing (5) with two screws (11).

7.

Tighten compressor screw (8) 5 lb-ft (7 N•m).

8.

Measure clearance between top edge of center support (4) and top of center support snapring groove (7) in transmission housing (5) with snapring gauge.

NOTE

Refer to table 5-14 to select. correct size snapring to be installed in

step 12.

9.

Release pressure from center support (4) by loosening compressor screw (8).

10.

Remove compressor bar screws (11), compressor bar (10) and screw (8), and compressor base (9) from center support (4).

11.

Install third clutch piston (2) in center support (4).

12.

Install center support snapring (1) in transmission housing (5). Ensure snapring (1) is fully seated.

13.

Tighten anchor bolt (12) 39-46 lb-ft (53-62 N•m)

14.

Apply liberal amount of oil-soluble grease on two new step-joint seal rings (3), and install two new step-joint seal rings (3) on hub of center support (4).

MEASURED

CLEARANCE

0.150-0.154 in.

(3.81-3.91 mm)

0.154-0.157 in.

(3.91-3.99 mm)

0.157-0.160 in.

(3.99-4.06 mm)

0.160-0.164 in.

(4.06-4.17 mm)

Table 5-14. Center Support Snapring.

SNAPRING

THICKNESS

0.148-0.150 in.

(3.76-3.81 mm)

0.152-0.154 in.

(3.86-3.91 mm)

0.155-0.157 in.

(3.94-3.99 mm)

0.158-0.160 in.

(4.01-4.06 mm)

SNAPRING

COLOR

White

Yellow

Green

Red

5-346


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install third clutch (para. 5-49).

5-347

TM 9-2320-272-24-4

5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b. Disassembly c . C l e a n i n g a n d I n s p e c t i o n d. Assembly e . I n s t a l l a t i o n

INITIAL SETUP:


All

SPECIAL TOOLS

Gear unit lifter (Appendix E, Item 58)

T o o l s




Snapring pliers (Appendix E, Item 125)

MATERIALS/PARTS


REFERENCES (TM)

TM 9-2320-272-24P


Center support removed (para. 5-50).



a . R e m o v a l

Attach gear unit lifter to gear unit main shaft (1) and remove gear unit (2) from transmission housing (3).

b. Disassembly

1.

Remove thrust washer (4), front sun gear (5), sun gear shaft (7), and thrust washer (6) from front planetary carrier (8).

2.

Remove front planetary carrier (8) and thrust washer (9) from planetary carrier drum (10).

3.

Remove snapring (12) from ring gear (13) and lift ring gear (13) out of planetary carrier drum (10).

4.

Remove center planetary carrier (11) from planetary carrier drum (10).

5.

Remove roller bearing (14) and bearing race (15) from main shaft (18).

6.

Remove snapring (19) from main shaft (18) and slide lower planetary sun gear (20) off main shaft (18).

7.

Remove main shaft (18) from rear planetary sun gear (23).

8.

Remove center ring gear (17) and rear planetary sun gear (23) from rear planetary carrier (22).

9.

Remove snapring (16) from center ring gear (17) and slide rear planetary sun gear (23) out of center ring gear (17).

10.

Remove snapring (21) from rear planetary carrier (22) and lift rear planetary carrier (22) out of planetary carrier drum (10).

5-348

5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE (Contd)

TM 9-2320-272-24-4

5 - 3 4 9

TM 9-2320-272-24-4


1.

2.

3.


4.

5.

6.

7.

8.

9.



Measure thickness of thrust washer (11). If thrust washer (11) thickness is less than 0.092 in.

(2.354 mm), discard thrust washer (11).

Measure clearance from thrust washer (11) to front sun gear (10). If clearance from thrust washer (11) to front sun gear (10) exceeds 0.005 in. (0.127 mm), discard thrust washer (11).

Measure thickness of thrust washers (6) and (9). If thickness is less than 0.091 in. (2.31mm), discard thrust washers (6) and (9).

Inspect thrust washers (6) and (9) for scoring. If scored, discard thrust washers (6) and (9).

Measure clearance of two sun gear shaft bushings (4) on main shaft (5). If clearance exceeds

0.006 in. (0.152 mm), discard two sun gear shaft bushings (4).

Measure clearance of front planetary carrier (7) bushing (8) on front sun gear (10). If clearance exceeds 0.005 in. (0.127 mm), discard front planetary carrier (7) bushing (8).

Measure clearance of sun gear shaft (3) on center support bushing. (2). If clearance exceeds 0.006 in.

(0.152 mm), discard sun gear shaft (3), or replace bushing (2) in center support (1) (para. 5-50).

5-350

TM 9-2320-272-24-4

5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE (Contd) d. Assembly

1.

2.

3.

4.

5.

6.

Position rear planetary carrier (18) in short splined end of planetary carrier drum (17) and install with snapring (21).

Position rear planetary sun gear (16) in center ring gear (15) until seated and install with snapring (14).

Install center ring gear (15) in planetary carrier drum (17), until seated against rear planetary carrier (18).

Install main shaft (22) into rear planetary sun gear (16), ensuring smaller end is installed first.

Install lower planetary sun gear (20) on rear of main shaft (22) with snapring (19).

NOTE

Use oil-soluble grease to hold bearing race and bearing in place.

Install bearing race (13) and bearing (12) on main shaft (22). Ensure lip of bearing race (13) faces away from center ring gear (15).

5-351

TM 9-2320-272-24-4


7.

8.

Install center planetary carrier (11) in long splined end of planetary carrier drum (9).

Place front planetary ring gear (7) in planetary carrier drum (9) over center planetary carrier (11) and install with snapring (6).

NOTE

Use oil-soluble grease to hold thrust washers in place.

Install thrust washer (5) on front planetary carrier (4).

Install front planetary carrier (4) in planetary carrier drum (9).

9.

10.

11.

12.

Install thrust washer (3) on sun gear (2).

Install front sun gear (2) on sun gear shaft (10). Ensure spring pin on sun gear shaft (10) is aligned with wide spline on front sun gear (2).

NOTE

Ensure sun gear teeth and front planetary pinion teeth are flush and the front of the sun gear shaft is past groove between double splines on the main shaft.

13.

Install sun gear shaft (10) over main shaft (8) in planetary carrier (9) until seated against bearing.

1 4 .

Install thrust washer (1) on sun gear (2) and over the gear shaft (10).

5-352

TM 9-2320-272-24-4

5-51. GEAR UNIT AND MAIN SHAFT MAINTENANCE (Contd) e. Installation

1.

Attach gear unit lifter to gear unit main shaft (12).

2.

Carefully lower gear unit (13) into transmission housing (14) with hoist. Ensure all gear teeth (15) mesh.

3.

Remove gear unit lifter from gear unit main shaft (12).

FOLLOW-ON TASK: Install center support (para. 5-50).

5-353

TM 9-2320-272-24-4

5-52. SECOND CLUTCH MAINTENANCE

THIS TASK COVERS: a. Removal b. Cleaning and Inspection c. Installation d. Establishing Clearance

INITIAL SETUP:


All

SPECIAL TOOLS

Second clutch clearance gauge (Appendix E,

Item 118)

TOOLS





Gear unit and main shaft removed (para. 5-51).



a. Removal

CAUTION

Second clutch consists of a backplate, four clutch plates, and four clutch discs. Keep all clutch parts together. Intermixing second clutch parts with any other clutch pack will cause transmission damage.

NOTE

Tag all second clutch parts for reassembly.

Remove snapring (l), four clutch discs (5), clutch plates (2), and backplate (4) from transmission housing (3).


Flying rust and metal particles may cause injury to personnel.

1.


2.


3.

Inspect clutch plate (2) for burned surfaces. If burned, discard clutch plate (2).

4.

Inspect clutch discs (5) for burned surfaces. If burned, discard clutch disc (5).

5.





5-354

5-52. SECOND CLUTCH MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-355

TM 9-2320-272-24-4

5-52. SECOND CLUTCH MAINTENANCE (Contd) c. Installation

1.

Install backplate (3) in transmission housing (2). Ensure that flat side of backplate (3) is up.

2.

Starting with clutch disc (1), alternately install four clutch discs (1) and four clutch plates (5) in transmission housing (2).

3.

Install snapring (4) on top of clutch plates (5).

d. Establishing Clearance

NOTE

Adapter housing and first clutch must be removed to establish

second clutch clearance. Refer to paras. 5-57 and 5-53.

Tilt rear end of transmission housing upward in order to establish clearance.

1.

Measure clearance between backplate (3) and transmission housing (2). Clearance should be

0.059-0.129 in. (1.49-3.28 mm).

2.

If second clutch clearance exceeds 0.059-0.129 in. (1.49-3.28 mm), replace clutch discs (1) with new, thicker clutch discs (1).

3.

If clutch clearance still exceeds 0.129 in. (3.28 mm) after completing step 1, replace backplate (3) with new, thicker backplate.

4.

If clearance is less than 0.059 in. (1.49 mm), replace backplate (3) with new, thinner backplate (3).

5.

If first clutch and adapter housing were removed to establish second clutch clearance, install them

(paras. 5-57 and 5-53).

5-356

5-52. SECOND CLUTCH MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install gear unit and main shaft (para. 5-51).

5-357

TM 9-2320-272-24-4

5-53. FIRST CLUTCH MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b . C l e a n i n g a n d I n s p e c t i o n c . I n s t a l l a t i o n d . E s t a b l i s h i n g C l e a r a n c e

INITIAL SETUP:


All

SPECIAL TOOLS

First clutch clearance gauge (Appendix E,

Item 45)

TOOLS




Snapring pliers (Appendix C, Item 125)

REFERENCES (TM)

TM 9-2320-272-24P


Second clutch removed (para. 5-52).



CAUTION

First clutch consists of a backplate, six clutch plates, and six clutch discs. Keep all clutch parts together. Intermixing first clutch parts with any other clutch pack will cause transmission damage.

a. Removal

NOTE

Tag all first clutch parts for reassembly.

Backplate, five clutch discs, four clutch plates, and rear planetary ring gear are removed as one unit.

1.

Remove snapring (5), backplate (6), five clutch discs (3), four clutch plates (2), and rear planetary ring gear (1) from transmission housing (4).

2.

Remove remaining two clutch plates (2) and clutch disc (3) from transmission housing (4).


1.


2.


3.

Inspect clutch discs (3) for burned surfaces. If surfaces are burned, discard clutch discs (3).

4.

Inspect clutch plate (2) for burned surfaces. If surfaces are burned, discard clutch plate (2).

NOTE

Cast iron backplates marked number 1, 2, and 3 must have same thickness as corresponding new malleable iron backplates 4,5, and 6.

5.




c. If thickness of backplate (6) marked No. 6 is less than 0.640 in. (16.26 mm), discard backplate (6).

5-358

5-53. FIRST CLUTCH MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-359

TM 9-2320-272-24-4

5-53. FIRST CLUTCH MAINTENANCE (Contd) c. Installation

1.

Starting with clutch plate (2), alternately install two clutch plates (2) and one clutch disc (3) in transmission housing (1).

2.

Install rear planetary ring gear (4) in transmission housing (1). Ensure all clutch plate (2) tangs and clutch disc (3) splines mesh.

3.

Starting with clutch disc (3), alternately install five clutch discs (3) and four clutch plates (2) on rear planetary ring gear (4).

4.

Install backplate (6) and snapring (5) in transmission housing (1). Ensure flat side of backplate (6) is installed first.

d. Establishing Clearance

1.

Measure clearance between snapring (5) and backplate (6) with first clutch clearance gauge. Clutch running clearance should be 0.074-0.147 in. (1.880-3.374 mm).

2.

If clutch running clearance exceeds 0.147 in. (3.734 mm), replace clutch plates (2) and discs (3) with new, thicker plates (2) and discs (3).

3.

If clutch running clearance still exceeds 0.147 in. (3.374 mm) after completing step 2, replace backplate (6) with new, thicker backplate (6).

4.

If clutch running clearance is less than 0.074 in. (3.374 mm), replace backplate (6) with new, thinner backplate (6).

5-360

5-53. FIRST CLUTCH MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install second clutch (para. 5-52).

5-361

TM 9-2320-272-24-4

5-54. TRANSMISSION GOVERNOR REPLACEMENT

THIS TASK COVERS a . R e m o v a l b . I n s t a l l a t i o n

INITIAL SETUP:


All

REFERENCES (TM)

TM 9-2320-272-24P

TOOLS



First clutch removed (para. 5-53)



MATERIALS/PARTS

Governor cover gasket (Appendix D, Item 241)


a. Removal

1.

Remove four screws (3), governor cover (4), and gasket (5) from transmission rear cover (2). Discard gasket (5).

2.

Rotate transmission governor (6) clockwise to disengage, and remove transmission governor (6) from transmission rear cover (2).

b. Installation

NOTE

Governor is properly seated only after counterclockwise rotation of governor gear is felt during installation.

1.

Insert plastic gear (7) end of transmission governor (6) into transmission governor bore (1) and push inward. Ensure governor (6) is properly seated.

2.

Install new gasket (5) and governor cover (4) on transmission rear cover (2) with four screws (3).

Tighten screws (3) 15-20 lb-R (20-27 N•m).

5-362

5-54. TRANSMISSION GOVERNOR REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install first clutch (para. 5-53).

5-363

TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE

THIS TASK COVERS: a . R e m o v a l b. Disassembly c. Cleaning and Inspection d. Assembly

INITIAL SETUP:


All

SPECIAL TOOLS



Rear bearing installer (Appendix E, Item 115)


Seal remover (Appendix E, Item 92)

Converter turbine bearing puller


Pin remover (Appendix E, Item 94)

Bearing installer (Appendix E, Item 10)

‘Iwo guide pliers (Appendix E, Item 59)

T o o l s


Outside micrometer (Appendix-E, Item 80)




Arbor press

MATERIALS/PARTS

Low clutch piston inner seal ring


Low clutch piston outer seal ring





REFERENCES (TM)

TM 9-2320-272-24P


Transmission governor removed (para. 5-54).

Transmission output shaft oil seal removed

(para. 4-78).



a . R e m o v a l

NOTE

Turn transmission housing with rear cover facing upward.

1.

Remove fourteen screws (1) and washers (5) from rear cover (2).

NOTE

Clean gasket remains from mating surfaces.

2.

Remove rear cover (2), low planetary carrier (9), gasket (4), and thrust washer (10) from transmission housing (3). Discard gasket (4).

3.

Remove sleeve spacer (6), speedometer drive gear (7), and governor drive gear (8) from low planetary carrier (9).

5-364

TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE (Contd)

5-365

TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE (Contd) b. Disassembly

1.

Remove dust cover (11) and oil seal (10) from rear cover (1) with seal puller and hook.

2 .

Remove beveled snapring (9) and rear output shaft bearing (8) from rear cover (1) with converter turbine bearing puller.

3.

Position spring compressor and arbor press on low clutch spring retainer (3) and apply pressure to spring retainer (3).

4.

Remove snapring (2) and spring compressor from low clutch spring retainer (3).

5.

Remove low clutch spring retainer (3) and twenty-six piston return springs (4) from low clutch piston (5).

6.

Remove low clutch piston (5) from rear cover (1).

7.

Remove outer seal ring (6) and inner seal ring (7) from low clutch piston (5). Discard seal rings (6) and (7).

8.

Remove plug (13), drain tube (12), and plug (17) from rear cover (1).

9.

Remove filter plug (14), O-ring (15), and governor filter (16) from rear cover (1).

5-366

TM 9-2320-272-24-4


5-367

TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE (Contd) c. Cleaning and Inspection

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.



Inspect rear cover (1) for breaks and cracks. Replace rear cover (1) if broken or cracked.

Measure governor clearance in bore (2) of rear cover (1). Replace rear cover (1) if clearance exceeds

.0035 in. (.0089 mm).

Inspect governor support pin (9) for looseness, bends, and breaks. Replace governor support pin (9) with pin remover if loose, bent, or broken.

Inspect low planetary carrier (5) for missing or twisted splines (6). Replace low planetary carrier (5) if splines (6) are missing or twisted.

Inspect low planetary carrier (5) for burrs. If burrs are found, remove using crocus cloth.

Inspect roller bearing (7) on low planetary carrier (5) and race (8) in rear cover (1). Replace bearing (7) and race (8) as a set if defective.

NOTE

Perform steps 9 and 10 only if bearing or race is defective.

Pin must be removed to remove bearing.

Remove pin (4) and roller bearing (7) from low planetary carrier (5). Discard pin (4).

Remove race (8) from rear cover (1) using bearing puller.

Measure thrust washer (3) thickness. Discard thrust washer (3) if thickness is less than 0.091 in.

(2.31mm).

Inspect thrust washer (3) for scoring. Discard if scored.

Inspect twenty-six piston return springs (10) for discoloration due to overheating. Discard piston return springs (10) if discolored.

Inspect twenty-six piston return springs (10) for broken coils or coils distorted due to wear. Discard piston return springs (10) if broken or distorted.

Inspect twenty-six piston return springs (10) for serviceability by checking load when compressed

with spring tester. Discard spring (10) if spring (10) does not give load according to table 5-15,

Spring Data.


SPRING


COLOR

Solid orange, yellow stripe

FREE LENGTH

1.28 in.

(32.5 mm)

COMPRESSED LENGTH

0.95 in.

(24.1 mm)

UNDER LOAD

13.6-16.4 lb

(60.5-72.9 N)

5-368

TM 9-2320-272-24-4


5-369

TM 9-2320-272-24-4

5-55. REAR COVER AND LOW PLANETARY CARRIER MAINTENANCE (Contd) d . A s s e m b l y

1.

Install governor filter (6), O-ring (5), and filter plug (4) in rear cover (1). Tighten filter plug (4)

50-70 lb-ft (68-95 N•m).

2.

Install drain tube (2) and plug (3) in rear cover (1). Tighten plug (3) 12-16 lb-ft (16-22 N•m).

3.

Install plug (7) in rear cover (1). Tighten plug (7) 4-8 lb-ft (5-11 N•m).

NOTE

Perform step 4 only if support pin was previously removed.

4.

Using pin installer, press new governor support pin (11) into rear cover (1) until end of pin (11) is

5.886-5.896 in. (14.950-14.975 cm) from outside face (12) of rear cover (1).

NOTE

Perform steps 5 and 6 only if bearing and bearing race were previously removed.

5.

Using bearing race installer, install bearing outer race (13) in rear cover (1).

NOTE

Install roller bearing before installing pin.

6.

Install roller bearing (10) and new pin (8) on low planetary carrier (14). Seat roller bearing (10) to shoulder on shaft (9).

7.

Install new thrust washer (15) if discarded during inspection.

5-370

TM 9-2320-272-24-4


5-371

TM 9-2320-272-24-4


8.

9.

NOTE

Ensure seal rings and lips face piston oil pressure side.

Use oil-soluble grease to hold in place.

Install new outer seal ring (6) and new inner seal ring (7) on low clutch piston (5).

Place low clutch piston (5) in rear cover (1).

10.

11.

12.

Place twenty-six piston return springs (4) in low clutch piston (5).

Place cupped side of clutch spring retainer (3) over piston return springs (4).

Place spring compressor and snapring (2) on clutch spring retainer (3) and compress twenty-six piston return springs (4).

13.

Install clutch spring retainer (3) with snapring (2).

14.

Remove spring compressor from clutch spring retainer (3).

15.

Install rear output shaft bearing (8) in rear cover (1) with bearing installer until seated.

16.

Install beveled snapring (9) in rear cover (1) with beveled side toward rear of transmission.

17.

Install oil seal (10) and dust shield (11) in rear cover (1).

18.

Install rear cover and low planetary carrier (para. 5-58).

5-372

TM 9-2320-272-24-4


FOLLOW-ON TASKS:

Install transmission governor (para. 5-54).

Install transmission output shaft oil seal (para. 4-78).

5-373

TM 9-2320-272-24-4

5-56. LOW CLUTCH REMOVAL AND CLEARANCE

THIS TASK COVERS: a . R e m o v a l b. Cleaning and Inspection c. Establishing Clearance

INITIAL SETUP:


All

TOOLS



MATERIALS/PARTS


REFERENCES (TM)

TM 9-2320-272-24P


Rear cover and low planetary carrier removed

(para. 5-55).



a. Removal

1.

Remove low planetary ring gear (1), snapring (3), and low gear ring hub (2) from adapter housing (6).

NOTE

Mark position of clutch plates in adapter housing for installation.

2.

Remove eight clutch plates (4) and seven clutch discs (5) from adapter housing (6).


1.


2.


3.


4.

Inspect clutch plates (4) for burned surfaces. If burned, discard clutch plates (4).

5-374

5-56. LOW CLUTCH REMOVAL AND CLEARANCE (Contd)

TM 9-2320-272-24-4

5-375

TM 9-2320-272-24-4

5-56. LOW CLUTCH REMOVAL AND CLEARANCE (Contd) c. Establishing Clearance

3.

4.

1.

2.

5.

Starting with clutch plate (2), alternately install eight clutch plates (2) and seven clutch discs (3) in adapter housing (1).

Measure distance from top edge of adapter housing (1) to top of clutch plate (2) with depth micrometer. Record measurement.

Position new rear cover gasket (4) on rear cover (5).

Measure distance from top of edge of piston (6) to gasket (4) with depth micrometer. Record measurement.

Subtract step 4 measurement from step 2 measurement. Record the difference. This measurement is low clutch clearance.

6.

Low clutch clearance, as determined in step 5, should be 0.073-0.141 in. (1.85-3.58 mm). If clutch clearance exceeds 0.141 in. (3.58 mm), replace clutch plates (2) and discs (3) with new, thicker plates (2) and discs (3).

7.

Remove eight clutch plates (2) and seven clutch discs (3) from adapter housing (1).

5-376

5-56. LOW CLUTCH REMOVAL AND CLEARANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install rear cover and low planetary carrier (para. 5-58).

5-377

TM 9-2320-272-24-4

5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE

THIS TASK COVERS a . R e m o v a l b. Disassembly c. Cleaning and Inspection d. Assembly

INITIAL SETUP:

APPLICABLE MODELS

All

SPECIAL TOOLS


TOOLS




Arbor press

MATERIALS/PARTS

Basic overhaul kit (Appendix D. Item 10)

Adapter housing gasket (Appendix D, Item 228)


REFERENCES (TM)

TM 9-2320-272-24P

EQUIPMENT CONDITION

Low clutch removed (para. 5-56)

SPECIAL ENVIRONMENTAL CONDITIONS


a. Removal

Remove adapter housing (1) and gasket (2) from transmission housing (3). Discard gasket (2).

b. Disassembly

1.

Position compressor tool on first clutch spring retainer (5) and arbor press.

2.

Apply pressure to first clutch ring retainer (5), and remove snapring (4) from adapter housing (1).

3.

Remove compressor tool from first clutch spring retainer (5).

4.

Remove first clutch spring retainer (5) and twenty-six springs (6) from first clutch piston (7).

5.

Remove first clutch piston (7) from adapter housing (1).

6.

Remove outer seal ring (8) and inner seal ring (9) from first clutch piston (7). Discard inner seal ring (9) and outer seal ring (8).

7.

Remove plug (10) from adapter housing (1).

5-378

TM 9-2320-272-24-4

5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE (Contd)

5 - 3 7 9

TM 9-2320-272-24-4

5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE (Contd) c. Cleaning and Inspection

1.


2.


3.

Inspect twenty-six piston return springs (4) for discoloration due to overheating. If discolored, discard piston return springs (4)

4.

Inspect twenty-six piston return springs (4) for broken coils or coils distorted due to wear. If broken or distorted, discard piston return springs (4).

NOTE

Perform step 5 if springs pass visual inspection.

5.

Using spring tester, compress each of twenty-six piston return springs (4) to 0.95 in. (24.1 mm) and check load. If piston return spring (4) does not give the correct load, discard piston return spring (4).

Refer to table 5-16, Spring Data.


SPRING COLOR FREE LENGTH COMPRESSED LENGTH UNDER LOAD


Solid orange, yellow stripe

1.28 in.

(32.5 mm)

0.95 in.

(24.1 mm)

13.6-16.4 lb.

(60.5-72.9 N)

d . A s s e m b l y

NOTE

Ensure seal rings and lips face piston oil pressure side.

Use oil-soluble grease to hold seal rings in place.

1.

Install new outer seal ring (6) and new inner seal ring (7) on first clutch piston (5).

2.

Place first clutch piston (5) in adapter housing (1).

3.

Place twenty-six piston return springs (4) in first clutch piston (5).

4.

Place cupped side of spring retainer (3) over piston return springs (4).

5.

Place compressor tool on spring retainer (3) and arbor press, and compress twenty-six piston return springs (4).

6.

Install spring retainer (3) with snapring (2).

7.

Remove compressor tool from spring retainer (3).

8.

Install plug (8) in adapter housing (1). Tighten plug (8) 4-8 lb-ft (5-11 N•m).

5-380

TM 9-2320-272-24-4

5-57. ADAPTER HOUSING AND FIRST CLUTCH PISTON MAINTENANCE (Contd)

FOLLOW-ON TASK: Install adapter housing, low clutch, low planetary carrier, and rear cover (para. 5-58).

5-381

TM 9-2320-272-24-4

5-58. ADAPTER HOUSING, LOW CLUTCH, LOW PLANETARY CARRIER, AND REAR

COVER INSTALLATION

THIS TASK COVERS:

Installation

INITIAL SETUP:


All

SPECIAL TOOLS

Two guide pins (Appendix E, Item 59)

TOOLS



MATERIALS/PARTS

Two gaskets (Appendix D, Item 228)


REFERENCES (TM)

TM 9-2320-272-24P



Installation

7.

8.

9.

3.

4.

5.

1.

Install new adapter housing gasket (8) on transmission housing (6).

2.

NOTE

Guide pins maintain gasket alignment.

Install two guide pins (7) in transmission housing (6).

Install adapter housing (9) over guide pins (7).

Install low ring gear hub (11) and snapring (10) on low planetary ring gear (1).

6.

Install low planetary ring gear (1) into adapter housing (9).

Starting with clutch plate (4), alternately install eight clutch plates (4) and seven clutch discs (5) in adapter housing (9).

10.

11.

12.

13.

NOTE

Use oil-soluble grease to hold thrust washer in place.

Install thrust washer (3) on low planetary carrier (2) hub.

Install low planetary carrier (2) into adapter housing (9).

Install governor drive gear (17), speedometer drive gear (16), and sleeve spacer (15) on low planetary carrier (2). Ensure governor drive gear (17) is seated over pin (19).

Install new rear cover gasket (18) and rear cover (14) over guide pins (7) with twelve washers (12) and screws (13). Finger-tighten screws (13).

Remove two guide pins (7) and install remaining two washers (12) and screws (13).

Alternately tighten fourteen screws (13) 180° apart. Tighten screws (13) 30 lb-ft (41 N•m).

Repeat tightening sequence on fourteen screws (13) 180° apart to achieve final torque. Tighten screws (13) 81-97 lb-ft (110-132 N•m).

5-382

TM 9-2320-272-24-4

5-58. ADAPTER HOUSING, LOW CLUTCH, LOW PLANETARY CARRIER, AND REAR

COVER INSTALLATION (Contd)

5-383

TM 9-2320-272-24-4

5-59. TRANSMISSION HOUSING MAINTENANCE

THIS TASK COVERS: a. Disassembly b. Cleaning and Inspection c . A s s e m b l y

INITIAL SETUP:


All

TOOLS



REFERENCES (TM)

TM 9-2320-272-24P



a. Disassembly

Remove four plugs (3) from transmission housing (1).


1.


2.


3.

If adapter (2) is defective, replace adapter (2).

c. Assembly

1.

Install four plugs (3) in transmission housing (1). Tighten 4-5 lb-ft (5-7 N-m).

NOTE

Perform step 2 if early model transmission is to have wide oil

pump installed (para. 5-39).

2.

Change data plate (4) part number to 23040127.

5-384

5-59. TRANSMISSION HOUSING MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-385

TM 9-2320-272-24-4

5-60. TRANSMISSION OIL PRESSURE TESTING

THIS TASK COVERS: a. Oil Cooler Pressure Test b. Main Pressure and Governor

Pressure Test c. Automatic Shift Speed Test

INITIAL SETUP:


All

SPECIAL TOOLS

Pressure gauge set (300 psi) (Appendix E,

Item 51)

TOOLS


Drill press

21/64 drill bit

1/4-18 NPTF tap

Pipe plug

Two pipe plugs

MATERIALS/PARTS


Cap and plug set (Appendix C,

Item 14)

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P



Transmission oil at proper level (TM 9-2320-272-10).

Vehicle at curb weight (empty) (TM 9-2320-272-10).

Wheels blocked (chocked) (TM 9-2320-272-10).




Personnel must be clear from underside and front of vehicle when engine is running.

a. Oil Cooler Pressure Test

CAUTION

Before disconnecting transmission pressure lines, clean surrounding surfaces and plug all openings to prevent entry of dirt or debris into transmission. Damage will occur if dirt or debris enters transmission.

1.

Disconnect oil cooler supply hose (1) from elbow (2) on top of oil cooler (7).

NOTE

Note elbow alignment for connection.

2.

Loosen nut (3) and remove elbow (2) and O-ring (4) from oil cooler (7). Discard O-ring (4).

3.

Using drill press and 21/64 drill bit, drill hole in side of elbow (2) opposite hose port.

4.

Tap hole in elbow (2) with 1/4-18 NPTF tap.

CAUTION

After tapping, elbow must be thoroughly cleaned and all burrs and shavings removed. Any shavings entering system will damage transmission.

5.

Remove elbow (2) from drill press and thoroughly clean.

6.

Install new O-ring (4) and elbow (2) in oil cooler (7) until aligned as noted in step 2.

7.

Tighten nut (3) until O-ring (4) is seated.

8.

Install pipe plug (8) on elbow (2).

9.

Connect oil cooler supply hose (1) to elbow (2).

5-386

5-60. TRANSMISSION OIL PRESSURE TESTING (Contd)

10.

Remove oil sampling valve (6) from elbow (5).

11.

Install pressure gauge and gauge hose (9) on elbow (5).

TM 9-2320-272-24-4

5-387

TM 9-2320-272-24-4


NOTE

Refer to TM 9-2320-272-10 when performing steps 12 through 20.

12. Set parking brake.

WARNING

Ensure all personnel are clear from underside and front of vehicle before starting engine. Transmission slipping into gear may cause injury to personnel.

13.

Start engine and check oil cooler connections for leaks.

CAUTION

Do not maintain stalled condition for longer than 30-second intervals. Transmission oil may overheat and cause transmission damage.

14.

Place transmission shift lever in 1-5 (drive) and operate engine at 1,200 rpm.

15.

Place transmission shift lever in N (neutral) and operate engine at normal operating temperature.

16.

Check transmission oil level.

17.

Operate engine at 1,650 rpm with transmission shift lever in N (neutral) and parking brake set.

Check pressure gauge and note reading.

18.

If pressure is less than 26 psi (179.2 kPa), check for hose or internal oil cooler leakage.

19.

If pressure exceeds 26 psi (179.2 kPa), check for cooler, cooler filter, or cooler hose restriction.

20.

Stop engine and disconnect gauge and hose (2) from elbow (1).

21.

Install oil sampling valve (3) in elbow (1).

22.

Remove pipe plug (5) from supply hose elbow (4).

23.

Install pressure gauge and hose (2) in supply hose elbow (4).

WARNING

Ensure all personnel are clear from underside and front of vehicle before starting engine. Transmission slipping into gear may cause injury to personnel.

NOTE

Refer to TM 9-2320-272-10 when performing steps 24 through 29.

24.

Set parking brake.

25.

Start engine and check oil cooler connections for leaks.

26.

Operate engine at 1,650 rpm with transmission shift lever in N (neutral) and parking brake set.

Check pressure gauge and note reading.

27.

If pressure is below 30 psi (207 kPa), check for hose or internal oil cooler leakage.

28.

If pressure exceeds 50 psi (345 kPa), check for cooler or cooler hose restriction.

29.

Stop engine and disconnect gauge and hose (2) from supply hose elbow (4).

30.

Install pipe plug (5) in elbow (4).

5-388


TM 9-2320-272-24-4

5-389

TM 9-2320-272-24-4

5-60. TRANSMISSION OIL PRESSURE TESTING (Contd) b. Main Pressure and Governor Pressure Test

2.

3.

4.

5.

6.

7.

1.

11.

12.

13.

14.

8.

9.

10.

WARNING

Ensure transmission-to-transfer case propeller shaft has been removed before performing this test. If test is performed with propeller shaft installed, wheel blocks (chocks) will not prevent vehicle from rolling and causing injury to personnel.

Remove transmission-to-transfer case propeller shaft (para. 3-148).

CAUTION

Before disconnecting transmission pressure lines, clean surrounding surfaces and plug all openings to prevent entry of dirt or debris into transmission. Damage will occur if dirt or debris enters transmission.

NOTE

Transmission-to-transfer case propeller shaft removal allows transmission output shaft to rotate to build up governor oil pressure. Upshift will not occur without governor pressure.

Have drainage container ready to catch oil.

Disconnect main pressure line (1) from adapters (2) and (5) and remove main pressure line (1).

Remove adapter (5) from main pressure port (6).

Disconnect governor pressure line (4) from adapters (3) and (9) and remove governor pressure line (4).

NOTE

Only M936/A1/A2 vehicles are equipped with check valve.

Remove adapter (9) and check valve (8) from transmission auxiliary governor pressure port (7).

Install 1/8-27 NPTF Thd pipe plug (13) in auxiliary governor pressure port (7).

Connect pressure gauge and hose (12) to main pressure port (6) with 1/8-27 NPTF Thd hose fitting (11).

NOTE

Refer to TM 9-2320-272-10 for steps 8 through 28.

Start engine, check pressure port connections for leaks, and check oil.

Operate engine at 625

± 25 rpm with transmission (10) shift lever in N (neutral) and parking brake set.

Note pressure reading on pressure gauge. If pressure is not 125 psi (802 kPa), repair transmission (10) as necessary.

NOTE

Do not maintain stalled condition for longer than 30-second intervals. Transmission oil may overheat and cause transmission damage.

Place transmission shift lever in 1-5 (drive) position.

Operate engine at 1,200

± 25 rpm and note pressure reading on pressure gauge. If pressure is not

180-205 psi (1,241-1,413 kPa), repair transmission (10) as necessary.

Stop engine and place transmission shift lever in N (neutral).

Disconnect pressure gauge and hose (12) from main pressure port (6) on left side of transmission (10).

5-390


TM 9-2320-272-24-4

5-391

TM 9-2320-272-24-4


15.

Remove pipe plug (4) from auxiliary governor pressure port (3) and install in main pressure port (5).

16.

Install pressure gauge and hose (2) in auxiliary governor pressure port (3).

17.

Start engine and check pressure port connection for leaks.

18.


19.

Place transmission shift lever in 1-5 (drive) position and operate engine at 1,650 rpm. Note reading on pressure gauge.

20.

If pressure is not 82-91 psi (565-627 kPa), repair transmission (1) as necessary

21.

Stop engine and disconnect pressure gauge and hose (2) from auxiliary governor pressure port (3).

22.

Remove pipe plug (4) from main pressure port (5).

NOTE

Only M936/A1/A2 vehicles are equipped with check valve.

23.

Install check valve (8) and adapter (9) in auxiliary governor pressure port (3). Ensure bleed hole end of check valve (8) is inserted into pressure port (3) first.

24.

Install governor pressure line (10) on adapters (9) and (12).

25.

Install adapter (7) in main pressure port (5).

26.

Install main pressure line (6) on adapters (7) and (11).

27.

Start engine and check pressure port connections for leaks.

28.


29.

Install transmission-to-transfer case propeller shaft (para. 3-148).

c. Automatic Shift Speed Test

1.

Road test vehicle and record engine rpm at shift points (TM 9-2320-272-10).

2.

With vehicle in operation, shift transmission through the range sequence. See table 5-17 for lever

range sequence.

3.

Check recorded engine shift point rpm with table 5-17.

4.

If shift points are incorrect, check modulator adjustment (para. 5-61). If modulator adjustment does

not correct shift speed, repair transmission (1) as necessary.

Table 5-17. Transmission Shift Point Check.

SELECTOR

LEVER RANGE

1-2

1-3

1-4

1-5 (drive)

THROTTLE

Fully open

AUTOMATIC

SHIFTING

1-2

2-2

2-2

2-3

3-4

4-5

ENGINE

(RPM)

1,900-2,050

1,900-2,050 (before converter lock-in)

1,600-1,825 (after converter lock-in)

2,000-2,150

2,030-2,140

2,015-2,130

5-392

5-60. TRANSMISSION

TM 9-2320-272-24-4

5 - 3 9 3

TM 9-2320-272-24-4

5-61. TRANSMISSION

THIS TASK COVERS: a . T e s t i n g

INITIAL SETUP:


All

TOOLS


REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P b . A d j u s t m e n t



Vehicle at curb weight (empty) (TM 9-2320-272-10).


Dry conditions, open roads, and easy grades.

NOTE

Vehicle engine must be at normal operating temperature of 175-

195°F (79-90°C) as indicated by temperature gauge. Transmission oil temperature must be at normal operating temperature of 120-

220°F (49-104°C) as indicated by temperature gauge.

Refer to TM 9-2320-272-10 for steps 1 through 7.

1.

Allow vehicle engine and transmission to reach normal operating temperatures with transmission shift lever in N (neutral) and parking brake set.

2.

After warmup, depress accelerator pedal until engine reaches 2,100 rpm. If engine does not reach

2,100 r-pm, see table 4-1, fuel system malfunction 15. Proceed with testing if engine reaches

2,100 rpm.

NOTE

Assistant will operate vehicle as directed by mechanic. Mechanic will observe and record engine rpm indicated by tachometer during shift changes.

3.

Place transmission shift lever in 1-2 (second) and road test vehicle.

4.

Accelerate at full throttle, 1,900-2,050 rpm, and note shift change. Record engine rpm at moment of shift change.

5.

Stop vehicle and repeat steps 3 and 4 in 1-3 (third).

6.

Stop vehicle and repeat steps 3 and 4 in 1-4 (fourth).

7.

Stop vehicle and repeat steps 3 and 4 in 1-5 (drive).

8.

Compare recorded engine rpm at shift points with correct shift point ranges given in table 5-17. If

all shift points are too high or too low by approximately same amount, adjust modulator (4).

1.

Inspect modulator (4) and cable (3) for looseness and improper installation.

5-394

TM 9-2320-272-24-4

5-61. TRANSMISSION

NOTE

Modulator will be adjusted if properly installed. Refer to para. 3-145 for correct modulator and cable installation and adjustment instructions.

2.

If looseness and/or improper installation are found, correct and retest modulator (4) and cable (3).

3.

Remove modulator link (2) from throttle lever (1) and reinstall modulator link (2).

4.

Retest modulator (4). If retest indicates defective modulation, replace modulator (4).

FOLLOW-ON TASKS: Fill transmission to proper oil level (LO 9-2320-272-12).

Start engine (TM 9-2320-272-10) and road test vehicle.

5-395

TM 9-2320-272-24-4

5-62. TRANSMISSION


Forward Stall Test

INITIAL SETUP:


All

TOOLS


REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P


• Parking brake set (TM 9-2320-272-10).

• Wheels blocked (chocked) (TM 9-2320-272-10).




Do not allow anyone to stand in front of vehicle when conducting a stall test.

WARNING

Do not allow anyone to stand in front of vehicle when conducting stall test. Vehicle movement may cause injury to personnel.

CAUTION

• Do not maintain the stalled condition longer than 30-second intervals due to rapid heating of transmission oil. Observe transmission oil temperature gauge. Normal operating range is 120-220°F (49-104°C).

• Observe engine coolant temperature gauge. Operating temperature is 175-195°F (79-90°C).

• If oil temperature reaches 300°F (148°C), or if thirty seconds is insufficient time to complete needed tests, transmission oil temperature must be lowered or damage to transmission may result.

• Run engine at 1,200-1,500 rpm with transmission in neutral for two minutes to cool oil between tests.

NOTE

• The stall test is conducted when engine and/or transmission are not performing satisfactorily The purpose of the stall test is to determine if transmission or engine is the malfunctioning unit.

• The vehicle’s transmission will stay in first speed during the stall tests regardless of transmission 5-4-3-2 and 1 quadrant position. Transmission does not and cannot upshift because the internal mechanism, output shaft, and governor are not turning. The stall test checks the engine performance, converter clutch operation or installation, and holding ability of the converter one-way clutch.

• Refer to TM 9-2320-272-10 for the following steps.

5-396

TM 9-2320-272-24-4

5-62. TRANSMISSION

1.

2.

3.

4.

5.

Apply service brakes and place transmission shift lever in any forward drive position 5-4-3-2-1.

Accelerate engine to full throttle (1,900-2,050 rpm).

NOTE

Perform step 3 only if engine speed exceeds 1,700 rpm.

If engine speed exceeds 1,700 rpm, check transmission oil level.

a. If oil level is low, fill to proper level.

b. If oil level is correct, repair transmission as necessary.

NOTE

Perform steps 4 and 5 only if engine speed is less than

1,900 rpm.

Refer to table 4-1, Mechanical Troubleshooting.

If engine speed is less than 1,400 rpm, troubleshoot engine for loss of power.

If engine is performing satisfactorily, repair transmission torque converter (para. 5-41).

FOLLOW-ON TASK: Start engine (TM 9-2320-272-10) and road test vehicle.

TM 9-2320-272-24-4

Section IV. TRANSFER CASE MAINTENANCE


a. Disassembly b. Cleaning and Inspection c. Assembly and Adjustment

INITIAL SETUP:


All

SPECIAL TOOLS

Crowfoot wrench (Appendix E, Item 163)

Two flange puller standoffs

(Appendix F, Item 1)

TOOLS

General mechanic’s tool kit (Appendix E. Item 1)

Mechanical puller (Appendix E, Item 102)




Arbor press

Feeler gauge

Prybar

Soft-faced hammer

Torque multiplier

MATERIALS/PARTS

Cylinder assembly (Appendix D, Item 92)


Three seals (Appendix D, Item 500)

Three locknuts Appendix D, Item 320)

Snapring Appendix D, Item 663)

Woodruff key (Appendix D, Item 727)

Two seals (Appendix D, Item 627)



Gasket sealant (Appendix C, Item 30)




TWO

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-214


Transfer case removed (para. 4-94 or para. 4-95).


Support transfer case with wood blocks before performing disassembly.

WARNING

Transfer case is heavy. Use wood blocks to prevent transfer case from tipping over and causing injury to personnel.

NOTE

Clean exterior of transfer case thoroughly before performing procedure.

1.

Using crowfoot wrench, remove interlock air cylinder (1) and push rod (2) from transfer case (3).

2.

Remove eight screws (5) and inspection cover (4) from transfer case (3).

3.

Remove locknut (6) and washer (7) from output shaft (14). Discard locknut (6).

4.

Using mechanical puller, remove output flange (8) and parking brake drum (9) from output shaft (14).

5-398

TM 9-2320-272-24-4

5-63. TRANSFER

5.

Remove actuating plate (10) from brakeshoe backing plate (11).

6.

Remove four screws (16), dustcover (12), and brakeshoe assembly (15) from companion flange (13).

5-399

TM 9-2320-272-24-4

5-63. TRANSFER

7.

Disconnect oil line (4) from elbows (3) and (5).

8.

Remove elbow (3) from oil pump (2).

NOTE

Perform steps 9 and 10 for vehicles equipped with transfer case power takeoff (PTO).

9.

Disconnect oil line (9) from elbows (5) and (8).

10.

Remove elbow (8) from PTO (10).

11.

Remove elbow (5), adapter (6), and filter screen (7) from transfer case (1). Clean filter screen (7).

NOTE

Mark position of oil pump for installation.

12.

Remove six screws (13), washers (12), and oil pump (11) from transfer case (1).

13.

Bend tabs of locking plates (15) away from screws (16).

14.

Remove four screws (16), locking plates (15), cover (14), cylinder (18), piston (19), and gasket (21) from transfer case (1) and declutch shaft (22). Discard gasket (21), piston (19), cylinder (18), and locking plates (15).

15.

Remove seals (17) and (20) from cover (14) and piston (19). Discard seals (17) and (20).

5-400

WITHOUT TRANSFER CASE PTO

5-63. TRANSFER

TM 9-2320-272-24-4

WITH TRANSFER CASE PTO

TM 9-2320-272-24-4

NOTE

Chain is necessary to prevent main and output flanges from rotating when removing hardware.

Tag main and front output flanges for installation.

16.

Install chain on main flange (5) and output flange (11) with two washers (9), screw (10), two washers (3), screw (2), and nut (4).

17.

Remove locknut (8) and washer (7) from main input shaft (6). Discard locknut (8).

18.

Remove locknut (1) and washer (13) from front output shaft (12). Discard locknut (1).

19.

Remove screw (10), two washers (9), nut (4), washer (3), screw (2), washer (3), and chain from main flange (5) and output flange (11).

20.

Using puller, remove main flange (5) and output flange (11) from main input shaft (6) and front output shaft (12).

NOTE

Perform steps 21 and 22 for vehicles equipped with PTO.

21.

Remove six screws (15), washers (16), and PTO (14) from transfer case (17).

22.

Remove setscrew (19), PTO drive gear (18). and seal (20) from main input shaft (6). Discard seal (20).

5-402

5-63. TRANSFER

TM 9-2320-272-24-4

WITH TRANSFER CASE PTO

5-403

TM 9-2320-272-24-4

5-63. TRANSFER

23.

Loosen setscrew (13) and remove collar (12), seal (ll), and baffle (10) from main input shaft (7).

Discard seal (11).

24.

Remove seven screws (20), washers (19), flange (3), and shim pack (4) from transfer case (5).

25.

Remove slinger (1) and seal (2) from flange (3). Discard seal (2).

26.

Remove four screws (17), washers (18), two screws (16), washers (15), and gear cover (14) from transfer case (5).

27.

Remove nineteen screws (9) and washers (8) from transfer case cover (21).

28.

Position puller on transfer case cover (21) with drive screw of puller over intermediate shaft (7) and two long screws through puller and into transfer case cover (21).

29.

Remove transfer case cover (21) from transfer case housing (22).

5-404

TM 9-2320-272-24-4

30.

Remove setscrew (24), hi-lo shift fork (23), and hi-lo shift shaft (25) from synchronizer gear (26) and transfer case housing (22).

31.

Remove main input shaft (7), rear output shaft (28), and intermediate shaft (27) from bearing races (29) and transfer case housing (22).

32.

Remove setscrew (32), declutch shaft (34), declutch fork (31), sliding clutch (30), and spring (33) from transfer case housing (22). Discard spring (33) if broken or distorted.

5-405

TM 9-2320-272-24-4

5-63. TRANSFER

33.

Remove hi-lo shaft seal (2) from transfer case housing (1). Discard seal (2).

34.

Remove six screws (6), washers (5), main input shaft cover (4), and shim pack (3) from transfer case housing (1).

35.

Remove seal (7) from main input shaft cover (4). Discard seal (7).

36.

Remove plug (12) from intermediate shaft cover (9).

37.

Remove six screws (11), washers (10), intermediate shaft cover (9), and shim pack (8) from transfer case housing (1).

38.

Remove six screws (14), washers (15), and front output shaft cover (16) from transfer case housing (1).

39.

Remove seal (13) from front output shaft cover (16). Discard seal (13).

40.

Remove front output shaft (17) from transfer case housing (1).

NOTE

When disassembling front output, rear output, and intermediate shafts, tag all bearings, spacers, and gears for installation.

41.

Using flat-axle type bearing puller, remove front output shaft bearing (18) from front output shaft (17).

42.

Remove snapring (19) from front output shaft bearing (18).

43.

Remove spacer (24) from rear output shaft (21).

44.

Using arbor press, remove rear output shaft bearings (20) and (23), and gear (22) from rear output shaft (21).

5-406

5-63. TRANSFER

TM 9-2320-272-24-4

5 - 4 0 7

TM 9-2320-272-24-4

5-63. TRANSFER

45.

46.

47.

48.

49.

50.

Remove snapring (8), speedometer drive gear (7), and woodruff key (4) from intermediate shaft (3).

Discard woodruff key (4) and snapring (8).

Using arbor press, remove intermediate bearing (6), intermediate high-speed gear (5), intermediate bearing (1), and intermediate low-speed gear (2) from intermediate shaft (3).

Remove companion flange spacer (9) from main input shaft (14).

Using arbor press, remove main input shaft bearing (16), bearing spacer (17), and high-speed gear (18) from main input shaft (14).

Remove high-speed gear spacer (19) and synchronizer gear (20) from main input shaft (14).

Using arbor press, remove main input shaft bearing (10), bearing spacer (11), low-speed gear (12), and low-speed gear spacer (13) from main input shaft (14).

1.


2.


3.

Inspect two dowel pins (15) of main input shaft (14) for breaks. If broken, replace dowel pins (15).

5-408

5-63. TRANSFER

5-63. TRANSFER

TM 9-2320-272-24-4

5-409

TM 9-2320-272-24-4

4.

Inspect three dowel pins (2) for bends and breaks. Replace dowel pins (2) if bent or broken.

5.

Remove filler plug (5) and drainplug (6) from transfer case housing (8) and inspect for stripped threads. Replace plugs (5) or (6) if threads are stripped.

6.

Inspect freeze plugs (7) and (9) for looseness. Replace freeze plugs (7) or (9) if loose.

7.

Inspect transfer case cover (3) and housing (8) for breaks, cracks, and stripped threads. Replace transfer case cover (3) or housing (8) if broken, cracked, or threads are not repairable (para. 2-5).

NOTE

Transfer case housing and cover bearings and bearing races are matched parts and must be replaced as a set.

Perform steps 9 and 10 if bearings or bearing races fail inspection.

8.

Inspect bearings (4) and bearing races (1) in accordance with TM 9-214. If damaged, replace bearing (4) and matched bearing race (1).

9.

Remove bearing race (1) from transfer case housing (8) or cover (3) by tapping alternately around outer edge of bearing race (1). Discard bearing race (1).

10.

Using arbor press, install new bearing race (1) on transfer case housing (8) or cover (3).

5-410

5-63. TRANSFER

TM 9-2320-272-24-4

5-411

TM 9-2320-272-24-4

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

NOTE

Prior to assembly, apply coat of oil to lubricate all gears, bearings, and shafts.

Measure thickness of bearing spacer (3). Replace bearing spacer (3) if thickness is less than

0.265 in. (6.73 mm).

Install low-speed gear spacer (5), low-speed gear (4), and bearing spacer (3) on main input shaft (6).

Ensure low-speed gear spacer (5) is aligned on dowel pin (8).

Using arbor press, install main input shaft bearing (2) on main input shaft (6).

Measure thickness of bearing spacer (10). Replace bearing spacer (10) if thickness is less than

0.143 in. (3.63 mm).

Install synchronizer gear (13), high-speed gear spacer (12), high-speed gear (11), and bearing spacer (10) on main input shaft (6). Ensure gear spacer (12) is aligned with dowel pin (7).

Using arbor press, install main input shaft bearing (9) on main input shaft (6).

Install companion flange spacer (1) on main input shaft (6).

Using arbor press, install intermediate low-speed gear (15) and intermediate hearing (14) on intermediate shaft (16).

Install intermediate high-speed gear (18) and roller bearing (21) on intermediate shaft (16).

Install new woodruff key (17) and speedometer gear (20) on intermediate shaft (16) with new snapring (19).

Using arbor press, install rear output shaft driven gear (24) and rear output shaft bearings (25) and (22) on rear output shaft (23).

Install rear output shaft spacer (26) on rear output shaft (23).

Using arbor press, install front output shaft bearing (28) on front output shaft (27).

Install snapring (29) on front output shaft bearing (27).

5-412

5-63. TRANSFER

TM 9-2320-272-24-4

5-413

TM 9-2320-272-24-4

5-63. TRANSFER

15.

16.

17.

18.

NOTE

Apply GAA grease to inside diameter of all seals.

Install front output shaft (8) in transfer case housing (1) until snapring (9) is flush with transfer case housing (1).

Install new front output shaft seal (4) in front output shaft cover (7).

Apply a thin coating of gasket sealer to mating surfaces of front output shaft cover (7) and transfer case housing (1).

Install front output shaft cover (7) on transfer case housing (1) with six washers (6) and screws (5).

Tighten screws (5) 40-65 lb-R (54-88 N•m).

Install new input shaft seal (3) on main input shaft cover (2).

Install sliding clutch (10) on front output shaft (8).

Position declutch fork (11) on sliding clutch (10).

19.

20.

21.

22.

Position declutch spring (13) under declutch fork (11) and insert declutch shaft (14) through declutch fork (11), declutch spring (13), and into transfer case housing (1).

23.

24.

Install declutch fork (11) on declutch shaft (14) with setscrew (12).

Install intermediate shaft (15), rear output shaft (16), and main input shaft (18) in three bearing races (17) on transfer case housing (1).

25.

Position hi-lo shift fork (19) on synchronizer gear (22).

26.

Insert hi-lo shift shaft (21) through hi-lo shift fork (19) and into transfer case housing (1).

27.

Install hi-lo shift fork (19) on hi-lo shift shaft (21) with setscrew (20).

5-414

5-63. TRANSFER

TM 9-2320-272-24-4

5-415

TM 9-2320-272-24-4

5-63. TRANSFER

28.

Apply gasket sealant to mating surfaces of transfer case cover (1) and housing (5).

29.

Install three dowel pins (2) on transfer case cover (1).

30.

Align dowel pins (2) on transfer case cover (1) with holes in transfer case housing (5) and install transfer case cover (1) on transfer case housing (5) with nineteen washers (4) and screws (3).

Tighten screws (3) 40-65 lb-ft (54-88 N•m).

31.

Tap around outer edge of bearing race (8) to seat against main input shaft bearing (9).

32.

Install baffle (7) on main input shaft (6).

NOTE

Perform steps 32 through 34 for vehicles equipped with PTO.

33.

Apply adhesive sealant to setscrew (11).

34.

Install new seal (12) and PTO drive gear (10) on recess of main input shaft (9) with setscrew (11).

Tighten setscrew (11) 12-16 lb-ft (16-22 N•m).

35.

Apply sealing compound to PTO (16) and transfer case (15) and install PTO (16) on transfer case (15) with six washers (14) and screws (13). Tighten screws (13) 140-65 lb-ft (54-36 N•m).

5-416

TM 9-2320-272-24-4

5-63. TRANSFER

36.

37.

38.

42.

43.

44.

Apply adhesive sealant to setscrew (24).

Install new seal (23) on retaining collar (25) with large lip toward baffle (7).

Install retaining collar (25) on recess of main input shaft (6) with setscrew (24). Tighten setscrew (24) 12-16 lb-ft (16-22 N•m).

39.

Apply a light coating of gasket sealant to mating surfaces of oil pump (26) and transfer case (15).

NOTE

Ensure to align pump drive with slot on main input shaft.

40.

41.

Install oil pump (26) on transfer case (15) with six washers (18) and screws (17). Tighten screws (17) 40-65 lb-ft (54-88 N-m).

Apply a light coating of gasket sealant to mating surfaces of speedometer drive cover (22) and transfer case (15).

Install speedometer drive cover (32) on transfer case (15) with six washers (21), four screws (20), and two screws (19). Tighten screws (19) and (20) 40-65 lb-ft (54-88) N•m).

Install new seal (28) and slinger (27) on flange (29).

Apply gasket sealant to new hi-lo shift shaft seal (30) and install on transfer case (15).

5 - 4 1 7

TM 9-2320-272-24-4

5-63. TRANSFER

NOTE

Step 45 establishes initial shim pack thickness for intermediate shaft.

45.

Install intermediate shaft cover (2) on transfer case (1) and tap alternately around outer edge with soft-faced hammer.

46.

Using feeler gauge, measure and record clearance between intermediate shaft cover (2) and transfer case (1).

47.

Remove intermediate shaft cover (2) from transfer case (1).

NOTE

Use measurement from step 46 plus a .003 in. (.7692 mm) shim for initial shim pack thickness.

48.

Install shim pack (3) and intermediate shaft cover (2) on transfer case (1) with six washers (4) and screws (5). Tighten screws (5) 40-65 lb-ft (54-88 N•m).

49.

Mount dial indicator on transfer case (1) with tip of plunger positioned through hole in intermediate shaft cover (2) on intermediate shaft (6).

NOTE

Perform step 50 to ensure intermediate shaft will rotate freely without end play.

50.

Check intermediate shaft end play as follows: a. Insert prybar through inspection hole (7) and force intermediate shaft (6) to rear of transfer case (1).

b. Set dial indicator to zero.

c. Using prybar, force intermediate shaft (6) to front of transfer case (1).

d. Record reading from dial indicator and add 0.003-0.006 in. (0.076-0.152 mm) to reading. This reading will be used for number of shims (3) to be removed.

51.

Remove dial indicator from transfer case (1).

5-418

5-63. TRANSFER

TM 9-2320-272-24-4

5 - 4 1 9

TM 9-2320-272-24-4

5-63. TRANSFER

52.

53.

54.

55.

56.

57.

58.

59.

60.

Remove six screws (5), washers (4), intermediate shaft cover (3), and shim pack (2) from transfer case (1).

NOTE

Use reading obtained in step 50d for number or thickness of shims to be removed or added for intermediate shaft adjustment.

Remove or add amount of shims (2) as recorded.

CAUTION

Do not apply sealing compound to shims.

Apply a sealing compound to lightly coat mating surfaces of transfer case (1) and intermediate shaft cover (3).

Install shim pack (2) and intermediate shaft cover (3) on transfer case (1) with six washers (4) and screws (5). Tighten screws (5) 40-65 lb-ft (54-88 N•m).

Install plug (6) on intermediate shaft cover (3). Tighten plug (6) 35 lb-ft 48 N•m)

NOTE

Step 57 establishes initial shim pack thickness for main input shaft.

Install main input shaft cover (7) on transfer case (1) and tap alternately around outer edge with soft-faced hammer.

Using feeler gauge, measure and record clearance between main input shaft cover (7) and transfer case (1).

Remove main input shaft cover (7) from transfer case (1).

NOTE

Use measurement from step 58 plus a .003 in. .0762 mm) shim for initial shim pack thickness.

Install shim pack (8) and main input shaft cover (7) on transfer case (1) with six washers (10) and screws (9). Tighten screws (9) 40-65 lb-ft (54-88 N•m).

5-420

TM 9-2320-272-24-4

5-421

TM 9-2320-272-24-4

61.

Mount dial indicator on transfer case (1) with tip of plunger on main input shaft (2).

NOTE

Perform steps 62 through 64 to ensure main shaft rotates freely without end play.

62.

Check main input shaft end play as follows: a. Using prybar through inspection hole (3), force main input shaft (2) to rear of transfer case (1) and hold.


c. Using prybar through inspection hole (3), force main input shaft (2) to front of transfer case (1).

d. Record reading on dial indicator. End play should be 0.0001-0.005 in. (0.00254-0.127 mm).

63.


64.

Remove six screws (7), washers (6), main input shaft cover (5), and shim pack (4) from transfer case (1).

NOTE

Use reading obtained in step 62d for number or thickness of shims to be removed or added for main input shaft adjustment.

65.


CAUTION


66.

Apply a light coating of sealing compound to mating surfaces of transfer case (1) and main input shaft cover (5).

67.

Install shim pack (4) and main input shaft cover (5) on transfer case (1) with six washers (6) and screws (7). Tighten screws (7) 40-65 lb-ft (54-88 N•m).

5-422

TM 9-2320-272-24-4

5-423

TM 9-2320-272-24-4

5-63. TRANSFER

NOTE

Steps 68 and 69 establish initial shim pack thickness for rear output shaft.

68.

Install companion flange (2) on transfer case (1) and tap alternately around outer edge with softfaced hammer.

69.

Using feeler gauge, measure and record clearance between companion flange (2) and transfer case (1).

70.

Remove companion flange (2) from transfer case (1).

NOTE

Use measurement from step 69 plus a 0.003 in. (0.0762 mm) shim for initial shim pack thickness.

71.

Install shim pack (3) and companion flange (2) on transfer case (1) with seven washers (4) and screws (5). Tighten screws (5) 60-100 lb-ft (81-136 N-m).

72.

Mount dial indicator on transfer case (1) with tip of plunger positioned on rear output shaft (6).

73.

Check rear output shaft (6) end play as follows: a. Using prybar through inspection hole (7), force rear output shaft (6) to front of transfer case (1) and hold.


c. Using prybar through inspection hole (7), force rear output shaft (6) to rear of transfer case (1).

d. Record reading on dial indicator. End play should be 0.0001-0.005 in. (0.00254-0.127 mm).

74.


5-424

5-63. TRANSFER

TM 9-2320-272-24-4

5 - 4 2 5

TM 9-2320-272-24-4

5-63. TRANSFER

75.

Remove seven screws (4), washers (3), and companion flange (5) from transfer case (1).

NOTE

Use reading obtained in step 73d for number or thickness of shims to be removed or added for rear output shaft adjustment.

76.


CAUTION


77.

Apply a light coating of sealing compound to mating surfaces of transfer case (1) and companion flange (5).

78.

Install shim pack (2) and companion flange (5) on transfer case (1) with seven washers (3) and screws (4). Tighten screws (4) 110-145 lb-ft (149-197 N•m).

NOTE


79.

Install main input flange (6) on main input shaft (9).

80.

Install front output flange (7) on front output shaft (8).

NOTE

Chain is necessary to prevent main and output flanges from rotating when removing hardware.

81.

Install chain on main input flange (6) with two washers (16) and screw (17).

82.

Install chain on front output flange (7) with washer (12), screw (11), washer (12), and nut (13).

83.

Apply a thin coating of gasket sealant to mating surfaces of washers (18) and (14), and install washers (18) and (14) and new locknuts (10) and (15) on front output shaft (8) and main input shaft (9). Tighten locknuts (10) and (15) 450-600 lb-ft (610-814 N•m).

5-426

5-63. TRANSFER

TM 9-2320-272-24-4

5-427

TM 9-2320-272-24-4

5-63. TRANSFER

84.

85.

86.

87.

88.

89.

90.

91.

92.

Install filter screen (3), adapter fitting (4), and elbow (5) on transfer case (2). Tighten elbow (5)

15 lb-ft (20 N•m).

NOTE

Perform steps 85 and 86 for vehicles equipped with PTO.

Install elbow (1) on PTO (7). Tighten elbow (1) 26 lb-ft (35 N•m).

Connect oil line (6) to elbows (5) and (1).

Install nipple end of elbow (13) on oil pump (8). Tighten elbow (13) 20 lb-ft (27 N•m).

Connect oil line (14) to elbows (5) and (13).

Install new seal (9) on cover (12).

Install new seal (17) on piston (16).

Install new gasket (18). new piston (16), new cylinder (15), and cover (12) on transfer case (2) with four new locking plates (11) and screws (10). Tighten screws (10) 5-10 lb-ft (8-13 N•m).

Bend tabs of locking plates (11) over heads of screws (10).

5-428

5-63.TRANSFER

TM 9-2320-272-24-4

5-429

TM 9-2320-272-24-4

5-63.

93.

94.

95.

96.

97.

98.

99.

Install brakeshoe assembly (12) and dust cover (9) on companion flange (10) with four screws (13). Tighten screws (13) 180-230 lb-ft (244-312 N•m).

Position actuating plate (6) against backing plate (7) so retainer opening (5) fits over brake lever stud (8) of backing plate (7).

NOTE


Install parking brake drum (4) and output flange (3) on output shaft (11).

Apply a thin coating of gasket sealant to mating surfaces of washer (2) and install washer (2) and new locknut (1) on output shaft (11). Tighten locknut (1) 450-600 lb-ft (610-814 N•m).

Remove nut (18), washer (17), screw (16), washer (17), screw (14), washer (19), and chain from main input flange (20) and front output flange (15).

Apply a thin coating of gasket sealant to mating surfaces of inspection plate (24) and transfer case (23) and install inspection plate (24) on transfer case (23) with eight screws (25). Do not tighten screws (25).

Using crowfoot wrench, install pushrod (22) and interlock air cylinder (21) on transfer case (23).

Tighten interlock air cylinder (21) 30-40 lb-ft (41-54 N•m).

5-430

5-63. TRANSFER

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install transfer case (para. 4-94 or para. 4-95).

5-431

TM 9-2320-272-24-4

Section V. FRONT AND REAR AXLE MAINTENANCE

5-64. DIFFERENTIAL

THIS TASK COVERS: a.

Disassembly b.

Cleaning, Inspection, and Repair

INITIAL SETUP:


All

SPECIAL TOOLS

Bearing replacer (Appendix E, Item 14)

Two puller screws (Appendix E, Item 104)

TOOLS

General mechanic’s tool kit


Mechanical puller kit (Appendix E, Item 102)

Inside micrometer






Arbor press

Torque multiplier

Vise

Soft-head hammer

Chain

Lifting device

Bearing preload tester c. Assembly and Adjustment

MATERIALS/PARTS




Three safety wires, 12 in. (Appendix D, Item 568)

Wear sleeve kit (Appendix D, Item 717)

Gasket and shim set (Appendix D, Item 248)

Six lockwashers (Appendix D, Item 350)

Locktab washer (Appendix D, Item 344)

Two cotter pins (Appendix D, Item 61)

Two oil seals (Appendix D, Item 500)



Safety wire, 36 in. (Appendix D, Item 568)




Blue oil-base pigment (Appendix C, Item 54)



Twine (Appendix C, Item 77)

White carbonate pigment (Appendix C, Item 78)

REFERENCES (TM)

LO 9-2320-272-12

TM 9-214

TM 9-2320-272-24P


Differential and carrier assembly removed

(para. 4-100).

NOTE

Front and rear differentials are repaired the same way.

1.

Remove safety wires (1) from two screws (2) and four screws (4). Discard safety wires (1).

5-432

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

2.

Remove two screws (2) and adjusting nut locks (3) from bearing caps (6).

CAUTION

Scribe bearing caps and saddles for installation. These items are machine-matched and damage will result if they are intermixed.

3.

Remove four screws (4), washers (5), and two bearing caps (6) from differential carrier housing (11).

NOTE

Tag bearings and races as matched parts for inspection and installation.

4.

Remove two adjusting nuts (9) and bearing races (8) from bearing saddles (10) and caps (6).

5.

Remove differential gear assembly (7) from differential carrier housing (11) and bearing saddles (10).

6.

Using puller, remove two tapered roller bearings (12) from differential housings (13).

7.

Remove safety wire (18) from eight slotted nuts (19). Discard safety wire (18).

CAUTION

Two gear housings and helical drive gear must be scribed for installation. These items are machine-matched and damage may result if they are intermixed.

8.

Remove eight slotted nuts (19) and screws (22) from two differential housings (13). Mark two differential housings (13) and helical ring gear (16) for installation.

9.

Remove four bevel spider gears (20), thrust washers (21), and spider (17) from differential housing (13).

10.

Remove two bevel side gears (15) and thrust washers (14) from differential housings (13).

5-433

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

11.

12.

13.

14.

15.

16.

17.

Remove two cotter pins (l), nuts (2), and companion flanges (3) from mainshaft (4). Discard cotter pins (1).

Remove six screws (9) and lockwashers (10) from rear bearing cover (8). Discard lockwashers (10).

Remove rear bearing cover (8), gasket (6), and thrust washer (5) from differential carrier housing (11). Discard gasket (6).

Remove oil seal (7) from rear bearing cover (8). Discard oil seal (7).

Remove eight screws (16) and washers (17) from front bearing cover (13).

Remove front bearing cover (15) and gasket (12) from differential carrier housing (11). Discard gasket (12).

Using puller, remove oil seal (13) and gasket (14) from front bearing cover (15). Discard oil seal (13) and gasket (14).

5-434

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

18.

Remove mainshaft and pinion gear assembly (4) from differential carrier housing (11).

NOTE

Tag and retain shims for measurement and installation.

19.

20.

21.

22.

23.

Using bearing remover, remove shims (19) from front of differential carrier housing (11).

Remove bearing (18) from rear of differential carrier housing (11).

Place mainshaft (4) in soft-jawed vise.

Using puller, remove rear bearing race (24) from rear of mainshaft (4).

Open tab(s) on locktab washer (21) and remove outer nut (20), locktab washer (21), keywasher (22), and inner nut (23) from mainshaft (4). Discard locktab washer (21).

5 - 4 3 5

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

24.

25.

26.

27.

28.

NOTE

Bearings and races are matched sets and must be kept together for inspection and installation.

Using arbor press, remove outer bearing (1), retainer (3), and spacer (5) from pinion gear (6) and mainshaft (7).

NOTE

Races may require light tapping to remove from retainer.

Using bearing replacer, remove races (2) and (4) from retainer (3).

Remove mainshaft (7) from vise.

Using arbor press, remove pinion gear (6) with bearing (8) from mainshaft (7).

Using puller, remove bearing (8) from pinion gear (6).

5-436

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

29.

30.

31.

32.

33.

34.

35.

36.

37.

Remove eight screws (9) and washers (10) from side cover (11).

Remove side cover (11) and gasket (12) from differential carrier housing (13). Discard gasket (12).

Remove six screws (17) and lockwashers (16) from bearing retaining plate (15). Discard lockwashers (16).

NOTE

Record number and thickness of shims for installation.

Remove bearing retaining plate (15) and shims (14) from differential carrier housing (13). Discard shims (14).

Remove safety wire (22) from three screws (23) on retaining plate (21). Discard safety wire (22).

Remove three screws (23) and retaining plate (21) from shaft (18).

Install two puller screws (24) in tapped jacking holes (25) in bearing cap (20) and remove bearing cap (20). Tighten screws (24) evenly while removing bearing cap (20). Remove puller screws (24) from bearing cap (20).

NOTE

Tag and retain shims for measurement and installation.

Remove shims (19) from differential carrier housing (13).

Using arbor press, remove two bearings (27) and races (26) from bearing cap (20).

5 - 4 3 7

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

38.

Remove ten screws (1), washers (5), access cover (2), and gasket (3) from differential carrier housing (4). Discard gasket (3).

39.

Place two soft-iron spacers (10) between bevel ring gear (6) and differential carrier housing (4).

40.

Using arbor press, remove helical pinion gear (7) from bevel ring gear (6).

41.

Remove spacer (9) and machine key (8) from shaft of helical pinion gear (7).

42.

Remove bevel ring gear (6) with bearing (11) from differential carrier housing (4).

43.

Remove setscrew (13) from differential carrier housing (4).

CAUTION

Drive bearing sleeve out by tapping evenly. Scoring will occur if sleeve tilts in housing.

44.

Using puller, remove bearing sleeve (12) from differential carrier housing (4).

45.

Using puller, remove bearing (11) from bevel ring gear (6).

5-438

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

1.

2.

3.

4.



CAUTION

Differential carrier housing and cap, bearings, and bearing races are machined or matched parts. Damage may result if they are intermixed. Replace all matched parts as sets if damaged.

Inspect differential carrier housing (14) and bearing caps (16) for scores, cracks, distortion, breaks, burrs, and wear. For repair of minor damage, refer to para. 2-16. Replace housing (14) and caps (16) if either part is damaged.

Inspect two adjusting nuts (15) for cracks, breaks, missing locking lugs, and damaged threads.

Replace adjusting nut(s) (15) if cracked, broken, locking lugs are missing, or threads are damaged.

5-439

TM 9-2320-272-24-4

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

NOTE

Replace entire differential gear assembly if helical ring gear, spider, spider gears, bevel gears, or thrust washer fails inspection.

Inspect two bearings (2) and races (1) (TM 9-214). Replace bearing (2) and race (1) as a set if either part fails inspection.

Inspect two differential gear housings (4) for chips, burrs, cracks, pitting, scoring, and breaks. For repair of minor damage, refer to para. 2-16. Replace entire differential gear assembly if differential gear housings (4) are damaged.

Measure inside diameter of bearing races (5) and outside diameter of differential gear housing hubs (3). The difference between measurements (press fit) must be within 0.0015-0.0035 in.

(0.0381-0.0889 mm). Replace entire differential gear assembly if press fit is not within limits.

Inspect four thrust washers (12), bevel spider gears (ll), two thrust washers (6), bevel side gears (7), spider (9), and helical ring gear (8) for cracks, breaks, chips, burrs, scoring, and pitting. For repair of minor damage, refer to para. 2-16. Replace entire differential gear assembly if any part fails inspection.

Measure outside diameter of four spider arms (10). Measurement should be 1.122-1.123 in.

(28.50-28.52 mm). Replace entire differential gear assembly if spider arm(s) (10) are not within limits.

Measure inside diameter of four bevel spider gears (11). Measurement should be 1.128-1.130 in.

(28.65-28.70 mm). Replace entire differential gear assembly if bevel spider gear(s) (11) are not within limits.

Inspect two bearings (19) and races (18) (TM 9-214). Replace bearing (19) and race (18) as a set if either part fails inspection.

Inspect bevel ring gear (13), sleeve (15), spacer (16), and helical pinion gear (17) for chips, breaks, cracks, burrs, nicks, and scores. For repair of minor damage, refer to para. 2-16. Replace bevel ring gear (13), sleeve (15), spacer (16), and helical pinion gear (17) if damaged.

Measure inside diameter of bearing races (20) and outside diameter of pinion gear shaft (21). The difference between measurements (press fit) must be within 0.0000-0.0015 in. (0.0000-0.0381 mm).

Replace helical pinion gear (17) and bearings(s) (19) if press fit is not within limits.

Inspect bearing (14) (TM 9-214). Replace bearing (14) if damaged.

Measure outside diameter of bevel ring gear (13) and inside diameter of race on bearing (14). The difference between measurements (press fit) must be within 0.0006-0.0011 in. (0.015-0.028 mm).

Replace bevel ring gear (13) and bearing (14) if press fit is not within limits.

Measure outside diameter of bearing (14) and inside diameter of spacer (15). The difference between measurements (press fit) must be within 0.0030-0.0058 in. (0.076-0.147 mm). Replace bearing (14) and sleeve (15) if press fit is not within limits.

5-440

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5-441

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

17.

18.

19.

20.

21.

22.

23.

Inspect two bearings (1) and races (2), bearing (7), and race (6) (TM 9-214). Replace bearings (1) or (7) and appropriate races (2) or (6) if damaged.

Inspect bevel pinion gear (3) and mainshaft (4) for chips, burrs, breaks, bends, and scoring. For repair of minor damage, refer to para. 2-16. Replace bevel pinion gear (3) or mainshaft (4) if damaged.

Measure inside diameter of bearing race (2) and outside diameter of middle step (8) of bevel pinion gear (3). The difference between measurements (press fit) must be within 0.0000-0.0020 in.

(0.000-0.051 mm). Replace bearing race (2) and bevel pinion gear (3) if press fit is not within limits.

Measure inside diameter of bearing race (10) and outside diameter of front step (9) of bevel pinion gear (3). The difference between measurements (press fit) must be within 0.0010-0.0025 in.

(0.025-0.064 mm). Replace bearing (1) and bevel pinion gear (3) if press fit is not within limits.

Measure inside diameter of bearing race (6) and outside diameter of mainshaft shoulder (5). The difference between measurements (press fit) must be within 0.0006-0.0019 in. (0.015-0.048 mm).

Replace bearing race (6) and mainshaft (40) if press fit is nut within limits.

Measure outside diameter of bearing (6) and inside diameter of rear bore (12) of differential carrier housing (11). The difference between measurements (press fit) must be +0.0009 to -0.0007 in.

(+0.023 to -0.018 mm). Replace bearing (6) and differential carrier housing (11) if press tit is not within limits.

Inspect companion flange (13), deflector (14), and wear sleeve (15) for cracks, breaks, bends, scoring, and wear. Replace companion flange (13), deflector (14), or wear sleeve (15) if cracked, broken, bent, scored, or worn. Follow instructions in wear sleeve kit, P/N 12375353, for replacement of wear sleeve (15).

5-442

5-64. DIFFERENTIAL AND DIFFERENTIAL CARRIER REPAIR (Contd)

TM 9-2320-272-24-4

5-443

TM 9-2320-272-24-4

5-64. DIFFERENTIAL AND DIFFERENTIAL CARRIER REPAIR (Contd) c. Assembly and Adjustment

1.

2.

3.

4.

5.

6.

7.

NOTE

Coat all bearings and gears with lubricating oil during reassembly.

Using bearing replacer, install inner bearing race (3) and outer bearing race (1) in retainer (2).

Ensure thick edges of races (1) and (3) are toward center of retainer (2).

Install bearing (4) on hub of bevel pinion gear (6). Thick inner race (10) must be seated against back edge of teeth (5) on bevel pinion gear (6).

NOTE

White carbonate pigment is used as a high-pressure lubricant.

Coat long splined end (7) of mainshaft (9) with white carbonate pigment.

Position bevel pinion gear (6) over mainshaft (9), ensuring internal splines in bevel pinion gear (6) align with splined end (7), and press bevel pinion gear (6) and bearing (4) onto mainshaft (9). Nose of bevel pinion gear (6) must seat against shoulder (8).

Place mainshaft (7) in soft-jawed vise.

NOTE

Collar is used to set preload on bevel pinion gear bearings. Ensure collar removed in disassembly is installed for preload test.

Install spacer (14) on hub (15) of bevel pinion gear (6) next to bearing (16).

Position small end (13) of retainer (12) over hub (15) and bearing (161 and place bearing (11) in retainer (12) over hub (15).

5-444


TM 9-2320-272-24-4

5-445

TM 9-2320-272-24-4

9.

10.

11.


8.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Install inner nut (4) on threaded portion of hub (5) of bevel pinion gear (7). Ensure stud (9) on inner nut (4) is facing away from retainer (6) and bevel pinion gear (7). Tighten inner nut (4)

800-1,000 lb-ft (1,085-1,356 N-m).

Install keywasher (3) on hub (5). Ensure hole in keywasher (3) aligns over stud (9) of inner nut (4).

Install new locktab washer (2) on hub (5). Ensure stud (9) sets into a hole in keywasher (3).

Install outer nut (1) on hub (5). Tighten nut (1) 1,OOO-1,200 lb-ft (1,356-1,627 N•m).

NOTE

Pinion bearings must be preloaded for proper operation of differential assembly.

Wrap twine around retainer (6) and attach to bearing preload tester to determine bearing preload.

Observe pointer and pull on bearing preload tester until retainer (6) starts to rotate. Record reading.

If original bearings are installed, bearing preload pull must be 1.2-2.4 lb (0.54-1.09 kg). If torque method is used to measure bearing preload, torque must be 4-8 lb-in. (0.5-0.9 N•m).

If new bearings are installed, bearing preload pull must be 3.6-5.5 lb (1.63-2.50 kg). If torque method is used to measure bearing preload, torque must be 5-25 lb-in. (0.41-0.62 N•m).

NOTE

If preload is not within given limits, perform steps 16 through 19.

If preload is within given limits, go to step 21.

Remove outer nut (1), locktab washer (2), keywasher (3), and inner nut (4) from hub (5) of bevel pinion gear (7).

Using arbor press, remove outer bearing (10), retainer (6), and spacer (11) from hub (5).

If preload valve (steps 13, 14, and 15) exceeds limits, use a thicker spacer (11) from bevel pinion gear spacer kit. If preload value is less than limits, use a thinner spacer (11).

Install parts on hub (5) following steps 5 through 11. Measure bearing preload using either twine and bearing preload tester or torque method. Repeat steps 16 through 19 until bearing preload is within limits of either step 14 or 15.

Remove mainshaft (8) from soft-jawed vise.

5-446

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5 - 4 4 7

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

21.

Bend tab(s) (4) on locktab washer over flats on outer nut (1).

22.

Using arbor press, install rear bearing inner race (3) on short splined end of mainshaft (2).

23.

Using arbor press, install bearing (7) in rear bore (5) of differential carrier housing (6).

24.

Install sleeve (8) in bore (13) with notches (10) toward shoulder of bore (13). Ensure hole (9) in sleeve (8) aligns with hole (12) in differential carrier housing (6).

25.

Install setscrew (11) through hole (12) until seated in sleeve (8).

26.

Press bearing (15) on hub (20) of bevel ring gear (21). Bearing (15) must rest against shoulder (14) on hub (20).

27.

Install spacer washer (16) on keyed end (19) of helical pinion gear (18).

28.

Install machine key (17) in keyed end (19) of helical pinion gear (18). Ensure exposed edges of machine key (17) are not burred after installation. Remove any burrs with fine mill file.

5-448

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

29.

30.

Place bevel ring gear (21) in differential carrier housing (6) with hub and bearing (15) pointing toward bore (22).

Support bevel ring gear (21) with two soft-iron semicircular blocks. Use support adapter (23) as an alternate method.

NOTE

White carbonate pigment is used as high-pressure lubricant.

31.

32.

Coat keyed end (19) of helical pinion gear (18) with pigment lubricant and align over bore in bevel ring gear (21). Ensure machine key (17) is aligned with keyway in bevel ring gear (21).

Using arbor press, install keyed end (19) of helical pinion gear (18) in bore of bevel ring gear (21).

NOTE

Light tapping with soft-head hammer or use of arbor press may be needed to install bearing.

33.

Remove blocks, turn differential carrier housing (6) over, and push bearing (15) into sleeve (16).

5-449

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

NOTE

Coat bearings and races with clean gear oil before installation.

Using bearing replacer, install race (2) in bearing cap (1). Thick edge of race (2) must be toward small end (6) of bearing cap (1).

Install bearings (3) and (4) and race (5) in bearing cap (1). Use replacer to seat race (5) in bearing cap (1). Wide edge of race (5) must face away from face of cap (1).

Starting with same thickness of shims (9) as removed, place shims (9) over shaft (8) and on differential carrier housing (7). Carefully align holes in shims (9) to holes in carrier housing (7).

Place bearing cap (1) over shaft (8) and press bearing cap (1) into position on shaft (8) to differential carrier housing (7).

Install retaining plate (10) on shaft (8) with three screws (12). Tighten screws (12) 42-54 lb-ft

(57-73 N-m) and install new safety wire (11) in screws (12).

Install new shims (13) and bearing cover (14) on differential carrier housing (7) with six new lockwashers (15) and screws (16). Select shims (13) of same thickness as removed. Tighten screws (16) 60.100 lb-ft (81-136 N-m).

To measure helical pinion gear (17) bearing preload, wrap twine around helical pinion gear (17) and attach to bearing preload tester. Observe pointer and pull on bearing preload tester until helical pinion gear (17) starts to rotate. Record value.

If original bearings are installed, bearing preload must be 4-8 lb-in. (.5-.9 N-m) If new bearings are installed, bearing preload must be 12-18 lb-in. (1.36-2.03 N-m).

NOTE

If preload is not within given limits, perform steps 42 through 45.

If preload is within given limits, go to step 47.

Remove six screws (16), lockwashers (15), bearing cover (14), and shims (13) from differential carrier housing (7). Remove shims (13) carefully to avoid creasing or damaging shims (13).

If preload scale (or torque) reading exceeds limits, add shims (13).

If preload scale (or torque) reading is less than lower limit, remove shims (13).

Install shims (13) and bearing cover (14) on differential carrier housing (7) with six lockwashers (15) and screws (16). Carefully align shims (13) with holes in differential carrier housing (7). Tighten screws (16) 60-100 lb-ft (81-136 N-m).

Repeat steps 40 through 45 as necessary.

5-450

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5-451

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

47.

48.

Position shims (2), same thickness pack as removed, on retainer (7) and slide mainshaft (4) into differential carrier housing (8). Align inner race (3) with rear roller bearing (9).

Align holes in shims (2), differential carrier housing (8), bore (1), and retainer (7) and install with eight washers (6) and screws (5). Tighten screws (5) 93-120 lb-ft (126-163 N•m).

CAUTION

49.

50.

Correct bevel ring gear and pinion gear contact pattern is critical to correct operation of differential and differential carrier assembly. Incorrect contact pattern can result in noisy operation or premature failure of these two gears.

Check bevel ring gear (10) and pinion gear (11) tooth contact pattern by applying blue oil-base pigment to at least three teeth of clean bevel ring gear (10). Turn mainshaft (4) for three full rotations of bevel ring gear (10).

Examine teeth contact pattern (13) of bevel ring gear (10) with pinion gear (11). Pattern should be centered both ways on teeth (12) and cover over two-thirds of tooth (12) contact surface.

NOTE

If pattern is not correct, perform steps 51 through 69.

If pattern is correct, go to step 71.

51.

If contact pattern resembles pattern (14), perform steps 55-59 and 63-69.

52.

If contact pattern resembles pattern (15), perform steps 55-58, 60, and 63-69.

53.


54.


5-452

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5-453

TM 9-2320-272-24-4

5-64. DIFFERENTIAL

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

Remove six screws (6), lockwashers (7), cover (8), and shims (9) from differential carrier housing (1).

Remove safety wire (15), three screws (16), and retaining plate (14). Discard safety wire (15).

Using two jacking screws (17), remove bearing retainer (13) and shim pack (12) from shaft (11) and shaft housing shoulder (10).

Remove eight screws (4), washers (5), mainshaft (3), and shim pack (2) from differential carrier housing (1).

NOTE

If adjustment is needed to correct bevel ring gear and pinion gear contact pattern, make initial shim changes of at least 0.010 in.

(0.25 mm).

For contact pattern of type in step 51, add shims to shim pack (2) and remove shims from shim pack (12).

For contact pattern of type in step 52, add shims to shim pack (12) and remove shims from shim pack (2).

For contact pattern of type in step 53, remove shims from pack (2) and add shims to shim pack (12).

For contact pattern of type in step 54, remove shims from shim pack (12) and add shims to shim pack (2).

Using dial indicator, check backlash (20) of bevel ring gear (18) and pinion gear (19).

Backlash (20) should be 0.005-0.015 in. (0.127-0.381 mm).

NOTE

If backlash needs correction, perform steps 55, 56, 57, and 58.

If bevel ring gear and pinion gear backlash are within limits, go to step 71.

If bevel ring gear and pinion gear backlash are not within limits, perform steps 65 and 66.

If backlash (20) is less than limits, add equal amounts of shims to shim packs (2) and (12).

If backlash (20) is greater than limits, remove equal amounts of shims from shim packs (2) and (12).

Carefully place mainshaft (3) and shim pack (2) in differential carrier housing (1) and install with eight washers (5) and screws (4). Tighten screws (4) 93-120 lb-ft (126-163 N•m).

Carefully align shim pack (12) to shaft housing shoulder (10) and press on bearing retainer (13) over shaft (11).

Install retaining plate (14) on sheet (11) with three screws (16). Tighten screws (16) 42-54 lb-ft (57-

73 N•m). Fasten new safety wire (15) to all three screws (16).

Carefully align shims (9) to bearing retainer (13) and install cover (8), shims (9), retainer (13), and shims (12) on shoulder (10) of carrier housing (1) with six new lockwashers (7) and screws (6).


5-454

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5-455

TM 9-2320-272-24-4

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

Coat top of new gasket (4) and gasket surface (11) with light coat of sealing compound and position gasket (4) on differential carrier housing (5).

Install access cover (3) on gasket (4) and differential carrier housing (5) with ten washers (2) and screws (1). Tighten screws (1) 27-40 lb-ft (37-54 N•m).

Coat gasket surface (6) with light coat of sealing compound.

Install new gasket (7) and side cover (8) on differential carrier housing (5) with eight washers (10) and screws (9). Tighten screws (9) 27-40 lb-ft (37-54 N•m).

Lubricate sealing surface of new oil seal (13) with GM grease, coat metal contact outer diameter with sealing compound, and install new gasket (14) and seal (13) in front bearing cover (15) with seal installer tool and arbor press.

NOTE

Ensure oil slots on retainer are not blocked with sealing compound or covered by new gasket.

Coat both sides of new gasket (12) with light coat of sealing compound and position on retainer (18).

Remove eight screws (16) and washers (17) from retainer (18).

Install front bearing cover (15), seal (13), gasket (12), and retainer (18) on carrier housing (5) with eight washers (17) and screws (16). Tighten screws (16) 93-120 lb-ft (126-163 N•m).

Lubricate sealing surface of new seal (25) with GAA grease, coat outside metal contact outer diameter with sealing compound, and install in bearing cover (26).

Coat new gasket (24) with light coat of sealing compound and position on differential carrier housing (5).

Place thrust washer (23) over mainshaft (22) and install rear bearing cover (26) with six new lockwashers (28) and screws (27). Tighten screws (27) 24-40 lb-ft (33-54 N•m).

82.

Do not tap or hammer companion flanges on driveshaft assembly.

Damage to bearings will result.

Install two companion flanges (21) on mainshaft (22) with two nuts (20). Tighten nuts (20)

300-400 lb-ft (407-542 N•m) and install two new cotter pins (19).

5-456

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

5-457

TM 9-2320-272-24-4

NOTE

Coat all bearings, races, gears, and thrust washers with clean gear oil before assembly.

83.

Install two bearings (1) and (4) on hubs of differential gear housings (2) and (3).

84.

Lay one differential gear housing (3), bearing side down, on work surface and install one thrust washer (8) and side gear (9) in differential gear housing (3).

85.

Place four bevel spider gears (6) and thrust washers (7) on spider (10) and place over bevel side gear (9) in housing (3).

86.

Place thrust washer (5) over hub of bevel side gear (11) and position bevel side gear (11) over spider gear assembly in differential gear housing (3).

5-458

TM 9-2320-272-24-4

87.

88.

89.

Carefully align index marks made during disassembly and position two differential gear housings (2) and (3) on helical ring gear (14) and install with eight screws (15) and slotted nuts (13). Tighten nuts (13) 130-170 lb-ft (176-231 N•m). Secure with new safety wire (12). Twist ends of safety wire (12) together until wire is tight. Remove and discard excess safety wire (12).

Place two races (16) over bearings (1) and (4) on differential gear (17) and set assembly in saddles (18) of differential carrier housing (20). Ensure races (16) seat inside threads of saddles (18).

If races (16) do not fully seat in saddles (18), check that helical ring gear (14) is in mesh with helical pinion gear (19).

5-459

TM 9-2320-272-24-4

90.

Position two caps (3) on saddles (5) and install with four washers (2) and screws (1). Finger-tighten screws (1).

91.

Start two adjusting nuts (6) in threads of saddles (5) and caps (3). Move caps (3) as necessary to align threads to adjusting nuts (6).

92.

Turn adjusting nuts (6) by hand until contact is made with races (4).

93.

Ensure helical ring gear (7) aligns with mating helical pinion gear (9). If necessary, loosen and tighten adjusting nuts (6) to align gears.

94.


NOTE

Ensure a notch of each adjusting nut aligns with top center of cap.

95.

To establish helical bearing preload, perform step a. or b.

a. Alternately tighten adjusting nuts (6) a total 1.5 to 2.75 notch widths.

b. Tighten each adjusting nut (6) 15-35 lb-in. (1.7-4.0 N•m).

96.

Install dial indicator on differential carrier housing (8) with indicator plunger perpendicular to edge of helical ring gear (7).

97.

Turn helical ring gear (7) one revolution in each direction. Runout reading on dial indicator must not exceed 0.008 in. (0.20 mm). If runout exceeds this value, loosen adjusting nuts (6) and screws (1) and repeat steps 90 through 95.

98.

Reposition dial indicator so plunger contacts tooth (10) and detects motion in plane of rotation of helical ring gear (7) as the gear rotates.

99.

Hold helical pinion gear (9) still and rock helical ring gear (7) back and forth. Observe backlash reading on dial indicator.

106.

Backlash should be 0.005-0.015 in. (0.127-0.381 mm). If reading is outside of these limits, replace helical ring gear (7) and helical pinion gear (9).

101.

Tighten four screws (1) 290-370 lb-ft (393-502 N•m).

102.

Install two locks (12) of adjusting nut (6) on caps (3) with screws (13). Tighten screws (13)

66-85 lb-ft (90-115 N•m).

103.

Install new safety wire (11) through four screws (1) and two screws (13). Twist safety wire (11) ends together, cut off and discard excess safety wire (11), and bend twisted ends of safety wire (11) out of way.

5 - 4 6 0

5-64. DIFFERENTIAL

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install differential and carrier assembly (para. 4-100).

5-461 (5-462 blank)

5-66.

5-67.

5-68.

5-69.

5-70.

5-71.

5-72.

5-73.

5-74.

5-75.

5-76.

5-77.

5-78.

5-79.

5-80.

5-81.

5-82.

5-83.

5-84.

5-85.

5-93.

5-94.

5-95.

5-96.

5-97.

5-98.

5-99.

5-100.

5-86.

5-87.

5-88.

5-89.

5-90.

5-91.

5-92.

TM 9-2320-272-24-4

5-65. SPECIAL

S e c t i o n V I . S P E C I A L P U R P O S E B O D I E S M A I N T E N A N C E

Van Body Replacement

Retraceable Beam Replacement

Retractable Beam Drive Shaft and Lock Maintenance

Retractable Beam Rollers Replacement

Side Doors Maintenance

Underframe Parts Replacement

Hinged Floor Maintenance

Exterior Side Panel Maintenance

Rear Wall Interior Panels Replacement

Interior Side Panels and Latches Replacement

Ceiling and Frame Maintenance

Hinged Roof Maintenance

Front Wall Registers Replacement

Ceiling Filler and Side Panels Replacement

Ceiling Rear Cover Replacement

Ceiling Air Ducts Replacement

Ceiling Transition Maintenance

Ceiling Deflector and Registers Replacement

Rear Splice Plate Replacement

Bonnet Frame Parts Replacement

Bonnet Access Door Maintenance

Bonnet Door Maintenance

Air Conditioner Replacement

Main Wiring Harness Replacement

Van Air Conditioner Wiring Harness Replacement

Van Heater Wiring Harness Replacement

Electric Heater (10 kW) Wiring Harness Replacement

Blackout Bypass Wiring Harness Maintenance

Emergency Lamp Wiring Harness Replacement

Blackout and Clearance Lights Wiring Harness Replacement

400 hz Supply Wiring Harness Replacement

Branched 400 hz Receptacle Wiring Harness Replacement

Right and Left Side Blackout Harness Maintenance

Telephone Post Wiring Harness Replacement

3 Phase Receptacle Wiring Harness Replacement

5-490

5-498

5-500

5-508

5-518

5-531

5-532

5-534

5-536

5-538

5-464

5-468

5-470

5-474

5-478

5-484

5-486

5-582

5-588

5-590

5-596

5-598

5-602

5-604

5-542

5-543

5-544

5-549

5-554

5-563

5-568

5-570

5-572

5-578

5-580

5-463

TM 9-2320-272-24-4

5-66. VAN



M934/A1/A2

TOOLS


MATERIALS/PARTS

Ten locknuts (Appendix D, Item 291)

Twelve locknuts (Appendix D, Item 321)


Two

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l Parking brake set (TM 9-2320-272-10).

l Ladders removed (TM 9-2320-272-10).



1.

Remove four locknuts (18), screws (13), washers (14), springs (15), and springs (16) from van body (1) and two frame brackets (8). Discard locknuts (18).

2.

Remove eight locknuts (12) and screws (9) from van body (1) and four frame brackets (8). Discard locknuts (12).

3.

Attach chain to four lifting brackets (2) and lifting device.

WARNING

All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may result in injury to personnel.

NOTE

Second assistant will help with steps 4 and 5.

4.

Raise van body (1) clear of frame (7), release parking brake, and remove vehicle from under van body (1).

5.

Lower van body (1) onto jack stands positioned evenly under van body (1).

6.

Remove four blocks (5) from frame brackets (8).

NOTE

Sills and hardware will be in position for removal after van body has been removed.

7.

Remove ten locknuts (3), bevel washers (4), screws (10, washers (11), and two sills (6) and (17) from van body (1). Discard locknuts (3).

8.

Remove chain from lifting device and four lifting brackets (2).

5-464

TM 9-2320-272-24-4

5-465

TM 9-2320-272-24-4

5-66. VAN

1.

2.

3.

Install two sills (6) and (17) on van body (1) with ten washers (11), screws (10), bevel washers (4), and new locknuts (3).

Position four blocks (5) on frame brackets (8).

Attach chain to four lifting brackets (2) and lifting device.

W A R N I N G

All personnel must stand clear during lifting operations. A snapped cable, or swinging or shifting load, may result in injury to personnel.

4.

5.

6.

7.

NOTE

Second assistant will help with steps 4 and 5.

Raise van body (1) from jack stands, and remove jack stands from under van body (1).

Position vehicle under van body (1) and set parking brake.

Lower van body (1) onto frame (7) and align holes of frame brackets (8) and van body (1).

Install van body (1) on four frame brackets (8) with eight screws (9) and new locknuts (12).

8.

Install van body (1) on two frame brackets (8) with four springs (15), springs (16), washers (14), screws (13), and new locknuts (18).

9.

Remove chains from lifting device and four lifting brackets (2).

5-466

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install ladders (TM 9-2320-272-10).

5-467

TM 9-2320-272-24-4



M9341/A1/A2

TOOLS


MATERIALS/PARTS

Two locknuts (Appendix D, Item 274)




REFERENCES (TM)

TM 9-237

TM 9-2320-272-10

TM 9-2320-272-24P



Van body sides fully expanded and secured

(TM 9-2320-272- 10).

Retractable beam rollers removed (para. 5-69).

Retractable beam drive shaft and lock removed

(para. 5-68).


Vehicle must be on level surface.

NOTE

All ten retractable beams are replaced the same way. This procedure is for the left-rear retractable beam.

1.

Break welds between side panel (1) and side panel support (13) and remove retractable beam (12)

(TM 9-237).

CAUTION

Remove retractable beam slowly from underframe. Failure to do so may result in damage to equipment.

2.

Slide retractable beam (12) under side panel (1) and remove from underframe (4) and channel (5).

3.

Remove two locknuts (7), washers (8), screws (11), seven screws (10), retainer (9), and seals (2), (3), and (6) from underframe (4). Discard locknuts (7) and seals (2), (3), and (6).

1.

Install new seals (6), (3), and (2), and retainer (9) on underframe (4) with seven screws (10), two screws (11), washers (8), and new locknuts (7).

CAUTION

Install retractable beam slowly into underframe. Failure to do so may result in damage to equipment .

2.

Slide retractable beam (12) under side panel (1) and install in under-frame (4) at channel (5).

3.

Install retractable beam (12) by welding retractable beam (12) to side panel (1) and side panel support (13) (TM 9-237).

5-468

5-67. RETRACTABLE

TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install retractable beam drive shaft and lock (para. 5-68).

Install retractable beam rollers (para. 5-69).

Retract van body sides (TM 9-2320-272-10).

5-469

TM 9-2320-272-24-4

THIS TASK COVERS: a. Removal b. Cleaning, Inspection, and Repair c. Installation


M934/A1/A2

TOOLS


MATERIALS/PARTS

Five keys (Appendix D, Item 266)

Locknut (Appendix D, Item 297)



Two

REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P





NOTE

Left and right retractable beam drive shafts and locks are replaced the same. This procedure is for the left retractable beam drive shaft and lock.

1.

Remove locknut (1) and lock (2) from under-frame stud (8). Discard locknut (1).

2.

Remove screw (4), paw1 (3), and lock (2) from underframe (5).

3.

Remove thirty screws (7) and five covers (6) from underframe (5).

4.

Remove four setscrews (15) from bushings (14).

CAUTION

Do not bend or strain ratchet shaft during removal. Doing so may result in damage to equipment.

NOTE

Remove all nicks, burrs, and corrosion from ratchet shaft and lubricate before removal.

Direct assistant to catch ratchet shaft components under van body during removal.

5.

Slowly pull ratchet shaft (9) and remove four bushings (14), nine bushings (13), spacers (12), sprockets (11), and five spacers (10) from under-frame (5).

5-470

5-68. RETRACTABLE

TM 9-2320-272-24-4

5-471

TM 9-2320-272-24-4

1.


2.


3.

Remove five keys (11) and bushings (10) from sprockets (4). Discard keys (11).

4.

Inspect bushings (10), (6), and (8) for wear and damage. If worn or damaged replace bushings (10), (6), or (8).

5.

Inspect ratchet shaft (2) for burrs, nicks, and corrosion. If damaged, repair with file or emery cloth.

If damage is excessive, replace.

6.

Test spring action of lock plunger (14). If spring action is weak, replace lock (14).

7.

Install five new keys (11) and bushings (10) on sprockets (4).

Do not bend or strain ratchet shaft during installation. Doing so may result in damage to equipment.

NOTE

Bevel forward end of ratchet shaft for installation.

Apply GAA grease on two feet of forward end of ratchet shaft for installation.

Direct assistant to install ratchet shaft components under van body when installing ratchet shaft.

1.

Slowly insert ratchet shaft (2) into underframe (1) and install five spacers (3), sprockets (4), spacers (5), nine bushings (6), and four bushings (8).

2.

Install four setscrews (9) in bushings (8) in underframe channels (7).

3.

Lubricate ratchet shaft (2) with GAA grease (LO 9-2320-272-12).

4.

Install five covers (17) on underframe (1) with thirty screws (18).

5.

Install lock (14) and paw1 (15) on underframe stud (12) and underframe (1) with new locknut (13) and screw (16).

5-472

5-68. RETRACTABLE

TM 9-2320-272-24-4

5-473

TM 9-2320-272-24-4

THIS TASK COVERS: a. Support Roller Removal b. Support Roller Installation c. End Roller Removal d. End Roller Installation


M934/A1/A2

TOOLS


MATERIALS/PARTS

Four cotter pins (Appendix D, Item 72)

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


Parking brake (TM 9-2320-272-10).


(TM 9-2320-272-10).

NOTE

All support rollers are removed basically the same way, This procedure is for left-rear support rollers.

1.

Remove seven screws (2), clamps (3), and cover (4) from underframe (1)

2.

Remove two cotter pins (5), support roller shaft (7), and support roller (6) from underframe (1).

Discard cotter pins (5).

1.

Install support roller (6) on underframe (1) with support roller shaft (7) and two new cotter pins (5).

2.

Install cover (4) on underframe (1) with seven clamps (3) and screws (2).

5-474

TM 9-2320-272-24-4

5-475

TM 9-2320-272-24-4

NOTE

All end rollers are replaced basically the same way. This procedure is for left-rear end rollers.

1.

Remove support roller (task a.).

2.

Remove two cotter pins (2), end roller shaft (3), and end roller (4) from underframe (1). Discard cotter pins (2).

1.

Install end roller (4) on underframe (1) with end roller shaft (3) and two new cotter pins (2).

2.

Install support roller (task b.).

5-476

TM 9-2320-272-24-4

FOLLOW-ON TASK: Retract van body sides (TM 9-2320-272-10).

5-477

TM 9-2320-272-24-4



M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS



Three rivets (Appendix D, Item 548)

Sixteen rivets (Appendix D, Item 547)






REFERENCES (TM)

TM 43-0213

TM 9-2320-272-10

TM 9-2320-272-24P




(TM 9-2320-272-10).

Side door window removed (para. 3-350).

NOTE

Left and right side doors are replaced the same way. This procedure is for the left side door.

1.

Remove two screws (1), lockwashers (2), bracket (3), and door check lever (4) from door (5). Discard lockwashers (2).

NOTE


2.

Remove fifteen screws (6) and door (5) from side panel of van body (7).

5-478

5-70. SIDE

TM 9-2320-272-24-4

5-479

TM 9-2320-272-24-4

1.

Remove three rivets (13), handle (12), and gasket (11) from pocket (10). Discard rivets (13) and gasket (11).

2.

Remove sixteen rivets (14) and pocket (10) from outer panel (9). Discard rivets (14).

3.

Remove two cotter pins (23), screws (19), washers (20), and rods (21) from upper case (2), lower case (18), and center case (22). Discard cotter pins (23).

4.

Remove pin (26) and handle (25) from center case (22).

5.

Remove four screws (27) and center case (22) from inner panel (24).

6.

Remove eight screws (1), upper case (2), and lower case (18) from inner panel (24).

7.

Remove fourteen screws (8), molding (7), seal (6), hinge (5), and seal (4) from door frame (17).

Discard seals (4) and (6).

8.

Break adhesive seal and remove two moldings (3) from inner panel (24).

9.

Remove two screws (16) and moldings (15) from inner panel (24).

1.


2.


3.

Inspect all movable components of center case (22) and lower and upper cases (2) and (18) for proper operation. Replace center case (22), lower case (18), or upper case (2) if damaged or defective.

4.

Inspect rods (21) for breaks and bends. Replace rods (21) if broken or bent.

5.

Inspect moldings (3) and (15) and pocket (10) for cracks and bends. Replace moldings (3), (15), or pocket (10) if cracked or bent.

6.

Inspect outer panel (9), door frame (17), and inner panel (24) for damage. Replace entire side door if either is damaged.

NOTE

Apply rustproofing compound to all inside surfaces and boxed-in areas (TM 43-0213).

Apply sealing compound to all exterior joints for installation.

1.

Install two moldings (15) on inner panel (24) with two screws (16).

2.

Apply adhesive to two moldings (3) and install on inner panel (24).

3.

Install new seal (4), hinge (5), new seal (6), and molding (7) on door frame (17) with fourteen screws (18).

4.

Install upper case (2) and lower case (18) on inner panel (24) with eight screws (1).

5.

Install center case (22) on inner panel (24) with four screws (27).

6.

Install handle (25) on center case (22) with pin (26).

7.

Install two rods (21) on center (22), upper case (2), and lower case (18) with two new cotter pins (23), washers (20), and screws (19).

8.

Install pocket (10) on outer panel (9) with sixteen new rivets (14).

9.

Install new gasket (11) and handle (12) on pocket (10) with three new rivets (13).

5-480

5-70.. SIDE

TM 9-2320-272-24-4

5-481

TM 9-2320-272-24-4

NOTE


1.

Install door (5) on side panel of van body (7) with fifteen screws (6).

2.

Install door check lever (4) and bracket (3) on door (5) with two new lockwashers (2) and screws (1).

5-482

5-70. SIDE

TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install side door window (para. 3-350).


5-483

TM 9-2320-272-24-4

5-71. UNDERFRAME



M934/A1/A2

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



Rivet gun Parking brake set (TM 9-2320-272-10).

MATERIALS/PARTS

Eight lockwashers (Appendix D, Item 400)

Two seals, 206 in. (Appendix D, Item 617)

Thirty-two rivets (Appendix D, Item 558)




NOTE


1.

Remove one hundred thirty-eight screws (14), two retainers (15), channels (12), and seals (13) from underframe (1). Discard seals (13).

2.

Remove thirty-two screws (4) and four covers (5) from under-frame (1).

3.

Remove eight nuts (3), lockwashers (2), screws (7), and four plates (6) from under-frame (1). Discard lockwashers (2).

4.

Remove thirty-two rivets (8) and eight tiedowns (9) from underframe (1). Discard rivets (8).

5.

Remove four screws (11) and angle bracket (10) from underframe (1).

1.

Install angle bracket (10) on underframe (1) with four screws (11).

2.

Install eight tiedowns (9) on underframe (1) with thirty-two new rivets (8).

3.

Install four plates (6) on underframe (1) with eight screws (7), new lockwashers (2), and nuts (3).

4.

Install four covers (5) on underframe (1) with thirty-two screws (4).

NOTE

Apply sealing compound to exterior joints for installation.

5.

Install two new seals (13), channels (12), and retainers (15) on underframe (1) with one hundred thirty-eight screws (14).

5-484

5-71. UNDERFRAME

TM 9-2320-272-24-4

5-485

TM 9-2320-272-24-4

5-72. HINGED



M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS

Fifty-six rivets (Appendix D Item 549)

Four seals, 39 in. (Appendix D, Item 617)

Seal, 203 in. (Appendix D, Item 631)

Adhesive (Appendix C, Item 3)


REFERENCES (TM)

TM 9-237

TM 9-2320-272-10

TM 9-2320-272-24P


Hinged end panel open (TM 9-2320-272-10)

Van body sides extended (TM 9-2320-272-10).

Counterbalance removed (para. 3-356).



NOTE

Left and right hinged floors are maintained the same way. This procedure is for left hinged floor.

NOTE

Assistant will help with step.

Remove fifty-five screws (3), four screws (2), and hinged floor (1) from hinge (4).

5-486

TM 9-2320-272-24-4

1.

Remove four screws (5) and two pivots (6) from hinged floor (1).

2.

Remove thirty screws (7), two retainers (8), four seals (9), and two channels (15) from hinged floor (1). Discard seals (9).

3.

Remove ten screws (13) and five pads (14) from hinged floor (1).

4.

Remove four screws (11) and handle (12) from hinged floor (1).

5.

Remove seal (10) from hinged floor (1). Discard seal (10).

NOTE

Perform step 6 only if inspection requires replacement of hinge.

6.

Remove fifty-six rivets (16) and hinge (4) from under-frame (17). Discard rivets (16).

5-487

TM 9-2320-272-24-4

5-72. HINGED

1.


2.


3.

Inspect hinged floor (1) for cracked, broken, and tom floor plates. If cracked, broken, or torn, replace hinged floor (1) (TM 9-237).

4.

Inspect retainers (8) and channels (15) for bends and breaks. If bent or broken, replace retainers (8) or channels (15).

5.

Inspect hinge (4) for breaks, cracks, and smooth operation. If cracked, broken, or not operating properly, replace hinge (4).

NOTE

Apply sealing compound to exterior joints prior to installation.

Insulate exterior joints and areas of metal-to metal contact with adhesive.

Perform step 1 only if hinge is to be replaced .

1.

Install hinge (4) on under-frame (17) with fifty-six new rivets (16).

2.

Install new seal (10) on hinged floor (1).

3.

Install handle (12) on hinged floor (1) with four screws (11).

4.

Install five pads (14) on hinged floor (1) with ten screws (13).

5.

Install two channels (15), four new seals (9), and two retainers (8) on hinged floor (1) with thirty screws (7).

6.

Install two pivots (6) on hinged floor (1) with four screws (5).

NOTE


Install hinged floor (1) on hinge (4) with fifty-five screws (3) and four screws (2).

5-488

5-72. HINGED

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Install counterbalance (para. 3-356).

Close hinged end panel (TM 9-2320-272-10).


5-489

TM 9-2320-272-24-4

5-73. EXTERIOR

THIS TASK COVERS: a. Disassembly b. Cleaning and inspection c. Assembly


M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS

Two hundred forty-eight rivets (Appendix D,

Item 547)

Twenty-four rivets (Appendix D, Item 551)

One hundred eighty-nine rivets (Appendix D,

Item 550)


Two seals, 206 in. (Appendix D, item 617)




Channel seal (Appendix D, Item 36)



REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P



Van body fully expanded and secured

(TM 9-2320-272-10).

Side panel front lock removed (para. 3-369).

Side panel rear lock removed (para. 3-368).

Side door removed (para. 5-70).

Retractable window removed (para. 3-351).



NOTE

Left and right exterior side panels are disassembled the same.

This procedure covers the right exterior side panel.

1.

Remove twenty-five screws (5) and retainers (3) and (15) from side panel frame (14).

2.

Remove seals (2) and (4) and channel (1) from side panel frame (14). Discard seals (2) and (4).

3.

Remove thirty screws (12) and five retainers (13) from seal (10) at side panel frame (14).

4.

Remove sixty-two screws (11), six retainers (9), and seal (10) from side panel frame (14). Discard seal (10).

5.

Remove six screws (8), two retainers (7), and seals (6) from side panel frame (14). Discard seals (6).

5-490

TM 9-2320-272-24-4

5-491

TM 9-2320-272-24-4

5-73. EXTERIOR

6.

7.

8.

9.

10.

11.

12.

Remove one hundred eighty-nine rivets (19), bracket (17), and seal (18) from skins (2) and (11) and side panel frame (8). Discard rivets (19) and seal (18).

Remove eighty-two nuts (5), screws (1), four screws (10), two retainers (4), and seals (3) from side panel frame (8). Discard seals (3).

Remove channel seal (9) from doorway of side panel frame (8). Discard channel seal (9).

Remove nine screws (6) and molding (7) from doorway of side panel frame (8).

NOTE

Perform steps 10 through 12 if skin is to be replaced.


Remove two hundred forty-eight rivets (12) and skins (2) and (11) from side panel frame (8). Discard rivets (12).

Remove eight screws (15) and two ladder hangers (14) from side panel frame (8).

Remove twenty-four rivets (16) and lower skin (13) from side panel frame (8). Discard rivets (16).

5-492

5-73. EXTERIOR SIDE PANEL MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-493

TM 9-2320-272-24-4

5-73. EXTERIOR SIDE PANEL MAINTENANCE (Contd) b. Cleaning and Inspection

1.


2.


3.

Inspect five retainers (12), retainers (13), (5), and (6) for cracks and bends. If cracked or broken, replace.

4.

Inspect bracket (3), retainers (9) and (10), and channel (11) for rust corrosion and breaks. If rusted corroded, or broken, replace.

5.

Inspect molding (4), two ladder hangers (8), and side panel frame (2) for cracks, breaks, and warpage. If cracked, broken, or warped, replace.

6.

Inspect skins (1) and (14) and lower skin (7) for tears and punctures. If torn or punctured, replace.

NOTE

l

Perform steps 1 through 3 if skin was removed.

l


1.

Install lower skin (7) on side panel frame (2) with twenty-four new rivets (23).

2.

Install two ladder hangers (8) on side panel frame (2) with eight screws (22).

3.

Install skins (1) and (14) on side panel frame (2) with two hundred forty-eight new rivets (21).

NOTE

l

Apply sealing compound to exterior joints for installation.

l

Apply adhesive to rubber and metal surfaces for installation.

4.

Install molding (4) on doorway of side panel frame (2) with nine screws (18).

5.

Install new channel seal (19) on doorway of side panel frame (2).

6.

Install two new seals (16) and retainers (5) on side panel frame (2) with eighty-two screws (15), nuts (17), and four screws (20).

7.

Install new seal (25) and bracket (24) on skins (1) and (14) and side panel frame (2) with one hundred eighty-nine new rivets (26).

5-494

5-73. EXTERIOR

TM 9-2320-272-24-4

5-495

TM 9-2320-272-24-4


8.

Install two new seals (6) and retainers (7) on side panel frame (14) with six screws (8).

9.

Install new seal (10) and six retainers (9) on side panel frame (14) with sixty-two screws (11).

10.

Install five retainers (13) on side panel frame (14) and seal (10) with thirty screws (12).

NOTE

New seals may need to be formed to fit on side panel frame.

11.

Install channel (1), new seals (2) and (4), retainer (3), and retainer (15) on side panel frame (14) with twenty-five screws (5).

5-496


TM 9-2320-272-24-4

FOLLOW-ON TASKS:

l

Install side panel rear lock (para. 3-368).

l

Install side panel front lock (para. 3-369).

l

Install retractable window (para. 3-351).

l

Install side door (para. 5-70).

l


5-497

TM 9-2320-272-24-4

5-74. REAR WALL INTERIOR PANELS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


MATERIALS/PARTS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P l

.

ll l l


l l ll l ll


Rear doors opened (TM 9-2320-272-10).


(TM 9-2320-272-10).

Inside telephone jack post removed (para. 3-374).

Blackout light switch removed (para. 3-373).

Fire extinguisher bracket removed (para. 3-416).

Electrical load center removed (para. 4-161).

Electrical junction box removed (para. 4-163).

Converter outlet box removed (para. 4-169).

Heater thermostat removed (para. 4-165).


Vehicle must be on a level surface.

NOTE

l

Rear wall exterior panels are not serviceable and if damaged are replaced as a unit with rear wall assembly.

l

Left and right rear wall interior panels are replaced the same way. This procedure is for the left rear wall interior panel.

NOTE


1.

Remove thirteen screws (4) and molding (1) from panel (2) and header (3).

2.

Remove twenty-two screws (5) and panel (2) from header (3).

3.

Remove eight screws (9) and two gussets (8) from skin (7) and underframe (6).

NOTE

l


l


1.

Install two gussets (8) on skin (7) and underframe (6) with eight screws (9).

2.

Install panel (2) on header (3) with twenty-two screws (5).

3.

Install molding (1) on panel (2) and header (3) with thirteen screws (4).

5-498

5-74. REAR WALL INTERIOR PANELS REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install heater thermostat (para. 4-165).

l

Install converter outlet box (para. 4-169).

l

Install electrical junction box (para. 4-163).

l

Install electrical load center (para. 4-161).

l

Install fire extinguisher bracket (para. 3-416).

l

Install blackout light switch (para. 3-373).

l

Install inside telephone jack post (para. 3-374).

l


l

Close rear doors (TM 9-2320-272-10).

5-499

TM 9-2320-272-24-4

5-75. INTERIOR SIDE PANELS AND LATCHES REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


MATERIALS/PARTS



Three grommets (Appendix D, Item 251)



Four rubber bumpers (Appendix D, Item 563)

Primer (Appendix C, Item 57)



REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P

EQUIPMENT CONDITION l


l


(TM 9-2320-272-10).

l

Hinged end panels removed (para. 4-155).

l l

Hinged floor removed (para. 5-72).

Hinged roof removed (para. 5-77).

l

Side doors removed (para. 5-70).



NOTE

Left and right interior side panels are replaced the same way. This procedure is for right interior side panel.

1.

Remove six screws (1) and three hooks (2) from side panel frame (3).

2.

Remove six screws (5) and three clips (6) from side panel frame (3).

3.

Remove two screws (8) and striker (7) from side panel frame (3).

4.

Remove two nuts (4), screws (10), lockwashers (11), and door check assembly (9) from door angle (15). Discard lockwashers (11).

5.

Remove two screws (12), striker (13), and two spacer plates (14) from side panel frame (3).

5-500

5-75. INTERIOR SIDE PANELS AND LATCHES REPLACEMENT (Contd)

TM 9-2320-272-24-4

5-501

TM 9-2320-272-24-4

5-75. INTERIOR SIDE PANELS AND LATCHES REPLACEMENT (Contd)

6.

Remove two screws (2) and grommets (3) from side panel frame (1). Discard grommets (3).

7.

Remove four screws (11) and two clips (12) from panel (13) and side panel frame (1).

8.

Remove four screws (16), washers (17), and rubber bumpers (18) from panel (5). Discard rubber bumpers (18).

9.

Remove eight screws (15) and four wood spacers (19) from panel (5).

10.

Remove eight screws (21) and four hangers (20) from panel (5).

11.

Remove four screws (23) and junction box (24) from panel (5).

12.

Remove eight screws (7) and plate (8) from panel (5).

13.

Remove eleven screws (22) and molding (25) from panel (5).

NOTE

Assistants will help with steps 14 and 15.

14.

Remove thirty-three screws (10) and panel (13) from side panel frame (1).

15.

Remove fifty-eight screws (9), molding (14), and panel (5) from side panel frame (1).

16.

Remove moldings (26), (4), and (6) from panel (5).

17.

Remove two moldings (27), moldings (28), and moldings (29) from panel (5).

5-502


TM 9-2320-272-24-4

5-503

TM 9-2320-272-24-4


18.

Remove eight screws (15) and plate (14) from panel (16).

19.

NOTE


Remove thirty-three screws (13), moldings (27), (28), (29), (12), (17), and (18), and panel (16) from side panel frame (4).

Remove nut (25) and washer (24) from latch (23).

20.

21.

22.

23.

24.

25.

26.

27.

Remove two screws (7), plate (8), gasket (9), shank (5), and O-ring (6) from latch (23). Discard

O-ring (6) and gasket (9).

Remove two cotter pins (22), pins (20), clevis (26), and clevis (21) from latch (23). Discard cotter pins (22).

Remove four nuts (11), lockwashers (10), and latch (23) from side panel frame (4). Discard lockwashers (10).

Remove two screws (31) and retainer (30) from side panel frame (4).

Remove clevis (21) from flush bolt (3).

Remove clevis (26) from horizontal bar (19).

Remove horizontal bar (19) and flush bolt (3) from side panel frame (4).

NOTE

Repeat steps 18 through 27 for removal of each front latch assembly.

28.

Remove screw (1) and grommet (2) from side panel frame (4). Discard grommet (2).

NOTE

l

Insulate areas of dissimilar metal-to-metal contact with zinc chromate primer.

l


l

Apply adhesive to rubber and metal surfaces.

1.

Install new grommet (2) on side panel frame (4) with screw (1).

2.

Position horizontal bar (19) and flush bolt (3) in side panel frame (4).

3.

Install clevis (26) on horizontal bar (19).

4.

Install clevis (21) on flush bolt (3).

5.

Install retainer (30) on side panel frame (4) with two screws (31).

6.

Install latch (23) on side panel frame (4) with four new lockwashers (10) and nuts (11).

7.

Install clevises (26) and (21) on latch (23) with two pins (20) and new cotter pins (22).

8.

Install new O-ring (6), shank (5), new gasket (9), and plate (8) on latch (23) with two screws (7).

9.

Install washer (24) and nut (25) on shank (5) and latch (23).

NOTE

l

Insulate entire structure with fibrous glass felt insulation.

l


10.

Install panel (16) and moldings (27), (28), (29), (12), (17), and (18) on side panel frame (4) with thirty-three screws (13).

11.

Install plate (14) on panel (16) with eight screws (15).

NOTE

Repeat steps 2 through 11 for installation of each front latch assembly.

5-504


TM 9-2320-272-24-4

5-505

TM 9-2320-272-24-4


16.

17.

18.

19.

20.

21.

22.

13.

14.

15.

12.

Install moldings (6), (4), and (25) on panel (5).

NOTE

l


l


Install panel (5) and molding (14) on side panel frame (1) with fifty-eight screws (9).

Install panel (13) on side panel frame (1) with thirty-three screws (10).

Install molding (24) on panels (5) and (13) with eleven screws (21).

Install plate (8) on panel (5) with eight screws (7).

Install junction box (23) on panel (5) with four screws (22).

Install four hangers (20) on panel (5) with eight screws (19).

Install four wood spacers (26) on panel (5) with eight screws (15).

Install four new rubber bumpers (18) on panel (5) with four washers (17) and screws (16).

Install two clips (12) on panel (13) with four screws (11).

Install two new grommets (3) on side panel frame (1) with two screws (2).

5-506

TM 9-2320-272-24-4


23.

Install two spacer plates (39) and striker (38) on side panel frame (1) with two screws (37).

24.

Install door check assembly (34) on door angle (40) with two new lockwashers (36), screws (35), and nuts (30).

25.

Install striker (32) on side panel frame (1) with two screws (33).

26.

Install three clips (29) on side panel frame (1) with six screws (31).

27.

Install three hooks (28) on side panel frame (1) with six screws (27).

FOLLOW-ON TASKS: l

Install side doors (para. 5-70).

l

Install hinged roof (para. 5-77).

l

Install hinged floor (para. 5-72).

l

Install hinged end panels (para. 4-155).

l


5-507

TM 9-2320-272-24-4

5-76. CEILING AND FRAME MAINTENANCE

THIS TASK COVERS: a. Removal b. Cleaning and Inspection c. Installation

INITIAL SETUP:


M934/A1/A2

TOOLS


Rivet gun

MATERlALS/PARTS


One-hundred sixteen rivets (Appendix D,

Item 552)

One-hundred forty-four rivets (Appendix D,

Item 553)

Eighty-eight rivets (Appendix D, Item 551)

Two-hundred eight rivets (Appendix D,

Item 542)





REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l


(TM 9-2320-272-10).

l

Ceiling air ducts removed (para. 5-81).

l

Ceiling filler and side panels removed (para. 5-79).

l

Ceiling rear cover removed (para. 5-80).

l

Rear doors removed (para. 4-154).

l

Ceiling transition removed (para. 5-82).

NOTE


1.

Remove one-hundred two rivets (6), ceiling panel (5), and two liner strips (1) from roof frame (2).

Discard rivets (6).

2.

Remove ninety-three rivets (4), ceiling panel (3), and two liner strips (1) from roof frame (2). Discard rivets (4).

5-508

5-76. CEILING AND FRAME MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-509

TM 9-2320-272-24-4


3.

Remove ninety-two rivets (3), ceiling panel (4), and two liner strips (2) from roof frame (1). Discard rivets (3).

4.

Remove seventy-six rivets (5), ceiling panel (6), and three liner strips (2) from roof frame (1).

Discard rivets (5).

NOTE

Left and right side moldings are removed the same way. This procedure covers the right side.

5.

Remove fifty-nine screws (11), molding (10), molding (12), and seal (9) from roof frame (1). Discard seal (9).

6.

Remove six nuts (13), screws (7), lockwashers (18), and two lifting brackets (17) from roof frame (1).


NOTE

l

Perform steps 7 and 8 only if roof is damaged and is to be removed (task b).

l


7.

Remove one-hundred twenty-six rivets (15), eighteen rivets (14), and one-hundred sixteen rivets (8) connecting roof panel (16) to roof frame (1). Discard rivets (8), (14), and (15).

8.

Remove roof panel (16) from roof frame (1) by lifting roof panel (16) and placing on supports.

5-510


TM 9-2320-272-24-4

5-511

TM 9-2320-272-24-4


9.

Remove twenty-three screws (2) and moldings (1), (3), and (4) from van body (11).

10.

Remove three screws (6) and angle bracket (7) from retainer (8)

11.

Remove fifteen screws (5), seal (9), retainer (8), and woodblock (10) from van body (11). Discard seal (9).


1.


2.

Inspect moldings (1), (3), and (4) for bends and breaks. If bent or broken, replace molding (l),

(3), or (4).

3.

Inspect angle bracket (7) and retainer (8) for cracks and breaks. If cracked or broken, replace.

4.

Inspect woodblock (10) for breaks. If broken, replace woodblock (10).

5.

Inspect moldings (13) and (14) for bends, breaks, and warpage. If bent, broken, or warped, replace molding (13) or (14).

6.

Inspect lifting bracket (12) for breaks and cracks. If broken or cracked, replace lifting bracket (12).

7.

Inspect roof panel (16) for tears and punctures. If torn or punctured, replace roof panel (16).

8.

Inspect roof frame (15) for breaks, warpage, and broken bows. If roof frame (15) is damaged, replace entire roof assembly.

9.

Inspect ceiling panels (17), (18), (19), and (20) for cracks and punctures. If cracked or punctured, replace.

5-512


TM 9-2320-272-24-4

5-513

TM 9-2320-272-24-4


l

Apply adhesive prior to installation.

l


1.

Install woodblock (10), new seal (9), and retainer (8) on van body (11) with fifteen screws (5). Leave three center holes of retainer open for angle bracket (7) installation.

2.

Install angle bracket (7) on retainer (8) with three screws (6).

3.

Install moldings (3), (4), and (1) on van body (11) with twenty-three screws (2).

NOTE

l

Perform steps 4 and 5 only if roof panel was removed.

l


l


4.

Lift roof panel (22) from supports and position on roof frame (20).

5.

Install roof panel (22) on roof frame (20) with one-hundred sixteen new rivets (13), eighteen new rivets (19), and one-hundred twenty-six new rivets (21).

6.

Install two lifting brackets (23) on roof frame (20) with six new lockwashers (24), screws (12), and nuts (18).

NOTE

Left and right side moldings are installed the same way. This procedure covers the right side.

7.

Install new seal (14), molding (15), and molding (17) on roof frame (20) with fifty-nine screws (16).

5-514


TM 9-2320-272-24-4

5-515

TM 9-2320-272-24-4


NOTE


8.

Install ceiling panel (6) and three liner strips (2) on roof frame (1) with seventy-six new rivets (5).

9.

Install ceiling panel (4) and two liner strips (2) on roof frame (1) with ninety-two new rivets (3).

10.

Install ceiling panel (7) and two liner strips (2) on roof frame (1) with ninety-three new rivets (8).

11.

Install ceiling panel (9) and two liner strips (2) on roof frame (1) with one-hundred two new rivets (10).

5-516


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install rear doors (para. 4-154).

l

Install ceiling transition (para. 5-82).

l l

Install ceiling rear cover (para. 5-80).

Install ceiling filler and side panels (para. 5-79).

l l

Install ceiling air ducts (para. 5-81).


5-517

TM 9-2320-272-24-4

5-77. HINGED ROOF MAINTENANCE


INITIAL SETUP:


M93/A1/A2

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS


EQUlPMENT CONDITION

Lifting device l


Rivet gun

Four chains

MATERIALS/PARTS

Three cotter pins (Appendix D, Item 56)

Fifty-two rivets (Appendix D, Item 555)

One-hundred fifty-seven rivets (Appendix D,

Item 553) l


(TM 9-2320-272-10).

l

Hinged roof-operated blackout circuit plungers removed (para. 3-377).

l


l


l

Left and right side blackout harness removed

(para. 5-98).






Two cushion pads (left side) (Appendix D,

Item 90)

Two cushion pads (Right side) (Appendix D,

Item 91)




Four grommets (Appendix D, Item 251)








NOTE

Left and right hinged roofs are maintained the same way. This procedure covers right side.

1.

Attach four chains to lifting device and hinged roof (1). Remove slack from chains.

2.

Remove four screws (3), two angle brackets (2), and holding rods (4) from hinged roof (1).

5-518

TM 9-2320-272-24-4

5-77. HINGED ROOF MAINTENANCE (Contd)

WARNING

All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury to personnel.

NOTE


3.

Remove sixty-nine screws (5) from van body (6) and hinged roof (1). Lift hinged roof (1) and position on supports.

4.

Remove chains from lifting device and hinged roof (1).

5-519

TM 9-2320-272-24-4

5-77. HINGED ROOF MAINTENANCE (Contd) b. Disassembly

1.

Remove twelve screws (27) and three clamps (28) from hinged roof frame (1).

2.

Remove six screws (25) and three holder assemblies (26) from hinged roof frame (1).

3.

Remove thirty screws (5) and moldings (4), (6), and (7) from panels (2) and (18).

4.

Remove four screws (11) and handle (12) from panel (2).

5.

Remove ten screws (13) and cover (14) from panel (2).

6.

Remove six screws (9) and plate (8) from panel (2).

7.

Remove six screws (19) and three bars (20) from fillers (22).

8.

Remove six screws (21) and three fillers (22) from panels (2) and (8).

9.

Remove two screws (16) and molding (15) from panels (2) and (18).

10.

Remove moldings (3), (23), and (24) from panels (2) and (18).

NOTE


11.

12.

Remove fifty-five screws (10) and panel (2) from hinged roof frame (1).

Remove forty-one screws (17) and panel (18) from hinged roof frame (1).

5-520


TM 9-2320-272-24-4

5-521

TM 9-2320-272-24-4


22.

23.

24.

25.

26.

13.

14.

15.

16.

17.

18.

19.

20.

21.

27.

Remove sixty-eight screws (26), hinge (14), and seal (13) from hinged roof frame (11). Discard seal (13).

Remove twenty-four rivets (29), retainer (30), and seal (28) from hinged roof frame (11). Discard seal (28) and rivets (29).

Remove cushion pads (12) and (27) from hinged roof frame (11). Discard cushion pads (12) and (27).

Remove fifty-two rivets (32), retainer (34), and seal (35) from hinged roof frame (11). Discard rivets (32) and seal (35).

Remove seals (31) and (33) from hinged roof frame (11). Discard seals (31) and (33).

Remove padlock and chain (2) and chain hook (1) from angle bracket (37).

Remove three screws (38) and angle bracket (37) from skin (7).

Remove cotter pin (24), nut (23), and washer (22) from handle (3). Discard cotter pin (24).

Remove two screws (4), handle (3), plate (5), gasket (6), and O-ring (36) from skin (7). Discard

O-ring (36) and gasket (6).

Remove two cotter pins (19), pins (16), and clevises (18) from latch (17). Discard cotter pins (19).

Remove four nuts (21), washers (20), and latch (17) from hinged roof frame (11).

Remove clevises (18) from bars (15) and (25).

Remove bars (15) and (25) from hinged roof frame (11).

Remove four screws (9) and grommets (10) from hinged roof frame (11). Discard grommets (10).

NOTE

l

Perform step 27 only if skin is to be removed (task c).

l


Remove one-hundred fifty-seven rivets (8) and skin (7) from hinged roof frame (11). Discard rivets (8).

5-522


TM 9-2320-272-24-4

5-523

TM 9-2320-272-24-4


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.


Inspect panels (2) and (11) for cracks and breaks. Replace panels (2) and (11) if cracked or broken.

Inspect moldings (3), (4), (5), (6), (10), (14), and (15) for warpage and breaks. Replace moldings (3),

(4), (5), (6), (10), (14), and (15) if moldings are warped or broken.

Inspect plate (7), handle (8), cover (9), three bars (12), and fillers (13) for bends and breaks. Replace plate (7), handle (8), cover (9), bars (12), and fillers (13) if bent or broken.

Inspect three clamps (17) and holder assemblies (16) for breaks and proper operation. Replace clamps (17) and holder assemblies (16) if damaged.

Inspect hinge (23) for breaks and proper operation. Replace hinge (23) if damaged.

Inspect retainers (28) and (29) for cracks and breaks. Replace retainer (28) or (29) if cracked or broken.

Inspect angle bracket (18), padlock and chain (19), chain hook (20), and handle (21) for breaks.

Replace angle bracket (18), padlock and chain (19), chain hook (20), and handle (21) if broken.

Inspect bars (24) and (27), and two clevises (25) for bends and breaks. Replace bars (24), (27) and clevises (25) if bent or broken.

Inspect latch (26) for proper operation. Replace latch (26) if damaged.

Inspect skin (22) for tears and punctures. Replace skin (22) if torn or punctured.

Inspect frame (1) for breaks. Replace entire hinged roof if damaged.

5-524


TM 9-2320-272-24-4

5-525

TM 9-2320-272-24-4


NOTE

l


l


l

Apply adhesive to both rubber and metal surfaces.

l

Perform step 1 only if skin was removed.

l


1.

Install skin (7) on hinged roof frame (11) with one-hundred fifty-seven new rivets (8).

2.

Install four new grommets (10) on hinged roof frame (11) with four screws (9).

3.

Install clevises (18) on bars (15) and (25) and position in slots of hinged roof frame (11).

4.

Install latch (17) on hinged roof frame (11) with four washers (20) and nuts (21).

5.

Install two clevises (18) on latch (17) with two pins (16) and new cotter pins (19).

6.

Install new O-ring (36), new gasket (6), plate (5), and handle (3) on skin (7) with two screws (4).

7.

Install handle (3) on latch (17) with washer (22), nut (23), and new cotter pin (24).

8.

Install angle bracket (37) on skin (7) with three screws (38).

9.

Install chain hook (1) and padlock and chain (2) on angle bracket (37).

10.

Install new seals (31) and (33) on hinged roof frame (11).

11.

Install new seal (35) and retainer (34) on hinged roof frame (11) with fifty-two new rivets (32).

12.

Install new cushion pads (12) and (27) on hinged roof frame (11).

13.

Install new seal (28) and retainer (30) on hinged roof frame (11) with twenty-four new rivets (29).

14.

Install new seal (13) and hinge (14) on hinged roof frame (11) with sixty-eight screws (26).

5-526


TM 9-2320-272-24-4

5-527

TM 9-2320-272-24-4


NOTE

l


l


15.

Install panel (18) on hinged roof frame (1) with forty-one screws (17).

16.

Install panel (2) on hinged roof frame (1) with fifty-five screws (10).

17.

Install molding (15) on panels (2) and (18) with two screws (16).

18.

Install moldings (3), (23), and (24) on panels (2) and (18).

19.

Install three fillers (22) on panels (2) and (18) with six screws (21).

20.

Install three bars (20) on fillers (22) with six screws (19).

21.

Install plate (8) on panel (2) with six screws (9).

22.

Install cover (14) on panel (2) with ten screws (13).

23.

Install handle (12) on panel (2) with four screws (11).

24.

Install moldings (4), (6), and (7) on panels (2) and (18) with thirty screws (5).

25.

Install three holder assemblies (26) on hinged roof frame (1) with six screws (25).

26.

Install three clamps (28) on hinged roof frame (1) with twelve screws (27).

5-528


TM 9-2320-272-24-4

5-529

TM 9-2320-272-24-4


1.

Attach four chains to lifting device and hinged roof (1).

All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury to personnel.

NOTE


2.

Lift hinged roof (1) from supports and install on van body (6) with sixty-nine screws (5).

3.

Install two holding rods (4) and angle brackets (2) on hinged roof (1) with four screws (3).

4.

Remove chains from lifting device and hinged roof (1).

NOTE

Hinged roof-operated blackout circuit plungers must be installed before side blackout harnesses are installed in load center.

5.

Install hinged roof-operated blackout circuit plungers (para. 3-377).

FOLLOW-ON TASKS: l


l


l

Install left and right side blackout harness (para. 5-98).

l


5-530

TM 9-2320-272-24-4

5-78. FRONT WALL REGISTERS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P



NOTE

All four front wall registers are replaced the same way. This procedure covers one register.

Remove four screws (2) and register (3) from front wall (1).

Install register (3) on front wall (1) with four screws (2).

5-531

TM 9-2320-272-24-4

5-79. CEILING FILLER AND SIDE PANELS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


MATERIALS/PARTS




TWO

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Inside telephone jacks (ceiling) removed l

(para. 3-374).

Blackout light switches and receptacles removed

(para. 3-373).

l

Ceiling deflectors and registers removed

(para. 5-83).

l

Blackout and emergency light fixtures removed

(para. 3-372).

l

Fluorescent light fixtures removed (para. 4-168).

l

Rear splice plate removed (para. 5-84).



NOTE

Left and right ceiling filler and side panels are replaced the same way. This procedure covers the left side.

a. Removal

1.

Remove thirty screws (9) and side panel (8) from lintel (6), air ducts (5) and (7), and filler panel (1).

2.

Remove seven screws (10) and filler panel (1) from filler angles (2) and (3) and transition (4).

3.

Remove forty-four screws (14) and side panel (15) from lintel (6), rear header (13), and air ducts (11) and (12).

NOTE

l


l


l


1.

Install side panel (15) on lintel (6), rear header (13), and air ducts (12) and (11) with forty-four screws (14).

2.

Install tiller panel (1) on filler angles (3) and (2) and transition (4) with seven screws (10).

3.

Install side panel (8) on lintel (6), air ducts (7) and (5), and filler panel (1) with thirty screws (9).

5-532

5-79. CEILING FILLER AND SIDE PANELS REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install rear splice plate (para. 5-84).

l

Install fluorescent light fixtures (para. 4-168).

l

Install blackout and emergency light fixtures (para. 3-372).

l

Install blackout light switches and receptacles (para. 3-373).

l

Install ceiling deflectors and registers (para. 5-83).

l

Install inside telephone jacks (ceiling) (para. 3-374).

5-533

TM 9-2320-272-24-4

5-80. CEILING REAR COVER REPLACEMENT


INlTlAL SETUP:


M934/A1/A2

TOOLS


MATERIALS/PARTS




TWO

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Rear splice plate removed (par. 5-84).



Remove eight screws (4), thirteen screws (5), and rear cover (3) from rear head (2) and air duct (1).

NOTE

l


l

Apply adhesive to metal surfaces.

l


1.

Install rear cover (3) on rear header (2) with eight screws (4).

2.

Install rear cover (3) on air duct (1) with thirteen screws (5).

5-534

5-80. CEILING REAR COVER REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install rear splice plate (para. 5-84).

5-535

TM 9-2320-272-24-4

5-81. CEILING AIR DUCTS REPLACEMENT


INITlAL SETUP:

APPLICABLE MODELS REFERENCES (TM)

M934/A1/A2 TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



l


MATERIALS/PARTS

l

Van sides fully expanded and secured


(TM 9-2320-272-10).

l



l


TWO



1.

Remove fifty-two screws (6) and two enclosures (7) from air ducts (3) and (5).

2.

Remove fourteen screws (4) from air ducts (3) and (5) and support (1).

3.

Remove forty-two screws (2) and air duct (3) from ceiling (9).

4.

Remove eighteen screws (8) and air duct (5) from ceiling (9).

5.

Remove nine screws (10) and support (1) from ceiling (9).

6.

Remove fifty-two screws (20) and two enclosures (19) from air ducts (17) and (21).

7.

Remove four screws (16) from air duct (17) and support (13).

8.

Remove six screws (18) from air duct (21) and support (13).

9.

Remove twenty-six screws (15) and air ducts (17) and (21) from ceiling (9).

10.

Remove ten screws (14) and support (13) from ceiling (9).

11.

Remove seven screws (12) and support (11) from ceiling (9).

b. Installation

NOTE


1.

Install support (11) on ceiling (9) with seven screws (12).

2.

Install support (13) on ceiling (9) with ten screws (14).

3.

Install air ducts (17) and (21) on ceiling (9) with twenty-six screws (15).

4.

Install air duct (21) on support (13) with six screws (18).

5.

Install air duct (17) on support (13) with four screws (16).

6.

Install two enclosures (19) on air ducts (21) and (17) with fifty-two screws (20).

7.

Position support (1) over bow of roof frame and install on ceiling (9) with nine screws (10).

8.

Install air duct (5) on ceiling (9) with eighteen screws (8).

9.

Install air duct (3) on ceiling (9) with forty-two screws (2).

10.

Install air ducts (3) and (5) on support (1) with fourteen screws (4).

11.

Install two enclosures (7) on air ducts (5) and (3) with fifty-two screws (6).

5-536

5-81. CEILING AIR DUCTS REPLACEMENT (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l


l


l


5-537

TM 9-2320-272-24-4

5-82. CEILING TRANSITION MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Assembly d. Installation

INITIAL SETUP:


M934/A1/A2

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



Rivet gun l


MATERIALS/PARTS

l

Van sides fully expanded and secured

(TM 9-2320-272-10).





l l





a. Removal

1.

Remove seven screws (4) from support (8).

NOTE

Assistants will help with step 2.

2.

Remove thirty screws (2) and transition (3) from ceiling (1).

1.

Remove seven rivets (6), retainer (7), seal (5), and support (8) from transition (3). Discard rivets (6) and seal (5).

2.

Remove ten rivets (18), two retainers (9), and seals (10) from transition (3). Discard seals (10) and rivets (18).

3.

Remove seven rivets (16), retainer (17), and seal (15) from transition (3). Discard seal (15) and rivets (16).

4.

Remove four screws (11) and filler angle (12) from transition (3).

5.

Remove three screws (13) and filler angle (14) from transition (3).

5-538

5-82. CEILING TRANSITION MAINTENANCE (Contd)

TM 9-2320-272-24-4

5-539

TM 9-2320-272-24-4


1.

Install filler angle (14) on transition (3) with three screws (13).

2.

Install tiller angle (12) on transition (3) with four screws (11).

NOTE


3.

Install new seal (15) and retainer (17) on transition (3) with seven new rivets (16).

4.

Install two new seals (10) and retainers (9) on transition (3) with ten new rivets (18).

5.

Align support (8) with flanges on transition (3) and install support (8), new seal (5), and retainer (7) on transition (3) with seven new rivets (6).

NOTE

l

Insulate inside of transition with duct lining insulation.

l


1.

Install transition (3) on ceiling (1) with thirty screws (2).

2.

Install support (8) on ceiling (1) with seven screws (4).

5-540


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install ceiling air ducts (par. 5-81).

l


l


5-541

TM 9-2320-272-24-4

5-83. CEILING DEFLECTOR AND REGISTERS REPLACEMENT


INITIAL SETUP:


REFERENCES (TM)

M934/A1/A2 TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS




a. Removal

1.

Remove twenty screws (3) and ten registers (4) from ceiling side panels (2) and deflectors (6).

2.

Remove one hundred screws (5) and ten deflectors (6) from air ducts (1) and ceiling side panels (2).

b. Installation

1.

Install ten deflectors (6) on air ducts (1) and ceiling side panels (2) with one hundred screws (5).

2.

Install ten registers (4) on ceiling side panels (2) and ten deflectors (6) with twenty screws (3).

5-542

TM 9-2320-272-24-4

5-84. REAR SPLICE PLATE REPLACEMENT


INITIAL SETUP:


REFERENCES (TM)

M934/A1/A2

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS


EQUIPMENT CONDITION


NOTE

Left and rear splice plates are replaced the same way. This procedure covers the right side.

a. Removal

Remove four screws (4) and splice plate (3) from side panel (1) and rear cover (2).

b. Installation

Install splice plate (3) on side panel (1) and rear cover (2) with four screws (4).

5-543

TM 9-2320-272-24-4

5-85. BONNET FRAME PARTS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS

Insulation (Appendix D, Item 260)

Two speed nuts (Appendix D, Item 667)

Eight rivets (Appendix D, Item 557)

Thirty-five rivets (Appendix D, Item 556)

One-hundred sixteen rivets (Appendix D,

Item 547)

One-hundred seventy-six rivets (Appendix D,

Item 542)

Sixteen rivets (Appendix D, Item 559)




REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Bonnet control rod removed (para. 3-361).

l

Van heater removed (para. 3-379).

l

Air conditioner (if equipped) removed (para. 5-88).

l

Bonnet access door removed (para. 5-86).

l

Bonnet door removed (para. 5-87).

a. Removal

1.

Remove twenty-seven screws (5) and drip molding (4) from bonnet frame (14).

2.

Remove seventeen screws (13) and door panel (12) from bonnet frame (14).

3.

Remove four screws (15) and plate (1) from outer panel (2) and bonnet frame (14).

4.

Remove thirty-eight rivets (3), twenty-four rivets (7), and outer panels (6) and (2) from bonnet frame (14) and bonnet lower panel (11). Discard rivets (3) and (7).

NOTE

l

Left and right fillers are removed the same way. This procedure is for the left filler.

l


5.

Remove sixty-four rivets (9), thirty-one rivets (10), bonnet lower panel (11), and two tillers (8) from bonnet frame (14). Discard rivets (9) and (10).

5-544

5-85. BONNET FRAME PARTS REPLACEMENT (Contd)

TM 9-2320-272-24-4

5-545

TM 9-2320-272-24-4


8.

9.

6.

7.

10.

11.

12.

NOTE

Left and right heater duct assemblies are removed the same way.

This procedure covers the right side.

Remove two fasteners (5) from support (14) and heater duct (2).

Remove four rivets (12) and two speed nuts (13) from support (14). Discard rivets (12) and speed nuts (13).

Remove three screws (11) and support (14) from front wall (15).

Remove thirty-six rivets (3), heater duct (2), and insulation (4) from bonnet floor (19). Discard rivets (3) and insulation (4).

Remove sixteen rivets (7), twenty-four rivets (8), thirty-six rivets (10), and inner panels (9) and (16) from bonnet frame (6) and bonnet floor (19). Discard rivets (7), (8), and (10).

Remove three screws (20) and post (1) from bonnet floor (19).

NOTE


Remove forty-three rivets (17), thirty-five rivets (18), and bonnet floor (19) from bonnet frame (6) and front wall (15). Discard rivets (17) and (18).

b. Installation

NOTE

l


l


l

Insulate all enclosed structure with fibrous glass felt insulation.

l


1.

Install bonnet floor (19) on bonnet frame (6) and front wall (15) with forty-three new rivets (17) and thirty-five new rivets (18).

2.

Install post (1) on bonnet floor (19) with three screws (20).

3.

Install inner panels (9) and (16) on bonnet frame (6) and bonnet floor (19) with thirty-six new rivets (10), twenty-four new rivets (8), and sixteen new rivets (7).

NOTE

Left and right heater duct assemblies are installed the same way.

This procedure covers the right side.

4.

Install new insulation (4) and heater duct (2) on bonnet floor (19) with thirty-six new rivets (3).

5.

Install support (14) on front wall (15) with three screws (11).

6.

Install two new speed nuts (13) on support (14) with four new rivets (12).

7.

Install heater duct (2) on support (14) with two fasteners (5).

5-546


TM 9-2320-272-24-4

5-547

TM 9-2320-272-24-4


10.

11.

12.

8.

9.

NOTE

l

Left and right fillers are installed the same way. The left filler is shown.

l


Install two fillers (8) and bonnet lower panel (11) on bonnet frame (14) with sixty-four new rivets (9) and thirty-one new rivets (10).

Install outer panels (6) and (2) on bonnet frame (14) and bonnet lower panel (11) with twenty-four new rivets (7) and thirty-eight new rivets (3).

Install plate (1) on outer panel (2) and bonnet frame (14) with four screws (15).

Install door panel (12) on bonnet frame (14) with seventeen screws (13).

Install drip molding (4) on bonnet frame (14) with twenty-seven screws (5).

FOLLOW-ON TASKS: l

Install bonnet door (para. 5-87).

l

Install bonnet access door (para. 5-86).

l

Install van heater (para. 3-379).

l

Install air conditioner (if equipped) (para. 5-88)

l

Install bonnet control rod (para. 3-361).

5-548

TM 9-2320-272-24-4

5-86. BONNET ACCESS DOOR MAINTENANCE


INITIAL SETUP:


M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS

One hundred forty-eight rivets (Appendix D,

Item 551)





REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Bonnet control rod removed (para. 3-361).

a. Removal

NOTE


Remove twelve screws (1) and access door assembly (2) from bonnet frame (3).

5-549

TM 9-2320-272-24-4

5-86. BONNET ACCESS DOOR MAINTENANCE (Contd)

b. Disassembly

1.

Remove twelve screws (1), hinge (2), and seal (21) from door frame (17). Discard seal (21).

2.

Remove four screws (5) and two angle brackets (4) from inner panel (3).

3.

Remove four screws (7), rod (8), and holder bracket (6) from inner panel (3).

4.

Remove screw (11), two nuts (9), screws (12), and bracket (10) from inner panel (3).

NOTE


5.

Remove thirty-three nuts (13), screws (18), seventy-four rivets (19), outer panel (20), three retainers (14), and seal (16) from door frame (17). Discard seal (16) and rivets (19).

NOTE

Perform step 6 if inner panel is to be replaced (subtask c.).

6.

Remove seventy-four rivets (15) and inner panel (3) from door frame (17). Discard rivets (15).

c. Cleaning

1.


2.

Inspect hinge (2) for breaks and proper operation. Replace hinge (2) if damaged.

3.

Inspect three retainers (14) for bends and breaks. Replace if bent or broken.

4.

Inspect angle brackets (4), holder bracket (6), and rod (8) for cracks and breaks. Replace if cracked or broken.

5.

Inspect outer panel (20) for tears and punctures. Replace outer panel (20) if tom or punctured.

6.

Inspect inner panel (3) for tears and punctures. Replace inner panel (3) if torn or punctured.

7.

Inspect door frame (17) for bend, cracks, and breaks. Replace door frame (17) if bent, cracked, or broken.

d. Assembly

NOTE

l


l


l


l

Perform step 1 only if inner panel was removed.

l


1.

Install inner panel (3) on door frame (17) with seventy-four new rivets (15).

2.

Install new seal (16), three retainers (14), and outer panel (20) on door frame (17) with thirty-three screws (18), nuts (13), and seventy-four new rivets (19).

3.

Install holder bracket (6) and rod (8) on inner panel (3) with four screws (7).

4.

Install screw (11) and two nuts (9) on bracket (10).

NOTE

Angle bracket can be installed on either side of door.

5.

Install bracket (10) on inner panel (3) with two screws (12).

6.

Install two angle brackets (4) on inner panel (3) with four screws (5).

7.

Install new seal (21) and hinge (2) on door frame (17) with twelve screws (1).

5-550


TM 9-2320-272-24-4

5-551

TM 9-2320-272-24-4


e. Installation

NOTE


Install access door assembly (2) on bonnet frame (3) with twelve screws (1).

5-552


TM 9-2320-272-24-4

FOLLOW-ON TASK: Install bonnet control rod (para. 3-361).

5-553

TM 9-2320-272-24-4

5-87. BONNET DOOR MAINTENANCE

THIS TASK COVERS: a. Removal b. Disassembly c. Cleaning and Inspection

d. Assembly

e. Installation

INITIAL SETUP:


M934/A1/A2

TOOLS


Rivet gun

MATERIALS/PARTS

Channel seals (as required) (Appendix D,

Item 623)

Forty-eight rivets (Appendix D, Item 547)

Fifty-two rivets (Appendix D, Item 551)




Cork (Appendix C, Item 24)



REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-273-24P



NOTE

Left and right bonnet doors are replaced the same way. This procedure covers the left side.

a. Removal

1.

Remove two screws (4) and washers (5) from bonnet door (3) and bonnet (1).

NOTE


2.

Remove seven screws (2) and bonnet door (3) from bonnet (1).

3.

Position bonnet door (3) squarely on four jack stands with outer panel facing upwards.

5-554

5-87. BONNET

TM 9-2320-272-24-4

5-555

TM 9-2320-272-24-4

5-87. BONNET

3.

4.

1.

2.

5.

6.

7.

8.

Remove six screws (16), spacer plate (15), seal (14), hinge (13), and seal (12) from frame (7). Discard seals (12) and (14).

Remove eighteen nuts (28), screws (11), and two retainers (4) from outer panel (10), frame (7). and seal (3).

NOTE


Remove seventeen rivets (9) and outer panel (10) from frame (7). Discard rivets (9).

Remove twenty-four rivets (27), intake assembly (17), intake panel (26) (if present), and preformed cork (1) from inner panel (2). Discard rivets (27) and cork (1).

Remove fourteen rivets (21), two channels (20), channel seals (19), and channels (18) from intake assembly (17). Discard rivets (21) and channel seals (19).

Remove ten rivets (22), two channels (23), channel seals (24), and channels (25) from intake assembly (17). Discard rivets (22) and channel seals (24).

Remove seven nuts (5), screws (8), retainer (6), and seal (3) from frame (7). Discard seal (3).

NOTE


Remove thirty-three rivets (29), two rivets (30), and inner panel (2) from frame (7). Discard rivets (29) and (30).

5-556

5-87. BONNET

TM 9-2320-272-24-4

5-557

TM 9-2320-272-24-4

5.87. BONNET

7.

8.

5.

6.

1.

2.

3.

4.


Inspect hinge (9) for breaks, corrosion, and proper operation. Replace hinge (9) if damaged.

Inspect retainers (8) and (5) and spacer plate (10) for bends and breaks. Replace retainers (8) and (5) and space plate (10) if bent or broken.

Inspect outer panel (4) and inner panel (7) for tears, cracks, and punctures. Replace outer panel (4) and inner panel (7) if torn, cracked, or punctured.

Inspect intake assembly (11) for cracks and bends. Replace intake assembly (11) if cracked or bent.

Inspect intake panel (3) for bends and breaks. Replace intake panel (3) if bent or broken.

Inspect channels (12), (13), (1), and (2) for bends and breaks. Replace if bent or broken.

Inspect frame (6) for bends, breaks, cracks, and warpage. Replace entire bonnet door assembly if frame (6) is damaged.

5-558

5-87. BONNET

TM 9-2320-272-24-4

5-559

TM 9-2320-272-24-4

5-87. BONNET

NOTE

l


l


l


l


1.

Install inner panel (2) on frame (7) with thirty-three new rivets (29) and two new rivets (30).

2.

Install new seal (3) and retainer (6) on frame (7) with seven screws (8) and nuts (5).

3.

Install two new channel seals (24), channels (23), and channels (25) on intake assembly (17) with ten new rivets (22).

4.

Install two new channel seals (19), channels (18), and channels (20) on intake assembly (17) with fourteen new rivets (21).

NOTE


5.

Install new preformed cork (1), intake panel (26) (if present), and intake assembly (17) on inner panel (2) with twenty-four new rivets (27).

6.

Install outer panel (10) on frame (7) with seventeen new rivets (9).

7.

Install two retainers (4) in seal (3) with eighteen screws (11) and nuts (28).

8.

Install new seal (12), hinge (13), spacer plate (15), and new seal (14) on frame (7) with six screws (16).

Ensure hinge is flush with top of door.

5-560

5-87. BONNET

TM 9-2320-272-24-4

5-561

TM 9-2320-272-24-4

5-87. BONNET

NOTE


Install bonnet door (3) on bonnet (1) with seven screws (2), two screws (4), and washers (5).

5-562

TM 9-2320-272-24-4

5-88. AIR


APPLICATION MODELS

M934/A1/A2

TOOLS


Chain

Lifting device

MATERIALS/PARTS

Cotter pin (Appendix D, Item 57)


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Cab tarpaulin and bows removed

(TM 9-2320-272-10).

l

Windshield lowered (TM 9-2320-272-10).

l

Companion seat lowered (TM 9-2320-272-10).

l

External power source disconnected

(TM 9-2320-272-10).

l

Battery ground cables disconnected (para. 3-126).

l

Air conditioner drain tube removed (para. 3-382).

l

Bonnet door removed (para. 5-87).



NOTE

Screw quantity for steps 1, 2, and 4 may differ from vehicle to vehicle. Record quantity removed for installation.

1.

Remove sixteen screws (6) and lower angle bracket (5) from lower panel mounting angle (7).

2.

Remove twelve screws (9) and lower panel mounting angle (7) from bonnet (11).

3.

Remove four screws (8) and two mounting angles (4) from bonnet (11).

4.

Remove fourteen screws (3), snap (2), and condenser guard (1) from air conditioner (10).

5-563

TM 9-2320-272-24-4

5-88. AIR

5.

Remove sixteen screws (1) and top enclosure (2) from bonnet (8) and air conditioner (7).

6.

Remove twelve screws (4) and right enclosure (3) from bonnet (8) and air conditioner (7).

7.

Remove four screws (14), plate (13), and bellows (12) from left enclosure (11).

8.

Remove ten screws (9) and left enclosure (11) from bonnet (8) and air conditioner (7).

9.

Remove cotter pin (16) and door rod (10) from swing arm (15). Discard cotter pin (16).

10.

Remove seven screws (6) and bottom enclosure (5) from bonnet (8) and air conditioner (7).

11.

Disconnect power cable (24) from air conditioner (7).

12.

Remove screw (26), ground cable (27), and lockwasher (25) from air conditioner (7). Discard lockwasher (25).

13.

Remove screw (23), ground cable (27), and lockwasher (28) from mounting plate (18) and bonnet floor (29). Discard lockwasher (28).

14.

Remove five screws (22) from mounting plate (18) and bonnet floor (29).

15.

Remove six screws (21) from mounting plate (17) and bonnet floor (29).

WARNING


A snapped cable, or swinging or shifting load may result in injury or death to personnel.

NOTE

Two assistants will help with step 16.

16.

Attach chains to lifting device and four lifting brackets (20) on air conditioner (7) and remove air conditioner (7) from bonnet (8). Position air conditioner (7) for access to bottom of unit.

17.

Remove six screws (19) and mounting plates (17) and (18) from air conditioner (7).

1.

Install mounting plates (17) and (18) on air conditioner (7) with six screws (19).

WARNING


A snapped cable, or swinging or shifting load may result in injury or death to personnel.

NOTE

Two assistants will help with step 2.

2.

3.

Attach chains to lifting device and four lifting brackets (20).

Position air conditioner (7) in bonnet (8).

4.

5.

Install mounting plate (17) on bonnet floor (29) with six screws (21).

Install ground cable (27) on mounting plate (18) and bonnet floor (29) with new lockwasher (28), and screw (23).

6.

Install ground cable (27) on air conditioner (7) with new lockwasher (25), and screw (26).

7.

Install mounting plate (18) on bonnet floor (29) with five screws (22).

8.

Connect power cable (24) to air conditioner (7).

9.

Remove lifting device and chains from air conditioner (7).

5-564

5-88. AIR

TM 9-2320-272-24-4

5 - 5 6 5

TM 9-2320-272-24-4

5-88. AIR

10.

Install bottom enclosure (5) on bonnet (7) and air conditioner (8) with seven screws (6).

11.

Install door rod (9) on swing arm (15) with new cotter pin (16).

12.

Install left enclosure (10) on bonnet (7) and air conditioner (8) with ten screws (11). Ensure door rod (9) is positioned through bellows (12).

13.

Install bellows (12) on left enclosure (10) with plate (13) and four screws (14).

14.

Install right enclosure (3) on bonnet (7) and air conditioner (8) with twelve screws (4).

15.

Install top enclosure (2) on bonnet (7) and air conditioner (8) with sixteen screws (1).

5-566

TM 9-2320-272-24-4

5-88. AIR

NOTE

Screw quantity for steps 16, 18, and 19 may differ from vehicle to vehicle. Install screws as recorded.

16.

Install condenser guard (17) on air conditioner (8) with snap (18) and fourteen screws (19).

17.

Install two mounting angles (22) on bonnet (7) with four screws (24).

18.

Install lower panel mounting angle (23) on bonnet (7) with twelve screws (25).

19.

Install lower angle bracket (21) on bonnet (7) and two mounting angles (22) with sixteen screws (20).

FOLLOW-ON TASKS: l

Install bonnet door (para. 5-87).

l

Install air conditioner drain tube (para. 3-382).

l

Connect battery ground cables (para. 3-126).

l

Connect external power source (TM 9-2320-272-10).

l

Raise companion seat (TM 9-2320-272-10).

l

Raise windshield (TM 9-2320-272-10).

l

Install cab tarpaulin and bows (TM 9-2320-272-10).

5-567

TM 9-2320-272-24-4

5-89. MAIN


INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l

Battery ground cables disconnected (para 3-126).

l

Fluorescent light tubes removed (para 3-371).

l

Emergency/blackout lamp and light removed

(para 3-372).

l

Blackout light switch and 110-volt receptacle removed (para 3-373).

NOTE

l

The left and right main wiring harnesses are replaced the same way. This procedure covers the right main wiring harness.

l

Tag wires for installation.

1.

Remove six screws (1) and cover (2) from load center (8).

2.

Remove three setscrews (9) and wires (3) from relay (10).

3.

Remove setscrew (15) and wire (16) from neutral bus (11).

4.

Remove three screws (13) and five wires (14) from 20 amp circuit breakers (12).

5.

Remove screw (4) and clamp (5) from plate (7) and wiring harnesses (6).

6.

Remove twelve screws (22) and clamps (21) from van ceiling (18) and main wiring harness (20).

7.

Remove grommet (23) from van side panel (17).

8.

Remove three screws (25) and wire clip (24) from van side panel (17).

9.

Remove main wiring harness (20) from van body (19).

1.

Position main wiring harness (20) on van body (19).

2.

Install wire clip (24) on side panel (17) of van body (19) with three screws (25).

3.

Install grommet (23) on side panel (17).

4.

Install twelve clamps (21) on main wiring harness (20) and van ceiling (18) with twelve screws (22).

5.

Install clamp (5) on harnesses (6) and plate (7) with screw (4).

6.

Install five wires (14) on 20 amp circuit breakers (12) with three screws (13).

7.

Install wire (16) on neutral bus (11) with setscrew (15).

8.

Install three wires (3) on relay (10) with three setscrews (9).

9.

Install cover (2) on load center (8) with six screws (1).

5-568

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l

Install blackout light switch and 110-volt receptacle (para. 3-373 l Install emergency/blackout lamp and light (para. 3-372).

l l

Install fluorescent light tubes (para. 3-371).


5-569

TM 9-2320-272-24-4

5-90. VAN


INITIAL SETUP:

APPLICABLE MODEL

M934/A1/A2

REFERENCES (TM)

TM 9-2320-272-24P

TM 9-2320-272-24P

TOOLS



l

Parking brake set (TM 9-2320-272-10) l


l


NOTE

Tag cables for installation.

1.

Remove twelve screws (4) and clamps (5) from wiring harness (6) and van ceiling (1).

2.

Disconnect plug (2) from air conditioner (3).

3.


4.

Remove screw (7) and clamp (8) from wiring harnesses (20) and (23) and plate (12).

5.

Remove nut (9), screw (15), two washers (10), cable assembly (14), ground cable (13), and wiring harness cable (11) from load center (16).

6.

Remove three screws (19) and wiring harness cables (18) from 30 amp circuit breaker (17).

7.

Remove wiring harness (20) from load center (16).

1.

Position wiring harness (20) on load center (16).

2.

Install three wiring harness cables (18) on 30 amp circuit breaker (17) with three screws (19).

3.

Install wiring harness cable (11), ground cable (13), and cable assembly (14) on load center (16) with screw (15), two washers (10), and nut (9).

4.

Install clamp (8) on wiring harnesses (23) and (20) and plate (12) with screw (7).

5.


6.

Connect plug (2) to air conditioner (3).

7.

Install twelve clamps (5) on wiring harness (6) and van ceiling (1) with twelve screws (4).

5-570

5-90. VAN

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l


l


5-571

TM 9-2320-272-24-4

5-91. VAN


INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l

Parking brake set (TM 9-2320-272-10) l


l


NOTE


1.

Remove twelve screws (6) and clamps (7) from van ceiling (1) and wiring harness (5).

2.

Remove two grommets (3) from van ceiling (1) and wiring harness (5).

3.

Disconnect two plugs (2) from heater (4).

5-572

5-91. VAN HEATER WIRING HARNESS REPLACEMENT (Contd)

TM 9-2320-272-24-4

5-573

TM 9-2320-272-24-4


4.

Remove thermostat cover (5) from thermostat (6).

5.

Remove four screws (4) and thermostat (6) from control center box (9).

6.

Remove two screws (2) and wires (3) from control center box (9).

7.

Remove four screws (7) and upper cover (1) from control center box (9).

8.


9.

Remove screw (10) and clamp (11) from wiring harnesses (18).

10.

Remove setscrew (14), screw (13), and two wires (15) from load center (12).

11.

Remove wiring harnesses (18) from van body (8).

b. Installation

1.

Position wiring harness (18) on van body (8) and install two wires (15) on load center (12) with screw (13) and setscrew (14).

2.

Place clamp (11) on wiring harnesses (18) and install on load center (12) with screw (10).

3.


4.

Install upper cover (1) on center control box (9) with four screws (7).

5.

Install two wires (3) on thermostat (6) with two screws (2).

6.

Install thermostat (6) on upper cover (1) with two screws (4).

7.

Install thermostat cover (5) on thermostat (6).

5-574


TM 9-2320-272-24-4

5-575

TM 9-2320-272-24-4


8.

Connect two plugs (2) to heater (4).

9.

Install two grommets (3) on wiring harness (5) and van ceiling (1).

10.


5-576

5-91. VAN HEATER WIRING HARNESS REPLACEMENT

(Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASKS: l


l


5-577

TM 9-2320-272-24-4

5-92. ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



Electrical tool kit (Appendix E, Item 40)

l


l


l

Ceiling filter and side panels removed (para. 5-79).

a. Removal

NOTE


1.


2.

Remove grommet (24) from van ceiling (25) and wiring harness (26).

3.

Remove wires (29) and (23) from heater (30).

4.

Remove thermostat cover (4) from thermostat (5).

5.

Remove two screws (3) and thermostat (5) from upper cover (7).

6.

Remove three insulated wire splicers (6) from wiring harness (8) and thermostat leads (2). Discard insulated wire splicers (6).

7.


8.


9.

Remove screw (12), clamp (13), and wiring harnesses (21) and (8) from load center (15).

10.

Remove screw (20) and wire (19) from neutral bus (14).

11.

Remove three screws (17) and wires (18) from 20 amp circuit breakers (16).

12.

Remove wiring harness (8) from van body (9).

b. Installation

1.

Position wiring harness (8) on van body (9).

2.

Install three wires (18) on 20 amp circuit breakers (16) with three screws (17).

3.

Install wire (19) on neutral bus (14) with screw (20).

4.

Install clamp (13) on wiring harnesses (8) and (21) and load center (15) with screw (12).

5.


6.

Install upper cover (7) on control center box (10) with four screws (1).

7.

Connect thermostat leads (2) to wiring harness (8) with three new insulated wire splicers (6).

8.

Install thermostat (5) on upper cover (7) with two screws (3).

9.

Install thermostat cover (4) on thermostat (5).

10.

Install wires (23) and (29) on heater (30).

5-578

TM 9-2320-272-24-4

5-92. ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT (Contd)

11.

Install grommet (24) on wiring harness (26) and van ceiling (25).

12.


FOLLOW-ON TASKS: l


l


5-579

TM 9-2320-272-24-4

5-93. BLACKOUT BYPASS WIRING HARNESS MAINTENANCE

THIS TASK COVERS: a. Removal b. Repair c. Installation

INITIAL SETUP:


M934/A1/A2

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



l


l

Battery ground cabled disconnected (para. 3-126)

a. Removal

NOTE

Tag wires for installation

1.


2.

Remove two setscrews (10) and wires (3) from 3-pole circuit breaker (5).

3.

Remove screw (8) and wire (9) from 30 amp circuit breaker (7).

4.

Remove two screws (13) and cover (14) from switch (11).

5.

Remove two screws (12) and switch (11) from van body (16).

6.

Loosen three screws (15) and remove wires (3) from switch (11).

7.


b. Repair

For wiring harness repair, refer to para. 3-131.

c. Installation

1.


2.

Install three wires (3) on switch (11) and tighten three screws (15).

3.

Install switch (11) on van body (16) with two screws (12).

4.

Install cover (14) on switch (11) with two screws (13).

5.

Install wire (9) on 30 amp circuit breaker (7) with screw (8).

6.

Install two wires (3) on 3-pole circuit breaker (5) with two setscrews (10).

7.


5-580

5-93. BLACKOUT BYPASS WIRING HARNESS MAINTENANCE (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Connect battery ground cables (para. 3-126).

5-581

TM 9-2320-272-24-4

5-94. EMERGENCY LAMP WIRING HARNESS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


MATERIALS/PARTS

Locknut (Appendix D, Item 294)

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P


l


l


l


NOTE


1.


2.

Remove two screws (6) and cover (5) from switch (8).

3.

Remove two screws (7) and switch (8) from switch box (10).

4.

Disconnect two wires (4) and wire (9) from switch (8).

5.

Remove four screws (3) and box (10) from van wall (2).

6.

Remove grommet (1) from switch box (10).

7.

Disconnect emergency lamp wiring harness lead (11) from emergency lamp wiring harness lead (12).

8.

Remove twelve screws (16) and clamps (15) from wiring harness (17) in van ceiling (13).

9.

Remove grommet (18) and wiring harness (17) from van ceiling (13).

5-582

5-94. EMERGENCY LAMP WIRING HARNESS REPLACEMENT (Contd)

TM 9-2320-272-24-4

5-583

TM 9-2320-272-24-4


10.

Disconnect lead (2) from circuit breaker (1).

11.

Remove two screws (5) and clamps (4) from wiring harness (3) and van body (12).

12.

Remove two screws (11) and clamps (6) from wiring harness (3) and van body (12).

13.

Remove locknut (8), screw (10), clamp (9), and wiring harness (3) from spare tire carrier bracket (7).

Discard locknut (8).

14.

Remove nut (13) and wire (15) from positive battery terminal (14).

b. Installation

1.

Install wire (15) on positive battery terminal (14) with nut (13).

2.

Install wiring harness (3) on spare tire carrier bracket (7) with clamp (9), screw (10), and new locknut (8).

3.

Install two clamps (6) on wiring harness (3) and van body (12) with two screws (11).

4.


5.

Connect lead (2) to circuit breaker (1).

5-584


TM 9-2320-272-24-4

5-585

TM 9-2320-272-24-4

6.

7.

8.

9.

10.

11.

12.

13.

14.


Install grommet (5) on van ceiling (1) and wiring harness (2).

Install twelve clamps (3) on van ceiling (1) and wiring harness (2) with twelve screws (4).

Connect emergency lamp wiring harness (14) to emergency lamp wiring harness lead (15).

Install grommet (17) on switch box (13).

Install two cables (7) and cable (12) on switch (11).

Install switch box (13) on van wall (6) with four screws (16).

Install switch (11) on switch box (13) with two screws (10).

Install cover (9) on switch (11) with two screws (8).

Install emergency lamp wiring harness (18) on van ceiling (1) with twelve clamps (19) and screws (20).

5-586


TM 9-2320-272-24-4

FOLLOW-ON TASKS: l


l


5-587

TM 9-2320-272-24-4

5-95. BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT


INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272- 10

TM 9-2320-272-24P


l

Parking brake set (TM 9-2320-272-10X l

Main power switch off (TM 9-2320-272-10).

l

Clearance and blackout marker lights removed

(para. 4-166).

l

Rear wall interior panels removed (para. 5-74).

l


l


l


a. Removal

NOTE


1.

Remove grommet (2) from van body (3) and wiring harness (1).

2.

Remove two screws (6) and clamps (7) from van body (3) and wiring harness (1).

3.

Disconnect two wiring harness connectors (4) from rear wiring harness connectors (5).

4.


5.

Remove five screws (10) and clamps (9) from van ceiling (13) and wiring harness (1).

6.

Remove four grommets (8) from van ceiling (13) and wiring harness (1).

7.


b. Installation

1.

Position wiring harness (1) on van body (14) and install four grommets (8) on van ceiling (13) and wiring harness (1).

2.

Install five clamps (9) on van ceiling (13) and wiring harness (1) with five screws (10).

3.

Install twelve clamps (12) on van ceiling (13) and wiring harness (1) with twelve screws (11).

4.

Connect two wiring harness connectors (4) to rear wiring harness connectors (5).

5.


6.

Install grommet (2) on wiring harness (1) and van body (3).

5-588

TM 9-2320-272-24-4

5-95. BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT (Contd)

FOLLOW-ON TASKS: l

Install ceiling air ducts (para. 5-81).

l


l

Install clearance and blackout marker lights (para. 4-166).

l

Install rear wall interior panels (para. 5-74).

l


l

Main power switch on (TM 9-2320-272-10).

5-589

TM 9-2320-272-24-4

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT


INITIAL SETUP:


M934/A1/A2 TM 9-2320-272-10

TM 9-2320-272-24P

TOOLS



l


MATERIALS/PARTS

l



l


a. Removal

NOTE


1.


2.

Remove four screws (5) and lower cover (4) from control center box (10).

3.

Remove screw (11) and wire (8) from terminal (9).

4.

Remove three screws (3) and wires (7) from circuit breaker (6).

5-590

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT (Contd)

TM 9-2320-272-24-4

5-591

TM 9-2320-272-24-4

5-96. 400 HZ SUPPLY WIRING HARNESS REPLACEMENT (Contd)

5.

Disconnect cables (13) and (12) from connectors (14) and (10).

6.

Remove eight screws (11) and electrical connector box cover (15) from electrical connector box (16).

7.

Disconnect four wires (7) from connector (14).

8.


9.

Remove screw (2) and clamp (3) from harnesses (4) and (8) and load center (5).

10.

Pull wiring harness (8) out of coupling (6) and remove from load center (5) and electrical connector box (16).

b. Installation

1.

Push wiring harness (8) through coupling (6), electrical connector box (16), and load center (5).

2.

Connect four wires (7) to connector (14).

3.

Install clamp (3) on harnesses (4) and (8) and load center (5) with screw (2).

4.


5.

Apply sealing compound to screws (11) and install electrical connector box cover (15) on electrical connector box (16) with eight screws (11).

6.

Connect cables (13) and (12) to connectors (10) and (14).

5-592

5-96. 400 HZ

TM 9-2320-272-24-4

5-593

TM 9-2320-272-24-4

7.

Install three wires (7) on circuit breaker (6) with three screws (3).

8.

Install wire (8) on terminal (9) with screw (11).

9.

Install lower cover (4) on control center box (10) with four screws (5).

10.


5-594

5-96. 400 HZ

TM 9-2320-272-24-4

FOLLOW-ON TASKS:



5-595

TM 9-2320-272-24-4

5-97. BRANCHED


a . R e m o v a l b . I n s t a l l a t i o n

INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P





NOTE


1.


2.

Remove two screws (3) and wires (4) from terminal (5).

3.

Remove six screws (10) and clamps (9) from branched 400 Hz receptacle harness (8) and van ceiling (7).

1.

Install 400 Hz branched receptacle harness (8) on van ceiling (7) with six clamps (9) and screws (10).

2.

Install two wires (4) on terminal (5) with two screws (3).

3.


5-596

5-97. BRANCHED

TM 9-2320-272-24-4

FOLLOW-ON TASKS:



5-597

TM 9-2320-272-24-4

5-98. RIGHT


a.

Removal b.

Repair c. Installation

INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P




(TM 9-2320-272-10).

Hinged roof-operated blackout circuit plungers removed (para. 3-377).

NOTE


1.


2.


3.

Remove screw (10) and wire (11) from relay (12).

4.

Remove screws (5) and (9) and wires (7) and (8) from rear door blackout switch (6).

NOTE

Perform steps 5 through 7 for left and right side of van body.

5.

Remove six screws (24), cover (22), and grommet (4) from van body (26).

6.

Remove nut (21), two screws (17), and two connector halves (18) from harness (23) and cover (22).

7.

Remove nut (3), two screws (25), and two connector halves (1) from harness (23) and ceiling truss (2) and pull harness (23) through hole in ceiling truss (2).

5-598

5-98. RIGHT

TM 9-2320-272-24-4

5-599

TM 9-2320-272-24-4

5-98. RIGHT

For wiring harness repair, refer to para. 3-131.

1.

Push harness (23) in through hole in ceiling truss (2) and position on load center (15).

5-600

TM 9-2320-272-24-4

5-98. RIGHT

NOTE

Perform steps 2 through 5 for left and right side of van body.

2.

Install two connector halves (1) on harness (23) and ceiling truss (2) with nut (3) and two screws (25).

3.

Install cover (22) on van body (26) with six screws (241.

4.

Install two connector halves (18) on harness (23) and cover (22) with nut (19) and two screws (17).

5.

Install grommet (4) on van body (26).

6.

Install wires (7) and (8) on rear door blackout switch (6) with screws (5) and (9).

7.

Install wire (11) on relay (12) with screw (10).

8.


9.


FOLLOW-ON TASKS:

Install hinged roof-operated blackout circuit plungers (para. 3-377).


5-601

TM 9-2320-272-24-4

5.99 TELEPHONE



INITIAL SETUP:


M934/A1/A2

TOOLS

Gal mechanic’s tool kit (Appendix E, Item 1)

REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320-272-24P

EQUIPMENT CONDITIONS


Inside telephone jacks removed (para. 3-374).


NOTE


1.

Remove six screws (4) and clamps (3) from wiring harness (2) and van ceiling (1).

2.


1.

Install wiring harness (2) on van body (5).

2.

Install wiring harness (2) on van ceiling (1) with six clamps (3) and screws (4).

5-602

5-99. TELEPHONE

TM 9-2320-272-24-4

FOLLOW-ON TASKS:


Install inside telephone jacks (para. 3-374).

5-603

TM 9-2320-272-24-4

5-100. 3 PHASE



INITIAL SETUP:


M934/A1/A2

TOOLS


REFERENCES (TM)

TM 9-2320-272-10

TM 9-2320272-24P





NOTE


1.


2.

Remove screw (3) and clamp (13) from wiring harness (2) and van body (4).

3.


4.

Remove three screws (10) and wires (11) from circuit breakers (9).

5.


6.


1.


2.

Install wiring harness (2) on van ceiling (14) with twelve clamps (15) and screws (16).

3.

Install three wires (11) on circuit breakers (9) with three screws (10).

4.


5.

Install clamp (13) on wiring harness (2) and van body (4) with screw (3).

6.


5-604

TM 9-2320-272-24-4

FOLLOW-&TASKS:



5-605

TM 9-2320-272-24-4

Section VII. WINCH, HOIST, AND POWER TAKEOFF MAINTENANCE

5-101. WINCH,

PARA.

NO.

5-102.

5-103.

5-104.

5-105.

5-106.

5-107.

5-108.

TITLE

Boom Elevating Cylinder Repair

Boom Elevating Cylinder Packing Replacement

Dump Roller Arm Maintenance

Dump Hoist Cylinder Maintenance

Boom Extension Cylinder Repair

Crane Swinger Gearcase Repair

Crane Control Valve Repair

5-102. BOOM


a.

Disassembly b.


INITIAL SETUP:


M936/A1/A2

SPECIAL TOOLS


Handle (Appendix E, Item 61)

TOOLS


Spanner wrench (Appendix E, Item 166)

MATERIALS/PARTS

Piston seal (Appendix D, Item 519)

Rod seal (Appendix D, Item 560)


Lockwire (Appendix D, Item 420)

Wiper strip (Appendix D, Item 720)

Packing (Appendix D, Item 510)

c . A s s e m b l y

MATERIALS/PARTS (CONTD)




REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P



• Boom elevating cylinder removed (para. 4-193)



Drycleaning solvent is flammable. Do not use near open flame.

PAGE

NO.

5-606

5-610

5-612

5-614

5-626

5-630

5-636

1.

Using spanner wrench, remove cylinder head (2) from elevating cylinder body (3).

2.

Remove piston rod (1) from elevating cylinder body (3).

3.

Remove lockwire (17), nut (18), washer (16), retainer (15), seal (14), piston (13), rod seal (5), cylinder head (2), and wiper strip (8) from piston rod (1). Discard lockwire (17), piston seal (14), rod seal (5), and wiper strip (8).

5-606

TM 9-2320-272-24-4

5-102. BOOM

4.

Remove packing nut (9), packing (10), bushing (11), and O-ring (12) from cylinder head (2). Discard

O-ring (12) and packing (10).

5.

Remove two half rings (4) from piston (13).

6.

Remove sleeve (7) from piston rod (1).

7.

Remove two lubrication fittings (6) from cylinder body (3) and piston rod (1).

5-607

TM 9-2320-272-24-4

5-102. BOOM

WARNING

Drycleaning solvent is flammable and will not be used near open flame. Use only in well-ventilated places. Failure to do this may result in injury to personnel.

1.

Clean all parts of elevating cylinder with drycleaning solvent and dry with lint-free cloth.

2.

Inspect piston rod (9) for burrs, scoring, scratches, and stripped threads. If minor scratches and burrs are present, remove with crocus cloth.

3.

If piston rod (9) is scored, scratched, or if stripped threads are evident, replace piston rod (9).

4.

Inspect piston (13) and cylinder body (1) for scoring. If piston (13) is scored, replace. If cylinder body (1) is scored, replace elevating cylinder.

1.

Install two lubrication fittings (2) in cylinder body (1) and piston rod (9).

2.

Install sleeve (10) in piston rod (9).

3.

Install two half rings (3) on piston (13).

4.

Install piston rod bushing (6) in cylinder head (5) with bushing installer and handle.

5.

Install new O-ring (4), new packing (7), packing nut (8), and new wiper strip (11) on cylinder head (5).

CAUTION

Be careful not to damage wiper strip when passing over threads on piston rod.

6.

Install cylinder head (5) on piston rod (9).

7.

Install new rod seal (12), piston (13), new seal (14), retainer (15), and washer (16) on piston rod (9).

8.

Install nut (18) on piston rod (9) and secure nut (18) with lockwire (17).

9.

Slide piston rod (9) into cylinder body (1) and install cylinder head (5) on cylinder body (1).

10.

Using spanner wrench, tighten cylinder head (5).

5-608

5-102. BOOM

TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install boom elevating cylinder (para. 4-193).

Lubricate elevating cylinder (LO 9-2320-272-12).

5-609

TM 9-2320-272-24-4

5-103. BOOM


a . R e m o v a l

INITIAL SETUP:


M936/A1/A2

SPECIAL TOOLS


TOOLS


Boom lifting device

MATERIALS/PARTS



b . I n s t a l l a t i o n

REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P



Boom lowered (TM 9-2320-272-10).



WARNING

All personnel must stand clear during lifting operations. A snapped cable, or shifting or swinging load ,may cause injury to personnel.

1.

Place wrecker boom (2) cylinder control lever (7) in UP position.

2.

Raise wrecker boom (2) with lifting device and install shipper braces (TM 9-2320-272-10).

3.

Place boom cylinder control lever (7) in LOWER position to release pressure from elevating cylinder (6).

4.

Using spanner wrench, loosen packing nut (3) from cylinder head (5).

5.

Slide nut (3) up on piston rod (1) to expose packing (4).

CAUTION

Use care not to scratch piston rod surface when removing packing.

6.

Slide packing (4) up piston rod (1) and remove. Discard packing (4).

1.

Coat packing (4) with GAA grease and position around piston rod (1).

2.

Install packing (4) into cylinder head (5) and slide nut (3) onto cylinder head (5).

3.

Using spanner wrench, tighten nut (3).

4.

Remove lifting device from wrecker boom (2).

5-610

5-103. BOOM

TM 9-2320-272-24-4

FOLLOW-ON TASK: Operate crane through full range (TM 9-2320-272-10) and check for leaks at cylinder.

5-611

TM 9-2320-272-24-4

5-104. DUMP


Removal b.

Disassembly c.

Inspection and Repair d.

e.

Assembly

Installation

INITIAL SETUP:


M929/A1/A2, M930/A1/A2

TOOLS


Brass drift

Soft-faced hammer

MATERIALS/PARTS


REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P



• Dump body removed (para. 4-144).


Do not operate dump controls when dump body is removed.

WARNING

Ensure dump control lever is in neutral and not moved. Injury to personnel may result if lift cylinder is operated when not secured.

NOTE

Left and right roller arms are replaced basically the same way.

This procedure covers right roller arm.

NOTE

Use soft-faced hammer to tap roller arm if necessary to complete step 1.

Remove roller arm (3) from hoist cylinder crosshead shaft (1).

1.

Using punch and hammer, remove two pins (2) from roller arm (3).

2.

Using brass drift and hammer, drive roller pin (5) out of roller arm (3) and roller (6).

3.

Remove roller (6) from roller arm (3).

1.

Inspect roller (6) and roller pin (5). If cracked or deeply grooved, replace roller (6) and roller pin (5).

2.

Inspect roller arm (3). If broken or cracked, replace.

3.

Inspect two bushings (4) in roller arm (3). If broken, cracked, or out-of-round, replace bushings (4).

NOTE

Perform steps 4 and 5 only if bushings need to be replaced.

4.

Using brass drift and hammer, drive two bushings (4) out of roller arm (3).

5.

Using wood block and hammer, drive one new bushing (4) in from each side of roller arm (3) until bushings (4) are flush with roller arm (3).

5-612

TM 9-2320-272-24-4

5-104. DUMP

1.

Position roller (6) in roller arm (3).

2.

Coat roller pin (5) with light film of GAA grease and insert through roller arm (3) and roller (6). Tap pins (5) into place with soft-faced hammer.

3.

Install roller (6) on roller arm (3) with two pins (2)

Install roller arm (3) on hoist cylinder crosshead shaft (1).

FOLLOW-ON TASKS:

Install dump body (para. 4-144).

Lubricate roller arms (LO 9-2320-272-12).

5-613

TM 9-2320-272-24-4

5-105. DUMP


a.

Removal b.

Disassembly c.

Cleaning and Inspection

INITIAL SETUP:


M929/A1/A2, M930/A1/A2

TOOLS



Soft-faced hammer




MATERIALS/PARTS

Eight lockwashers (Appendix D, Item 393)

Preformed packing (Appendix D, Item 511)


Cotter pin (Appendix D, Item 75)

Cap and plug set (Appendix C, Item 14)


Clean hydraulic oil (Appendix C, Item 35)

d. Assembly e . I n s t a l l a t i o n

REFERENCES (TM]

LO 9-2320-272-12

TM 9-2320-272-10

TM 9-2320-272-24P


Dump body removed (para. 4-144).

Dump roller arms removed (para. 5-104).


Do not operate dump controls when dump body is removed.

WARNING

Ensure dump control is in neutral and not moved. Injury to personnel may result if lift cylinder is operated when not secured.

NOTE

A 4x4 block of wood is recommended for use as support.

1.

Raise hoist cylinders (3) and (9) from subframe (4) and place wood support between subframe (4) and cylinders (3) and (9).

2.

Remove four screws (2), lockwashers (1), two upper crosshead retainers (5), lower crosshead retainers (7), and crosshead (8) from two piston rods (6). Discard lockwashers (1).

CAUTION

Plug all hydraulic lines or openings to prevent dirt from entering and damaging components.

NOTE

Cross fitting to hoist cylinder hoses must be disconnected from cross fittings first. Then hoses can be removed from hoist cylinders.

Have drainage containers ready to catch oil.

Tag all parts for installation.

3.

Disconnect hydraulic hoses (18) and (14) from right cross fitting (17).

5-614

TM 9-2320-272-24-4

5-105. DUMP

4.

Disconnect hydraulic hoses (19) and (15) from left cross fitting (16).

5.

Disconnect hydraulic hoses (18) and (14) from right and left cylinder ports A (10) and (12).

6.

Disconnect hydraulic hoses (19) and (15) from right and left cylinder ports B (11) and (13).

5-615

TM 9-2320-272-24-4

5-105. DUMP

7.

Remove eight screws (3), lockwashers (4), four bearing caps (2), and hoist cylinders (5) and (1) from subframe (6). Discard lockwashers (4).

2.

3.

4.

1.

5.

6.

NOTE

Both hoist cylinders are disassembled the same way. Steps 1 through 12 cover the left hoist cylinder.

Remove two square-head screws (18) from cylinder base (7) and slide hinge pin (19) out of cylinder base (7).

Remove three screws (11) from gland (12) and cylinder head (14).

Tap gland (12) free of cylinder head (14) and slide off piston rod (16).

Remove ten screws (10) and lockwashers (9) from cylinder head (14) and hoist cylinder housing (8).


Tap cylinder head (14) free of hoist cylinder housing (8) and slide cylinder head (14) off piston rod (16).

Remove packing (13) and O-ring (15) from cylinder head (14). Discard packing (13) and O-ring (15).

CAUTION

Use care when performing step 7 to prevent damage to cylinder bore or piston.

7.

Pull piston rod (16) and piston (17) straight out of hoist cylinder housing (8).

5-616

5-105. DUMP

TM 9-2320-272-24-4

5 - 6 1 7

TM 9-2320-272-24-4

5-105. DUMP

8.

Remove cotter pin (12) and slotted nut (13) from piston rod (8) and piston (9). Discard cotter pin (12).

9.

Slide piston (9) off piston rod (8).

10.

Remove three piston rings (11) from piston grooves (10).

NOTE

Tag bypass plugs, springs, and check balls for installation.

11.

Remove three bypass plugs (6), springs (5), and check balls (4) from hoist cylinder housing (7).

12.

Remove orifice plug cover (1) and orifice plug (2) from cylinder base (3).

NOTE

Use clean lint-free cloth to wipe parts clean. After parts are cleaned and inspected, coat them with a light film of clean hydraulic oil.

1.

Wipe check balls (4) clean and inspect. Replace if scratched, chipped, or marked.

2.

Wipe piston (9) clean and inspect. Replace if cracked or broken.

3.

Measure outside diameter of piston (9). If outside diameter is less than 5.236 in. (132.994 mm), replace piston (9).

4.

Wipe piston rod (8) clean and inspect. Replace if scratched, chipped, or scored.

5.

Measure outside diameter of piston rod (8). If outside diameter is less than 1.994 in. (50.648 mm), replace piston rod (8).

5-618

5-105. DUMP

TM 9-2320-272-24-4

5-619

TM 9-2320-272-24-4

5-105. DUMP

6.

Wipe head (5) and gland (6) clean and inspect. If cracked or broken, replace head (5) or gland (6).

7.

Measure inside diameter of head (5) and gland (6). If inside diameter is not 2.010 in. (51.05 mm), replace head (5) or gland (6).

8.

Measure free length of three bypass springs (1). If length is not 1.25 in. (31.75 mm), replace bypass spring (1).

9.

Compress each bypass spring (1) to 0.938 in. (23.8 mm) length. If torque reading is not 10 lb&

(14 N•m), replace bypass spring (1).

10.

Inspect three piston rings (11) for breaks. If any ring (11) is broken, replace all three rings (11).

11.

Wipe orifice plug (2) and hoist cylinder walls (4) clean and inspect. If scratched or chipped, replace orifice plug (2) or hoist cylinder walls (4).

NOTE

Both hoist cylinders are assembled in the same way. Steps 1 through 12 cover the left hoist cylinder.

1.

Install three piston rings (11) on piston grooves (10).

2.

Slide piston (9) on piston rod (8) until seated and install with slotted nut (13) and new cotter pin (12).

CAUTION

Use care when performing step 3 to prevent damage to cylinder bore or piston.

3.

Slide piston (9) and piston rod (8) in cylinder housing (3).

4.

Install new O-ring (7) on cylinder head (5).

5-620

5-105. DUMP

TM 9-2320-272-24-4

5-621

TM 9-2320-272-24-4

5-105. DUMP

5.

6.

7.

8.

9.

10.

11.

12.

Slide cylinder head (17) over piston rod (18) and position on cylinder housing (19).

Install cylinder head (17) on cylinder housing (19) with ten new lockwashers (12) and screws (13).

Tighten screws (13) 8-10 lb-ft (11-14 N-m).

Install packing (16) around piston rod (18) in cylinder head (17). Use fingers to position new packing (16).

Slide gland (15) over piston rod (18) until seated against packing (16) and install on cylinder head (17) with three screws (14).

Install orifice plug (2) and orifice plug cover (1) in cylinder base (3).

NOTE

Short bypass tube connector block is located in middle of cylinder.

Install two bypass check balls (7), springs (6), and plugs (5) in short bypass tube connector block (4).

NOTE

Long bypass tube connector block is located at head end of cylinder.

Install one bypass check ball (10), spring (9), and plug (8) in long bypass tube connector block (11).

Position hinge pin (21) in cylinder base (3) until aligned with holes for screws (20) and install two square-head screws (20).

5-622

TM 9-2320-272-24-4

5-105. DUMP

1.

Position hoist cylinders (27) and (22) on subframe (28) with bypass tubes (26) facing down.

2.

Install each hoist cylinder (27) and (22) with two bearing caps (23), four new lockwashers (25), and screws (24).

NOTE

To properly identify hose connection points, the cylinder port with bypass tube extending to the middle of the cylinder will be identified as port B. The cylinder port with bypass tube extending full length of the cylinder will be identified as port A.

3.

Connect hydraulic hoses (31) and (35) to left cylinder port A (38), right cylinder port A (29), and right cross fitting (34).

4.

Connect hydraulic hoses (32) and (36) to left cylinder port B (30), right cylinder port B (37), and left cross fitting (33).

5-623

TM 9-2320-272-24-4

5-105. DUMP

5.

Position crosshead (2) on piston rods (1) and (3) and install with two upper crosshead retainers (7), lower crosshead retainers (8), four new lockwashers (4), and screws (5).

6.

Raise hoist cylinders (6) and (9) and remove wood block.

5-624

5-105. DUMP

TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Install dump roller arms (para. 5-104).

Install dump body (para. 4-144).

Fill hydraulic reservoir to proper oil level (LO 9-2320-272-12).

Start engine (TM 9-2320-272-10) and operate dump through full range. Check for leaks and proper operation.

5-625

TM 9-2320-272-24-4

5-106. BOOM


a.

Disassembly b.


INITIAL SETUP:


M936/A1/A2

SPECIAL TOOLS


Handle (Appendix E, Item 61)

TOOLS



MATERIALS/PARTS

Wiper strip (Appendix D, Item 720)

Lockwire (Appendix D, Item 421)






c. Assembly

REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-24P


Extension cylinder removed (para. 4-196)




1.

Using spanner wrench, remove cylinder head (21 from cylinder body (3).

2.

Remove piston rod (11 from cylinder body (3).

3.

Remove lockwire (14) and piston rod nut (15) from piston rod (1). Discard lockwire (14).

4.

Remove washer (13), two U-cup retainers (9), U-cups (10), piston (11), cylinder head (2), and wiper strip (5) from piston rod (1). Discard wiper strip (5).

5.

Remove packing nut (4), packing (6), O-ring (8), and piston rod bushing (7) from cylinder head (2).

Discard O-ring (8) and packing (6).

6.

Remove two half rings (12) from piston (11).

5-626

5-106. BOOM

TM 9-2320-272-24-4

5-627

TM 9-2320-272-24-4

5-106. BOOM

WARNING



1.

Clean all boom extension cylinder components with drycleaning solvent and dry with lint-free cloth

(para. 2-14).

2.

Inspect piston rod (6). Remove scratches and burrs with crocus cloth. Replace if scored or threads are stripped.

3.

Inspect piston (11) and cylinder body (1). Replace piston (11) or cylinder body (1) if scored.

1.

Install two half rings (12) on piston (11).

2.

Using bushing installer and handle, install piston rod bushing (5) in cylinder head (7).

3.

Install new O-ring (8), new packing (4), packing nut (2), and new wiper strip (3) on cylinder head (7).

NOTE

Use care not to damage wiper strip when passing over threads on piston rod.

4.

Install cylinder head (7) on piston rod (6).

5.

Install two U-cup retainers (9), U-cups (10), piston (11), and washer (13) on piston rod (6) with piston rod nut (15) and new lockwire (14).

6.

Slide piston rod (6) into cylinder body (1) and install cylinder head (7) on cylinder body (1). Using spanner wrench, tighten cylinder head (7).

5-628

TM 9-2320-272-24-4

FOLLOW-ON TASKS:

Lubricate extension cylinder (LO 9-2320-272-12).

Install extension cylinder (para. 4-196).

5-629

TM 9-2320-272-24-4

6-107. CRANE


a.

Disassembly b.


INITIAL SETUP:

APPUCABLE MODELS

M936/A1/A2

TOOLS



Arbor press

Mandrel

MATERIALS/PARTS

Two gearcase gaskets (Appendix D, Item 233)

Gearcase seal (Appendix D, Item 6241

Fifteen lockwashers (Appendix D, Item 350)

Two woodruff keys (Appendix D, Item 734)


Two woodruff keys (Appendix D, Item 736)

Woodruff key (Appendix D, Item 735)


c . A s s e m b l y

REFERENCES (TM)

LO 9-2320-272-12

TM 9-2320-272-24P


Crane swinger gearcase removed (para. 4-200).




WARNING

7.

8.



3.

4.

1.

Thoroughly clean exterior with drycleaning solvent (para. 2-14).

NOTE

2.

Have drainage container ready to catch oil.

Remove two drainplugs (8) from crane swinger gearcase (13) and drain lubricant from crane swinger gearcase (13).

Reinstall two drainplugs (8) in crane swinger gearcase (13).

Remove four screws (11), lockwashers (12), shaft bearing cap (10), and gasket (9) from crane swinger gearcase (13). Discard lockwashers (12) and gasket (9).

5.

Remove four screws (5), lockwashers (4), gearcase motor mounting cap (6), and gasket (7) from crane swinger gearcase (13). Discard lockwashers (4) and gasket (7).

6.

Remove six screws (l), lockwashers (14), cover (2), and gasket (3) from crane swinger gearcase (13).

Discard lockwashers (14) and gasket (3).

Using arbor press and mandrel, remove gear shaft assembly (20) from crane swinger gearcase (13).

Remove screw (15), lockwasher (25), and retaining washer (24) from gear shaft assembly (20).


5-630

TM 9-2320-272-24-4

NOTE

Use puller to remove bearing and gear.

9.

Remove upper bearing (23), thrust washer (22), gear (21), gear washer (16), lower bearing (17), seal (18), and two woodruff keys (19) from gear shaft assembly (20). Discard woodruff keys (19) and seal (18).

5-631

TM 9-2320-272-24-4

5-107. CRANE

10.

Using arbor press and mandrel, remove coupling (11) and woodruff key (8) from shoulder shaft (10).

Discard woodruff key (8).

11.

Using arbor press and mandrel, press crane swinger gearcase (5) shoulder shaft (10) down until bearing (1) is removed.

12.

Turn crane swinger gearcase (5) over and press bearing (1) and shoulder shaft (10) assembly from crane swinger gearcase (5).

13.

Remove two bushings (2), springs (3), spacers (4), washers (6), and woodruff keys (9) from shoulder shaft (10). Discard woodruff keys (9).

14.

Remove worm gear (7) from shoulder shaft (10).

WARNING



CAUTION

Do not spin-dry bearings with compressed air.

1.

Clean all crane swinger gearcase (5) components with drycleaning solvent.

2.

Inspect four bearings (1). Replace if scored, pitted, or broken.

3.

Inspect crane swinger gearcase (5), gearcase motor mounting cap (14), shaft bearing cap (15), and gearcase cover (12) for cracks and breaks. Replace if cracked or broken.

4.

Inspect shoulder shaft (10), worm gear (7), and gearshaft (13). Replace if broken, cracked, chipped, or out-of-round.

5-632

TM 9-2320-272-24-4

5-633

TM 9-2320-272-24-4

5-107. CRANE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Install two new woodruff keys (9), washers (6), spacers (4), springs (3), and bushings (2) on shoulder shaft (10).

Install worm gear (7) on shoulder shaft (10).

Using arbor press and mandrel, install shoulder shaft bearings (1) on shoulder shaft (10) and press shoulder shaft (10) into crane swinger gearcase (5) until bearing (1) is flush with end of crane swinger gearcase (5).

Turn crane swinger gearcase (5) over and, using arbor press and mandrel, press second shoulder shaft bearing (1) into crane swinger gearcase (5). Ensure bearing (1) is flush with crane swinger gearcase (5).

Install new woodruff key (8) on shoulder shaft (10).

Install new seal (14) on gear shaft (16).

Using arbor press and mandrel, press bearing (13) onto gear shaft (16).

Position lower thrust washer (12) and two new woodruff keys (15) on gear shaft (16) and, using arbor press and mandrel, press gear (17) onto gear shaft (16) over woodruff keys (15).

Position upper thrust washer (18) on gear shaft (16) and, using arbor press and mandrel, press bearing (19) onto gear shaft (16).

Install retaining washer (20), new lockwasher (21), and screw (22) on gear shaft (16). Tighten screw (22) 44-61 lb-ft (60-83 N•m).

Install new gasket (23) and gearcase cover (24) on crane swinger gearcase (5) with six new lockwashers

(25) and screws (11). Tighten screws (11) 44-61 lb-ft (60-83 N•m).

Install new gasket (28) and shaft bearing cap (27) on crane swinger gearcase (5) with four new lockwashers (26) and screws (34). Tighten screws (34) 44-61 lb-ft (60-83 N•m).

Install coupling (29) in crane swinger gearcase (5).

Install new gasket (30) and mounting cap (31) on crane swinger gearcase (5) with four new lockwashers

(32) and screws (33). Tighten screws (33) 44-61 lb-ft (60-83 N•m).

5-634

5-107. CRANE

TM 9-2320-272-24-4

FOLLOW-ON TASKS: Fill crane swinger gearcase with lubricant (LO 9-2320-272-12).

Install crane swinger gearcase (para. 4-200).

5-635

TM 9-2320-272-24-4

5-108. CRANE


a.

Disassembly b.


INITIAL SETUP:


M936/A1/A2

SPECIAL TOOLS

Seal retainer remover and replacer


TOOLS


Soft-jawed vise

MATERIALS/PARTS

Relief valve kit (Appendix D, Item 533)

Load check valve kit (Appendix D, Item 270)

Eight snaprings (Appendix D, Item 665)



Four O-rings (Appendix D, Item 489)

Four lockwashers (Appendix D, Item 350)



c. Assembly

REFERENCES (TM)

TM 9-2320-272-24P


Crane control valve removed (para. 4-201).

GENERAL SAFETY INSTRUCT IONS



NOTE

Do not perform this procedure unless relief valve kit and load check valve kit are available.

WARNING


1.

Thoroughly clean exterior of crane control valve (3) with drycleaning solvent (para. 2-14).

2.

Remove eight snaprings (21), pins (20), and four handles (19) from base (2) and crane control valve (3). Discard snaprings (21).

3.

Remove four nuts (13), lockwashers (14), screws (1), control brackets (15) and (7), and base (2) from crane control valve (3). Discard lockwashers (14).

4.

Remove nipple adapter (17) and O-ring (16) from crane control valve (3). Discard O-ring (16).

5.

Remove nipple (18) from nipple adapter (17).

NOTE

Mark position and angle of tube and all elbows for assembly.

6.

Remove tube (6), connector (5), and O-ring (4) from crane control valve (3). Discard O-ring (4)

7.

Remove two elbows (10), three adapters (11), and two O-rings (12) from crane control valve (3).

Discard O-rings (12).

8.

Remove four elbows (9) and O-rings (8) from crane control valve (3). Discard O-rings (8).

5-636

5-108. CRANE

TM 9-2320-272-24-4

5-637

TM 9-2320-272-24-4

5-108. CRANE

NOTE

All spring-centered spool valves in the control valve are removed and disassembled the same way. Three spool valves are stamped with a D (double action) on the shank of the spool valve. The fourth is stamped with an S (single action) and is located next to the oil outlet port in the control valve. Steps 9 through 12 will cover a double-action valve only.

9.

Remove spool valve cap (3) and spool valve (2) from crane control valve (1).

10.

Clamp spool valve (2) in soft-jawed vise.

11.

Using improvised compression tool, compress spring (6) and remove snapring (4), outer spacer (5), spring (6), travel limit washer (7), and inner spacer (8) from spool valve (2).

12.

Using seal retainer remover and replacer, remove retainer (24), seal (25), and O-ring (26) from crane control valve (1). Discard seal (25) and O-ring (26).

NOTE

All check valves in the control valve are removed and assembled the same way. Check valves located adjacent to valve spools marked with a D (double action) are identical. The check valve located by the valve spool marked S (single action) contains only one spring and poppet. All other components are the same as the D-type spools. Steps 13 and 14 cover a check valve adjacent to a D-type spool.

Do not remove check seat sleeve from control valve. Check valve parts should be identified so they may be returned to their original position during assembly.

13.

Remove two check valve caps (9), springs (17), and poppets (14) from crane control valve (1).

14.

Remove backup ring (16), O-ring (15), backup ring (13), backup ring (12), O-ring (11), and

O-ring (10) from each check valve cap (9). Discard backup ring (16), O-ring (15), backup ring (13), backup ring (12), O-ring (11), and O-ring (10).

5-638

TM 9-2320-272-24-4

5-108. CRANE

15.

Remove relief valve (23) from crane control valve (1). Discard relief valve (23).

16.

Remove seat retainer plug (18), drain sleeve (20), and seat retainer (19) from crane control valve (1). Discard seat retainer (19).

17.

Remove poppet spring (22) and poppet assembly (21) from crane control valve (1). Discard poppet assembly (21) and poppet spring (22).

5-639

TM 9-2320-272-24-4

5-108. CRANE

WARNING

Drycleaning solvent is flammable and toxic. Do not use near open flame and always have a tire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container.


1.

Clean all control valve components with drycleaning solvent and dry with lint-free cloth (para. 2-14).

2.

Inspect spool valve (1) and crane control valve (2). Replace crane control valve (2) if grooved, scratched, cracked, or broken.

7.

8.

9.

10.

4.

5.

1.

2.

3.

6.

NOTE

Drain sleeve should go into control valve far enough to leave two or three full threads exposed. Installing seat retainer plug at this point sets the seat retainer to the proper depth.

Install new seat retainer (13) and drain sleeve (14) in crane control valve (2).

Install seat retainer plug (12) in crane control valve (2).

Install new poppet assembly (15) and poppet spring (16) in crane control valve (2) so poppet assembly (15) points toward seat retainer (13).

Install new relief valve (17) on crane control valve (2).

Install new O-rings (4) and (5), new backup rings (6) and (7), new O-ring (9), and new backup ring (10) on each check valve cap (3).

Install two poppets (8), springs (ll), and check valve caps (3) into crane control valve (2).

NOTE

The remaining check valve caps are assembled the same way.

Clamp spool valve (1) in soft-jawed vise.

Using improvised compression tool, compress spring (21) and install inner spacer (23), travel limit washer (22), spring (21), and outer spacer (20) on spool valve (1) with new snapring (19).

Install spool valve (1) and spool valve cap (18) in crane control valve (2).

Using seal retainer remover and replacer, install new O-ring (26), new seal (25), and retainer (24) on crane control valve (2).

5-640

5-108. CRANE

TM 9-2320-272-24-4

5-641

TM 9-2320-272-24-4

5-108. CRANE

NOTE

Install all parts in steps 11 through 13 in their marked location and angle on control valve.

The three remaining spool valves are assembled into the control valve in the same way.

11.

Install four new O-rings (8), elbows (9), two new O-rings (12), three adapters (ll), two elbows (10), new O-ring (4), connector (5), and tube (6) on crane control valve (3).

12.

Install nipple adapter (17) on nipple (18).

13.

Install new O-ring (16) and nipple adapter (17) on crane control valve (3).

14.

Install right control bracket (7), left control bracket (15), four screws (1), new lockwashers (14), and nuts (13).

and base (2) on crane control valve (3) with

15.

Align four operating handles (19) with holes in base (2) and control spool valves (21), and install four operating handles (19) with eight pins (20) and new snaprings (22).

5-642

5-108. CRANE CONTROL VALVE REPAIR (Contd)

TM 9-2320-272-24-4

FOLLOW-ON TASK: Install crane control valve (para. 4-201).

5-643/(5-644 blank)

TM 9-2320-272-24-4

CHAPTER 6

SHIPMENT AND LIMITED STORAGE

Section I.

General Preparation of Vehicle for Shipment (page 6-1)

Section II.

Loading and Movement (page 6-2)

Section III.

Limited Storage (page 6-2)

Section I. GENERAL PREPARATION OF VEHICLE FOR SHIPMENT

6-1. SCOPE a.

This section provides instructions on preserving and protecting vehicles for shipment.

b.

Protection for vehicles and accompanying equipment must be sufficient to protect the material against deterioration and physical damage.

6-2. CLEANING

W A R N I N G


Cleaning materials or paints containing chlorinated hydrocarbon class solvents are not to be used on composite taillights and parking lights. Damage to taillight and parking light lenses may result.

Prior to application of preservatives, surfaces must be cleaned to ensure removal of corrosion, soil, grease, or vehicle acid and alkali residues.

a.

Interior of Vehicle. Remove all dirt and other foreign matter from all painted metal surfaces of

vehicle by scrubbing with cloths soaked in drycleaning solvent (appendix C, item 71). DO NOT apply solvent to electrical equipment or rubber parts of any nature. Use trichloroethylene (appendix C, item 76) to

clean electrical parts and electrical contact points. Use warm water for cleaning rubber parts. Apply preservative compounds to rubber parts as required (TM 9-247).

b.

Exterior of Vehicle. Clean exterior surfaces of vehicle to ensure removal of all dirt and foreign matter. After cleaning, immediately dry parts to remove excess cleaning solutions or residual moisture.

Allow parts to air-dry or wipe with clean, dry, lint-free cloth (appendix C, item 21).

6-3. LUBRICATION

W A R N I N G


After cleaning has been accomplished, wipe all grease fittings clean with drycleaning solvent (appendix C,

item 71) and lubricate vehicle in accordance with LO 9-2320-272-12. Remove excess grease after lubrication and before processing.

6-1

TM 9-2320-272-24-4

6-4. PRESERVATION

All critical unpainted metal surfaces must be protected during shipment. Use procedures and materials listed in steps a. and b. below. If the preservatives listed below are not available, oil or grease listed in

LO 9-2320-272-12 may be used for this purpose, but is effective for only a few days; therefore, equipment protected must be closely watched for signs of corrosion. When selecting preservatives, use only those that will not damage the surface to which they are applied.

a.

Battery Leads. Disconnect both batteries (para. 3-126). Each battery lead terminal, including the

jumper lead ends, must be wrapped with tape (appendix C, item 73).

b.

Miscellaneous Preservation. Coat all unpainted, exposed, or machined metal surfaces on the

exterior of the vehicle with corrosion-preventive compound (appendix C, item 25).

6-5. PACKAGING

Electrical Openings. Cover all electrical receptacles with tape (appendix C, item 73) or with plastic caps

which will afford the same degree of protection.

6-6. PACKING

Pack all Basic Issue Items (BII) and Additional Authorization List (AAL) items to prevent mechanical damage.

6-7. SHIPMENT OF ARMY DOCUMENTS

Prepare all Army shipping documents accompanying vehicle in accordance with DA Pam 738-750.

Section II. LOADING AND MOVEMENT

6-8. LOADING AND MOVEMENT

For transportability guidance handling and movement of vehicles, refer to TM 55-2320-272-15-1.

Section III. LIMITED STORAGE

6-9. SCOPE

Commanders are responsible for ensuring that all vehicles issued or assigned to their command are maintained in a serviceable condition and properly cared for and that personnel under their command comply with technical instructions. Lack of time, trained personnel, or proper tools may result in a unit being incapable of performing maintenance for which it is responsible. In such cases, unit commanders may, with the approval of major commanders, place a vehicle that is beyond the maintenance capability of the unit in administrative storage. For detailed maintenance information, refer to AB 750-1.

6-10. LIMITED STORAGE INSTRUCTIONS

a.

Time Limitations. Administrative storage is restricted to a period of 90 days and must not be extended unless the vehicle is reprocessed in accordance with step b.

6-2

TM 9-2320-272-24-4

6-10. LIMITED STORAGE INSTRUCTIONS (Contd) b.

Storage Procedure. Perform disassembly only as required to clean and preserve exposed surfaces.

Except as otherwise noted, and to the maximum extent consistent with safe storage, place the vehicle in administrative storage in as nearly a completely assembled condition as possible. Install and adjust equipment so that the vehicle may be placed in service and operated with minimum delay.

(1) The vehicle should be stored on level ground in the most favorable location available, preferably one which affords protection from exposure to the elements and from pilferage.

(2) Perform semiannual Preventive Maintenance Checks and Services (PMCS) (para. 2-12) on vehicle intended for administrative storage. This maintenance consists of inspecting, cleaning, servicing, preserving, lubricating, adjusting, and replacing minor repair parts as required.

(3) Remove both batteries (para. 3-125), place in covered storage, and maintain a charged condition.

storage.

(4) Provide access to the vehicle to permit inspection, servicing, and subsequent removal from

6-11. INSPECTION IN LIMITED STORAGE

a.

Conduct visual inspection of vehicles in limited storage at least once a month and immediately following hard rains, heavy snowstorms, windstorms, or other severe weather conditions. Perform disassembly as required to fully ascertain the extent of any discovered deterioration or damage. Maintain a record of these inspections for each vehicle. Attach record to vehicle so it is protected from the weather, b.

Perform necessary reprocessing for limited storage when rust or deterioration is found on any unpainted area. Immediately repair damage caused to vehicle by severe weather conditions. Repair damage to On-Equipment Materiel (OEM) as necessary. Thoroughly clean, dry, and repaint painted surfaces showing evidence of wear.

6-12. REMOVAL FROM LIMITED STORAGE

Materiel removed from administrative storage will be:

(1) Restored to normal operating conditions.

(2) Repaired as required.

(3) Returned to normal PMCS schedule using last type service completed as a starting point.

(4) Calibrate equipment as required (TM 43-180).

6-3 (6-4 blank)

TM 9-2320-272-24-4

APPENDIX A

REFERENCES

A-1. SCOPE

This appendix lists all forms, field manuals, and technical manuals for use with this manual.

A-2. PUBLICATIONS INDEX

The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this manual.

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Pam 25-30

Functional User’s Manual for The Army Maintenance Management System (TAMMS) . . . . DA Pam 738-750

A-3. FORMS

The following forms pertain to this manual. See DA Pam 25-30, Consolidated Index of Army Publications and Blank Forms, for index of blank forms. See DA Pam 738-750, The Army Maintenance Management

System (TAMMS), for instructions on the use of maintenance forms pertaining to this manual.

Unit Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A R 2 2 0 - 1

U.S. Army Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 285

Equipment Operator’s Qualification Record (Except Aircraft). . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 348

Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . .

. . . . . . . . . . . . . . DA Form 2028

Recommended Changes to Equipment Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2

Organizational Control Record for Equipment. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . DA Form 2401

Exchange Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . DA Form 2402

Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . DA Form 2404

Maintenance Request Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . DA Form 2405

Materiel Condition Status Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . DA Form 2406

Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DA Form 2407

Maintenance Request - Continuation Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407-1

Equipment Log Assembly (Records) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408

Equipment Control Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9

Equipment Maintenance Log (Consolidated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2409

Packaging and Improvement Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DD Form 6

Preventive Maintenance Schedule and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 314

Accident Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DD Form 518

Processing and Deprocessing Record for Shipment, Storage, and

Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397

U.S. Government Motor Vehicle Operator’s Identity Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OF Form 346

Operator Report on Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 91

Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SF Form 364

Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368

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A-4. FIELD MANUALS

NBC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FM 3-4

NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-5

Camouflage..

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

FM 5-20

Operation and Maintenance of Army Materiel in Extreme Cold Weather (0°F to -65°F). . . . . . . . . . FM 9-207

General Fabric Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FM 10-16

Petroleum Supply Point Equipment and Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-69

First Aid for Soldiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11

Manual for the Wheeled Vehicle Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305

Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70

Northern Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71

Metal Body Repair and Related Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 43-2

A-5. TECHNICAL MANUALS

Chemical, Biological, and Radiological (CBR) Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-220

Operator’s and Unit Maintenance Manual (Including Repair Parts and Special Tool List) for Decontaminating Apparatus, Portable, DST, 1 1/2 Quart, ABC-M11) . . . . . . . . . . TM 3-4230-204-12&P

Operator’s and Organizational Maintenance Manual:

For Alarm, Chemical Agent, Automatic: Portable, Manpack, M8. . . . . . . . . . . . . . . . . . . TM 3-6665-225-12

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 5-725

Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214

Operator’s Manual for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237

Deep-Water Fording of Ordnance Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-238

Use and Care of Hand Tools and Measuring Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-243

Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance Materiel, and Related Materials Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247

Operator, Organizational, Direct Support and General Support Maintenance Manual

Including Repair Parts and Special Tool Lists (Including Depot

Maintenance Repair Parts and Special Tools) Various Machine Gun Mounts and Combinations Used on Tactical and Armored Vehicles Mounts. . . . . . . . . . . . . . . . . TM 9-1005-245-14

Operator’s Manual for Truck, 5-Ton, 6x6, M939 and M939A1 Series (Diesel), Truck,

Cargo: 5-Ton, 6x6, Dropside, M923, M923A1, M925, M925A1. . . . . . . . . . . . . . . . . . . . . TM 9-2320-272-10

Unit, Direct, and General Support Maintenance Rear Parts, Special Tools List for

Truck, 5-Ton, 6x6, M939 and M939A1 Series (Diesel),

Truck, Cargo, 5-Ton, 6x6, Dropside, M923, M923A1, M925, and M925A1. . . . . . . . . . . TM 9-2320-272-24P

Operator’s, Unit, Direct Support, and General Support Maintenance Manual for

Care, Maintenance, Repair, and Inspection of Pneumatic Tires and Inner Tubes . . . . . TM 9-2610-200-14

Maintenance, Direct and General Support Level Generator Assembly

(Prestolite Model AMA-5102UT) (Leece-Neville Models) . . . . . . . . . . . . . . . . .

Direct Support, General Support, and Depot Maintenance Manual

(Including Repair Parts) for Starter, Engine, Electrical, Assembly

(Delco-Remy Model 1113943) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direct Support and General Support Maintenance Manual

(Including Repair Parts and Special Tools List) for Starter, Engine, Electrical

(Leece-Neville Model M001707 2MB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . TM 9-2920-225-34

. . . . . . TM 9-2920-242-35

. . . . . . TM 9-2920-243-34

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A-5. TECHNICAL MANUALS (Contd)

Operator’s Manual for Lathe, Brake Drum, Floor Mounted, 60-Inch Rated Swing;

25 Inch Maximum Drum Diameter, 115 Volt, 60 Cycle, Single Phase . . . . . . . . . . . . . . . TM 9-4910-482-10

Operator’s Manual: Grinding Machine, Valve Face, Bench Mounting,

9/32 Inch to 11/16 Inch Chuck, 0 to 45 Degree Valve Face Angle Adjustment, 115-Volt,

AC/DC, 60-Cycle, Single Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-484-10

Operator’s and Organizational Maintenance Manual Including Repair Parts and

Special Tools List for Simplified Test Equipment for Internal Combustion Engines. . . TM 9-4910-571-12&P

Operator’s, Unit, Intermediate Direct Support, and Intermediate General Support

Maintenance Manual for Lead-Acid Storage Batteries; 4HN, 24-Volt; 2HN, 12-Volt. . . . TM 9-6140-200-14

Principles of Automotive Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000

Packaging of Materiel: Preservation Vol. I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-1

Packaging of Materiel: Packing Vol. II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-2

Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139

Transportability Guidance (Trucks, 5-Ton, 6x6, M809 series)

Truck, Cargo, WWN, M813; Truck Cargo, Dropside, WWN, M813A1. . . . . . . . . . . . . TM 55-2320-260-15-1

Administrative Storage of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 740-90-1

Storage and Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 743-200-1

General Packing Instructions for Field Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 746-10

Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use

(U.S. Army Tank-Automotive Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6

Cooling Systems: Tactical Vehicles (Reprinted W/Basic Including Cl and C2) . . . . . . . . . . . . . . . TM 750-254

A-6. TECHNICAL BULLETINS

Load-Testing Vehicles Used to Handle Missiles and Rockets: Medium Wrecker: M62;

Medium Wrecker, Truck: M543 Series and M816 and Wrecker, Truck Tractor,

M246 Series and M819 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB 9-352

Tactical Wheeled Vehicles: Repair of Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-247-40

Standards for Oversea Shipment or Domestic Issue of Special Purpose Vehicles,

Combat, Tactical, Construction, and Selected Industrial and Troop Support,

US Army Tank-Automotive Materiel Readiness Command . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-281-35

Truck, 5-Ton, 6x6 M939 Series Truck, Warranty Procedures for Cummins Engine,

Model NHC 250 (NSN 2815-01-111-2262) and Allison Transmission

Model MT654CR (2520-01-117-30101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-295-15/21

Warranty Program for Truck, 5-Ton, 6x6 M939A2 Series Truck, Cargo:

5-Ton, 6x6, Dropside, M923A2, M925A2 Truck, Cargo: 5-Ton, 6x6, XLWB, M927A2 . . . . TB 9-2300-358-24

Mandatory Brake Hose Inspection and Replacement-Tactical Vehicles. . . . . . . . . . . . . . . . TB 9-2300-405-14

Security of Tactical Wheeled Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-422-20

Calibration and Repair Requirements for the Maintenance of Army Materiel. . . . . . . . . . . . . . . . . TB 43-180

Equipment Improvement Report and Maintenance Digest

(US Army Tank-Automotive Command) Tank and Automotive Equipment . . . . . . . . . . . . TB 43-0001-39-1

Safety, Inspection, and Testing of Lifting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0142

Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials Handling Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209

Non-Aeronautical Equipment, Army Oil Analysis Program (AOAP) . . . . . . . . . . . . . . . . . . . . . . . TB 43-0210

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A-6. TECHNICAL BULLETINS (Contd)

Purging, Cleaning, and Coating Interior Ferrous and Term Sheet Vehicle Fuel Tanks . . . . . . . . TB 43-0212

Corrosion Prevention and Control Including Rustproofing Procedures for

Tactical Vehicles and Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0213

Functional Grouping Codes; Combat, Tactical, and Support Vehicles and

Special Purpose Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-93-1

Maintenance Expenditure Limits for FSC Group 23, FSC Classes 2310, 2320, 2340, a n d 2 3 5 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB 750-98-23

Use of Antifreeze Solutions, Antifreeze Extender, Cleaning Compounds, and

Test Kit in Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651

Occupational and Environmental Health: Hearing Conservation . . . . . . . . . . . . . . . . . . . . . . TB MED 501

Description, Use, Bonding Techniques, and Properties of Adhesives . . . . . . . . . . . . . . . . . . . . TB ORD 1032

Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB SIG 222

A-7. OTHER PUBLICATIONS

Preventive Medicine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR 40-5

Army Acquisition Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-1

Identification and Distribution of DA Publications and Issue of Agency and

Command Administrative Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-2

Dictionary of United States Army Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-25

Authorized Abbreviations and Brevity Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-50

Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-40

Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-55

The Army Driver and Operator Standardization Program (Selection, Training, Testing, and

Licensing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR 600-55

Packing of Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR 700-15

Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100

Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) . . . . . . . CTA 50-970

Methods of Preservation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-P-116

Marking for Shipment and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-129

Magnetic Particles Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-1949

Inspection, Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-6866

Vehicles, Wheeled, Preparation for Shipment and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-V-62038

Softwood Lumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MM-L-751

Winterization Kits for Army Tank-Automotive Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 9-16

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APPENDIX B

MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

a. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance categories.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance categories.

c.

Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from section II.

d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.

B-2. MAINTENANCE FUNCTIONS

Maintenance functions will be limited to and defined as follows:

a.

Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards.

c.

Service. Operations required periodically to keep an item in proper operating condition; i.e., to clean

(includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gasses.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by setting the operating characteristics to specified parameters.

e.

Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

f.

Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.

g.

Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.

“Replace” is authorized by the MAC and is shown as the 3d position code of the SMR code.

i.

Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, modules (component or assembly), end item, or system.

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B-2. MAINTENANCE FUNCTIONS (Contd) j.

Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like-new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like-new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurement (hours/miles, etc.) considered in classifying Army equipment/components.

B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II a.

Column (1) - Group Number. Column 1 lists functional group code numbers, the purpose of which is to identity maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End item group number shall be “00.”

b. Column (2) - Component/Assembly. Column 2 contains the names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

NOTE

Those components that are unique to M939A2 series vehicles are identified in column 2 by an asterisk (*).

c.

Column (3) - Maintenance Function. Column 3 lists the functions to be performed on the item

listed in column 2. (For detailed explanation of these functions, see para. B-2.)

d. Column (4) - Maintenance Category. Column 4 specifies, by the listing of a work-time figure in the appropriate subcolumn(s), the category of maintenance authorized to perform the function listed in column 3. This figure represents the active time required to perform that maintenance function at the indicated category of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance categories, appropriate work-time figures will be shown for each category. The work-time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance categories are as follows:

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator or Crew

Unit Maintenance

Direct Support Maintenance

General Support Maintenance

e.

Column (5) - Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual tools) and special tools, TMDE, and support equipment required to perform the designated function.

f.

Column (6) - Remarks. This column shall, when applicable, contain a letter code, in alphabetic order, which shall be keyed to the remarks contained in section IV

B-2

TM 9-2320-272-24-4

B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS,

SECTION III a.

Column (1) - Reference Code. The tool and test equipment reference code correlates with a code used in the MAC, section II, column 5.

b. Column (2) - Maintenance Category. The lowest category of maintenance authorized to use the tool or test equipment.

c.

Column (3) - Nomenclature. Name or identification of the tool or test equipment.

d. Column (4) - National/NATO Stock Number. The National Stock Number (NSN) of the tool or test equipment.

e.

Column (5) - Tool Number. The manufacturer’s part number.

B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV a.

Column (1) - Reference Code. The code recorded in column 6, section II.

b. Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC, section II.

B-3

TM 9-2320-272-24-4

Number

01

0100

0101

Section II. MAINTENANCE ALLOCATION CHART

(2) (3)

(4)

Maintenance Category component/Assembly

Maintenance

Function

Unit

F H

(5) (6)

Tools and

Equipment Remarks

ENGINE

Engine Assembly

Engine Assembly*

Mount, Engine Lifting

Bracket, Engine Mounting

Head, Cylinder Assembly

Sleeve, Cylinder

Liner, Cylinder*

0102

Crankshaft

Inspect

Test

Service

Replace

Repair

Overhaul

Inspect

Test

Service

Replace

Repair

Overhaul

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

0.1

0.1

1.5

2.0

1.5

2.0

0.2

0.2

8.0

8.0

0.2

2.0

0.2

4.0

16.0

40.0

2 thru 5

2 thru 5

7 thru 9

7, 11 thru

13

14.0

40.0

2 thru 5

2 thru 5

7 thru 9

12, 13,

34 thru 37

6 thru 9

6 thru 9

5.0

0.3

2.0

6 thru 9

6 thru 9

7, 11 thru

13

0.3

2.0

7, 11, 13

23,34 thru

36

1.5

5.0

6.0

7, 11 thru

13

7, 11 thru

13

B

A

A

A

V

Damper, Vibration

0.2

0103

Flange, Crankshaft

Flywheel, Ring Gear

Housing, Flywheel Gear

Ring Gear, Flexplate*

Inspect

Replace

Inspect

Adjust

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace thru 9,

23

0.5

1.0

0.2

0.5

0.4

1.0

1.0

4.0

1.0

1.0

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6

*(M939A2 only)

B - 4

TM 9-2320-272-24-4

(1)

G r o u p

Number

Section II. MAINTENANCE ALLOCATION CHART (Contd)

(2) (3)

(4)

Maintenance Category

(5)

Component/Assembly

Maintenance

Function

C

Unit

O F

H

(6)

Tools and


ENGINE (Contd)

0103 Housing, Flywheel*

(Contd)

Inspect

Replace

0.5

4.0

6 thru 9,

23

Cover, Rear*

Inspect

Replace

0.1

0.2

1.0

6 thru 9,

23

Seal, Rear Oil* Inspect

Replace

0.1

6.0

A

0104 Piston Assembly

Piston Assembly*

Rod, Connecting

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

6 thru 9,

23

0.3

5.0

9 thru 11

2.0

9 thru 11

0.3

5.0

9 thru 11,

23

2.0

9 thru 11

0.3

2.0

7, 11 thru

13

0105 Valve Cover

Inspect

Replace

Valve Cover*

Assembly, Rocker Lever*

Inspect

Adjust

Replace

Rod, Push, Intake/Exhaust* Inspect

Replace

Shaft, Rocker Lever*

Inspect

Replace

Inspect

Replace

Tube, Oil Manifold*

Spring, Valve

Inspect

Replace

Inspect

Replace

Valves, Intake and Exhaust Inspect

Replace

Cover, Front Gear

Seal, Front Oil

Repair

Inspect

Replace

Inspect

Replace

0.1

0.1

1.0

1.0

0.5

0.5

1.5

0.1

0.5

0.3

2.0

0.1

2.0

0.3

0.5

0.2

0.2

2.0

2.0

9 thru 11

2 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

1.5

7, 11 thru

13

0.5

9 thru 13

6 thru 9

6 thru 9

A

A

A

* (M939A2 only)

B-5

TM 9-2320-272-24-4

(1)

Number


(2)

(3)

(4)


(5)


Maintenance

Function

U n i t

C O F H

(6)

Tools and

Equipment R e m a r k s

ENGINE (Contd)

0105 Housing, Front Gear*

(Contd)

Inspect

Replace

Shaft Assembly, Rocker Arm Inspect

Replace

Bearing, Camshaft Inspect

Replace

0.1

0.2

4.0

0.3

2.0

6 thru 9

A

Camshaft

Camshaft, Gear

Camshaft*

Camshaft, Gear*

Bushings, Camshaft*

Tappets*

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

6 thru 9

0.5

2.0

7, 11 thru

13

0.2

1.0

7, 11 thru

13

0.2

2.0

7, 11 thru

13

0.5

1.5

7, 11 thru

13, 20

0.2

2.0

7, 11 thru

13, 20

0.2

6.5

7, 11 thru

13, 20

0.1

4.0

7, 11 thru

13, 20

0106 Crankcase Breather

Pump, Oil*

Oil (Dipstick) Tube

Cooler, Engine Oil*

Head, Filter*

Oil Pan*

Tube, Oil Suction*

Pump, Oil

Inspect

Replace

Inspect

Replace

Inspect

Replace

Replace

Repair

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

0.2

0.5

1.0

0.3

1.0

1.5

0.1

0.5

0.1

0.5

4.0

4.2

0.1

0.5

0.5

2.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

6 thru 9

4.0

7, 10 thru

13

A

A

* (M939A2 only)

B-6

TM 9-2320-272-24-4

(1)

Number

Section II. MAINTENANCE ALLOCATION CHART (Contd)

12)

(3)

(4)


(5)


Maintenance

Function

Unit

C O F

H

(6)

Tools and

Equipment R e m a r k s

ENGINE (Contd)

0106 Oil Pan

(Contd)

Oil Filter

Oil Cooler, Engine

0108 Manifold, Intake

Manifold, Exhaust

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

0.2

0.1

0.5

1.0

0.5

0.7

1.0

0.5

3.0

0.5

2.0

6 thru 9

2 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

03

FUEL SYSTEM

0301 Injectors, Fuel

0.5

Inspect

Test

Adjust

Replace

Repair

Calibrate

Overhaul

1.5

0.5

7, 11 thru

13

0.5

7, 11 thru

13

6 thru 9

1.0

7, 11 thru

13

2.0

7, 11 thru

13

1.0

7, 11 thru

13

Injectors, Fuel*

0.5

Inspect

Test

Replace

Repair

2.0

1.5

7, 11 thru

13, 22, 38

6 thru 9

1.0

7, 11 thru

13, 22, 25

0302 Pump, Fuel Supply Inspect

Replace

Adjust

Repair

Calibrate

Overhaul

0.5

2.0

6 thru 9

2.0

7, 11 thru

13

4.0

7, 11 thru

13

2.0

7, 11 thru

13

4.0

7, 11 thru

13

Lines and Fittings, Injection Inspect

Pump* Replace

Tubes, Fuel Injector* Inspect

Replace

0.1

0.5

0.1

1.0

2 thru 5

2 thru 5

A

D

* (M939A2 only)

B-7

TM 9-2320-272-24-4

(1)

Number


(2) (3)


Maintenance

Function

(4)


Unit

C O F H

(5)

(6)

Tools and


FUEL SYSTEM (Contd)

0302 Fuel Injection Pump*

(Contd)

0.5

Inspect

Test

Adjust

Calibrate

Replace

Repair

2.0

5.0

7, 11 thru

13, 33

1.0

7, 11 thru

13, 33

6.0

7, 11 thru

13, 33

2 thru 5,

23, 39

4.0

7, 11 thru

13, 27 thru

32

U

0304

Fuel Transfer Pump*

Cleaner, Air

Element

0305

Lines and Connections, Vent Inspect

Replace

Indicator, Air Cleaner

Hoses and Clamps

Hoses and Clamps,

Turbocharger*

Inspect

Test

Replace

Inspect

Replace

Inspect

Replace

Tube, Oil Drain*

Inspect

Replace

Inspect

Replace

Service

Replace

0306

Turbocharger Assembly*

Tank, Fuel

Bracket, Fuel Tank

Mounting

Lines and Fittings, Fuel

Valve, Fuel Selector

Lines and Fittings, Fuel

Pump to Engine

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

0.2

0.5

0.2

0.1

0.2

0.2

0.1

0.1

0.1

0.1

0.1

0.2

0.3

0.5

0.5

0.5

1.0

0.2

0.5

0.5

1.0

1.0

0.6

1.0

1.0

1.0

1.5

1.0

1.0

1.5

1.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

A

A

A

C

A

D

A

A

A

A

A

D

A

A

D

*(M939A2 only)

B - 8

TM 9-2320-272-24-4

Number

0 3 0 8

0309

0311

0312


(2)

(3)

(4)


(5)


Maintenance

Function

F

(6)

Tools and

Equipment

Remarks

FUEL SYSTEM (Cod)

Governor, Fuel Pump (AFC)

Spring Pack, Fuel Pump

Governor, Fuel Pump (VS)

Lower Spring Pack,

Fuel Pump

Upper Spring Pack,

Fuel Pump

Governor, Fuel Injection

Pump*

Inspect

Test

Replace

Inspect

Test

Replace

Inspect

Test

Replace

Inspect

Test

Replace

Inspect

Test

Replace

Inspect

Replace

Repair

0.5

1.2

2.5

7, 11 thru

13

7, 11 thru

13

0.5

1.0

2.0

7, 11 thru

13

7, 11 thru

13

0.5

1.0

2.0

2.0

7, 11 thru

13

7, 11 thru

13

0.5

1.0

2 . 0

7, 11 thru

13

7, 11 thru

13

0.5

1.0

7, 11 thru

13

7, 11 thru

13

0.2

0.1

0 . 5

7, 11 thru

13

7, 11 thru

13

0.1

A

Fuel Filter

Filter, Fuel Water Separator

Aids, Engine Starting

Lines and Fittings

Pump, Hand Primer

Harness and Switch

Control, Accelerator and

Throttle Linkage

Service

Replace

Service

Replace

Inspect

Replace

Inspect

Replace

Inspect

Test

Replace

Inspect

Adjust

Replace

0.1

0.5

0.5

0.5

1.0

0.1

1.0

0.1

0.2

1.0

0.2

0.5

1.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 15

2 thru 5

2 thru

5

A

D

* (M939A2 only)

B-9

TM 9-2320-272-24-4

Number

04

0401

05

0501

0502

0503

0504

0505



(3)

Maintenance

Function c

(4)


U n i t

O

(5) (6)

Tools and


EXHAUST SYSTEM

Pipe, Exhaust and Tail

Muffler

Shield, Vertical Exhaust

Inspect

Replace

Inspect

Replace

Inspect

Replace

COOLING SYSTEM

Radiator

Tank, Surge

Inspect

Service

Replace

Repair

Inspect

Service

Replace

Radiator Hoses Inspect

Replace

Canister, Thermostat*

Coolant Lines, Air

Compressor

Inspect

Replace

Shroud, Radiator Fan

Inspect

Replace

Water Manifold and Headers Inspect

Replace

Inspect

Replace

Actuator, Fan Clutch

Thermostats and Housing

Pump, Water*

Pump, Water

Belt, Water Pump

Fan Assembly

Clutch, Fan Drive

Pulley, Belt Tensioner*

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Adjust

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

0.2

0.2

0.2

0.3

2.0

0.2

0.1

0 2

1.0

0.2

0.5

0.1

0.5

0.1

1.0

0.5

0.1

0.1

0.1

0.1

1.5

0.5

1.0

0.1

0.3

0.5

0.1

1.0

0.2

0.5

2.0

0.2

2.0

0.1

1.0

0.5

0.2

0.4

0.2

1.0

0.1

0.5

3.0

1.0

1.0

1.5

1.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 9

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

A

E

A

A

A

A

A

A

A

*(M939A2 only)

B-10

TM 9-2320-272-24-4

(1)

Group

Number


(2)


(3)

Maintenance

Function

(4)


Unit

C

O F H

(5) (6)

Tools and


0505

(Contd)

0507

COOLING SYSTEM (Contd)

Drivebelt, Fan

Fan Actuator*

Aftercooler, Engine*

Inspect

Replace

Inspect

Replace

Inspect

Replace

06 ELECTRICAL SYSTEM

0601 Alternator

Belt, Alternator

Inspect

Adjust

Replace

0603 Starter

0606 Valve, Fuel Shutoff Electrical

Inspect

Replace

0607 Switches and Circuit

Breakers

Inspect

Test

Replace

Instruments and Gauges

Inspect

Test

Replace

Repair

Inspect

Test

Replace

0608 Control, Directional Turn

Indicator

Inspect

Test

Replace

Repair

Flasher

Inspect

Adjust

Test

Replace

Repair

Box, Protective Control

Inspect

Replace

Test

Replace

0609 Lights

0610 Unit, Sending

Inspect

Adjust

Replace

Inspect

Replace

Switch, Stoplight Inspect

Replace

Buzzer, Warning Control

Inspect

Replace

0.1

0.1

0.1

0.2

0.1

0.1

0.1

0.1

0.1

0.3

0.8

0.3

1.0

0.2

0.3

0.1

0.5

1.5

1.0

1.0

0.7

1.0

0.2

1.0

0.2

0.5

0.2

0.5

0.3

0.7

0.2

0.5

0.1

0.3

0.1

0.5

0.1

0.6

0.5

1.0

0.3

1.0

0.7

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

A

A

A

G

A

A

A

A

A

A

* (M939A2 only)

B-11

TM 9-2320-272-24-4

(1)

Number

S e c t i o n I I . M A I N T E N A N C E A L L O C A T I O N C H A R T ( C o n t d )

(2)


(3)

Maintenance

Function


Unit

C O

(4)

F H

(5)

Tools and

(6)


0610

(Contd)

ELECTRICAL SYSTEM (Contd)

Transponder, Fuel Pump

Inspect

Replace

0611 Horn

Switch, Horn

Inspect

Replace

Inspect

Replace

0612

0613

Battery

Cables, Battery

Box, Battery

Harness, Chassis Wiring

Inspect

Test

Service

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Test

Replace

Repair

07 TRANSMISSION

0705 Modulator Control Cable

Adjust

Replace

0708 Torque Converter/Flywheel Replace

Assembly

Repair

0.1

0.1

0.5

0.1

0.1

0.1

0.2

0.3

0.5

0.1

0.5

0.5

0.5

0.8

0.5

1.8

1.5

0.5

1.0

0.5

0.7

1.0

4.5

8.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

6 thru 9

5.0

7, 11 thru

14

A

A

A

H

A

A

A

0710 Transmission Assembly

0.2

A Inspect

Test

Service

Adjust

Replace

Repair

0.5

1.0

1.0

2.5

6 thru 9

2 thru 5

6 thru 9

6.0

6 thru 9

8.0

10.0

6 thru 9,

20.0

I

11 thru 14

0721

Linkage, Shift Cable

Transmission Oil Cooler

Lines and Fittings

Transmission Oil Cooler*

Overhaul

Inspect

Adjust

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

0.1

0.2

0.2

0.1

2.0

1.0

1.5

1.0

1.0

6 thru 9

6 thru 9

6 thru 9

6 thru 9

2 thru 5

A

A

D

* (M939A2 only)

B-12

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

F u n c t i o n

(4)


Unit

General

Support

C O F H

(5)

(6)

Tools and


TRANSMISSION (Contd)

0721

Lines and Fittings*

(Contd)

08

TRANSFER CASE ASSEMBLY

0801 Transfer Case Assembly

Inspect

Replace

0.1

1.0

0.3

0.5

5.0

3.0

2 thru 5

2 thru 5

6 thru 9

4.0

6 thru 14

9.5

A

A

J

Coupling, Yoke Input and o u t p u t

Flange, Output

Cushion, Mounting

Gear, Speedometer

Seals, Input and Output

Shaft

Bearings, Gears, and

Shafts

Inspect

Service

Replace

Repair

Overhaul

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

0.3

0.3

0.2

0.5

1.0

1.0

1.0

0.2

0.5

2.0

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

0.5

2.0

7, 11 thru

14

3.0

7, 11 thru

14

0803 Controls and Linkage

Cylinder, Air Shift

Inspect

Adjust

Replace

Repair

Inspect

Replace

Repair

0.5

0.5

0.3

1.5

1.0

2.0

0.7

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

09 PROPELLER SHAFTS

0900 Shaft Assembly, Propeller

Joint, Universal

Dampener, Vibration

Bearing, Center

Inspect

Service

Replace

Repair

Inspect

Service

Replace

Service

Replace

Inspect

Replace

0.3

0.5

1.5

1.0

0.2

0.3

1.5

0.1

0.7

0.2

1.5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

A

A

* (M939A2 only)

B-13

TM 9-2320-272-24-4

(1)

Number


(2)

Component/ Assembly

(3)

Maintenance

Function

(4)


Unit

General

Support

C O F H

(5) (6)

Tools and

Equipment Remark

10 FRONT AXLE

1000 Front Axle Assembly

1002 Carrier Assembly,

Differential

Inspect

Service

Replace

Overhaul

Inspect

Service

Replace

Repair

0.5

1.0

0.5

0.5

5.0

7.0

10.0

2 thru 5

6 thru 9

2 thru 5

6 thru 9

4.0 7, 11 thru

13

A

K

A

Seal, Pinion

Flange, Companion

1004 Arms, Steering

Boot, Dust (CV)

Knuckle, Steering

Axle Shaft and

Universal Joint

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Inspect

Service

Replace

Inspect

Service

Replace

0.2

2.0

0.3

0.2

0.3

0.7

0.1

0.2

0.2

0.3

1.5

2.0

1.6

2.5

2.5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

A

11 REAR AXLE

1100 Rear Axle Inspect

Service

Replace

Repair

0.1

0.5

1.0

4.0

2

2 thru 5

4.0 7, 11 thru

13

14.0

I

A

Rear Axle Assembly

1102 Carrier Assembly,

Differential

Overhaul

Inspect

Service

Replace

Repair

Overhaul

Inspect

Service

Replace

Repair

0.3

0.5

0.5

0.5

4.0

4.0

7.0

14.0

2 thru 5

6 thru 9

6 thru 9

2 thru 5

6 thru 9

4.0 6, 11 thru

13

K

Seal, Pinion

Flange, Companion

Inspect

Replace

Inspect

Replace

Repair

0 . 2

1.0

0.2

1.0

1.6

6 thru 9

6 thru 9

6 thru 9

B-14

TM 9-2320-272-24-4


(2) (3)

(4)


(5)


Maintenance

Function

Tools and

Equipment

(6)

Remarks

Number

12

1201

BRAKES

Drum, Handbrake

1202

1206

1208

Shoes, Handbrake

Linkage, Handbrake

Brakeshoes, Parking

Brakeshoes, Service

Air Manifold*

Valve, Treadle

Chamber, Service Brake

Chamber, Spring Brake

Valve, Safety Air Pressure

Valve, Front Airbrake

Chamber (Limiting Valve)

Reservoir, Air Primary/

Secondary

Reservoir, Air Wet Tank

Pressure and Spring Brake

Valve, Hand Control

Valves, Brake Air Control

Miscellaneous

* (M939A2 only)

Repair

Inspect

Adjust

Replace

Repair

Inspect

Replace

Inspect

Test

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Test

Replace

Inspect

Replace

Inspect

Replace

Inspect

Adjust

Replace

Repair

Inspect

Adjust

Replace

Inspect

Adjust

Replace

0.1

0.1

0.1

0.3

0.5

1.0

0.5

1.0

3.0

0.3

1.5

0.3

0.5

2.0

0.5

1.0

1.5

0.1

0.5

0.5

1.0

0.7

1.0

0.1

1.0

0.2

1.5

0.5

1.0

0.5

1.0

0.1

0.5

0.1

0.5

1.0

0.5

1.0

1.5

1.0

1.0

0.3

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

19

2 thru 5,

22

6 thru 9

2 thru 5,

18

2 thru 5,

21

6 thru 8

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

6 thru 9

2 thru 5

6 thru 9

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

A

A

A

B-15

TM 9-2320-272-24-4

Section II. MAINTENANCE ALLOCATION CHART

(Contd)

Maintenance

Function

1208

(Contd)

1209

1211

BRAKES (Contd)

Valve, Brake Lock Control

Lines and Fittings,

Airbrake System

Compressor, Air

Governor, Air

Evaporator, Alcohol

Mounting and Lines,

Air Compressor*

Compressor, Air*

Trailer Airbrake Connections and Controls

Hose, Trailer Airbrake

Test

Replace

Inspect

Replace

Inspect

Test

Replace

Repair

Inspect

Test

Adjust

Replace

Inspect

Service

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

13 WHEELS AND HUBS

1311

Hub. Wheel*

Bearings, Wheel Hub

Inspect

Replace

Repair

Inspect

Service

Adjust

Replace

Wheel (M939A1/A2) Inspect

Replace

Drum, Brake

Seals, Inner and Outer Hub*

Valve Assembly, Wheel*

W/Filter

Inspect

Replace

Repair

Inspect

Replace

Inspect

Service

Replace

Repair

*(M939A2 only)

B-16

Unit

C O F

0.5

0.5

0.1 0.5

1.0

0.1

0.5

1.5

2.5

0.1

0.5

0.3

0.5

0.1

0.2

0.5

0.1 0.1

1.0

0.1

3.0

0.1

0.1

0.3

0.5

3.0

0.1

1.5

2.0

0.5

1.0

0.5

2.5

0.1

1.0

0.2

1.5

0.5

2.5

0.1

0.5

1.0

1.5

2.0

H

Equipment

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2

2 thru 5

2 thru 5,

15

2 thru 5,

19, 20

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

2 thru 5

2 thru 5

A

A

A

A

G

A

A

A

A, Q

A

TM 9-2320-272-24-4

(1)

Number


(2) (3)


Maintenance

Function

(4)


Unit

C O F

GENERAL

Support

H

(5) (6)

Tools and


WHEELS AND HUBS (Contd)

1311 Wheel (M939)

(Contd)

Hub, Wheel

0.1

2 thru 5

A

1313 Tires

Tubes

Inspect

Replace

Inspect

Replace

Inspect

Service

Replace

Repair

Rebuild

Replace

Repair

0.2

0.2

1.0

0.2

1.5

0.2

1.0

1.0

0.5

1.0

2 thru 5

2 thru 5

20, 21

2 thru 5

2.0

2 thru 5

2 thru 5

L

L

L

A

A,L

L

14 STEERING

1401 Link, Front Drag

Tie Rod Assembly

Arm, Pitman Steering

Column, Steering (Lower)

Column, Steering (Upper)

Wheel, Steering

1407 Gear, Steering Assembly

1410 Pump, Hydraulic and

Reservoir

Power Steering Pump

Assembly

1411 Lines and Fittings,

Power Steering

Inspect

Service

Replace

Inspect

Service

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

Replace

Repair

Inspect

Replace

Inspect

Service

Adjust

Replace

Repair

Inspect

Service

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

0.1

0.1

0.1

0.2

1.0

0.2

0.5

0.2

0.2

1.0

0.2

0.2

1.5

1.5

0.1

1.0

0.2

1.5

1.0

1.0

0.2

2.5

2.0

2.5

2.0

0.5

3.0

2.5

1.0

1.5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

1 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

2 thru 5

1 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

2 thru 5

6 thru 9

2 thru 5

A

A

A

D

* (M939A2 only)

B-17

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

(4)


Unit

General

Support

C O F H

(5) (6)

Tools and

Equipment

Remarks

STEERING (Contd)

1412 Cylinder, Steering Assist

Inspect

Adjust

Replace

Repair

0.2

0.5

1.5

2.0

2 thru 5

2 thru 5

6 thru 9

15

FRAME AND TOWING

ATTACHMENTS

1501 Frame 0.5

Bumper, Front

Brackets, Frame

1503 Pintle

1504 Carrier, Spare Wheel

1506 Wheel, 5th

Inspect

Repair

Inspect

Replace

Inspect

Replace

Inspect

Service

Replace

Inspect

Replace

Inspect

Service

Replace

Repair

0.1

0.1

0.1

0.2

0.5

0.2

2.0

1.0

0.1

0.5

1.0

2.5

1.0

2.0

2.5

6 thru 14

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

M

A

A

A

A

A

16

SPRlNGS AND SHOCK

ABSORBERS

1601 Front Spring 0.2

A

Shackles

Springs, Rear and Seat

1604 Absorber, Front Shock

1605 Rod, Rear Torque

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

0.2

0.1

0.1

3.0

2.0

1.0

0.4

4.0

2.0

0.5

0.1

1.5

2.0

1 thru 5

2 thru 5

1 thru 5

2 thru 5

1 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

A

A

A

18

BODY, HOOD, AND CAB

1801 Doors 0.1

A

Inspect

Service

Adjust

Replace

Repair

0.1

0.5

1.0

1.0

2 thru 5

2 thru 5

2 thru 5

6 thru 10,

26

Cab Inspect

Replace

0.1

6.0

6 thru 9

A

P

B-18

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

(4)


Unit

General

Support

C 0 F

H

(5) (6)

Tools and


BODY, HOOD, AND CAB (Contd)

1801

Hood

(Contd)

1802

1806

Cab Engine Cover

Fenders

Boards, Running

Cab Insulation

Inspect

Adjust

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

1810

1812

Seats

Body, Cargo

Troop Seat and Racks

Tailgate

Doors

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Replace

Repair

Roof, Ceiling, Sides, Floors Replace and Underframe

Repair

0.1

0.1

0.1

0.5

0.1

0.1

0.2

0.2

0.2

0.5

2.0

2.0

1.0

1.0

1.0

1.0

2.5

2.0

1.0

0.5

2.0

1.0

1.0

3.0

10.0

2.0

5.0

2 thru 5

6 thru 9

6 thru 10

6 thru 9

6 thru 9

6 thru 10

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

6 thru 10

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

6 thru 10,

26

8.0

7, 11 thru

13

16.0

7, 10 thru

13

A

N

A

A

N

A

A

A

T

A

C, N

A

C, N

N

N

Mount, Front Cab

0.1

Mount, Rear Cab

Counterbalance

Electrical Wiring

Heater

Air Conditioner

Inspect

Replace

Inspect

Replace

Service

Replace

Replace

Repair

Replace

Repair

Inspect

Replace

0.1

0.2

2.0

2.0

1.0

8.0

4.0

4.0

4.0

1.0

4.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

6 thru 9

6 thru 9

6 thru 9

S

B-19

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

(4)


Unit

C 0

F H

(5) (6)

Tools and


BODY, HOOD, AND CAB (Contd)

1812

Boarding Ladders and

(Contd) Hardware

20 HOIST, WINCH, AND

POWER TAKEOFF (PTO)

Inspect

Replace

2001 Winch, Front and Rear

Band, Automatic

Cable, Winch

Drum, Brake (Front Only)

Adjust

Replace

Shaft, Hydraulic Pump

Drive Assembly

Inspect

Replace

Repair

Lines and Fittings, Hydraulic

Inspect

Replace

Boom, Assembly

Inspect

Test

Service

Replace

Repair

Hoist Cylinders and Power

Replace

Controls Hoist Cylinder

Repair

Inspect

Service

Adjust

Replace

Repair

Overhaul

Adjust

Replace

Inspect

Service

Replace

Repair

Valve, Control

Replace

Repair

0.1

0.3

0.1

0.5

0.5

0.5

0.5

3.0

0.5

1.0

0.5

1.0

0.3

1.0

2.0

0.2

0.2

0.3

4.0

2.0

2.0

0.5

0.5

15.0

8.0

8.0

2.0

11.0

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

6 thru 9

6 thru 9

6 thru 9

6.0

7, 11 thru

13

6 thru 9

4.0

7, 11 thru

13

A

A, R

R

O

A

R

R

R

D

Cylinder, Boom Elevating

Inspect

Replace

Repair

0.2

2.0

6 thru 9

3.0

7, 11 thru

13

A

Motor, Winch, Front

Cylinder, Extension

Motor and Gearbox,

Hydraulic Swing

Inspect

Repair

Replace

Repair

Replace

Repair

0.2

2.0

3.5

2.0

2 thru 5

6 thru 9

4.0

7, 11 thru

13

6 thru 9

5.0

7, 11 thru

13

B-20

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

(4)


Unit

General

Support

C O F H

(5) (6)

Tools and


HOIST, WINCH, AND

PTO (Contd)

2001

Winch Hoist Assembly

(Contd)

Cable, Winch Hoist

Valve, Control Assembly

Motor, Hydraulic

Reservoir, Hydraulic Oil

PTO and Winch Control

Cables*

Hydraulic Tubing, Winch

Pump*

Propeller Shaft, Front

Winch Dump Controls*

2004 PTO, Transfer

Case

PTO, Transmission

PTO, Shift Linkage

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Adjust

Replace

Inspect

Service

Adjust

Replace

Repair

Inspect

Service

Replace

Repair

Replace

Repair

Inspect

Replace

Inspect

Service

Replace

0.5

0.5

0.1

0.1

0.1

0.1

0.1

0.1

0.2

0.5

0.5

2.0

0.5

0.2

0.2

0.8

1.4

0.2

0.3

4.5

4.0

2.5

4.0

2.0

2.0

1.0

0.5

5.0

2.5

1.0

3.0

1.0

2 thru 5

2 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 9

6 thru 8

6 thru 8

2 thru 5

6 thru 8

2 thru 5

6 thru 8

6 thru 9

6 thru 9

2 thru 5

6 thru 9

A, R

A, R

A, R

A

A

A

A

A

22

BODY CHASSIS AND

ACCESSORY ITEMS

2201

Bows

0.1

A

Cover, Cab Top

Curtains, Body Cover

2202

Motor, Windshield Wiper

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

0.1

0.1

0.1

1.0

0.5

1.0

0.7

1.5

1.0

2 thru 5

2 thru 5

6 thru 9

2 thru 5

6 thru 9

2 thru 5

A

T

A

T

A

* (M939A2 only)

B-21

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

C

(4)


Unit

General

Support

O F H

(5) (6)

Tools and


BODY CHASSIS AND

ACCESSORY ITEMS (Contd)

2202 Arm and Blade, Windshield

Inspect

(Contd) Wiper Adjust

Replace

Washer Bottle and Controls Service

Replace

Mirror, Rearview

Spotlight

Inspect

Replace

Replace

Repair

2207

Windshield

Heater Valves

Heater, Personnel

Inspect

Replace

Inspect

Replace

Inspect

Replace

33

SPECIAL PURPOSE KITS

3303 Winterization Kits

Kit, Engine Coolant Heater Inspect

Install

Kit, Radiator Cover

Inspect

Install

Kit, Hardtop Cab

Inspect

Install

Kit, Fuel Burning Personnel

Inspect

Heater Install

Kit, Pioneer Tool Bracket

Kit, Swingfire Heater

Inspect

Inspect

Install

3305 Kit, Deepwater Fording Inspect

Install

3307 Special Purpose Kits

Kit, Troop Seat and Rack

Inspect

Install

Kit, Air Dryer Inspect

Install

Kit, A-Frame Inspect

Install

Install Kit, Fire Extinguisher

Mounting

Kit, Chemical Agent Alarm Install

Mounting

0.1

0.1

0.1

0.1

0.1

0.2

0.2

0.1

0.1

0.2

0.2

0.2

0.1

0.2

0.2

0.1

0.2

1.0

0.5

0.5

0.5

0.5

1.0

3.0

3.5

1.0

1.0

1.0

4.0

10.0

1.2

6.0

3.6

3.0

1.0

8.0

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

6 thru 9

6 thru 9

2 thru 5

6 thru 9

2 thru 5

6 thru 9

6 thru 9

6 thru 9

6 thru 9

2 thru 5

2 thru 5

2 thru 5

A

A

A

A

A

A

P

A

P

A

P

A

P

A

P

P

A

P

A

P

A

P

A

P

A

P

P

B-22

TM 9-2320-272-24-4

(1)

Group

Number


(2)

(3)

(4)


(5)


Maintenance

Function

Unit

C O

SPECIAL PURPOSE KITS (Contd)

3307 Kit, Machine Gun Mounting

(Contd)

Kit, Decontamination (M13)

Apparatus Mounting

Kit, Mud Guard

Kit, Rifle Mounting

Install

Install

Kit, Hand Airbrake

Kit, 100-Amp Alternator

Kit, Convoy Warning Light

Kit, European Mini-Lighting

Kit, Automatic Throttle

Kit, Atmospheric Fuel Tank

Vent System

Kit, Vehicle Tiedown

Kit, Hydraulic Hose

Chafe Guard

43

CTIS SYSTEM

4316 Lines and Fittings, Air*

4317

Dryer, Air W/Filter*

Control Unit (ECU),*

Electronic

Valve, Relief Safety*

Controller, Pneumatic*

Wiring Harness, Electrical*

Switch, Pressure*

Warning Light, Amber*

Seals, Air (Front and Rear)*

Install

Install

Inspect

Replace

Inspect

Service

Replace

Repair

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Test

Replace

Install

Inspect

Install

Inspect

Install

Install

Ins tall

Install

Install

Install

0.1

0.1

3.5

3.0

0.5

0.1

0.5

0.1 0.2

0.5

0.5

1.5

0.1

0.5

0.1

0.5

0.1 0.1

1.0

1.5

0.1

1.5

1.5

0.1

0.1

0.1

0.1

0.5

1.0

4.0

2.0

4.0

1.4

2.5

5.0

2.0

2.0

2.0

2 thru 15

2 thru 5

2 thru 5

6 thru 9

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

15 thru 17

* (M939A2 only)

(6)

A

D

D

A

A

A

A

P

P

P

P

A

P

P

P

A

P

P

P

P

P

B-23

TM 9-2320-272-24-4

(1)

Number


(2)


(3)

Maintenance

Function

(4)


U n i t

General

Support

C O F H

(5) (6)

Tools and


CTIS SYSTEM (Contd)

4317 Filter, Compressed Air*

(Contd)

Inspect

Replace

Repair

0.8

1.0

1.0

2 thru 5

2 thru 5

A

47 GAUGES (NON-ELECTRICAL)

4701 Drive, Tachometer* 0.1

A

Speedometer

Tachometer

4702 Gauge, Air Pressure

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

0.1

0.1

0.1

0.6

1.0

1.0

0.5

2 thru 5

2 thru 5

2 thru 5

2 thru 5

A

A

A

*(M939A2 only)

B-24

TM 9-2320-272-24-4

21

22

23

24

25

17

18

19

20

14

15

16

26

27

28

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

REFERENCE MAINTENANCE

CODE CATEGORY

(3)

NOMENCLATURE

(4)

NATIONAL/NATO

STOCK NUMBER

(5)

TOOL

NUMBER

1

2

3

4

5

6

7

8

9

10

11

12

13

O

O

O

O

F

H

F

F

O

F

F

O

O

O

O

F

H

H

H

O

O

O

F

F

H

H

F

F

Organizational Maintenance

Tool Kit

5180-00-762-1737

No. 1 Common Organizational 4910-00-754-0654

Maintenance Tool Kit

No. 1 Supplemental Organiza-

4910-00-754-0643 tional Maintenance Tool Kit

No. 2 Common Organizational

4910-00-754-0650

Maintenance Tool Kit

General Mechanic’s Tool Kit 5180-00-177-7033

Tool Kit, Direct Support 5180-00-762-1740

Automotive Maintenance and

Repair Tool Kit

4910-00-754-0705

Automotive Maintenance Shop

4910-00-348-7696

Equipment, Wheeled Vehicles,

Set A

Tool Kit, General Mechanic’s

Shop Equipment, Field

Maintenance Welding

General Support Tool Kit

5180-00-699-5273

3470-00-357-7268

5180-00-762-1741

No. 1 Supplemental Automotive 4910-00-754-0706

Maintenance and Repair Tool Set

No. 2 Supplemental Automotive

4910-00-754-0707

Maintenance and Repair Tool Set

Tool Kit, General Support

Bearing Punch

5180-01-147-5824

5120-01-285-5192

Air Seal Installer

5120-01-285-7620

Air Gauge Assembly

Adjusting Tool, Brakeshoe

Tool, Wheel Assembly

Bolt, Inserter Tool

Pliers, Brake Repair

Tube Reducer

Engine Barring Tool

Wrench Box

5220-01-298-5730

5120-01-154-3029

4910-01-218-4490

4910-01-220-1512

5120-01-152-2318

4730-01-284-9086

5120-01-285-5193

Nozzle Cleaning Kit

5120-01-178-5351

2915-01-285-2527

5180-00-357-7737

Tool Kit, Glass Cutting

Tube, Separation

Puller, Side Plug

4910-01-336-8204

5120-01-343-2585

5704499

SC4910-95-CL-A74

SC4910-95-CL-A73

SC4910-95-CL-A72

SC5180-90-CL-N26

5704500

SC4910-95-CL-A31

SC4910-95-CL-A02

SC5180-90-CL-N05

SC3470-95-CL-A08

5704501

SC4910-95-CL-A62

SC4910-95-CL-A63

5704171

20511262

20511263

20511320

J34061

J35193

J35198

J33111

23622

3377371

CXM 1519

3376947

SC4940-95-CL-A18

KDEP-1052

KDEP-1056

B-25

TM 9-2320-272-24-4

REFERENCE

CODE

M

N

O

P

Q

R

G

H

I

E

F

C

D

A

B

J

K

L

S

T

U

V

Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS (Contd)

(1) (2)

REFERENCE MAINTENANCE

CODE CATEGORY

(3)

NOMENCLATURE

(4)

NATIONAL/NATO

STOCK NUMBER

(5)

TOOL

NUMBER

32

33

34

29

30

31

35

36

37

38

39

H

H

H

H

H

H

H

H

H

H

H

Tappet Holder

Spring Compressor

Plunger Lift Device

Rack Extension

Fuel Pump Test Stand

Cylinder Liner Clamps

Mechanical Puller

Cylinder Liner Puller

Torque Angle Gauge

Tester, Injector Nozzle

Puller Kit

5120-01-345-2586

5120-01-341-6000

4910-01-338-6241

5340-01-341-6572

4910-01-194-7667

5120-01-262-7309

5120-01-291-5769

5120-01-143-2032

5120-01-386-5992

4910-00-255-8641

5180-00-999-4053

KDEP-1068

KDEP-1505

1-688-130-135

9-681-233-100

DFP 156

3822503

3822786

3376015

3823878

7551255

J24420C

Section IV. REMARKS

REMARKS

Perform PMCS as shown in TM 9-2320-272-10.

Engine overhaul will be in accordance with DMWR 9-2815-500.

Welding will be in accordance with TM 9-237.

Repair of lines and fittings will be in accordance with TM 9-243.

Test and repair of radiator will be in accordance with TM 750-254.

Repair of alternator will be in accordance with TM 9-2920-225-34.

Repair of starter will be in accordance with TM 9-2920-243-34.

Repair of batteries will be in accordance with TM 9-6140-200-14.

Transmission overhaul will be in accordance with DMWR 9-2520-522.

Transfer overhaul will be in accordance with DMWR 9-2520-530.

Overhaul of front and rear axle will be in accordance with DMWR 9-2520-508.

Tires/Tubes: Repair and Inspection TM 9-2610-200-14

Storage TM 743-200-1

Repair of frames will be in accordance with TB 2300-247-40.

Metal body repair will be in accordance with FM 43-2.

Overhaul of front and rear winches will be in accordance with DMWR 9-3830-501.

Refer to kit installation instructions for kit installation.

Inspection of brake lines will be in accordance with TB 9-2300-405-14.

Service/inspection of winch/hoist wire rope/cables will be in accordance with

TB 43-0142 and TB 9-0352.

Repair of heaters will be in accordance with TM 9-2540-205-24&P.

Repair of canvas will be in accordance with FM 10-16.

Operation of fuel pump test stand, P/N DFP 156, will be in accordance with

TM 9-4910-778-14&P.

Engine overhaul will be in accordance with DMWR 9-2815-358.

B-26

TM 9-2320-272-24-4

APPENDIX C

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

Section I. Introduction (page C-l).

Section II. Expendable/Durable Supplies and Materials List (page C-2).


This appendix lists expendable/durable supplies and materials you will need to maintain M939 series vehicles. This listing is for informational purpose only and is not authority to requisition listed items.

C-2. EXPLANATION OF COLUMNS

Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the INITIAL SETUP of applicable tasks under the heading of MATERIALS/PARTS.

b. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.

C - Operator/Crew

O - Organizational Maintenance

F - Direct Support Maintenance

C .

Column (3) - National Stock Number. This is the National Stock Number assigned to the item; use it to request or requisition the item.

d. Column (4) - Description, CAGEC, and Part Number. Indicates the federal item name and, if required, a description to identify the item. The last line for each item indicates the Commercial and

Government Entity Code (CAGEC) (in parentheses) followed by a part number. These codes are identified as:

CAGEC

0 5 9 7 2

MANUFACTURER

Loctite Corporation

1 9 2 0 0

1 9 2 0 7

58536

62377

71984

72932

75037

77220

78500

79819

80064

80244

81348

U.S. Army Research and Development Command

U.S. Army Tank-automotive and Armaments Command,

AMSTA-IM-MM

Federal Commercial Item Promulgated by General

Services Administration

Permatex Industrial

Dow Corning Corp.

Gulf Oil Corp.

Minnesota Mining and Manufacturing Company

Dana Corp.

Rockwell Heavy Vehicle Systems Inc.

BT Office Products Intl. Inc.

Naval Ship Systems Command

General Services Administration

Federal Specifications

C-l

TM 9-2320-272-24-4

C-2. EXPLANATION OF COLUMNS (Contd)

81349

81755

Military Specification Promulgated by Military

Lockheed Martin Company

96599

96906

96980

97403

Fischbein-Dave Company

Military Standards

American Grease Stick Company

U.S. Army Communications - Electronic Command Center

98308 Castrol Industrial North America

e.

Column (5) - Unit of Issue. This column indicates the size of container issued for each NSN. This measure is expressed by an abbreviation [such as ea (each), oz (ounce), gal. (gallon)]. If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.

C-2

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

2

3

4

6

7

8

9

5

10

EXPENDABLE/DURABLES SUPPLIES AND MATERIALS LIST

LEVEL

NATlONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

O

F

O

F

O

O

O

C

C

O

6830-00-264-6751

0040-00-142-9193

8040-00-262-9062

8030-01-014-5869

8040-00-833-9563

8040-00-543-7170

8040-00-262-9005

6850-00-174-1806

6850-00-181-7929

6850-00-181-7933

6850-00-181-7940

8030-00-251-3980

ACETYLENE, TECHNICAL: gas filled acetylene,

(81348) BB-A-106

225 cubic feet

ADHESIVE, LIQUID: ethyl cyanacrylic resin, type II

(81349) MILA-46050

10 1 ounce bottles per box

ADHESIVE, LIQUID: silicone, rubber, Silastic 732RTV (clear) non-hardening type I

(81348) MMM-A-139

1 pint

ADHESIVE SEALANT: anaerobic threadlock, medium strength,

MIL-S-46163, type II, grade N,

Loctite 242,

(05972) 24231

50 milliliter

ADHESIVE: silicone rubber,

MIL-A-46106, type I,

(97403)

1 kit

ADHESIVE: synthetic rubber, class II,

(80244) MMM-A-189 CL2

1 pint can

ADHESIVE: synthetic rubber,

MMM-A-1617, type II,

(79819) 1357

1 gallon can

ANTIFREEZE: arctic grade, permanent type, fluorescent yellow,

(81349) MILA-11755

55 gallon drum

ANTIFREEZE: ethylene glycol, permanent type, inhibited {-60°F

(-51°C)} blue-green in color,

(81349) MILA-46153

1 gallon container

5 gallon container

55 gallon drum

ANTISEIZE COMPOUND: temperature resistant lubricant, MIL-A-907,

Loctite, antiseize, 1050°F (566°C),

(05972) 76764

1 pound can with brush top

CU-FT

BX

PT

ML

KT

PT

GAL.

GAL.

GAL.

GAL.

GAL.

LB

C-3

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

11

EXPENDABLE/DURABLES SUPPLIES AND MATERIALS LIST (Contd)

(2)

LEVEL

(3)

NATlONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

O

1 2

13

14

15

16

17

18

19

20

21

22

2 3

O

F

O

F

0

0

0

0

O

O

O

O

8105-00-837-7754

8125-01-082-9697

6850-00-974-3738

5340-00-450-5718

8030-00-682-6745

5120-00-273-9793

7510-00-164-8893

6850-00-926-2275

6850-00-598-7328

5350-00-221-0872

7920-00-044-9281

8010-01-160-6741

8010-00-959-4661

BAG: plastic, polyethylene,

(58536) A-A-1799

500 bags per box

BOTTLES: oil sample,

(81996) PD 8125-1

1 2 0 b o t t l e s b o x

CALIBRATING OIL: gulf 45A,

(72932) 45A

55 gallon drum

CAP AND PLUG SET:

(19207) 10935405

1 set

CAULKING COMPOUND: rubber, synthetic

(81349) MIL-C-18255

1 kit

CHALK LINE AND REEL: selfchalking, hand crank rewind,

(81349) GGG-C-291

50 feet

CHALK: marking, white,

(81348) SS-C-266

1 gross

CLEANING COMPOUND: windshield, concentrated

(81348)

16 ounce bottle

CLEANING COMPOUND KIT engine cooling system

(81349) MIL-C-10597

1 kit

CLOTH, ABRASIVE (crocus):

9 inch x 11 inch sheets,

(58536) A-A-1206

50 sheets/package

CLOTH, CLEANING: lint-free, general purpose, white,

(81349) MIL-C-85043

10 pound box

COATING: polyurethane, chemical agent resistant, green 383,

MIL-C-46168C, type II,

(19207) 5584154

1 gallon can

COATING: battery box, nondrying epoxy,

(81349) MIL-C-22750

1 kit

BX

BX

GAL.

SET

KT

EA

CR

OZ

KT

PG

LB

GAL.

KT

C-4

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

24


(2)

LEVEL

(3)

NATIONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

F

25

26

27

28

29

30

31

32

33

34

O

F

O

O

O

O

C

C

C

O

5330-00-069-3321

8030-00-244-1297

9150-00-265-9406

7930-00-282-9699

9150-00-935-1017

8040-01-378-0235

8040-00-664-4134

8040-00-728-3088

9620-00-233-6712

9150-01-197-7698

9150-01-197-7690

9150-01-197-7689

9150-01-197-7692

9150-00-530-7369

9150-00-027-2954

4720-00-845-0630

CORK Type IB, Class 2

(81348) Spec HH-C-576

36 inch x 36 inch

CORROSION PREVENTIVE

COMPOUND: grade II, soft film

(81349) MIL-C-16173

1 gallon can

CUTTING FLUID:

(81348) C-O-376

1 gallon can

DETERGENT: nonsudsing, general purpose, liquid,

(80244) MIL-D-16791 type I

1 gallon

GAA GREASE: automotive and artillery, MIL-G-10924,

(98308) BRAYCOTE610

14 ounce can

GASKET COMPOUND: shellac, heavy-bodied, hard setting,

(62377)

2 ounce bottle

1 pint bottle

GASKET SEALANT: silicone rubber,

MIL-A-46106, type 1,

(78500) 1199-T-3842

1 kit

GRAPHITE, POWDERED:

MIL-SS-G-659

(81348) SSG659

1 pound kit

GREASE, AUTOMOTIVE AND

ARTILLERY (MIL-G-10924)

(81349)

2-1/4 ounce tube

1-3/4 pound can

6-1/2 pound can

35 pound can

120 pound drum

GREASE, SILICONE INSULATED: electric motor,

(71984) Molykote DC44

5.3 ounce tube

HOSE: nonmetallic, rubber synthetic, black, fuel/oil resistant

(23040) C2AZ9324C

3/8 inch ID, 5/8 inch OD

EA

GAL.

GAL.

GAL.

OZ

OZ

PT

KT

KT

OZ

LB

LB

LB

LB

OZ

FT

C-5

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

3 5


(2)

LEVEL

(3)

NATIONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

C

36

3 7

38

3 9

40

41

42

43

0

F

F

O

0

C

C

C

9150-00-402-2372

6850-01-160-3868

6850-01-287-8067

5350-00-193-1341

5350-00-271-5966

2640-00-256-5527

6810-00-597-3608

6810-00-275-6010

9140-00-286-5289

9140-00-286-5286

9140-00-286-5297

9140-00-286-5294

9140-00-286-5284

9140-00-286-5285

9140-00-286-5283

H Y D R A U L I C F L U I D :

SAE 15W40 (O-1236)

(81349) MIL-L-46167

5 gallon can

INHIBITOR, CORROSION: liquid cooling system; powder

(81348) MIL-A-54009

1 quart bottle

1 gallon bottle

LAPPING AND GRINDING

COMPOUND: valve-grinding compound, grease-mixed, grit 220 fine,

(58536) A-A-1203 type I

1 pound can

LAPPING AND GRINDING

COMPOUND: valve-grinding compound, grease-mixed, grit 120 coarse,

(58536) A-A-1203 type I

1 pound can

LUBRICANT, TIRE AND RIM: liquid,

(96980) AA18

1 gallon

METHYL ALCOHOL, METHANOL:

(81348) O-M-232

1 gallon can

5 gallon can

OIL, FUEL, DIESEL DF-1: Winter

(81349) (W-F-800) gauge

55 gallon drum, 18 gauge bulk

OIL, FUEL, DIESEL DF-2: Regular

(81348) (W-F-800) gauge


OIL, FUEL, DIESEL DF-A: Arctic

(81348) (VV-F-800)

55 gallon drum, 16 gauge


GAL.

Q T

GAL.

LB

LB

GAL.

GAL.

GAL.

GAL.

GAL.

GAL:

GAL.

GAL.

GAL:

GAL.

GAL.

GAL.

C-6

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

44


(2)

LEVEL

(3)

NATIONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

C

45

46

47

48

49

50

51

52

C

C

C

C

C

C

C

O

9150-00-402-4478

9150-00-49 1-7197

9150-00-234-5197

9150-01-035-5390

9150-01-422-9342

9150-00-183-7807

9150-01-035-5393

9150-01-035-5394

9150-00-188-9858

9150-00-191-2772

9150-00-186-6668

9150-00-189-6729

9150-00-183-7808

9130-01-031-5816

6830-00-292-0129

OIL, LUBRICATING, ENGINE: arctic (ice, sub-zero) OEA

(SEA OW-20)

(19200) (9377757)

1 quart can


OIL, LUBRICATING, GEAR,

EXPOSED: CW

(81348) (W-L-751)

5 pound can


MULTI-PURPOSE: GO 75

(81349) (MIL-L-2105)

1 quart can



MULTI-PURPOSE: GO 80/90

(81349) (MIL-L-2105)

5 gallon can


OIL, LUBRICATING, OE/HDO: 1OW

(81349) (MIL-L-2104)

5 gallon drum


OIL, LUBRICATING: internal combustion engine, tactical service, OE/HDO 10,

(81349) MIL-L-2104

5 gallon drum

OIL, LUBRICATING, OE/HDO: 30W

(81349) (MIL-L-2104)


OIL, TURBINE FUEL,

AVIATION: grade JP-8

(81349) bulk

OXYGEN, TECHNICAL: gas filled oxygen,

(81348) BB-A-925

240 cubic feet (to be filled/refilled locally)

QT

GAL.

GAL.

LB

QT

GAL.

GAL.

GAL:

Q T

GAL.

GAL:

Q T

GAL.

GAL:

GAL.

GAL.

GAL.

GAL.

CU-FT

C-7

TM 9-2320-272-24-4

(1)

REFERENCE

CODE NO.

53


(2)

LEVEL

(3)

NATlONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

F

54

55

56

57

58

59

60

61

62

63

F

F

O

F

O

O

O

O

O

C

9150-00-250-0933

8010-00-247-4334

5210-00-640-6177

9620-00-233-6712

0010-00-145-0312

7920-00-205-1711

4020-00-23 1-2581

8105-00-290-0340

8030-00-111-6404

8030-00-204-9149

8030-01-054-0740

PETROLATUM: technical, oil-soluble g r e a s e ( V a s e l i n e )

(81348) W-P-236

7-1/2 pound can

PIGMENT: iron, blue, oil base

(substitute for Prussian blue),

(81348) TT-P-381

1/2 pint can

PLASTIGAGE: clearance range green

(77220) PG-1

12 each box

POWDERED GRAPHITE:

MIL-SS-G-659

(81348) SSG659

1 pound can

PRIMER: zinc chromate

(81348) Spec TT-P-1757

1 pint can

RAG: wiping, unbleached cotton and cotton-synthetic, mixed colors

(58536) A-A-531

50 pound bale

ROPE, FIBROUS: 3 strand,

3/8 inch diameter, 1-1/8 inch circumference, 1,350 pound capacity

(81348) TR605

406.667 yards, minimum

SACK: shipping, water resistant, ten pound load capacity,

(58536) A-A-160

250 each box

SEALING COMPOUND: plastic epoxy, resin, MIL-R-46082, type II, Loctite RC/640,

(05972) 64031

50 cubic centimeters

SEALING COMPOUND: plastic, tetrafluoroethylene, Loctite 277,

(05972) 59241


SEALING COMPOUND; polyester and plastic, tetrafluoroethylene,

Loctite 592-31,

(05972)


LB

PT

BX

LB

P-r

LB

YD

BX

CC

CC

CC

C-8

TM 9-2320-272-24-4


(1)

REFERENCE

CODE NO.

(2)

LEVEL

(3)

NATIONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

65

66

67

68

69

70

71

72

73

F

O

O

C

O

O

F

O

O

8030-00-247-2525

8030-00-252-3391

8030-00-180-6222

8030-00-503-0316

8030-00-656-1426

6810-00-264-6618

3439-00-224-3567

6850-01-277-0595

6850-01-244-3207

8030-00-889-3535

5970-00-4 19-4291

11 ounce tube

SEALING COMPOUND: nonhardening, MIL-S-45180, type II,

Permatex no. 2,

(80064) 1756371

11 ounce tube

SEALING COMPOUND: resin, synthetic, MIL-R-46082, type I,

Loctite 75,

(05972) 669-31


SEALING COMPOUND: nonhardening, Permatex no. 51H

(pipe joint compound),

(77247) 51H

4 ounce can

SEALING COMPOUND: liquid resin, nonhardening, type III,

(77247) MIL-S-45180

1 pint can

SODIUM BICARBONATE: technical

(81348) 0-5-576

1 pound box

SOLDER: rosin core, 60/40,

0.094 inch diagnostic,

(81348) QQ-S-571

5 pound spool

SOLVENT, DRYCLEANING: type III, biodegradable

(81348) 134 Hi-Solv

5 gallon

55 gallon drum

TAPE, ANTISEIZING: white,

MIL-T-27730,

(81755) P5025-2R

1/2 inch wide x 260 inches long x 0.0035 inch thick with snap-on shell

TAPE, INSULATION: electrical

MIL-I-24391, 3/4 inch wide, black

(75037)

108 feet roll

OZ

OZ c c

OZ

PT

LB

LB

GAL.

GAL.

EA

FT

C-9

TM 9-2320-272-24-4


(1)

REFERENCE

CODE NO.

(2)

LEVEL

(3)

NATIONAL STOCK

NUMBER

(4)

DESCRIPITON

(5)

UNIT OF

ISSUE

74

75

76

77

78

79

80

81

82

O

F

O

O

F

O

F

F

F

5970-01-189-6927

7510-00-290-2023

6810-00-678-4418

4020-00-291-5901

8010-00-239-5736

9525-00-990-7799

9505-00-198-9125

8030-00-222-0503

5510-00-270-6031

TAPE, INSULATION: electrical

(81349) MIL-I-24391

3/4 inch wide x 10 yards long x

0.0085 inch thick

TAPE, PRESSURE SENSITIVE: masking, 1/2 inch wide, tan,

A-A-883 type II

(81348) PPP-T-42

60 yards per roll

TRICHLOROETHYLENE: liquid

(81349) O-T-634

1 gallon can

TWINE: cotton (string), 16 ply

(81348) A-A-1451

375 yard ball

WHITE LEAD: basic carbonate, paste in oil,

(96906) MS35599-1 type B

1 pound can

WIRE, NON-ELECTRICAL: safety wire

(96906) QQ-N-281, Class A

1 pound roll

WIRE: non-electric, iron,

(80244) 22-W-1642-125-36

1 pound roll

WOOD PRESERVATIVE:

(81349) MIL-S-13518

1 gallon can

WOOD, LAMINATED

DECKING: red or white oak, ungraded, MIL-W-3912, treated with preservative TT-W-572,

(97403) 12319E0079

228 inches X 11.5 inches X 1.12

inches

EA

EA

GAL.

YD

LB

LB

LB

GAL.

EA

C-10

TM 9-2320-272-24-4

APPENDIX D

MANDATORY REPLACEMENT PARTS

Section I. Introduction (page D-l).

Section II. Mandatory Replacement Parts (page D-2).


This appendix list mandatory replacement parts you will need to maintain M939, M939A1, and M939A2 series vehicles.

D-2. EXPLANATION OF COLUMNS a.

Column (1) - Item Number. This number is assigned to each entry in the listing and is referenced in the Initial Setup of applicable task under the heading of MATERIALS/PARTS.

b.

Column (2) - Nomenclature. Name or identification of part.

c.

Column (3) - Part Number. The manufacturer’s part number.

d. Column (4) - National/NATO Stock Number. The national stock number of the part.

D-l

15

16

17

22

23

24

25

26

27

18

19

20

21

28

29

30

31

(1)

7

8

9

10

11

12

13

14

ITEM

NO

1

2

3

4

5

6

TM 9-2320-272-24-4

Section II. MANDATORY REPLACEMENT PARTS

(2) (3) (6)

NOMENCLATURE

Adapter

Adapter

Adjuster Parts Kit

Air Compressor Repair Kit

Anchor Bolt

Anchor Plunger Kit (Left)

Anchor Plunger Kit (Right)

Backing Ring

Banjo Seal

Basic Overhaul Kit

Bearing

Bearing

Bearing Retainer

Bearing Shell

Brake Band

Brakeshoe Lining

Brakeshoe Lining and

Assembly Kit

Breakoff Screw

Breakoff Screw

Breakoff Screw

Bushing

Bushing

Bushing

Bushing

Bushing

Bushing

Bushing

Bypass Disc

Bypass Seat

Bypass Spring

Bypass Valve

PART

NUMBER

3903845

ER22663

1164

3801808

231013398

1173

1174

032590

3903380

6884259

6071-2RS

69867

2411521

214950

214951

214952

214953

7409663

2740-D-1122

2000-P-1446

2 423 450 005

1 423 450 056

2 910 172 197

S1003A

55602H

S1077

7411156

7409666

7954534

23011924

200819

153526

251152

3902338

NATIONAL/NATO

STOCK NUMBER

5307-01-196-4246

4730-01-127-6697

2530-01-278-7364

4910-01-272-5374

5360-01-145-6923

5330-01-135-4069

5330-01-195-5268

2520-01-140-2376

3110-01-126-1287

3110-00-100-2368

5365-01-235-2580

3120-01-087-3004

3120-01-155-4442

3120-01-157-3316

3120-01-155-8707

2530-00-740-9663

2530-01-135-0187

2530-01-326-6127

5305-01-336-0006

5305-01-301-5112

5305-01-335-9965

5326-00-598-5255

3120-00-740-9344

5365-00-362-1880

3120-00-741-1156

3120-00-740-9666

3120-01-120-8450

4730-01-078-2732

4820-00-400-5189

2815-00-131-1700

5360-00-932-7452

2815-01-211-5270

D-2

(1)

39

40

41

42

35

36

37

38

ITEM

NO

32

33

34

43

44

45

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

46

47

48

49

TM 9-2320-272-24-4

Section II. MANDATORY REPLACEMENT PARTS (Contd)

(2) (3) (6)

NOMENCLATURE

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Camshaft Bore Cork Gasket

Camshaft Bushing

Camshaft Bushing

Chamfered Washer

Channel Seal

Checkball

Compression Ring

Compression Ring

Connecting Rod Bearing

Connector

Copper Washer

Cooper Washer

Copper Washer

Copper Washer

PART

NUMBER

9333-1

100670

157870

23014094

7373291-2

8622757

187350

650330

3901434

MS27144-1

007603014106

3912889

2916710613

2916710619

MS24665-283

MS24665-500

210492

MS24665-362

MS24665-134

IF316

MS2466-172

AN415-4

MS24655-490

MS24665-214

MS24665-353

MS24665-351

MS24665-369

MS24665-498

MS24665-335

MS24665-361

MS24665-300

MS24665-655

MS24665-493

AN415-6

NATIONAL/NATO

STOCK NUMBER

5330-00-729-4427

3120-00-573-0391

3120-00-906-6657

5310-01-145-6923

5330-01-026-7512

2520-00-008-7306

4310-01-197-1882

4310-01-079-5245

3120-01-275-7665

5935-00-167-7775

5330-12-156-4523

5310-01-271-5706

5325-01-276-8488

5330-01-301-1763

5310-00-842-3044

5310-00-187-9567

5310-01-246-4339

5310-00-298-1498

5315-00-839-5820

5315-00-816-1794

5315-00-187-9370

5315-01-057-8371

5315-00-059-0205

5315-00-080-3503

5315-00-839-5822

5315-00-893-5821

5315-00-059-0187

5315-00-849-9854

5315-00-012-0123

5315-00-059-0184

5315-00-234-1863

5315-00-187-9414

5315-00-018-7988

5315-01-018-9991

D-3

(1)

ITEM

NO

66

74

75

76

77

84

85

86

87

88

78

79

80

81

82

83

93

94

95

96

89

90

91

92

97

98

67

68

69

70

71

72

73

Cotter Pin

NOMENCLATURE

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

Cotter Pin

TM 9-2320-272-24-4


(2) (3) (6)

PART

NUMBER

MS24665-132,

A82-1

MS34665-627

MS24665-502

MS24665-423

MS24665-381

MS24665-427

MS24665-491

L6451-101

MS24665-631

MS24665-49

MS24665-359

MS24665-628

MS24665-238

137159

CO2-40-4

MS24665-5

MS24665-285

MS24665-153

MS24665-151

MS24665-357

20511322Z

3801260

215090

175831

7084738

8380498

A-3261-S-253

390415

3076189

3917737

69519

70550

3917883

NATIONAL/NATO

STOCK NUMBER

5315-00-839-2325

5330-01-080-5021

5330-01-272-1282

5315-00-475-2514

2815-01-124-0232

5315-01-270-8286

5315-00-013-7308

5315-00-849-5582

5315-00-013-7228

5315-00-839-2326

5315-00-879-2910

5315-00-059-0206

5315-00-187-9591

5315-00-597-7399

5315-01-136-4542

5315-00-013-7214

5315-00-846-0126

5315-00-239-8027

5315-00-013-7159

5315-01-135-9506

5315-00-236-8345

5315-01-359-1451

5315-00-185-0037

5315-00-815-1405

5315-00-298-1481

2530-01-272-2912

3120-01-132-9339

5330-00-064-4399

5340-00-485-0945

2590-00-471-5343

2590-00-471-5344

3040-01-149-1111

D-4

TM 9-2320-272-24-4

(1)

ITEM

NO.

126

127

128

1 2 9

130

121

122

123

124

125

131

1 3 2

114

115

116

117

118

119

120

99

100

101

102

103

104

105

106

107

1 0 8

109

110

111

112

113

Dowel Pin

Dowel Ring

Drive Pin

Drivebelt

Dustcap Assy

Dustcap Assy

Expansion Plug

Expansion Plug

Expansion Plug

Fan Drive Repair Kit

Fastener

Felt Seal

Felt Washer

Felt Washer

Felt Washer

Felt Washer

Felt Washer

Felt Washer

Felt Washer

Ferrule

Fiber Washer

Filter

F i l t e r

Filter

Filter Element Kit

Filter Element Kit

Filter Kit

Filter Screen

Filter Strip

Fluid Pressure Kit

Fluid Pressure Kit

Flywheel Seal Ring

Frame Seal

Freeze Plug

S e c t i o n I I . M A N D A T O R Y R E P L A C E M E N T P A R T S ( C o n t d )

(2)

NOMENCLATURE

(3)

PART

NUMBER

3904483

60575

S-2286

3912004

DCL6N-3

SERUR14-16

3032693

156075

3900965

F212028

7529309

7411160

5X625

7409928

7417093

7409929

7411154

7411159

7417094

2297-N-5630

14079550

3313281

146483

599791

ERS-28001

12503

AR 51480

23010654

12277066

3652-11

256476

6770492

7373300

213394

(4)

NATIONAL/NATO

STOCK NUMBER

5315-01-270-8285

5365-00-428-6201

5305-00-804-6318

3030-01-217-3754

2530-01-286-0108

5340-01-271-2420

5340-01-271-2419

5340-01-194-8936

2540-00-562-0422

5330-00-741-1160

5330-00-740-9312

5310-00-740-9928

5330-00-741-7093

5330-00-740-9929

5330-00-741-1154

5330-00-741-1159

5330-00-741-7094

4730-01-272-0582

5330-00-107-3925

2940-01-157-6309

2910-00-790-8736

4460-01-284-2344

4330-01-272-2937

4330-01-284-6203

2940-00-404-3057

2940-01-140-8227

9320-01-109-5696

4330-01-243-0055

2910-00-152-2033

5330-00-999-3760

9390-00-737-3300

5310-01-087-0682

D-5

TM 9-2320-272-24-4

D-6

( 1 )

ITEM

NO.

1 3 3

1 3 4

135

136

137

138

139

140

1 4 1

142

143

1 4 4

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165


Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

G a s k e t

Gasket

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

Gasket

Gasket

Gasket

G a s k e t

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

(2)

NOMENCLATURE

Freeze Plug

Freeze Plug

Fuel Filter

Fuel Injection Pump

Maintenance Kit

Fuel Injection Pump Repair Kit

(3)

PART

NUMBER

213395

216524

33472

57k0144

1417010008

3048341

3923054

3911941

3914388

1235675

7539072

A 5 7 1 1

153518

154088

7 0 4 4 1

3060912

3914310

3913032

3913025

35913027

130226

3914391

1164431

11664480

33069823

3031007

29501160

3905449

7979274

3910642

154916

7979275

1227128

(4)

NATIONAL/NATO

STOCK NUMBER

5340-01-087-0681

5340-012-086-6193

2910-01-201-7719

2910-01-339-0423

2910-01-339-7912

5330-01-262-5118

5330-01-190-9555

5330-01-272-1146

5330-01-190-1905

5330-01-299-6616

5330-00-753-9072

5310-01-133-5847

5330-01-044-2096

5330-00-961-9470

5330-00-508-0411

5330-01-272-1142

5330-01-287-8656

5330-01-901-1828

5330-01-302-0780

5330-01-301-1829

5330-00-106-6370

5330-01-272-1138

5330-00-143-7797

5330-00-252-3274

5330-01-137-4487

5330-01-165-2314

5330-01-120-8090

5330-01-271-8307

5330-00-740-9600

5330-01-271-8306

5330-01-071-5727

5330-00-734-6993

5330-01-115-0604

TM 9-2320-272-24-4

(1)

ITEM

NO.

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

175

176

177

178

179

180

181

182

183

166

167

168

169

170

171

172

173

174


Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

(2)

NOMENCLATURE

(3)

PART

NUMBER

I 1089995

I 65274

142234

134276

12255817

3011273

3017750

307613

151911

12256082-1

134285

110453

157551

68210

3008017

3008591

3012972

3069101

70089-l

320-1850

154018

3054841

3921852

3908096

3914301

3929253

3915772

3914017

3914302

3917780

3911942

3915800

3201386

1 7 6 0 2 7

(4)

NATIONAL/NATO

STOCK NUMBER

I 5330-00-182-3489

5330-00-246-0309

5330-00-659-3178

5330-00-193-7652

5330-01-379-4345

5330-01-267-0399

5330-00-861-8592

5330-01-147-4071

5330-00-961-6314

5330-01-374-0400

5330-00-465-5818

5330-00-143-8371

5330-00-143-8376

5330-00-328-8656

I

5330-01-079-6514

5330-01-086-3523

5330-01-131-2967

5330-00-026-2931

5330-00-537-2382

5330-01-181-0631

5330-00-852-7347

5330-01-285-4827

5330-01-272-1145

I 5330-01-266-3294

I 5330-01-271-4308

I 5330-01-317-3213

5330-01-263-6179

5330-01-289-3135

5330-01-272-1143

5330-01-321-2053

5330-01-281-9013

5330-01-270-8144

5330-01-181-0630

5330-00-129-9389

D-7

TM 9-2320-272-24-4

D-8

(1)

ITEM

NO.

215

216

217

218

219

206

207

208

209

210

211

212

213

214

200

201

202

203

204

205

225

226

227

228

229

230

231

232

233

220

221

222

223

224

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket


(2)

NOMENCLATURE

(3)

PART

NUMBER

3047159

12302621

7376584

3021735

50161-2

6884872

10900396

7346886

7346896

291882

20510093-4Z

11663365

7973339

7409821

7409822

3914308

7409933

7409931

7409932

20511420

2208-U-697

35-P-8

22-P-24-2

70705

12288013

6771366

23016347

23014221

23045099

11592566

3918174

7535583

830431

10876133

(4)

NATIONAL/NATO

STOCK NUMBER

5330-00-131-7072

5330-01-232-1487

5330-00-737-6584

5330-01-082-6985

5330-01-285-1601

5330-01-111-9291

5330-00-419-5872

5330-00-734-6886

5330-00-641-2466

5330-01-123-6409

5330-01-271-9407

5330-01-054-4011

5330-00-895-3424

5330-00-740-9821

5330-00-057-3823

5330-01-271-6404

5330-00-740-9933

5330-00-166-4333

5330-00-740-9932

5330-01-361-5600

5330-00-549-7694

5330-00-485-0895

5330-00-485-0865

5330-00-562-1176

5330-00-781-7774

5330-00-911-9411

2840-01-068-1713

5330-00-557-6518

5330-01-219-2555

5330-00-414-6695

5330-01-271-5791

5330-00-415-1484

5330-00-415-1488

5330-00-826-5202

TM 9-2320-272-24-4

258

259

260

2 6 1

262

263

252

253

2 5 4

255

256

257

264

265

(1)

ITEM

NO.

234

235

236

237

238

239

240

2 4 1

242

243

244

245

246

247

248

249

250

251

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket

Gasket


(4)

( 2 )

NOMENCLATURE

(3)

PART

NUMBER

Gasket

Gasket

Gasket

Gasket

Gasket and Seal Set

Gasket and Shim Set

Governor Filter

Governor Filter O-ring

Grommet

Grommet

Half-Keeper

Hi-Lo Shaft Seal

Injector Overhaul Kit

Injector Sleeve

Injector Sleeve

Inner Seal Ring

Inner Seal Ring

Insulation

Insulator

I n s u l a t o r

Isolator

J a m n u t

K e y

10876132

7529300

MS51071-7

981072

35-P-41

100764

173086

23011670

118394

3008947

HFB642010-A1

3780-Q-381

2208-S-1033

5518441

7346807

6882687

6882689

7035447,

7 4 7 R

MS35489-135

127554

A-1205-P-1758

AR-51522

3 9 0 9 8 8 6

3011934

23011471

6883031

12302774

11669319-1

12256707

11669109

MS51967-18

51967-18

8327444

NATIONAL/NATO

STOCK NUMBER

5330-00-826-5203

5365-01-129-0399

6680-00-882-0965

5220-00-982-4259

5330-01-133-0205

5330-00-506-4866

5330-00-132-0247

5330-00-001-1984

5330-01-129-6541

5330-01-292-9575

5330-01-272-1148

5330-01-341-6583

5330-00-513-1443

4330-01-074-9642

5330-01-080-3254

5340-00-264-7182

5325-00-263-6648

5340-01-143-6048

5330-01-132-8346

2910-00-117-3689

2910-01-271-9826

2910-01-146-0048

4310-01-006-4952

5330-01-083-3065

5970-01-114-3753

5340-01-104-7843

5340-01-101-0005

5310-00-763-8919

5315-00-281-7652

D-9

TM 9-2320-272-24-4

(1)

ITEM

NO.

291

292

293

294

295

296

297

286

287

288

289

290

270

271

272

273

274

275

276

277

266

267

268

269

278

279

280

281

282

283

284

285

298

299

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Key

Key Washer

Keyway Insert

Leather Washer

Load Check Valve Kit

Lock Pin

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut


(2)

NOMENCLATURE

(3)

PART

NUMBER

7535631

114638

5-X-663

77121-l

5704273

10166

MS21045-4

MS51943-46

MS21045-3

MS51922-5

MS21044N4

MS51922-13

5590560

9 4 2 2 7 9

MS51922-9

MS21045-7

MS21245-L10

MS21044-N3

MS51922-17

MS21045-8

MS51922-61

1779-Z-260

MS51922-21

3 9 1 3 3 7 1

12301125

MS51943-36

MS21045-C3

MS17830-06C

MS51943-40

MS51943-39

MS51922-53

MS51922-1

MS51968-8

MS51943-34

(4)

NATIONAL/NATO

STOCK NUMBER

5315-01-217-2269

5310-00-887-8325

5330-01-133-7262

5310-00-760-7493

4820-01-093-5785

5315-01-284-9812

5310-00-061-7325

5310-00-935-3569

5310-00-061-7326

5310-00-959-7600

5310-00-877-5796

5310-00-984-3807

5310-01-126-9404

5310-01-193-6884

5310-00-984-3806

5310-00-274-9364

5310-00-449-2381

5310-00-877-5797

5310-00-087-4652

5310-00-062-4952

5310-00-832-9719

5310-00-949-6280

5310-00-959-1488

5310-01-287-5742

5310-01-210-0199

5310-00-814-0672

5310-00-263-2862

5310-00-176-6341

5310-00-488-3888

5310-00-488-3889

5310-00-225-6408

5310-00-088-1251

5310-00-732-0559

5310-00-241-6658

D - 1 0

TM 9-2320-272-24-4

(1)

ITEM

NO.

314

323

324

325

326

327

315

316

317

318

319

320

321

322

305

306

307

308

309

310

311

312

313

300

301

302

303

304

328

329

330

331

3 3 2


Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

(2)

NOMENCLATURE

(3)

PART

NUMBER

MS51922-6

9422305

8712289-5

3906216

MS51943-33

FCO30005

MS51943-35

AN365-1024A

7373244

MS21044-N8

MS21045-10

MS21045-12

MS51922-37

MS51943-32

MS21083C12

MS51943-38

MS21045-14

11609727-2

MS21045-5

9422301

1227-K-1051

MS51943-44

MS51943-2

NAS1021-N17

3311501033

2304890

S-212

MS21045-6,

456702

9419479

MS51943-5

9422298

MS21045-18

G-9415992

5310-01-409-1642

5310-01-249-0904

5310-01-150-5914

5310-00-057-7153

5310-00-421-3991

(4)

NATIONAL/NATO

STOCK NUMBER

5310-00-143-6102

5310-01-130-4274

5310-00-044-3342

5310-01-270-8251

5310-00-814-0673

5310-01-270-8342

5310-00-935-9021

5310-00-208-1918

5310-00-269-7044

5310-00-877-5795

5310-00-982-5009

5310-00-982-5012

5310-00-067-9507

5310-00-935-9022

5310-00-923-4219

5310-00-994-1006

5310-00-982-5014

5310-00-176-6690

5310-00-982-4912

5310-01-149-4407

5310-01-099-0397

5310-00-241-6664

5310-01-374-0508

5310-00-325-1900

5310-01-143-0512

5310-00-748-0548

5310-00-011-7051

5310-00-982-4908

D-11

TM 9-2320-272-24-4

355

356

357

358

359

360

3 5 0

351

3 5 2

353

354

361

362

363

364

(1)

ITEM

NO.

333

334

339

340

341

342

343

344

335

336

337

338

345

346

347

348

3 4 9


Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

( 2 )

NOMENCLATURE

Locknut

Locknut

Locknut

Locknut

Locknut

Locknut

L o c k n u t

Lockplate

Lockplate

Lockstrap

L o c k t a b

Locktab Washer

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

( 3 )

PART

NUMBER

MS519221-1

131245

MS21042-8

MS51943-4

MS51943-6

MS51943-10

109319

3 9 1 4 7 0 8

3039305

6880899

028426

8758258

MS35335-33

MS35338-62

MS35338-63

MS12203-2

MS35338-8,

S-604

210104-8S

MS35338-42

MS35338-43

MS45904-73

MS35338-46

MS35333-44

MS35335-42

MS35335-32

MS27183-14

138485

MS353335-35,

138489

WA-LH8-3

MS35338-52

MS35043-53

7410218,

MS35338-45

( 4 )

NATIONAL/NATO

STOCK NUMBER

5315-00-088-1251

5310-00-013-1245

5310-00-807-1468

5310-00-935-3750

5310-01-344-8250

5310-00-455-9967

2518-00-406-8936

5310-01-330-8313

5340-01-056-0037

5310-01-135-6758

5310-00-147-3274

5310-00-209-0786

5310-00-274-8710

5310-00-274-8715

5310-00-159-6209

5310-00-261-7340

5310-00-003-4094

5310-00-045-3299

5310-00-045-3296

5310-00-130-9065

5310-00-194-1483

5310-00-595-7237

5310-00-596-7691

5310-00-080-6004

5310-00-627-6128

5310-00-031-2673

5310-00-754-2005

5310-00-926-5885

5310-00-407-9566

D-12

(1)

ITEM

NO.

3 8 0

381

3 8 2

383

3 8 4

3 8 5

386

387

3 9 4

395

3 9 6

397

3 9 8

388

389

3 9 0

3 9 1

392

393

365

366

367

368

369

370

371

372

373

374

375

3 7 6

3 7 7

3 7 8

379

TM 9-2320-272-24-4


NOMENCLATURE

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwaasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

L o c k w a s h e r

Lockwasher

Lockwasher

Lockwasher

L o c k w a s h e r

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

(2)

( 3 )

PART

NUMBER

1229-S-513-C

MS35333-49

MS35333-41

MS35340-48

MS35335-31

2379-10ZF

MS35333-40

MS45904-84

MS35335-30

MS35338-41

MS35333-47

MS35340-43

MS35338-50

MS35333-78

MS45904-76

3910266

MS35338-49

MS35338-47

3912897

MS35336-9

MS35335-34

9 6 9 0 6

0 6 8 5 3

MS35335-40

MS35333-39

AN3066-12

MS35233-38

MS35338-50

MS35338-51

378003

9 4 1 1 4 1 7

2 916 699 092

2 916 699 085

2 916 699 083

( 4 )

NATIONAL/NATO

STOCK NUMBER

5310-01-062-3384

5310-00-582-6714

5310-00-167-0721

5310-00-834-7606

5310-00-596-7693

5310-01-135-4828

5310-00-550-1130

5310-00-935-8984

5310-00-209-0788

5310-00-045-4007

5310-00-550-3714

5310-00-721-7809

5310-00-820-6653

5310-00-261-7156

5310-00-061-1258

5310-01-270-8423

5310-00-167-0680

5310-00-209-0965

5310-01-270-8405

5310-00-550-0248

5310-00-510-6674

5310-00-959-4679

5310-00-119-4864

5310-00-275-3683

5310-00-576-5752

5975-00-793-5550

5310-00-559-0070

5310-00-004-5034

5310-00-584-7888

5310-00-838-1490

5310-00-799-4910

5310-01-300-7037

5310-01-301-1875

5310-01-301-7811

D-13

TM 9-2320-272-24-4

(1)

ITEM

NO.

406

407

408

409

410

411

412

413

414

415

416

399

400

401

402

403

404

405

417

418

419

420

421

422

423

424

425

426

427

428

429

430


O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwasher

Lockwire

Lockwire

Lockwire

(2)

NOMENCLATURE

Lubrication Valve

Manifold Pressure

Compensator Maintenance Kit

15434

(3)

PART

NUMBER

MS35335-39

MS35338-44

26X-3074

MS45904-68

20X-0196

MS45904-72

MS35335-36

MS35335-60

181466

S-622

WA-LM7-2

MS35336-39

S-610

S-606

178556

120380

11500207

1613,

MS35338-48

MS51848-14

MS45904-74

22-W-1642-100

MS20995F9H2

MS20995F91

6834624

57K0143

145504

130240

3910824

MS28775-032

6762127

MS28778-10

(4)

NATIONAL/NATO

STOCK NUMBER

5310-00-800-0695

5310-00-582-5965

5310-00-889-2528

5310-00-889-2527

5310-00-550-3503

5310-00-209-1239

5310-00-484-1718

5310-00-562-6557

5310-00-486-5355

5310-00-194-9213

5310-01-300-8400

5310-00-410-6756

5310-00-017-8556

5310-00-209-2946

5310-01-206-7306

5310-00-584-5272

5310-00-171-1735

9505-00-554-0098

9505-00-846-0941

2520-00-557-5900

2910-01-339-0422

5330-01-051-4243

5330-00-106-6969

5330-01-272-1123

5330-01-281-8997

5330-01-049-7374

5330-01-010-9693

5330-00-285-9842

D-14

446

447

448

449

450

451

452

453

454

455

456

457

458

459

460

461

462

463

(1)

ITEM

NO

431

432

433

434

435

436

437

438

439

440

441

442

443

444

445

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

TM 9-2320-272-24-4


(2) (3)

(6)

NOMENCLATURE

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

PART

NUMBER

3909397

12301126

MS35489-6

N72259

N72260

MS28775-238

AN6290-6

131026

137075

67270

3019116

70624

3024789

3910260

3913994

TS33-016 70

3910503

3916284

FCO30020

FD76A

FD145A

FD0077

233955

ER-82141

MS29513-115

MS28775-219

MS28775-225

MS28778-12

154129

MS28775-113

3032874

68061-A

100478

213768

NATIONAL/NATO

STOCK NUMBER

5330-01-272-1120

5330-01-210-2155

5325-00-263-6632

5330-00-152-1759

5330-01-166-3662

5330-00-579-75745

5330-00-804-5695

5330-00-143-8485

5330-00-420-9624

5330-00-171-3879

5330-01-160-7458

5330-00-506-4874

5330-01-145-5381

5330-01-272-1124

5330-01-291-6537

5330-01-272-1121

5330-01-272-1122

5330-01-271-9372

5330-01-123-2832

5330-01-271-9374

5330-01-079-6513

5330-00-074-2692

5330-01-129-0384

5330-00-248-3847

5330-00-579-7925

5330-00-579-7927

5330-00-251-8839

5330-00-948-6482

5330-00-582-2855

5330-01-220-2389

5330-00-970-3461

5330-00-081-9289

5330-01-072-8983

D-15

TM 9-2320-272-24-4

(1)


(2) (3)

(6)

NOMENCLATURE

ITEM

NO

464

465

466

467

468

469

470

471

472

473

474

475

476

477

478

479

480

481

482

483

490

491

492

493

494

495

496

484

485

486

487

488

489

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

O-ring

Oil Filter

Oil Filter Element

Oil Pan Gasket

Oil Pump Kit

Oil Seal

Oil Seal

PART

NUMBER

NATIONAL/NATO

STOCK NUMBER

582826

MS28775-249

M83461/1-427

MS28775-243

MS28778-20

MA28775-128

AS3551-12

MS28775-232

MS27183

7374401

20510736

5330-00-522-8544

5330-01-019-2448

5330-01-183-0985

5330-00-579-7544

5330-00-816-3546

5330-00-702-5643

5330-00-776-2830

5330-00-585-8247

5310-01-317-1812

5330-00-984-3756

4730-01-279-1519

154087

3037236

5330-00-772-7657

5330-01-331-9293

MS28778-8

3007759

282818

18048

028466

032586

032616

5330-00-808-0794

5330-01-072-4436

5330-01-217-0734

5330-01-280-6503

5310-01-135-6754

5330-01-143-2780

5330-01-149-7229

032571

032615

M83461/1-012

5330-01-135-4809

5330-01-135-4068

5330-01-046-3300

MS28775-206 5330-01-133-5858

M832484/1-324 5330-01-005-3704

MS28778-16 5330-00-804-5694

M83461/1-219

PH3519

PF297

3032861

3802278

A-1205-E2137

10938292

5330-01-128-3954

2940-01-110-2489

2940-00-950-8410

5330-01-147-0748

2815-01-268-8753

5330-01-271-9362

5330-00-145-8355

D-16

498

499

500

505

506

507

508

509

510

501

502

503

504

511

512

519

520

521

522

523

513

514

515

516

517

518

524

525

526

527

528

529

(1)

ITEM

NO

497

TM 9-2320-272-24-4


(2) (3) (6)

NOMENCLATURE

Oil Seal

Oil Seal

Oil Seal

Oil Seal

Oil Seal

Oil Seal

Oil Seal

Oil Seal

Oil Seal Kit

Oil Seal Kit

Oil Sleeve

Outer Bearing Oil Seal

Outer Seal Ring

Packing

Packing

Packing

Packing Ring

Pin

Piston Inner Seal Ring

Piston Outer Seal Ring

Piston Ring

Piston Rings

Piston Seal

Piston Seal Ring

Plastic Backup Washer

Power Steering Filter Kit

Power Steering Parts Kit

Pressure Regulator Plunger

Pumping Element Kit

Rear Cover Plate Gasket

Rear Cover Plate Seal

Regulator Channel Filler

Regulator Channel Seal

PART

NUMBER

4591SCR,

A-1205-Z-2132

211255

208069

A-1205-U-1737

28-P-52

23016643

6773311

A-1205-U-1633

3802387

3802389

1844-J-634

7431447

6883035

10900300

11609215

032634-A1

032361

7412376

23015880

6833981

180810

3802110

10900304

6758740

028435

ERS27788

20510093-26Z

391852

20510093-25Z

151623

M39807

10906350

7373301

NATIONAL/NATO

STOCK NUMBER

5330-01-271-9410

5330-00-135-6382

5300-00-006-2529

5330-01-023-0269

5330-00-237-7828

5330-01-219-2375

5330-00-999-3752

5330-01-126-0565

5330-01-344-0567

2520-01-132-6841

5330-00-961-3596

5330-01-104-8934

5330-00-523-4235

5330-00-269-4953

5330-01-135-0682

5330-01-195-5757

2510-00-741-2376

5330-01-146-6053

5365-01-010-9689

2815-01-079-3290

2815-01-271-9792

5340-00-523-4305

5330-00-582-0456

5310-01-161-6131

2530-01-137-5921

2530-01-272-2910

5340-01-331-9625

5330-01-271-9544

5330-01-082-1906

5330-00-005-0858

2510-00-179-5708

9390-00-737-3301

D-17

ITEM

NO

530

531

532

533

534

535

536

537

538

539

540

541

542

543

544

545

546

547

548

549

550

551

552

553

554

555

556

557

558

559

560

561

TM 9-2320-272-24-4

(1)


(2) (3) (6)

562

NOMENCLATURE PART

NUMBER

NATIONAL/NATO

STOCK NUMBER

Relay Valve Kit

Relay Valve Kit

Relief Fitting

Relief Valve Kit

Repair Kit

Repair Kit

Resilient Mount

Retaining Ring

599913

599911

70295

5704274

3011472

AR73350

7521436

110827

2530-01-284-4287

2530-01-284-4288

4730-00-011-3175

2590-00-606-2383

5330-00-480-6133

2815-00-913-2074

5340-00-040-2073

5330-00-785-7894

Retaining Ring

Retaining Ring

Retaining Ring

MS16625-1100

3901996

401309

5365-00-807-2636

5325-01-280-5592

5325-00-613-7796

Ring Seal

Rivet

900877 2590-01-119-4103

MS20600AD6W4 5320-00-528-3276

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

Rivet

7B5049

RV876

5320-00-262-6492

5320-01-146-9582

MS20600-MP8W/4 5320-01-068-2340

MS20600AD5W2 5320-00-582-3302

RV200-6-3 5320-00-582-3268

MS20600AD8W7 5320-00-721-5384

MS24662-234

RV200-6-4

RV200-6-2

MS20470A6-6

5320-00-930-7865

5320-00-582-3276

5320-00-584-1285

5320-00-242-1580

ADJUST644

MS20470A5-8

MS20473A6-9

CR9163-6-6

RV200-6-1

MS24661-226

RV200-6-5

Rod Seal

RQV Governor Cover Housing

MS28775-222

57K0141

Maintenance Kit

RQV Governor Cover Maintenance Kit 57K0142

5320-00-956-7355

5320-00-234-8557

5320-00-264-3266

5320-00-582-3499

5320-00-616-4350

5320-00-231-3663

5320-00-582-3301

5330-00-338-4460

2910-01-338-4460

2910-01-338-6473

D-18

(1)

ITEM

NO

563

564

565

566

567

568

569

570

571

572

573

574

575

576

583

584

585

586

587

588

577

578

579

580

581

582

589

590

591

592

593

594

595

Rubber Bumper

Rubber Bushing

Rubber Grommet

Rubber Seal

Safety Wire

Safety Wire

Screw

Screw

Screw

Screw-Assembled Lockwasher






Screw Assembled Lockwasher















Screw Assembled Washer

Seal

Seal

TM 9-2320-272-24-4


(2) (3) (6)


NUMBER

425648

9414109

423569

70772

3021470

3012472

7372083-1

MS90726-59

423568

11663070

11664479-1

3010593

423518

30105494

3010590

3010596

3010592

3010597

425567

67946

3900216

7535643

7409618

MS35489-19

12256106

ASTM AS41

22W1642125

MS90726-97

MS51106-421

522875

425841

187995,

7373271

455176

NATIONAL/NATO

STOCK NUMBER

5340-00-766-3330

5365-00-740-9618

5325-00-276-6091

5330-01-120-8454

9505-00-248-9842

9505-00-198-9125

5305-00-225-9092

5305-00-940-9517

5306-00-042-5841

5305-00-696-5285

5305-01-225-2106

5305-00-042-5648

5305-01-229-9587

5306-01-226-0798

5305-00-477-6769

5305-01-144-6233

5305-01-112-4312

5305-01-090-7626

5305-00-912-5113

5305-00-042-3568

5305-01-104-9018

5306-01-106-3850

5305-01-197-3449

5305-00-638-0714

5305-01-130-6100

5305-01-119-8621

5305-01-088-6019

5305-01-176-8018

5305-01-086-7036

5305-00-042-5597

5365-00-197-9327

5310-01-188-0997

D-19

ITEM

NO

596

597

598

599

600

601

602

603

604

605

606

607

608

609

610

611

612

613

614

615

616

617

618

619

620

621

622

623

624

625

626

627

628

629

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

Seal

TM 9-2320-272-24-4

(1)


(2) (3) (6)


NUMBER

8265

186780

188318

145530

3902466

7059240

3909410

3903475

032579

11607302-7

10937693-3

17657/55-542465

10875107-7

7409940

500207

E-450121VG

3003156

3915707

8735035

8735034

87350536

10608E44S

10937640

10915159

7373291-3

10937691

10937727

12302744

500163

S-1003-A

23010610

1205-Y-1633

C-366005

A-1205-D-2162

NATIONAL/NATO

STOCK NUMBER

5310-00-246-0221

5330-00-864-5422

5330-01-301-1761

5330-01-201-3623

5330-01-272-1246

5330-00-414-3754

5330-01-192-2037

5330-01-791-8047

5330-01-143-4186

5330-00-340-3637

2510-01-197-4200

5330-01-150-9691

5330-01-119-5801

5330-00-292-1600

5330-00-585-3210

5330-01-131-5416

5330-01-072-8830

5340-01-281-7792

5330-00-470-2115

5330-00-419-9468

5330-00-419-9469

5330-00-020-5375

5330-00-338-0774

9390-00-405-0215

5330-00-152-3217

5330-01-098-6555

5330-01-016-1245

5330-01-209-7354

5330-00-178-2191

5365-00-598-5255

2840-01-141-9503

5330-01-137-4799

2590-01-134-9834

5330-01-308-0175

D-20

(1)

636

637

638

639

640

641

642

643

644

645

646

647

648

649

650

651

652

653

654

655

656

657

658

659

660

661

ITEM

NO

630

631

632

633

634

635

Seal

Seal

Seal

Seal

Seal Assembly

Seal Assembly

Seal Ring

Seal Ring

Seal Ring

Seal Ring

Seal Ring

Seal Ring

Seal Ring

Seal Ring

Seal Washer

Seal Washer

Seal Washer

Seal-Locking Retainer

Self-Locking Screw

Self-Locking Screw

Self-Locking Screw

Shim

Shim

Side Cover Gasket

Sleeve

Sleeve

Sleeve

Sleeve Bearing

Slotted Nut

Snapring

Snapring

Snapring

TM 9-2320-272-24-4


(2) (3) (6)


NUMBER

A-1205-N-2120

11607267-2

10937683-2

8380420

12375801

3033677,

3071085

6880389

6830187

23014632

6839163

23017696

MS28775-111

032570

035552

3918191

3903037

3914896

3909063

940937

MS35764-1297

9409225

68192

12256738-1

7346899

C5165X4

8120115B,

120115B

8 12011B

7346983

7979183

N5002-500MD

S-16255

1229-H-2816

NATIONAL/NATO

STOCK NUMBER

5330-01-272-1147

9320-00-421-7230

9390-00-158-2408

9320-00-451-8080

5330-00-740-9550

5330-00-005-0407

5330-01-141-9579

2520-00-405-1842

2520-00-557-6211

5330-00-374-4873

2520-01-130-5770

5330-00-579-8108

5330-01-135-4067

5330-01-135-4808

5310-01-340-8469

5310-01-195-1441

5310-01-331-9411

5310-01-143-0542

5305-00-292-4594

5306-01-052-2402

5305-00-638-2362

5365-00-378-2885

5365-01-110-8183

5330-00-734-6899

4730-00-969-6941

4730-00-054-2571

3120-00-537-0614

5310-00-740-9621

5325-00-914-5837

2815-00-815-0355

5325-01-162-7624

D-21

677

678

679

680

681

682

683

684

685

686

687

688

689

690

691

692

693

TM 9-2320-272-24-4

(1)


(2) (3) (6)

NOMENCLATURE

ITEM

NO

662

663

664

665

666

667

668

669

670

671

672

673

674

675

676

Snapring

Snapring

Snapring

Snapring

Soft Ball Bearing

Speed Nut

Spring

Spring Center Nut

Spring Center Nut

Spring Guide

Spring Nut

Spring Nut

Spring Nut

Springtite Assembly

Steering Knuckle Boot

Replacement Kit

Steering Parts Kit

Steering Parts Kits

Stop Screw

Suction Flange Gasket

Terminal

Thrust Ring Set

Thrust Washer

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

1790522K

5223281

5225875

67963

MS20659-127

157280

31P-27

MS3367-1-0

MS3367-3-9

MS3367-2-0

MS3367-1-9,

SST2SC

MS3367-6-9

12256372

MS3367-7-9

MS3367-1-9

MS3367-4

11669079-5

PART

NUMBER

112302

1229-U-2829

378391

MS90707-1050

213769

17-10015-13

68274

MS51968-14

10883157

23045085

7951891

5305-18

MS13532-35

1164243

5704510

NATIONAL/NATO

STOCK NUMBER

5325-00-420-9696

5325-01-129-6849

5325-00-477-0304

5325-00-419-3322

3110-01-079-8190

5310-00-885-7734

5360-00-664-5343

5310-00-732-0560

5305-00-139-7074

4710-00-557-5885

5310-01-122-2060

5310-01-122-2060

5315-00-814-3530

5306-00-238-5661

2530-01-25-9272

2530-01-339-7913

2530-01-340-0365

5306-00-281-1651

5330-00-171-7267

5940-00-113-3147

5310-00-469-4039

5975-00-984-6582

5975-00-451-5001

5975-00-899-4606

5975-00-074-2072

5975-00-133-8696

5340-01-104-9012

5975-00-570-9598

5975-01-013-2742

5975-00-727-5153

4730-01-331-6630

D-22

(1)

ITEM

NO

694

695

696

697

698

699

700

701

702

703

704

705

706

717

718

719

720

721

722

723

724

725

726

727

707

708

709

710

711

712

713

714

715

716

TM 9-2320-272-24-4


(2) (3) (6)

NOMENCLATURE

Tiedown Strap

Tiedown Strap

Tiedown Strap

Tiedown Strap

Top Cover Gasket

Transmission Oil Filter

Turbocharger Repair Kit

Two-Piece Seal

Universal Joint Kit

Universal Joint Parts Kit

Universal Plate

Valve Guide Pin

Valve Repair Kit

Valve Repair Kit

Valve Seat Inseat

Valve Spring

Vent Door Weatherseal

Washer

Washer

Washer

Washer

Washer

Washer

Wear Sleeve Kit

Weatherseal

Wiper

Wiper Strip

Wood

Wood

Wood

Wood

Wood

Woodruff Key

Woodruff Key

PART

NUMBER

MS3367-5-9

MS2367-202

MS3367-2-9

MS3367-3-0

7535079

6883044

3802149

032791A1

CP85WB62

5704528

7335053

6834410

289352

17BV361

170296

6836928

7373317

3902425

3906659

6834908

11511514

65003-S

3901798

99293

12368265

7409553

2012993-4

11682324-1

11682324-2

11682323-1

11682323-2

11665738

MS35756-8

MS35756-6

NATIONAL/NATO

STOCK NUMBER

5975-00-111-3208

5975-00-156-3253

5975-00-985-6630

5330-00-138-8388

2520-01-124-6469

2950-01-271-2345

2530-01-131-7445

2520-01-280-4129

2520-00-460-6477

5340-01-119-5682

2520-01-011-1068

2530-01-134-1834

4820-01-034-0971

5340-00-933-3009

5360-01-123-5483

9390-00-737-3317

5310-01-209-0508

5310-01-270-8417

5310-00-557-5942

5310-01-286-5452

5310-01-099-2550

5310-01-270-8388

4910-01-313-4621

9390-01-285-9623

2590-00-740-9553

5330-00-972-2635

2510-01-180-6164

5315-00-616-5526

5315-00-616-5514-

D-23

TM 9-2320-272-24-4

(1)


(2) (3) (6)

NOMENCLATURE

ITEM

NO

728

729

730

731

732

733

734

735

736

737

738

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

Woodruff Key

PART

NUMBER

MS35756-14

MS35756-17

MS20067-270

MS35756-13

MS35756-1

MS35756-38

8328341

MS35756-21

MS35156-20

M20067-493

9300-1

NATIONAL/NATO

STOCK NUMBER

5315-00-616-5520

5315-00-012-4553

5315-00-042-3293

5315-00-616-5521

5315-00-616-5519

5315-00-043-1789

5315-00-281-7651

5315-00-616-5500

5315-00-616-5501

5315-01-119-5239

5315-00-276-4438

D-24

TM 9-2320-272-24-4

A P P E N D I X E

COMMON AND SPECIAL TOOL IDENTIFICATION LIST

E - l . S C O P E

This appendix list common and special tools outside of the general mechanic’s toolkit which you will need when servicing M939 series vehicles.

E-2. EXPLANATION OF COLUMNS a.

Column (1) - Item Number. This number is assigned to each entry in the listing and is referenced in the Initial Setup of applicable task under the heading of special tools, test equipment, or tools.

b. Column (2) - Item Name. Name or identification of special or common tool.

c.

Column (3) - National Stock Number. This identifies the manufacturer’s part number or catalog number assigned to each tool or kit.

d. Column (4) - Part Number. This is the National Stock Number assigned to each tool or kit; use it to request or requisition the tool or kit.

e.

Column (5) - Reference. This is the supply catalog number in which the common tool can be found.

Special tools are not found in supply catalogs and are referenced individually in the reference column.

E-1

REFERENCE

CODE NO.

1

2

3

6

7

4

5

13

14

15

16

17

18

19

20

21

22

23

24

8

9

10

11

12

25

26

27

28

29

30

31

TM 9-2320-272-24-4

(1)

COMMON AND SPECIAL TOOL IDENTIFICATION LIST (Contd)

(2) (3) (4) (5)

32

33


NUMBER

NATIONAL/NATO

STOCK NUMBER

REFERENCE

General's Mechanic Tool Kit

Adapters

Adjusting Wrench

Air Gauge Assembly

Air Seal Installer

Angle Cutter, 60

Ball Joint Vise

SC5180-90CL-N26

J-24459

3375165

20511320

20511263

GGG-C-613

1160002854

5180-00-177-7033

5120-01-054-4045

4910-01-097-6927

5220-01-298-5730

5120-01-285-7620

5133-00-228-2323 4940-95-CL-BO2

4910-00-999-1506 Special Tool

Barring Tool

Bead Cutting Tool

ST-747

ST-788

Bearing Installer J-25393A

Bearing Installer, Front Support J-24457

Bearing Punch 20511262

4910-00-150-5798

5110-00-932-2089

5120-01-132-5448

5120-01-141-9459

5120-01-285-5192

Special Tool

Special Tool

Special Tool

Special Tool

Bearing Replacer 7950082 5120-00-795-0082 Special Tool

Bearing Replacer

Bearing Replacer

Belt Tension Gauge

Bolt Inserter Tool

Boring Tool, Oil Pump

Brake Reliner

Brake Repair Pliers

Brakeshoe Adjusting Tool

Burnishing Tool

7950159

J-28435

ST-1136

5120-00-795-0159

5120-01-134-8449

5220-01-141-5776

5120-00-792-1612

5120-01-132-5470

Special Tool

J-35198

3375206

J-34061

ST-708

4910-01-220-1512

4910-01-085-7824

MILR 13495TYCR1 4910-00-173-5310 4910-95-CL-A31

J-33111 5120-01-152-2318

5120-01-154-3029

4910-00-999-1503 Special Tool

Special Tool

Bushing Installer

Bushing Installer, Center

Support

Bushing Replacer

3005319

J-24794

J-36376

Cam Busing Replacement Tool ST-782

Center Support Lifter

Cleaning Brush

J-24455

ST-876

Compressor Bar and Screw

Compressor Base

Compressor, Low and First

Spring

Compressor, Piston Ring

Crosshead Guide Spacer

J-24475

J-24475-A

J-24452

ST-755

ST-633

5120-01-132-5469

5120-00-953-9664

5120-01-054-4001

7920-00-168-3244

5120-01-132-5449

5120-01-132-5449

5120-01-054-7221

5120-00-116-7676

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

4910-00-150-5797

E-2

REFERENCE

CODE NO.

34

35

36

37

38

39

40

41

42

43

44

45

46

57

58

59

60

61

62

63

64

65

50

51

52

53

54

55

56

TM 9-2320-272-24-4

(1)


(2) (3) (4) (5)

REFERENCE

47

48

49


NUMBER

Cutter Seat

Cylinder Liner Clamps

Dial Indicator

ST-662

3822503

196A

Driver Handle

Driver Handle

J-24202-4

J-8092

Dust Shield Installer

Electrical Tool Kit

J-24198

7550526

Engine and Transmission Sling J-36130-812

Engine Barring Tool

Engine Barring Tool

Engine Repair Stand

3377321

3377371

3375193

First Clutch Clearance Gauge J-26914

Forward Clutch Clearance

Gauge

J-29146

Fourth Clutch Clearance Gauge J-29156

Front Support Lifter

Fuel Injecion Tester

(Test Stand)

J-24473

11020200

Fuel Pump Test Stand

Gauge, Hydraulic Pressure

Gauge Block

Gauge, Injector Protrusion

Gauge, Keystone

Gauge, Mechanical Force

Gauge, Wheel Alignment

Toe-In/Out

Gear Pump Block Plate

DFP 156

3005456

ST-547

3376220

J-24599

WA361

Gear Unit Lifter

Guide Pin

Guide Pin

Handle

Heat Gun

Holding Fixture

Holding Fixture Adapter Set

Holding Fixture Base

ST-844

J-24454

J-1927-1

J-24315-1

7010321

500A

J-23642

J-24462

J-3289-20

NATIONAL/NATO

STOCK NUMBER

4910-00-999-1208

5120-01-262-7309

5120-00-277-8840

5120-01-054-4042

5120-00-677-2259

5120-01-054-4052

5180-00-876-9336

4910-01-353-2519

5120-01-262-7307

5120-02-285-5193

4910-00-977-7506

5210-01-065-9030

5210-01-134-8224

5120-01-134-8225

5120-01-054-4056

4910-00-817-7431

4910-01-194-7667

4910-00-792-8304

5210-01-157-3091

5210-00-690-7949

5220-01-028-1109

5210-01-018-2832

5210-00-529-1205

5365-00-904-2159

5120-01-054-4057

5120-01-144-4483

5315-01-141-9458

5120-00-601-2234

4940-00-561-1002

5120-01-132-5468

5120-01-054-4043

5120-01-144-4484

4910-95-CL-A63

Special Tool

Special Tool

Special Tool

4910-95-CL-A31

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

4910-95-CL-A31

4910-95-CL-A74

Special Tool

Special Tool

Special Tool

Special Tool

E-3

TM 9-2320-272-24-4

(1)


(2) (3) (4) (5)

REFERENCE

CODE NO.

66

67

68

69

70

71

72

73

74

75

88

89

90

91

92

81

82

83

84

85

86

87

76

77

78

79

80

93


NUMBER

NATIONAL/NATO

STOCK NUMBER

REFERENCE

Indicator, Level and Angle

Injection Sleeve Extractor

Injector Leakage Detector

Injector and Valve Adjustment

Kit

Injector Body Wrench

3375855

ST-1140

3375375

3375842

4910-00-074-0020

4910-00-150-5858

5120-01-029-6861

4910-00-548-7984

Special Tool

Special Tool

Special Tool

ST-1298 5120-00-033-2738

Injector Nozzle Tester

Injector Sleeve Cutter

Injector Sleeve Expander

Tool/Cutter

Injector Sleeve Holding Tool

Injector Sleeve Installation

Mandrel/Driver

Injector Timing Fixture

Inner Wheel Socket

Liner Clamp Set

7551255

ST-884

ST-880

ST-1179

ST-1227

3375522

5120-00-378-4411

3376669

Liner Driver, Engine

Cylinder Sleeve

ST-1229

Micrometer Set, Outside, 0-6 in.

GGG-C-105

TYICLISTA

Micrometer, Depth 445BS-6RL

Micrometer, Inside, 0-1 In.

Micrometer, Inside, 2-12 In.

Mounting Plate

GGG-C-105

124B

11600040

Mounting Plate

Multimeter

Nozzle Cleaning Kit

Oil Filter Wrench

Oil Primer Pump

J-29927

1P0540

Oil Pump Body Centering Band J-24461

Output Shaft Oil Seal Installer

Output Shaft Seal and

Dust Shield Remover

Output Shaft Seal and

Dust Shield Remover

3375133

AN/PSM-45

3376947

J-24620

J-24171

J-29355

4910-00-255-8641

4910-00-981-3105

3441-00-922-6699

5120-00-104-1795

5120-00-981-3108

4910-01-394-0391

5120-00-378-4411

5120-00-104-1816

5120-00-999-1206

5210-00-554-7134

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

4910-95-CL-A63

5120-00-619-4045 4910-95-CL-A63

5210-00-221-1918

5120-00-221-1921 4910-95-CL-A63

4910-00-977-7505

4910-01-128-2685 Special Tool

6625-01-139-2512 4910-95-CL-A72

2915-01-285-2527

5120-01-037-1595

5120-01-217-9642

5120-01-054-4044

5120-01-132-5466

5120-01-048-2153

5120-01-135-1978

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

E-4

TM 9-2320-272-24-4

(1)


(2) (3) (4) (5)

REFERENCE

REFERENCE

CODE NO.

94

95

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

96

97

98

99

100


NUMBER

Pin Remover

Piston Return Spring

Compressor

Piston Ring Expander

Piston Ring Groove Gauge

Plunger Lift Device

Portable Magnetic Tester

Power Steering Pressure

Gauge Kit

Puller Kit

Puller Kit, Mechanical

Puller Kit, Universal

Puller Screw

J-28708

J-6438-01

ST-763

ST-560

1-688-130-135

ST-1166

7010267

1178

GGG-P 781

J-24420

8366689

Puller Set, Bearing

Converter Turbine

Puller, Crosshead Guide

Puller, Cylinder Liner

Puller, Main Bearing Cap

Puller, Mechanical

J-26956

ST-1134

3376015

ST-1178

3822786

Puller, Mechanical

Puller, Side Plug

Rack Extension

CG60DB

KDEP-1056

9-681-233-100

7950136 Rear Axle Oil Seal Wiper

Replacer

Retainer Ring Depth Tool

Ring Bearing Installer

J-24453

J-24447

ST-691 Rocker Lever Bushing Block

And Mandrel

Seal Retainer Remover and

Replacer

Y-56205

Second Clutch Clearance Gauge J-26918

Separation Tube

Shaft Installation Tool

Slide Hammer

Slide Hammer

Snap Gauge

KDEP-1052

3375204

3376617

J-6125-1

A210605

NATIONAL/NATO

STOCK NUMBER

5120-01-176-3893

5120-01-132-5465

5120-00-150-7486

5210-00-999-1209

4910-01-338-6241

6635-01-128-2676

4910-00-627-7043

5120-00-313-9496 4910-95-CL-A72

5180-00-423-1596 4910-95-CL-A31

5180-00-999-4053

5120-00-836-6689

Special Tool

Special Tool

5120-01-134-2338

4910-00-150-5848

5120-01-143-2032

5120-01-141-5777

5120-01-291-5769

5120-00-620-0020

5120-01-343-2585

5340-01-341-6572

5120-00-795-0136 Special Tool

5120-01-054-4050

5120-01-054-4054

3460-00-999-1210

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

5210-01-132-5467

4910-10-336-8204

4910-01-118-3747

Special Tool

Special Tool

5120-01-187-3626

5120-01-112-2165 Special Tool

5220-00-449-7013 4910-95-CL-A63

E-5

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

TM 9-2320-272-24-4

(1)


(2) (3) (4) (5)

REFERENCE

REFERENCE

CODE NO.

124

125

126

127

128

129

130

131

132

133

134


NUMBER

Snapring Gauge

Snapring Gauge

Soldering Torch Kit

J-24208-4

J-6843-01

LP-999

Spindle Bearing Sleeve Remover 7950127

Spindle Bearing Sleeve Replacer

(Front Axle Oil Seal)

Spring Compressor

Main Regulator and Lockup

Spring Pack Adjusting Tool

7950129

J-24459

ST-984

Spring Tester

Spring Tester

Spring Tester

Tappet Holder

J-22738-02

SPT

3375182

KDEP-1068

NATIONAL/NATO

STOCK NUMBER

5120-01-116-5016

5120-00-293-0186

3439-00-542-0531

5120-00-378-4301

5120-00-795-0129

5120-01-054-4045

4910-00-150-5805

4940-01-138-8259

6635-00-641-7346

4910-01-142-4929

5120-01-345-2586

Special Tool

4910-95-CL-A62

4910-95-CL-A74

Special Tool

Special Tool

Special Tool

4910-95-CL-A63

135

136

Tappet Spring Compressor

Telescoping Gauge Set

KDEP-1505

GGG-G-17

5120-01-341-6000

5210-00-473-9350 4910-95-CL-A63

Test Kit

Tester, Injector Spray Angle

Third Cluth Clearance Gauge

Tool Driver

Torque Angle Gauge

Torque Wrench

Torque Wrench Adapter

Torque Wrench, 1/2-In. Drive

Torque Wrench, 3/4 In. Drive

MILT 13011B

11600056

J-26916

ST-1122

3823878

ST-753-1

ST-669

A-A-2411

TES18000A

Torque Wrench, 3/8-In Drive

Transmission Jack

TE-12A

9037-20BM

J-26282 Transmission Shift Lever

Seal Installer

Transmission Shift Lever

Seal Remover

Travel Template

J-26401

Tube Reducer

Vacuum Tester

3375355

23622

ST-1257

Valve Guide Arbor ST-954

Valve Guide Arbor (Mandrel Set) ST-663

4910-00-250-2423

4910-00-999-1501

5210-01-141-9457

4910-00-150-5843

5120-01-386-5992

2815-00-972-9661

5120-00-103-4987

5120-00-640-6364

5120-01-118-3679

5120-00-230-6380

4910-00-585-3622

5120-01-115-1161

5120-01-118-6264

4910-01-074-0020

4730-01-284-9086

4910-01-144-3837

4910-00-150-5804

3460-00-999-1173

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

Special Tool

4910-95-CL-A31

4910-95-CL-A31

4910-95-CL-A31

4910-95-CL-A62

Special Tool

Special Tool

E-6

TM 9-2320-272-24-4

(1)


(2)

NOMENCLATURE

(3)

PART

NUMBER

(4)

NATIONAL/NATO

STOCK NUMBER

(5)

REFERENCE

REFERENCE

CODE NO.

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

Valve Pin Remover J-24412-2

Valve Seat Insert Extractor ST-1279

Valve Seat Insert Staking Tool ST-1124

Valve Seat Insert Tool

Vernier Caliper, 0-6 In.

Wheel Assembly Tool

Wrench Box

Wrench, Cup Retainer

Wrench, Crowfoot

Wrench, Crowfoot Injector

ST-257

GGG-C-111

J-35193

CXM 1519

ST-995

GGG-C-1507

ST-1072

Wrench, Locknut

Wrench, Spanner

3375166

4C4734

Wrench, Spanner

Gauge, Pressure

Flowmeter, 2-30 GPM

Flowmeter, 10-100 GPM

8747917

PDSS-1P-210A-004

701-030

801-100

5120-01-048-3128

5120-01-128-2679

4910-00-150-5844

4910-00-345-3708

5210-00-113-1548

4910-01-218-4490

5120-01-178-5351

5120-00-155-7492

5120-00-184-8390

4910-00-185-8511

4910-01-097-6928

5120-01-440-1710

6680-01-188-0289

Special Tool

Special Tool

4910-95-CL-A31

Special Tool

Special Tool

Special Tool

Special Tool

1U6680

Special Tool

E-7/(E-8 blank)

-

-

-

-

TM 9-2320-272-24-4

A P P E N D I X F

ILLUSTRATED LIST OF MANUFACTURED ITEMS

S e c t i o n I . I N T R O D U C T I O N

This appendix includes complete instructions for making items authorized to be manufactured or fabricated at Unit, Direct Support and General Support Maintenance levels.

All bulk materials needed to manufacture the item are listed by part number or specification number in a tabular list on the illustration.

S e c t i o n I I . M A N U F A C T U R E D I T E M S P A R T N U M B E R I N D E X

MATERIALS

DESCRIPTION

Mild Tool Steel Bar

NSN

9510-00-042-1493

Figure F-l. Flange Puller Standoff.

NOTE:

1.

Dimensions shown are in inches with metric equivalent.

2.

All dimensions are +/- 0.30 in. (0.76 mm).

INSTRUCTIONS:

Fabricate and finish per diagram above.

F-1

TM 9-2320-272-24-4

S e c t i o n I I . M A N U F A C T U R E D I T E M S P A R T N U M B E R I N D E X ( C o n t d )

MATERIALS

DESCRIPTION

Screw

NSN

5305-01-072-4270

Figure F-2. Guide Screw.

NOTES:

1.

Two guide screws are required.

2.

Fabricate from screw part number 177734 (NSN 5305-01-072-4270) or equivalent.

PROCEDURE:

1.

Remove head of screw at A.

2.

Cut slot in screw at B. Slot shall be large enough to accommodate screwdriver tip.

F-2

TM 9-2320-272-24-4

A P P E N D I X G

TORQUE LIMITS

This appendix provides general torque limits for screws used on M939, M939A1, and M939A2 vehicles.

Special torque limits are indicated in the maintenance procedures for applicable components. The general torque limits given in this appendix shall be used when specific torque limits are not indicated in the maintenance procedure. These general torque limits cannot be applied to screws that retain rubber components. The rubber components will be damaged before the correct torque limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the screw or nut until it touches the metal bracket, then tighten it one more turn.

Table G-l lists dry torque limits. Dry torque limits are used on screws that do not have lubricants

applied to the threads. Table G-2 lists wet torque limits. Wet torque limits are used on screws that have

high-pressure lubricants applied to the threads. For metric fasteners, refer to table G-3 for torque limit requirements.

a.

Measure the diameter of the screw you are installing.

c..

d.

Under the heading SIZE, look down the lefthand column until you find the diameter of the screw you are installing (there will usually be two lines beginning with the same size).

In the second column under SIZE, find the number of threads per inch that matches the number of threads you counted in step b.

CAPSCREW HEAD MARKINGS

Manufacturer's marks may vary. These are all SAE

Grade 5 (3-line).

Metric screws are of three grades: 8.8, 10.9, and 12.9.

Grades & Manufacturer’s marks appear on the screw head.

b.

Count the number of threads per inch.

e.

To find the grade screw you are installing, match the markings on the head to the correct picture of CAPSCREW HEAD

MARKINGS on the torque table.

f.

Look down the column under the picture you found in step e. until you find the torque limit (in lb-ft or N°m) for the diameter and threads per inch of the screw.

G-1

TM 9-2320-272-24-4

Table G-1. Torque Limits for Dry Fasteners.

CAPSCREW HEAD MARKINGS

11

18

10

16

9

14

8

14

24

14

20

13

20

12

18

20

28

18

24

16

_____

5/8

5/8

3/4

3/4

7/8

1

7/8

1

1-1/8

3/8

7/16

7/16

1/2

1/2

9/16

9/16

1/4

1/4

5/16

5/16

3/8

TORQUE

SIZE

SAE GRADE

N0.1or2

SAE GRADE

N0. 5

SAE GRADE

NO. 6 or 7

SAE GRADE

N0. 8

DIA.

THREADS

DIA.

INCHES PER INCH MILLIMETERS

POUND NEWTON POUND NEWTON POUND NEWTON

POUND NEWTON

FEET METERS

FEET METERS FEET METERS FEET METERS

1-1/4

1-3/8

1-1/2

_______

_______

_______

6.35

6.35

7.94

7.94

9.53

9.53

11.11

11.11

12.70

12.70

14.29

14.29

15.88

15.88

19.05

19.05

22.23

22.23

25.40

25.40

28.58

31.75

34.93

38.10

6 8.14

11 14.92

13 17.63

18 24.41

20 27.12

28 37.97

30 40.68

39 52.88

41 55.60

51 69.16

55 74.58

63 85.43

95 128.82

105 142.38

115 155.94

160 216.96

175 237.30

235 318.66

250 339.00

________

5 6.78

_____

_____

_ _ _ _

_____

______

_____

_ _ _ _

590

660

800.

880

150

170

270

295

395

435

49

55

75

85

110

120

8

10

17

19

31

35

______

1,460-

1,680

1,940-

2,200

203.40

230.52

366.12

400.02

535.62

589.86

800.04

894.96

1,084.8-

1,193.3

66.44

74.58

101.70

115.26

149.16

162.72

10.85

13.56

23.05

25.76

42.04

47.46

_ _ _ _ _

1,979.8.

2,278.l

2,630.6-

2,983.2

10

_ _ _ _

19

_ _ _ _

34

_ _ _ _

55

_ _ _ _

74.58

_ _ _ _

85

115.26

_ _ _

_ _ _ _

120 162.72

_ _ _

_ _ _ _

167 226.45

_ _ _

_ _ _ _

280 379.68

_ _ _ _

_ _ _ _

440 596.64

_ _ _ _

_ _ _

660 894.96

_ _ _ _

_ _ _ _

_ _ _ _ _ _ _ _

13.56

_ _ _ _

25.76

_ _ _

46.10

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

12

14

24

27

44

49

120

155

170

70

78

105

210

240

375

420

605

675

910 1,233.96

990 1,342.44

1,2801,735.68

1,440 1,952.64

1,820 2467.92

2,000

2,712.00

2,3803,227.28

2,720 3.688.32

3,1604,284.96

3,560 4,827.36

284.76

325.44

508.50

569.52

820.38

915.30

16.27

18.98

32.54

36.61

59.66

66.44

94.92

105.77

142.38

162.72

210.18

230.52

G-2

TM 9-2320-272-24-4

Table G-2. Torque Limits for Wet Fasteners.


SIZE

SAE GRADE

No.1 or 2

SAE GRADE

No .5

TORQUE

SAE GRADE

N0.6 or 7

SAE GRADE

No.8

DIA.

THREADS DIA.

POUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTON

INCHES PER INCH

MILLIMETERS FEET

METERS FEET METERS FEET METERS FEET METERS

5/8

5/8

3/4

3/4

7/8

7/8

1

1

1-1/8

7/16

7/16

1/2

1/2

9/16

9/16

1/4

1/4

5/16

5/16

3/8

3/8

1-1/4

1-3/8

1-1/2

14

20

13

20

12

18

24

16

24

20

28

18

11

18

10

16

9

14

8

14

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

6.35

6.35

7.94

7.94

9.53

9.53

11.11

11.11

12.70

12.70

14.29

14.29

15.88

15.88

19.05

19.05

22.23

22.23

25.40

25.40

28.58

31.75

34.93

38.10

25.2

27.0

35.1

36.9

45.9

49.5

11.7

16.2

18.0

4.5

5.4

9.9

56.7

76.89

85.5

115.94

94.5

128.14

103.5

140.35

144.0

195.26

157.5

213.57

211.5

286.79

225.0

305.10

34.17

36.61

47.60

50.04

62.24

67.12

6.1

7.32

13.42

15.87

21.97

24.41

_ _ _ _ _

_ _ _ _

_____

_ _ _ _ _

_ _ _ _ _

______

_ _ _ _ _

_ _ _ _ _

7.2

9.0

15.3

17.1

27.9

31.5

9.76

12.20

20.75

23.19

37.83

42.71

9.0

_____

17.1

____

30.6

_ _ _

12.20

_____

23.19

_ _ _ _

41.49

_ _ _ _

44.1

49.5

67.5

76.5

99.0

108.0

59.80

67.12

49.5

_ _ _

67.12

_ _ _

91.53

103.73

76.5

_ _ _ _ _

103.73

_ _ _ _ _

134.24

108.0

146.45

146.45

_ _ _ _ _ _ _ _ _

135.0

183.06

150.3

203.81

_____ _ _ _ _ _

153.0

207.47

243.0

329.51

252.0

341.71

_ _ _ _ _ _ 265.5

360.02

_ _ _ _ _

355.5

482.06

396.0

536.98

391.5

530.87

_____ _ _ _ _ _

531.0

594.0

720.04

805.46

720.0976.32-

792.0

1,073.95

594.0

_____

_ _ _ _ _

805.46

_ _ _ _ _

_ _ _ _ _

_ _ _ _

_____

_____

_____

1,314.0-

1,512.0

1,746.0.

1,980.0

1,781.78-

2,050.27

2,367.58-

2,684.88

_ _ _ _

_ _ _ _

_ _ _ _

_ _ _ _

63.0

70.2

94.5

108.0

139.5

153.0

10.8

12.6

21.6

24.3

39.6

44.1

189.0

216.0

337.5

378.0

544.5

607.5

819.0

1,110.56

891.0

1,208.20

1,152.01,562.11-

1,296.0

1,757.38

1,637.99- 2,221.11-

1,800.00

2,440.80

2,142.0.

2,904.55-

2,448.0

3,319.49

2,844.0.

3,856.46

3,204.0

4,344.62

256.28

292.90

457.65

512.57

738.34

823.77

85.43

95.19

128.14

146.45

189.16

207.47

14.64

17.09

29.29

32.95

53.70

59.80

G-3

TM 9-2320-272-24-4


Table G-3.. Torque Limits for Metric Fasteners.

SIZE

M12

M14

M16

M20

M24

M6

M8

M10

M30

M36

POUND

FEET

7-11

21 - 35

45 - 65

80-120

130-190

200-280

400-520

700-900

1,400 - 1,800

2,400 - 3,000

TORQUE

NEWTON

METERS

9.49 - 14.92

28.48-47.46

61.02 - 88.14

108.48 - 162.72

176.28 - 257.64

271.20 - 379.68

542.40 - 705.12

949.20 - 1,220.40

1,898.40 - 2,440.80

3.254.40 - 4,068.OO

G-4

TM 9-2320-272-24-4

A P P E N D I X G ( C o n t d )

Tubing Application Tightening Assembly Instructions.

Slide tubing over barbed insert until it bottoms on fitting.

1. Slide nut and sleeve on tubing.

2. Slide I.D. of tubing onto fitting insert until it bottoms.

3. Assemble nut to fitting body.

4. Tighten assembly finger-tight to cover body threads.

1.

2.

3.

4.

Slide nut and sleeve on tubing.

Slide I.D. of tubing onto fitting insert until it bottoms.

Assemble nut to fitting body.

Finger-tighten nut. From that point, tighten with a wrench two complete turns.

1. Cut tubing to desired length. Ensure ends are cut reasonably square.

2. Slide tubing into preassembled fitting and push until tube bottoms.

3. Tighten nut as indicated in chart. Another check on proper assembly is dimension A, when nut is fully tightened.

DISASSEMBLY - Remove nut and pull tubing out of fitting body. Insert will remain on tubing.

REASSEMBLY - Push tubing and insert into fitting body until it bottoms. Thread nut onto fitting body and tighten as in step 3.

TUBE O.D. TIGHTEN NUT TO:

1/4

3/8

1/2

5/8

3/4

A

85 - 115 lb-in. (9.6 - 13.0 N°m) .085/.105

12 - 17 lb-ft (16.3 - 23.1 N°m) .125/.145

25 - 33 lb-ft (33.9 - 44.7 N°m) .100/.120

26 - 35 lb-ft (35.3 - 47.5 N°m)

.115/.135

38 - 50 lb-ft (51.5 - 67.8 N°m) .180/.200

G-5

TM 9-2320-272-24-4


Tubing Application Tightening Assembly Instructions (Contd).

1. Slide nut and sleeve on tubing. Threaded end of nut (1) must face out.

2. Insert tubing into fitting. Ensure tubing is bottomed on fitting shoulder.

3. Thread nut onto fitting body until it is hand tight.

4. From that point, tighten with a wrench the number of turns indicated at right.

Some tasks require the use of a torque wrench adapter when the nut or screw cannot be reached with a regular socket on the end of the torque wrench. These adapters add to the overall length of the torque wrench and make the dial or scale reading less than the actual torque applied to the nut or screw. To prevent overtorquing and damage to equipment, calculate correct dial or scale reading using Conversion

Formula (para. G-5).

G-6

TM 9-2320-272-24-4


Corrected dial or scale readings are determined by the use of the following formula:

Corrected = reading

Required t o r q u e v a l u e +

Length of torque wrench + Length of adapter

Length of torque wrench

NOTE

The length of the torque wrench is measured from the center of the handle to the center of the drive. The length of the adapter is measured from the center of the drive to the center of the wrench.

In this example, the torque wrench measures 22 in. (55.9 cm) and the adapter is 3 in. (7.6 cm). The required torque is 19 lb-ft (25.8 N°m).

Corrected = reading

C o r r e c t e d = reading

Corrected = reading

Corrected = reading

19 lb-ft (25.8 N•m) +

19 lb-ft (25.8 N•m) +

22 in. (55.9 cm) + 3 in. (7.6 cm)

22 in. (55.9 cm)

25 in. (63.5 cm)

22 in. (55.9 cm)

19 lb-ft (25.8 N•m) +

1.14

17 lb-ft (23.1 N•m)

G-7/(G-8 blank)

Foldout 1.

Foldout 2.

Foldout 3.

Foldout 4.

Foldout 5.

Foldout 6.

Foldout 7.

Foldout 8.

Foldout 9.

Foldout 10.

A P P E N D I X H

S C H E M A T I C A N D W I R I N G D I A G R A M S

M939/A1 Electrical System Wiring Diagram

M939A2 Electrical System Wiring Diagram (1 of 2)

M939A2 Electrical System Wiring Diagram (2 of 2)

M939/A1 Cab Air System Diagram

M939/A1 Air Supply Line Diagram

M939/A1 Air Control Line Diagram

M939/A1 Air Vent Line Diagram

M939A2 Schematic Diagram for M939 Expansible Van

M939A2 CTIS Electrical/Pneumatic Diagram

M939A2 Air Supply Line to CTIS Diagram

TM 9-2320-272-24-4

H-3

H-5

H-7

H-9

H-11

H-13

H-15

H-17

H-19

H-21

H-1 /(H-2 blank)

TM 9-2320-272-24-4

Para Page

A

100-amp alternator harness replacement:

Installation.. .......................

3-427b 3- 1098

Removal.. ............................

3-427a 3- 1096

100-amp alternator replacement:

Installation.. .......................

3-426b 3-1094

Removal..............................

3-426a 3-1094

100-amp voltage regulator replacement:

Installation .........................

3.428b 3-1100

Removal ..............................

3-428a 3-1100

3-phase receptacle wiring harness replacement:

Installation.. .......................

5-100b 5-604

Removal.. ............................

5-100a 5-604

400 Hz converter harness conduit replacement:

Installation.. .......................

4-164b 4-794

Removal..............................

4-164a 4-794

400 Hz converter replacement:

Installation.. .......................

4-169b 4-804

Removal.. ............................

4-169a 4-804

400 Hz supply wiring harness replacement:

Installation.. .......................

5-96b 5-592

Removal ..............................

5 - 9 6 a 5 - 5 9 0

A-frame kit maintenance:

Inspection.. .........................

3-414b 3-1048

Installation.. .......................

3-414c 3-1048

Removal ..............................

3-414a 3-1046

Accelerator linkage (M939/A1) maintenance:

Adjustment.. .......................

3-42c

3-124

Installation.. .......................

3-42b 3-124

Removal.. ............................

3-42a 3-124

Accelerator linkage (M939A2) maintenance:

Adjustment.. .......................

3-43f 3- 128

Assembly ............................

3 - 4 3 d 3 - 1 2 8

Cleaning and inspection ...... 3-43c 3-128

Disassembly.. .....................

3-43b 3-126

Installation.. .......................

3-43e 3-128

Removal.. ............................

3-43a 3-126

Accelerator pedal, bracket, rod, and stopscrew replacement:

Installation.. .......................

3-41b 3-123

Removal.. ............................

3-41a 3-123

INDEX

Para Page

Access door, bonnet, maintenance:

Assembly ............................

5 - 8 6 d 5 - 5 5 0

Cleaning and inspection......

5 - 8 6 c 5 - 5 5 0

Disassembly.. .....................

5-86b 5-550

Installation.. .......................

5-86e 5-552

Removal ..............................

5 - 8 6 a 5 - 5 4 9

Access step, spare tire carrier, cargo, replacement:

Installation.. .......................

3-260b 3-720

Removal.. ............................

3-260a 3-720

Access step, spare tire carrier, dump and tractor, replacement:

Installation.. .......................

3-255b 3-711

Removal ..............................

3-255a 3-710

Accessory drive and pulley, engine, maintenance:

Accessory drive assembly .... 4 - 2 6 e 4 - 1 9 0

Accessory drive cleaning and inspection .........................

4-26d 4-188

Accessory drive disassembly.. ....................

4-26c 4-188

Accessory drive installation. 4-27f 4-190

Accessory drive pulley installation.. .....................

4-26g 4-192

Accessory drive pulley r e m o v a l .................... .........

4 - 2 6 a 4 - 1 8 6

Accessory drive removal.. .... 4-26b 4-186

Actuator, front brake, repair:

Adjustable actuator assembly ..........................

4-112e 4-598

Adjustable actuator disassembly.. .....................

4-112a 4-596

Cleaning and inspection ......

4-112c 4-596

Stationary actuator assembly ..........................

4-112d 4-598

Stationary actuator disassembly.. ....................

4-112b 4-596

Actuator, rear brake, repair:

Assembly ............................

4-113c 4-602


4-113b 4-600

Disassembly.. .....................

4-113a 4-600

Adapter housing and first clutch piston maintenance:

Assembly.. ..........................

5-57d 5-380


5 - 5 7 c 5 - 3 8 0

Disassembly.. .....................

5-57b 5-378

Removal.. ............................

5-57a 5-378

Adapter housing, low clutch, low planetary carrier, and rear cover installation:

Installation.. .......................

5-58 5-382

Index 1

TM 9-2320-272-24-4

Adjustment, bearing, wheel:

Front wheel bearing adjustment.. .......................

3-225a 3-648

Rear wheel bearing adjustment.. .......................

3-225b 3-650

Air Fuel Control (AFC) fuel pump filter replacement:

Installation.. .......................

3-31b 3-108

Removal.. ............................

3-31a 3-108

Aftercooler and tubes

(M939A2) replacement:

Installation.. .......................

3-76b 3-218

Removal.. ............................

3-76a 3-216

Air cleaner assembly and mounting bracket maintenance:

Inspection.. .........................

3-15b 3-52

Installation.. .......................

3-15c 3-54

Removal.. ............................. ..3-15a

3-52

Air cleaner hose (M939A2) maintenance:

Assembly.. ..........................

3-13d 3-48

Disassembly.. .....................

3-13b 3-48

Inspection.. .........................

3-13c 3-48

Installation.. .......................

3-13e 3-49

Removal.. ............................

3-13a 3-48

Air cleaner indicator and tube maintenance:


3 - 1 2 c 3 - 4 4

Installation.. .......................

3-12d 3-46

Removal.. ............................

3-12b 3-44

Testing.. .............................

3-12a 3-42

Air cleaner intake pipe

(M939/A1) maintenance:

Inspection.. .........................

3-14b 3-50

Installation.. .......................

3-14c 3-50

Removal.. ............................

3-14a 3-50

Air compressor (M939/A1) maintenance:

Assembly ............................

4 - 3 1 e 4 - 2 2 6

Cleaning.. ...........................

4-31c 4-220

Disassembly.. .....................

4-31b 4-218

Inspection and repair.. ........

4-31d 4-220

Installation and timing.......

4 . 3 1 f 4 - 2 3 2

Removal.. ............................

4-31a 4-214

Air compressor (M939A2) maintenance:

Assembly.. ..........................

4-52c 4-322


4 - 5 2 b 4 - 3 1 8

Disassembly.. .....................

4-52a 4-314

Air compressor and lines


Installation.. .......................

3-206b 3-576

Removal.. ............................

3-206a 3-574

Para Page

INDEX (Contd)

Para

Page

Air compressor coolant lines


Cleaning and inspection...... 3-57b 3-168

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-57c

3-168

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-57a 3-168

Air compressor coolant supply and return tubes (M939/A1) maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55c 3-161

Return tube installation . . . . . 3-55e 3-163

Return tube removal . . . . . . . . . . . 3-55b 3- 161

Supply tube installation . . . . . 3-55d 3-162

Supply tube removal . . . . . . . . . . . 3-55a 3-160

Air conditioner drain tube replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-382b 3-938

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-382a 3-938

Air conditioner manual starter switches replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-167b 4-800

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-167a 4-799

Air conditioner replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-88b 5-564

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-88a 5-563

Air couplings replacement:

Front air couplings

Installation . . . . . . . . . . . . . . . . . . . . . . . 3-208d 3-590

Front air couplings removal 3-208a 3-584

Rear air couplings installation (M923/A1/A21 3-208e 3-592

Rear air couplings removal

(M923/A1/A2) . . . . . . . . . . . . . . . . . . . 3-208b 3-586

Rear air couplings installation (M929/A1/A2,

M931/A1A2, M934/A1/A2,

M936/A1/A2) . . . . . . . . . . . . . . . . . . . .

3-208f 3-594


(M929/A1/A2,

M931/A1/A2,

M9341/A1/A2,

M936/A1/A2) . . . . . . . . . . . . . . . . . . . .

3-208c 3-588

Air cylinder, transfer case interlock, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-83b 4-506

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-83a 4-506

Air dryer and check valve maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464d 3-1272

Cleaning and inspection...... 3-464c 3-1272

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-464b 3-1272

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-464e 3-1274

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-464a 3-1270

Air dryer filter replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-465b 3-1276

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-465a 3-1276

Index 2

TM 9-2320-272-24-4

Air dryer kit (M923/A1/A2,

M9251/A1/A2, M927/A1/A2,

M928/A1/A2, M934/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-412b 3-1026

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-412a 3-1022

Air dryer kit (M929/A1/A2,

M930/A1/A2, M931/A1/A2,


Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-413b 3-1039

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-413a 3-1032

Air Fuel Control (AFC) tube

(M939A2) maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18b

3-61

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-18c

3-61

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-18a

3-61

Air gauge replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-87b

3-252

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-87a 3-252

Air governor maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-207d 3-582

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-207b 3-580

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-207a 3-580

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-207c 3-582

Air lines, fabrication . . . . . . . . . . . . . . .

3-452

3-1232

Air manifold tee, brake chamber, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-189b 3-520

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-189a 3-520

Air manifold, rear axle, maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-463c 3-1268

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-463a 3-1268

Air reservoir (supply tank), primary, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-202b 3-564

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-202a 3-562

Air reservoir (supply tank), secondary, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-203b 3-568

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-203a 3-566

Air reservoir drainvalves replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-205b 3-572

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-205a 3-572

Air reservoir one-way check valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-186b 3-514

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-186a 3-514

Air reservoir, emergency spring brake (supply tank), replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-204b 3-570

Removal .............................. 3-204a 3-570

Para Page

INDEX (Contd)

Para

Page

Air seals, hub, leak test:

Front hub leak test . . . . . . . . . . . . . 3-462a 3-1264

Rear hub leak test . . . . . . . . . . . . . .

3-462b 3-1266

Air vent control assembly, fresh, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-293b 3-784

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-293a 3-784

Airbrake hand control valve

(M931/A1/A2, M932/A1/A2) trailer, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-210b 3-598

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-210a 3-598

Alcohol evaporator replacement:

Installation ,........................ 3-211b 3-600

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-211a 3-600

Alternator and mounting bracket (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-79b 3-226

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-79a 3-224

Alternator drivebelts


Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78b

3-222

Installation and adjustment . . . . . . . . . . . . . . ......... 3-78c

3-222

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-78a 3-222

Alternator pulley (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-81b 3-232

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-81a 3-232

Alternator, 100-amp, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-426b 3-1094

Removal . . . ........................... 3-426a 3-1094

Alternator, mounting bracket, and pulley (M939A2) maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-80e 3-230

Alternator and mounting bracket installation . . . . . . . . . . 3-80d 3-230

Alternator and mounting bracket removal . . . . . . . . . . . . . . . .

3-80a 3-228

Pulley installation . . . . . . . . . . . . . . 3-80c 3-230

Pulley removal . . . . . . . . . . . . . . . . . . . . 3-80b

3-229

Amber warning light replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-469b 3-1283

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-469a 3-1283

Anchor post, toggle clamp, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-358b 3-897

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-358a 3-897

Index 3

TM 9-2320-272-24-4

Para

Appendix A, references:

Field manuals . . . . . . . . . . . . . . . . . . . . A-4

Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Other publications . . . . . . . . . . . . . . A-7

Publications index . . . . . . . . . . . . .. A-2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Technical bulletins . . . . . . . . . . . . . . A-6

Technical manuals . . . . . . . . . . . . . . A-5

Appendix B, Maintenance

Allocation Chart (MAC):

Explanation of columns in remarks, section IV . . . . . . . B-5

Explanation of columns in the MAC, section II . . . . . . . B-3

Explanation of columns in tool and test equipment requirements, section III . . . . . . . . . . . . . . . . . . . . . . . . .

B-4

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1

Maintenance functions . . . . . . . .

B-2

Appendix C, expendable/durable supplies and materials list:

Explanation of columns . . . . . . .

C-1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .

C-1

A-2

A-1

A-4

A-1

A-1

A-3

A-2

B-3

B-2

B-3

B-1

B-1

C-1

C-1

Appendix D, mandatory replacement parts:

Explanation of columns . . . . . . . D-2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D-l

Appendix E, common and special tool identification list:

Explanation of columns... . . . .

E-2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-1

Appendix F, illustrated list of manufactured items . . . . . . . . . . . . . .

F- 1

D-l

D-l

E-1

E-1

F-1

Appendix G, torque limits:

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G-1

How to use torque table...... G-3

Torque limits . . . . . . . . . . . . . . . . . . . . . .

G-2

Appendix H, schematic and wiring diagrams . . . . . . . . . . . . . . . . . . . .

H1

G-1

G-1

G-1

H-1

Approach plates, fifth wheel, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-249b 3-698

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-249a 3-698

Arm, pitman, replacement

(Ross):

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-227b 3-653

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-227a 3-653

Arm, pitman, replacement

(Sheppard):

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-228b 3-654

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-228a 3-654

Page

INDEX (Contd)

Para Page

Arm, roller, dump, maintenance:

Assembly.. ..........................

5- 104d 5-613

Disassembly .......................

5-104b 5-612


5-104c 5-612

Installation.. .......................

5-104e 5-613

Removal.. ............................

5-104a 5-612

Army documents, shipment of.. .........................

6-7

Army Petroleum, Oils, and

6-2

Lubricants (POL). .................

1-8 1-2

Assembly, PMCS .................... 2-18

2-58

Assist cylinder, steering, replacement:

Assembly.. ..........................

3-233c 3-664

Disassembly .......................

3-233b 3-664

Installation.. .......................

3-233d 3-666

Removal.. ............................

3-233a 3-662

Travel adjustment.. ............ 3-233e 3-666

Atmospheric fuel tank vent system kit replacement:

Installation.. .......................

3-44lb 3- 1141

Removal.. ............................

3-441a 3-1140

Atomizer (M939/A1), ether, replacement:

Installation.. .......................

3-37b 3-117

Removal.. ............................

3-37a 3-117

Atomizer and temperature sensor (M939A2), ether, replacement:

Installation.. .......................

3-38b 3- 118

Removal.. ............................

3-38a 3- 118

Automatic brake (hoist winch) adjustment:

Adjustment.. .......................

3-383 3-940

Automatic throttle kit

(M936/A1) replacement:

Installation.. .......................

3-440b 3-1136

Removal.. ............................

3-440a 3-1134

Auxiliary outlet socket and receptacle (M936/A1/A2) replacement:

Installation.. .......................

3-110b 3-298

Removal.. ............................

3-110a 3-298

Axle breather, front and rear, replacement:

Installation.. .......................

3-159b 3-438

Removal.. ............................

3-159a 3-438

Axle carrier differential, front and rear, maintenance:


4-100b 4-564

Installation.. .......................

4-100c 4-565

Removal.. ............................

4-100a 4-564

Index 4

TM 9-2320-272-24-4

Axle engagement air cylinder, transfer case, front, replacement:

Installation.. .......................

Removal ..............................

Axle leakage test:

Corrective action .................

Test.. ..................................

Axle seal, front, replacement:

Installation.. .......................

Removal ..............................

Axle shaft, rear, maintenance:

Inspection ...........................

Installation.. .......................

Removal ..............................

Axle, forward-rear and rearrear, replacement:

Installation.. .......................

Removal..............................

Axle, front, replacement:

Installation.. .......................

Removal ..............................

4-84b 4-508

4 - 8 4 a 4 - 5 0 8

4-106b 4-582

4-106a 4-582

3-160b 3-439

3-160a 3-439

3-157b 3-433

3-157c 3-433

3-157a 3-433

4-101b 4-570

4-101a 4-566

4 - 9 9 b 4 - 5 6 0

4 - 9 9 a 4 - 5 5 8

B

Backrest cushion, companion seat cushion, frame, and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-286b 3-770

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-286a 3-770

Backrest cushion, driver’s seat cushion, frame and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-285b 3-768

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-285a 3-768

Baffles, seals, and plates, radiator, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-272b 3-738

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-272a 3-738

Battery box cover replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-123b 3-332

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-123a 3-332

Battery box heater pad, engine coolant, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-404b 3-994

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-404a 3-994

Battery box replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-128b 3-342

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-128a 3-342

Battery cable and terminal adapter replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-124b 3-334

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-124a 3-334

Para Page

INDEX (Contd)

Para Page

Battery ground cable maintenance:

Connection.. ........................

3-126b 3-338

Disconnection ......................

3-126a 3-338

Battery maintenance:

Inspection and cleaning.. .... 3-125b 3-336

Installation.. .......................

3-125c 3-337

Removal.. ............................

3-125a 3-336

Beam rollers, retractable, replacement:

End roller installation....... .. 5 - 6 9 d 5 - 4 7 6

End roller removal ..............

5-69c 5-476

Support roller installation... 5 - 6 9 b 5 - 4 7 4

Support roller removal.. ......

5-69a 5-474

Beam, retractable beam drive shaft and lock, maintenance:

Cleaning, inspection, and repair.. .......................

5-68b 5-472

Installation.. .......................

5-68c 5-472

Removal.. ............................

5-68a 5-470

Beam, retractable, replacement:

Installation.. .......................

5-67b 5-468

Removal.. ............................

5-67a 5-468

Bearing adjustment, wheel:

Front wheel bearing adjustment.. .......................

3-225a 3-648

Rear wheel bearing adjustment.. .......................

3-225b 3-650

Bearing sleeve, spindle, replacement:

Installation.. .......................

4-97b 4-549

Removal.. ............................

4-97a 4-548

Bearings, crankshaft and main, maintenance:


5-8b 5-50

End play clearance.. ............

5-8d 5-56

Installation.. .......................

5-8c 5-52

Removal.. ............................

5-8a 5-48

Blackout and clearance lights wiring harness replacement:

Installation.. .......................

5-95b 5-588

Removal.. ............................

5-95a 5-588

Blackout and emergency light fixtures replacement:

Installation.. .......................

4-166b 4-798

Removal.. ............................

4-166a 4-798

Blackout bypass wiring harness maintenance:

Installation.. .......................

5-93c 5-580

Removal.. ............................

5-93a 5-580

Repair.. ...............................

5-93b 5-580

Index 5

TM 9-2320-272-24-4

Para

Blackout circuit plungers, hinged roof-operated, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-377b 3-924

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-377a 3-924

Blackout light maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117c 3-308

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-117b 3-308

Installation. . . . . . . . . . . . . . . . . . . . . . . . . 3-117d 3-308

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-117a 3-308

Blackout light switch and

110-volt receptacle replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-373b 3-916

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-373a 3-916

Blackout light switch, side and rear door maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-376b 3-922

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-376a 3-922

Blackout panel, window replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-352b 3-890

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-352a 3-890

Block, cylinder liners and, maintenance:


5-46

Cylinder liners installation. 5-7d

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

5-7b

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7a

5-36

5-34

Block, cylinder liners and, maintenance:

Cylinder liner and engine block cleaning and inspection . . . . . . . . . . . . . . . . . . . . . . . . .

5-28d 5-190

Cylinder liner inspection . . . . . 5-28a 5-184

Cylinder liner installation... 5-28f 5-194

Cylinder liner removal . . . . . . . . . 5-28b 5-186

Engine block assembly . . . . . . . .

5-28e 5-192

Engine block disassembly.. . 5-28c 5-188

Body assembly, cargo, maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-142d 4-718

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-142a 4-716

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-142c 4-718

Body, dump, maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-144c 4-728

Inspection and repair . . . . . . . . . .

4-144b 4-727

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-144a 4-726

Body, van, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-66b 5-466

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-66a 5-464

Body, wrecker, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-152b 4-750

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-152a 4-748

Page

INDEX (Contd)

Para Page

Bonnet access door maintenance:

Assembly.. ..........................

5-86d 5-550


5 - 8 6 c 5 - 5 5 0

Disassembly.. .....................

5-86b 5-550

Installation.. .......................

5-86e 5-552

Removal.. ............................

5-86a 5-549

Bonnet door maintenance:

Assembly.. ..........................

5-87d 5-560


5 - 8 7 c 5 - 5 5 8

Disassembly.. .....................

5-87b 5-556

Installation.. .......................

5-87e 5-562

Removal.. ............................

5-87a 5-554

Bonnet frame parts replacement:

Installation.. .......................

5-85b 5-546

Removal.. ............................

5-85a 5-544

Bonnet handle and control rod replacement:

Installation.. .......................

3-361b 3-900

Removal.. ............................

3-361a 3-900

Boom elevating cylinder packing replacement:

Installation. ........................

5-103b 5-610

Removal.. ............................

5-103a 5-610

Boom elevating cylinder repair:

Assembly.. ..........................

5-102c 5-608


5-102b 5-608

Disassembly.. .....................

5-102a 5-606

Boom elevating cylinder replacement:

Installation.. .......................

4-193b 4-911

Removal.. ............................

4-193a 4-910

Boom extension cylinder repair:

Assembly. ...........................

5-106c 5-628


5-10b 5-628

Disassembly .......................

5-106a 5-626

Boom extension cylinder replacement:

Installation.. .......................

4-196b 4-920

Removal.. ............................

4-196a 4-920

Boom floodlight wire replacement:

Installation.. .......................

3-385b 3-946

Removal.. ............................

3-385a 3-946

Boom repair and adjustment:

Assembly.. ..........................

4-204c 4-952


4-204b 4-950

Disassembly.. .....................

4-204a 4-950

Vertical adjustment.. ..........

4-204d 4-953

Boom replacement:

Installation.. .......................

4-194b 4-914

Removal.. ............................

4-194a 4-912

Index 6

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Boom roller maintenance:

Assembly ............................

4-197d 4-924


Disassembly.. .....................

4-197b 4-922

Installation.. .......................

4-197e 4-924

Removal..............................

4-197a 4-922

Boom, inner, replacement:

Installation.. .......................

4-195b 4-918

Removal..............................

4-195a 4-916

Boot, steering knuckle, maintenance:


Installation.. .......................

3-155c 3-430

Removal.. ............................

3-155a 3-430

Bows, cargo body cover, replacement:

Installation.. .......................

3-341b 3-872

Removal ..............................

3-341a 3-872

Box, battery, replacement:

Installation.. .......................

3-128b 3-342

Removal.. ............................

3-128a 3-342

Box, electrical junction, replacement:

Installation.. .......................

4-163b 4-792

Removal ..............................

4-163a 4-792

Box, electrical load center, maintenance:

Assembly ............................

4-161c 4-782

Disassembly.. .....................

4-161b 4-782

Installation.. .......................

4-161d 4-784

Removal.. ............................

4-161a 4-776

Box, electrical, maintenance:

Inspection ...........................

4-162b 4-790

Installation.. .......................

4-162c 4-790

Removal..............................

4-162a 4-790

Brace, dump safety, installation:

Installation.. .......................

4-145b 4-730

Removal.. ............................

4-145a 4-730

Bracket (M939/A1), personnel fuel burning heater mounting, replacement:

Installation.. .......................

4-216b 4- 1006

Removal ..............................

4-216a 4-1006

Bracket (M939A2), personnel fuel burning heater and mounting, replacement:

Installation.. .......................

4-217b 4-1008

Removal ..............................

4-217a 4-1008

Bracket (M939A2), surge tank and, replacement:

Installation.. .......................

3-62b 3-184

Removal ..............................

3 - 6 2 a 3 - 1 8 4

Bracket, fuel can, replacement:

Installation.. .......................

4-187b 4-896

Removal.. ............................

4-187a 4-896

Para Page

Bracket, hood crossmember, maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-132c 4-692

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-132a 4-692

Bracket, parking brake cable and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-175b 3-488

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-175a 3-486

Bracket, rod, and stopscrew, accelerator pedal, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-41b 3-123

Removal ..............................

3 - 4 1 a 3 - 1 2 3

Bracket, steering gear (Ross), and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-117b 4-616

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-117a 4-614

Bracket, steering gear

(Sheppard), and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-118b 4-620

Removal a............................. 4-118a 4-618

Bracket, wet air reservoir

(supply tank) and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-200b 3-552

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-200a 3-548

Brackets (M939A2), upper radiator hoses and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-58b 3-170

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-58a 3-170

Brackets, engine lifting, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-40b 4-278

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-40a 4-278

Brake chamber, air manifold tee, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-189b 3-520

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-189a 3-520

Brake chamber, combination spring (emergency) and service, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-182b 3-506

Removal . . . . . . . . . . . . . . ............... 3-182a 3-506

Brake chamber, service, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-181b 3-504

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-181a 3-504

Brake chamber, spring

(emergency), maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193c 3-528

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-193a 3-528

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193b 3-528

Index 7

TM 9-2320-272-24-4

Brake lever and switch, parking, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-174b 3-484

Removal ..............................

3-174a 3-484

Brake mechanism checks and adjustments (front and rear):

Brakeshoe check and adjustment . . . . . . . . . . . . . . . . . . . . . . . 3-179a 3-498

Checking brakeshoe wear ... 3-179b 3-500

Mechanism inspection . . . . . . . . . 3-179c 3-500

Brake modification kit

(M939A2), engine exhaust brake, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-447b 3-1194

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-447a 3-1186

Brake modification kit

(M939A2), engine exhaust brake, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-448b 3-1214

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-448a 3-1204

Brake pedal (treadle) valve

(M936/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-198b 3-542

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-198a 3-540

Brake pedal (treadle) valve repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-108c 4-586


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-108a 4-584

Brake pedal (treadle) valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-197b 3-538

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197a 3-536

Brake pedal maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-196c 3-534

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-196b 3-534

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-196a 3-534

Brake proportioning valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-199b 3-546

Removal. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .

3-199a 3-546

Brake spider, front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-183b 3-508

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-183a 3-508

Brake spider, rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-184b 3-510

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-184a 3-510

Brake valve, spring parking, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-194b 3-530

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-194a 3-530

Para Page

INDEX (Contd)

Para Page

Brake valve, spring, maintenance:

Adjustment.. .......................

Installation.. .......................

Removal..............................

Brake, (hoist winch), automatic, adjustment:

Adjustment .........................

Brake, parking, adjustment:

Lever arm adjustment.. ......

Major adjustment.. .............

Minor adjustment.. .............

Test ....................................

Brakedrum dustcover, parking, replacement:

Installation.. .......................

Removal..............................

Brakedrum, parking and service, repair:

Cleaning .............................

Inspection.. .........................

Brakeshoe replacement:

Installation.. .......................

Removal..............................

Brakeshoe, parking and service, repair:

Inspection.. .........................

Parking brakeshoe assembly ..........................

Parking brakeshoe disassembly.. ....................

Service brakeshoe assembly ..........................

Service brakeshoe disassembly.. ....................

Brakeshoes, parking, replacement:

Installation.. .......................

Removal ..............................

Branched 400 hz receptacle wiring harness replacement:

Installation.. .......................

Removal..............................

Breather, axle, front and rear, replacement:

Installation.. .......................

Removal ..............................

Breather, transmission replacement:

Installation.. .......................

Removal ..............................

Brushguard, radiator, maintenance:

Inspection and repair..........

Installation.. .......................

Removal ..............................

3-173b 3-482

3-173c 3-482

3-173a 3-482

3 - 3 8 3 3 - 9 4 0

3-172d 3-480

3-172c 3-480

3-172b 3-478

3-172a 3-478

3-177b 3-494

3-177a 3-494

4-110a 4-592

4-110b 4-592

3-180b 3-502

3-180a 3-501

4-111c 4-595

4-111e 4-595

4-111a 4-594

4-llld 4-595

4 - l l l b 4 - 5 9 4

3-176b 3-492

3-176a 3-490

5 - 9 7 b 5 - 5 9 6

5 - 9 7 a 5 - 5 9 6

3-159b 3-438

3-159a 3-438

3-136b 3-372

3-136a 3-372

4-136b 4-702

4-136c 4-704

4-136a 4-700

Index 8

TM 9-2320-272-24-4

Para

Page

INDEX (Contd)

Brushguard, window, replacement:

Installation.. .......................

Removal..............................

Bumper, front spring, replacement:

Installation.. .......................

Removal ..............................

Bumper, hood, replacement:

Installation.. .......................

Removal ..............................

Bumper, rear spring, replacement:

Installation.. .......................

Removal ..............................

Bumperette replacement:

Installation.. .......................

Removal..............................

Bumpers, ladder rack, replacement:

Installation.. .......................

Removal..............................

Bumpers, rubber, side panel, replacement:

Installation.. .......................

Removal..............................

Bumpers, tailgate, replacement:

Installation.. .......................

Removal ..............................

Bushing, ether thermal close valve and, replacement:

Installation.. .......................

Removal.. ............................

Bushing, front spring, maintenance:

Inspection ...........................

Installation.. .......................

Removal ..............................

Bushing, transmission mount, replacement:

Installation.. .......................

Removal ..............................

Bypass tubing, fuel drain

(M939/A1) and, replacement:

Installation.. .......................

Removal ..............................

3-355b 3-893

3-355a 3-893

3-164b 3-450

3-164a 3-450

3-274b 3-741

3-274a 3-741

3-165b 3-451

3-165a 3-451

3-246b 3-694

3-246a 3-694

3-366b 3-907

3-366a 3-907

3-367b 3-908

3-367a 3-908

3-261b 3-721

3-261a 3-721

3 - 3 6 b 3 - 1 1 6

3 - 3 6 a 3 - 1 1 6

3-163a 3-448

3-163c 3-448

3-163b 3-448

4 - 7 7 b 4 - 4 9 2

4 - 7 7 a 4 - 4 9 2

3 - 1 7 b 3 - 5 8

3 - 1 7 a 3 - 5 6

C

Para Page

Cab cowl vent screen and door replacement:

Installation.. .......................

3-299b 3-793

Removal.. ............................

3-299a 3-793

Cab door catch replacement:

Installation.. .......................

3-321b 3-821

Removal..............................

3-321a 3-821

Cab door check rod replacement:

Installation .........................

3-318b 3-817

Removal.. ............................

3-318a 3-817

Cab door dovetail replacement:

Installation.. .......................

3-310b 3-809

Removal.. ............................

3-310a 3-809

Cab door dovetail wedge replacement:

Installation.. .......................

3-309b 3-808

Removal.. ............................

3-309a 3-808

Cab door glass maintenance:

Adjustment.. .......................

3-314c 3-813

Installation.. .......................

3-314b 3-813

Removal ..............................

3-314a 3-813

Cab door glass repair:

Assembly ............................

4-137b 4-706

Disassembly.. .....................

4-137a 4-706

Cab door hinge replacement:

Installation.. .......................

3-320b 3-820

Removal ..............................

3-320a 3-820

Cab door inspection hole cover replacement:

Installation.. .......................

3-312b 3-811

Removal ..............................

3-312a 3-811

Cab door lock replacement:

Installation.. .......................

3-313b 3-812

Removal.. ............................

3-313a 3-812

Cab door regulator assembly replacement:

Installation.. .......................

3-317b 3-816

Removal.. ............................

3-317a 3-816

Cab door replacement:

Installation.. .......................

3-319b 3-318

Removal.. ............................

3-319a 3-818

Cab door weatherseal replacement:

Installation.. .......................

3-311b 3-810

Removal.. ............................

3-311a 3-810

Cab grab handle replacement:

Installation .........................

3-288b 3-773

Removal.. ............................

3-288a 3-773

Cab heat and defrost air ducting replacement:

Installation.. .......................

3-297b 3-791

Removal.. ............................

3-297a 3-791

Index 9

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Cab heat shield, rear exhaust pipe, support bracket and, maintenance:

Inspection.. .........................

3-49b 3-142

Installation.. .......................

3-49c 3-142

Removal ..............................

3 - 4 9 a 3 - 1 4 2

Cab hood stop bracket replacement:

Installation .........................

3-273b 3-740

Removal ..............................

3-273a 3-740

Cab insulation replacement:

Installation.. .......................

3-306b 3-804

Removal ..............................

3-306a 3-804

Cab mount, rear, replacement:

Installation.. .......................

3-305b 3-802

Removal.. ............................

3-305a 3-802

Cab protector shield, dump, maintenance:


4-146b 4-732

Installation.. .......................

4-146c 4-732

Removal.. ............................

4-146a 4-731

Cab top seal and retainer replacement:

Installation.. .......................

3-316b 3-815

Removal.. ............................

3-316a 3-815

Cab turnbuttons and lashing hooks replacement:

Installation.. .......................

3-303b 3-798

Removal.. ............................

3-303a 3-798

Cab windshield hinge assembly replacement:

Installation.. .......................

3-280b 3-756

Removal.. ............................

3-280a 3-756

Cab windshield repair:

Assembly.. ..........................

4-138b 4-708

Disassembly.. .....................

4-138a 4-708

Cab, mount, front, replacement:

Installation.. .......................

3-304b 3-800

Removal.. ............................

3-304a 3-800

Cable and bracket, parking brake, replacement:

Installation.. .......................

3-175b 3-488

Removal.. ............................

3-175a 3-486

Cable assembly (M939/A2), front lights, replacement:

Installation.. .......................

4-65b 4-390

Removal..............................

4 - 6 5 a 4 - 3 8 8

Cable, hinged roof and floor counterbalance, maintenance:

Cable adjustment.. .............

3-356c 3-895

Installation.. .......................

3-356b 3-894

Removal.. ............................

3-356a 3-894

Para

Page

Cable, hoist, winch, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-384b 3-944

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-384a 3-942

Cable, transfer case Power

Takeoff (PTO) control, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-205b 4-954

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-205a 4-954

Cable, transmission modulator, maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-145c 3-400

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-145b 3-400

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-145a 3-398

Calibration, fuel pump set up

Checking and adjusting governor weight pressure . . 5-181 5-116

Checking and adjusting throttle lever travel . . . . . . . . . . . 5- 18h

5- 114

Fuel pump run-in . . . . . . . . . . . . . . . . 5-18c

5-108

Mounting pump to test stand . . . . . . . . . . . . . . . . . . . . . . . . .

5-18b 5-106

Shutdown and removal from test stand . . . . . . . . . . . . . . . . .

5-18n 5-119

Testing and adjusting fuel pressure . . . . . . . . . . . . . . . . . . . . . 5-18j

5-116

Testing and adjusting governor fuel pressure....... 5-18k 5-116

Testing and adjusting idle speed (VS governor only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18m 5-118

Testing and adjusting idle speed . . . . . . . . . . . . . . . . . . . . . . . . .

5-18g 5-112

Testing and adjusting pump main pressure . . . . . . . . . 5-18i

5-114

Testing and adjusting throttle leakage . . . . . . . . . . . . . . . . 5-18f 5- 112

Testing governor cutoff........ 5-18e 5-110

Testing pump seals for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18d 5-110

Throttle shaft cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18a 5-104

Cam follower housing maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19d 4-150


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-19b 4-146

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-19e 4-152

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19a 4-144

Index 10

TM 9-2320-272-24-4

Camshaft and gear maintenance:

Assembly ............................

Check backlash.. .................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Camshaft and gear maintenance:

Assembly.. ..........................


Check backlash and end play.. ..........................

Disassembly.. .....................

Installation.. .......................

Removal ..............................

Capacitor, governor piping maintenance:

Inspection.. .........................

Installation .........................

Removal ..............................

Capacitor, transfer case, replacement:

Installation.. .......................

Removal..............................

Cargo body assembly maintenance:


Installation.. .......................

Removal ..............................

Repair .................................

Cargo body frame rail sill maintenance:

Fabrication.. .......................

Inspection.. .........................

Installation.. .......................

Removal ..............................

Cargo spare tire carrier (M923,

M925, M927, M928) replacement:

Installation.. .......................

Removal ..............................

Cargo spare tire carrier

(M923A1/A2,M925A1/A2,

M927A1/A2, M928A1/A2) replacement:

Installation.. .......................

Removal ..............................

Cargo spare tire carrier access step replacement:

Installation.. .......................

Removal.. ............................

5-9e

5-9a

5-9d

5-62

5-58

5-60

5-9c 5-60

5-9f 5-62

5-9b 5-58

5-27e

5-27d

5-27a

5-27c

5-27f

5-27b

3-135b

5-180

5-178

5-174

5-176

5-181

5-176

3-135c 3-368

3-135a 3-364

4-91b

4-91a

4-142b

4-142d

4-142a

4-142c

3-366

4-522

4-522

4-718

4-718

4-716

4-718

4-143c 4-723

4-143b 4-722

4-143d 4-725

4-143a 4-722

3-258b 3-716

3-258a 3-716

3-259b 3-718

3-259a 3-718

3-260b 3-720

3-260a 3-720

Para Page

INDEX (Contd)

Para Page

Cargo stowage box replacement:

Installation.. .......................

3-346b 3-880

Removal.. ............................

3-346a 3-880

Cargo tailgate replacement:

Installation.. .......................

3-343b 3-876

Removal.. ............................

3-343a 3-876

Cargo troop seat replacement:

Installation.. .......................

3-340b 3-870

Removal.. ............................

3-340a 3-870

Cargo upper and lower wheel splash guard replacement:

Installation.. .......................

3-342b 3-874

Removal.. ............................

3-342a 3-874

Carrier differential top cover gasket and side cover gasket replacement:

Side cover gasket installation.. .....................

3-158d 3-437

Side cover gasket removal..

3-158c 3-437

Top cover gasket installation.. .....................

3-158b 3-436

Top cover gasket removal .... 3-158a 3-434

Ceiling air ducts replacement:

Installation.. .......................

5-81b 5-536

Removal.. ............................

5-81a 5-536

Ceiling and frame maintenance:


5-76b 5-512

Installation.. .......................

5-76c 5-514

Removal.. ............................

5-76a 5-508

Ceiling deflector and registers replacement:

Installation.. .......................

5-83b 5-542

Removal.. ............................

5-83a 5-542

Ceiling filler and side panels replacement:

Installation.. .......................

5-79b 5-532

Removal.. ............................

5-79a 5-532

Ceiling rear cover replacement:

Installation.. .......................

5-80b 5-534

Removal.. ............................

5-80a 5-534

Ceiling transition maintenance:

Assembly.. ..........................

5-82c 5-540

Disassembly.. .....................

5-82b 5-538

Installation.. .......................

5-82d 5-540

Removal.. ............................

5-82a 5-538

Center support maintenance:

Assembly.. ..........................

5-50d 5-344


5-50c 5-342

Disassembly.. .....................

5-50b 5-342

Installation.. .......................

5-50e 5-346

Removal.. ............................

5-50a 5-340

Central Tire Inflation System

(CTIS) operation ...................

1-25 1-78

Index 11

TM 9-2320-272-24-4

Para

Central Tire Inflation System

(CTIS) troubleshooting . . . . . . . . . . 2-25 2-267

Characteristics, capabilities, and features, equipment . . . . . . .

1-13 1-5

Check valve, air dryer and, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-464d 3-1272


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-464b 3-1272

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-464e 3-1274

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-464a 3-1270

Check valve, air reservoir oneway, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-186b 3-514

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-186a 3-514

Checks, door, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-365b 3-906

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-365a 3-906

Chemical agent alarm mounting bracket kit replacement:

Chemical alarm wiring harness installation . . . . . . . . . . 3-417d 3-1064

Chemical alarm wiring harness removal .............. 3-417a 3-1058

Detector and alarm bracket installation.. .....................

3-417c 3-1062

Detector and alarm bracket removal.. ...........................

3-417b 3-1060

Chock anchors, front and rear field (M936/A1), replacement:

Installation.. .......................

3-244b 3-690

Removal.. ............................

3-244a 3-690

Circuit breaker harness and circuit breaker maintenance:

Circuit breaker harness installation.. .....................

4-158e 4-770

Circuit breaker harness removal.. ...........................

4-158a 4-770

Circuit breaker installation.. .....................

4-158d 4-770

Circuit breaker removal.. .... 4-158b 4-770

Repair.. ...............................

4-158c 4-770

Circuit breaker replacement:

Installation.. .......................

3-105b 3-288

Removal.. ............................

3-105a 3-288

Clamp, ladder locking, replacement:

Installation.. .......................

3-360b 3-899

Removal.. ............................

3-360a 3-899

Cleaning, general.. .................. 2-14

2-54

Cleaning, general preparation of vehicle for shipment ..........

6-2

6-1

Page

INDEX

(Contd)

Para Page

Clevis, winch cable, replacement:

Installation.. .......................

3-326b 3-832

Removal.. ............................

3-326a 3-831

Clip, side locking pin retaining, replacement:

Installation.. .......................

3-344b 3-878

Removal.. ............................

3-344a 3-878

Cluster, instrument, maintenance:

Assembly.. ..........................

3-83c 3-242

Disassembly.. .....................

3-83b 3-242

Installation.. .......................

3-83d 3-244

Removal.. ............................

3-83a 3-238

Clutch (M939/A1), fan drive, maintenance:

Assembly.. ..........................

4-61c 4-364


4-61b 4-363

Disassembly.. .....................

4-61a 4-356

Fan drive clutch operation check. ................

4-61d 4-368

Clutch (M939/A1), fan drive, replacement:

Installation.. .......................

3-75b 3-214

Removal.. ............................

3-75a 3-214

Clutch (M939A2), fan drive, maintenance:

Assembly.. ..........................

4-62c 4-374


4-62b 4-372

Disassembly.. .....................

4-62a 4-370

Clutch actuator (M939/A1), fan drive, maintenance:

Inspection.. .........................

3-73b 3-210

Installation.. .......................

3-73c

3-210

Removal.. ............................

3-73a 3-210

Clutch, first, maintenance:


5-53b 5-358

Establishing clearance ........

5-53d 5-360

Installation.. .......................

5-53c 5-360

Removal.. ............................

5-53a 5-358

Clutch, forward, maintenance:

Assembly ............................

5-47d 5-328


5-47c 5-326

Disassembly .......................

5-47b 5-322

Installation.. .......................

5 - 4 7 e 5-331

Removal.. ............................

5 - 4 7 a 5-322

Clutch, fourth, maintenance:

Assembly.. ..........................

5-48d 5-336


5-48c 5-334

Disassembly.. .....................

5-48b 5-332

Installation.. .......................

5-48e 5-336

Removal.. ............................

5 - 4 8 a 5-332

Clutch, low planetary carrier, adapter housing, and rear cover, low, installation:

Installation.. .......................

5-58

5-382

Index 12

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Clutch, low, removal and, clearance:


5-56b 5-374


5 - 5 6 c 5 - 3 7 6

Removal.. ............................

5-56a 5-374

Clutch, second, maintenance:


5-52b 5-354


5-52d 5-356

Installation.. .......................

5-52c 5-356

Removal.. ............................

5-52a 5-354

Clutch, third, maintenance:


5-49b 5-338

Installation.. .......................

5-49c 5-339

Removal.. ............................

5-49a 5-338

Combination spring

(emergency) and service brake chamber replacement:

Installation.. .......................

3-182b 3-506

Removal.. ............................

3-182a 3-506

Companion seat cushion, backrest cushion, and frame replacement:

Installation.. .......................

3-286b 3-770

Removal.. ............................

3-286a 3-770

Compartment, map, replacement:

Installation.. .......................

3-287b 3-772

Removal.. ............................

3-287a 3-772

Compensator, manifold pressure, maintenance:

Assembly.. ..........................

5 - 3 3 d 5-226


5 - 3 3 c 5 - 2 2 6

Installation.. .......................

5-33e 5-226

Disassembly .......................

5-33b 5-224

Removal.. ............................

5-33a 5-224

Composite light and bracket, front and rear, replacement:

Composite light lamp installation.. .....................

3-118n 3-320

Composite light lamp removal.. ...........................

3-118m 3-320

Front composite light installation.. .....................

3-118b 3-311

Front composite light removal.. ...........................

3-118a 3-310

Installation (M923/A1/A2)... 3-118d 3-312

Installation (M929/A1/A2)...

3-118h 3-314


3-118j 3-316


3-1181 3-318

Installation (M936/A1/A2)... 3-118f 3-313

Removal (M923/A1/A21.......

3-118c 3-312

Removal (M929/A1/A2) ....... 3-118g 3-314

Removal (M931/A1/A2) ....... 3-118i 3-316

Removal (M934/A1/A2) ....... 3-118k 3-318

Removal (M936/A1/A2) ....... 3-118e 3-313

Para Page

Compressed air and brake system operation ..................

1-23 1-55

Compressed air and brake system troubleshooting.. ....... 2-23 2-177

Compressor, air, (M939/A1), maintenance:

Assembly.. ..........................

4-31e 4-226

Cleaning.. ...........................

4-31c 4-220

Disassembly.. .....................

4-31b 4-218

Inspection and repair ..........

4-31d 4-220

Installation and timing.......

4-31f 4-232

Removal.. ............................

4-31a 4-214

Compressor, air, (M939A2), maintenance:

Assembly.. ..........................

4-52c 4-322

Cleaning and inspection ...... 4-52b 4-318

Disassembly.. .....................

4-52a 4-314

Conduit, electrical load center, replacement:

Installation.. .......................

4-170b 4-806

Removal.. ............................

4-170a 4-806

Contact, brush, horn, replacement:

Installation.. .......................

3-102b 3-282

Removal ..............................

3-102a 3-282

Control box, personnel fuel burning heater, replacement:

Installation.. .......................

4-214b 4-1003

Removal.. ............................

4-214a 4-1002

Control box, protective, replacement:

Installation.. .......................

3-115b 3-304

Removal.. ............................

3-115a 3-304

Control cable, throttle, maintenance:

Inspection.. .........................

3-45b 3-136

Installation.. .......................

3-45c 3-136

Removal.. ............................

3-45a 3-134

Control switch, floodlight, maintenance:

Assembly.. ..........................

3-120d 3-324

Disassembly.. .....................

3-120b 3-324

Inspection.. .........................

3-120c 3-324

Installation.. .......................

3-120e 3-325

Removal ..............................

3-120a 3-324

Control system operation.. ......

1-20 1-25

Control Unit, Electronic (ECU), replacement:

Installation.. .......................

3-468b 3-1282

Removal.. ............................

3-468a 3-1282

Control valve, front axle engagement, transfer case, replacement:

Installation.. .......................

3-144b 3-396

Removal.. ............................

3-144a 3-396

Index 13

TM 9-2320-272-24-4

Control valve, lock-in, transfer case front axle, replacement:

Installation. . . . . . . . . . . . . . . . . . . . .. .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Control valve, transmission, replacement:

Installation... . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . .. . . . . . . . . . . . . . . .

Control valve, washer, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . .. . . . . . . . . . . . . . . . . .

Control valve, windshield wiper, replacement:

Installation . . . . . . . .. . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Controls, defrost and heat, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Converter, 400 Hz, replacement:

Installation . . . .. . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light harness

(M929/A1/A2, M930/A1/A2) replacement:

Installation . . . .. . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light harness


Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mount


Installation . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mount


Installation . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light mount replacement:

Installation ............ . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Convoy warning light resistor and leads replacement:

Installation... . . . . . . . . . . .... . . . .

Removal. . . . . . . . . . . . . . .. . . . . . . .

3-147b 3-404

3-147a 3-404

5 - 4 4 b 5 - 3 0 6

5 - 4 4 a 5 - 3 0 6

3-191b 3-524

3-191a 3-524

3-192b 3-526

3-192a 3-526

3-294b 3-786

3-294a 3-786

4-169b 4-804

4-169a 4-804

3-434b 3-1118

3-434a 3-1116

3-435b 3-1122

3-435a 3-1120

3-432b 3-1112

3-432a 3-1112

3-431b 3-1110

3-431a 3-1108

3-430b 3-1106

3-430a 3-1104

3-437b 3-1128

3-437a 3-1128

3-436b 3-1126

3-436a 3-1124

Para Page

INDEX (Contd)

Para Page

Convoy warning light switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-438b 3-1130

Removal . . . . . . . . .. . . . . . . . . . . . . . . . .

3-438a 3-1130

Coolant hoses and lines


Installation . . . . .. . . . . . . . . . . . . . . . . 3-56b

3-166

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

3-56a 3-164

Coolant hoses and tubes


Radiator inlet hoses and tube installation . . . . . . . . . . . . . . . 3-54j

3-158

Radiator inlet hoses and tube removal... . . . . . . . . . . . . . . . 3-54a

3-154

Radiator outlet hoses and tee installation . . . . . . . . . . . . . . . . .

3-54g

3-156

Radiator outlet hoses and tee removal . . . . . . . . . . . . . . . . . . .

3-54d 3-156

Surge tank hose installation 3-54h 3-156

Surge tank hose removal..... 3-54c 3-156

Thermostat housing hose, radiator bypass tube, and hose installation . . . . . . . . . . . . . . .

3-54i

3-158

Thermostat housing hose, radiator bypass tube, and hose removal . . . . . . . . . . . . . . . . . . . . .

3-54b 3-154

Transmission oil cooler hoses and tube installation 3-54f

3-156

Transmission oil cooler hoses and tube removal.... 3-54e 3-156

Coolant lines (M939A2), air compressor, replacement:


Installation . . . . . . . . . . . . . . . . . . . . .

3-57c 3-168

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-57a 3-168

Coolant lines (M939A2), turbocharger and, replacement:

Installation . . . . . . .. . . . . . . . . . . . . . . 3-2 lb

3-70

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-21a 3-68

Coolant supply and return tubes (M939/A1), air compressor, maintenance:

Inspection . . . . . . . . . .. . . . . . . . . . . . . 3-55c 3-161

Return tube installation . . . . . 3-55e

3-163

Return tube removal . . . . . . . . . . . 3-55b 3-161



Coolant, heater engine, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-397b 3-974

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

3-397a 3-974

Cooling system maintenance. . . 4-59

4-352

Index 14

TM 9-2320-272-24-4

Para

Page

INDEX (Contd)

Cooling system servicing:

Cleaning and flushing system . . . . . . . . . . . . . . . . . . . . . . . . 3-53c

3-150

Depressurizing system........ 3-53a 3-150

Draining system . . . . .. . . . . . . . . . . . 3-53b 3-150

Filling system . . . . . . . . . . . . . . . . . . . 3-53d 3-152

Coupling hoses (M931/A1/A2,

M932/A1/A2), emergency and trailer, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . 3-209b 3-596

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-209a 3-596

Couplings, air, replacement:

Front air couplings installation . . . . . . . . . . . . . . . . . . 3-208d 3-590

Front air couplings removal 3-208a 3-584

Rear air couplings installation (M923/A1/A2) 3-208e 3-592


(M923/A1/A2) . . . . . . . . . . . . . . . . . . . 3-208b 3-586

Rear air couplings installation (M929/A1/A2,

M931/A1/A2, M934/A1/A2,

M936/A1/A2)...................

3-208f 3-594


(M929/A1/A2,

M931/A1/A2,

M934/A1/A2,

M936/A1/A2) . . . . . . . . . . . . . . . . . 3-208c 3-588

Cover (in-cab), engine access, replacement:

Installation . . . . . . . . . . . . . . . . . . . 4-140b 4-712

Removal. . . . . . . . . . . . . . . . . . . . . . .

4-140a 4-712

Cover, battery box, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-123b 3-332

Removal . . . . . . . . . . . . . . . . . . . . . .

3-123a 3-332

Cover, cab door inspection hole, replacement:

Installation . . . . . . . . . . . . . . . . . . .

3-312b 3-811

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-312a 3-811

Cover, ceiling rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

5-80b 5-534

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 - 8 0 a 5 - 5 3 4

Cover, crankshaft rear, seal and, replacement:

Installation . . . . . . . . . . . . . . . . . . .

4-17b

4-136

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-17a

4-136

Cover, engine access, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-13b 4-124

Removal ..........................

4 - 1 3 a 4 - 1 2 4

Para Page

Cover, fuel filter and, maintenance:


Installation (M939/A1) ......

Installation (M939A2)........

Removal (M939/A1) ............

Removal (M939A2).............

Cover, housing assembly, replacement:

Installation.. .......................

Removal ..............................

Cover, kit, radiator, replacement:

Installation.. .......................

Removal ..............................

Cover, R.Q.V. governor, maintenance:

Adjustment.. .......................

Assembly.. ..........................

Cleaning and inspection .........................

Disassembly.. .....................

Installation.. .......................

Removal., ............................

Cover, R.Q.V. governor, maintenance:

Adjustment.. .......................

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Crane control valve repair:

Assembly.. ..........................


Disassembly.. .....................

Crane control valve replacement:

Installation.. .......................

Removal.. ............................

Crane hydraulic filter maintenance:

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Crane hydraulic swinger motor replacement:

Installation.. .......................

Removal ..............................

3-30c

3-30d 3-106

3-30e 3-107

3-30b 3-105

3-30a

3-106

3-104

3-333b 3-852

3-333a 3-852

3-395b 3-970

3-395a 3-970

5 - 3 4 e 5 - 2 3 0

5 - 3 4 d 5 - 2 3 0

5 - 3 4 c 5 - 2 2 8

5 - 3 4 b 5 - 2 2 8

5 - 3 4 f 5 - 2 3 0

5 - 3 4 a 5 - 2 2 8

5 - 3 5 f 5 - 2 3 8

5 - 3 5 d 5 - 2 3 4

5 - 3 5 c 5 - 2 3 4

5 - 3 5 b 5 - 2 3 4

5 - 3 5 e 5 - 2 3 6

5 - 3 5 a 5 - 2 3 2

5-108c 5-640

5-108b 5-640

5-108a 5-636

4-201b 4-940

4-201a 4-938

3-391d 3-962

3-391c 3-962

3-391b 3-960

3-391e 3-962

3-39 la 3-960

4-199b 4-934

4-199a 4-934

Index 15

TM 9-2320-272-24-4

Crane swinger gearcase repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107c 5-634

Cleaning, inspection, and repair . . . . . . . . . . . . . . . . . . . . . . 5-107b 5-632

Disassembly . . . . . . . .. . . . . . . . . . . . . . 5-107a 5-630

Crane swinger gearcase replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . .

4-200b 4-936

Removal . . . . . . . . . . . .. . . . . . . . . . . . . . .

4-200a 4-936

Crane swivel valve maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . .

4-198c 4-930

Removal . . . . . . . . . . . . . . . . . . . . . . . . .

4-198b 4-928

Wiring harness connection . . . . . . . . . . .. . . . . . . . . . . 4-198d 4-932

Wiring harness disconnection . . . . . . . . . . . . . . . . .

4-198a 4-926

Crane wiring harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . .

3-386b 3-950

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-386a 3-948

Crankcase breather and tube maintenance:

Breather and tube installation (M939/A1)......

3-2e

Breather and tube removal

3-6

(M939/A1) .........................

3-2a

Breather tuba installation (M939A2)....... 3-2d

Breather tube removal

(M939A2) .........................

3-2b


3-2c

Crankshaft and gear maintenance:

Assembly.. ..........................

5-29e

Check end play ...................

5-29a


5-29d

Disassembly.. .....................

5-29c

Installation.. .......................

5-29f

Removal.. ............................

5-29b

Crankshaft and main bearings maintenance:


5-8b

End play clearance.. ............ 5-8d

3-2

3-4

3-4

3-4

5-202

5-196

5-199

5-198

5-202

5-197

5-50

5-56

5-52

5-48

Installation.. .......................

5-8c

Removal.. ............................

5-8a

Crankshaft rear cover and seal replacement:

Installation. ........................

4-17b

Removal.. ............................

4-17a

Crankshaft vibration and damper replacement:

Inspection.. .........................

4-14c

Installation.. .......................

4-14d

Removal.. ............................

4-14b

Runout and wobble check... 4-14a

4-136

4-136

4-128

4-128

4-126

4-126

Para Page

INDEX (Contd)

Para

Page

Cross tube replacement:

Installation.. .......................

4-104b 4-578

Removal.. ............................

4-104a 4-578

Cross-shaft, transfer case, replacement:

Installation.. .......................

4-87b 4-514

Removal.. ............................

4-87a

4-514

Crossheads, fuel crossover connectors and, replacement:

Inspection.. .........................

4-30b

4-210

Installation and adjustment.. .....................

4-30c 4-212

Removal.. ............................

4-30a

4-210

Crossmembers, torsion bars and, replacement:

Installation.. .......................

4-134b 4-696

Removal.. ............................

4-134a 4-696

CTIS wiring harness replacement:

Installation.. .......................

3-470b 3-1286

Removal.. ............................

3-470a 3-1284

Cylinder head repair

(M939/A1):

Assembly.. ..........................

5-3d 5-14

Cleaning.. ...........................

5-3b 5-6

Disassembly.. .....................

5-3a 5-2

Inspection.. .........................

5-3c 5-6

Cylinder head repair

(M939A2):

Assembly.. ..........................

5-25e

5-164

Cleaning.. ...........................

5-25b 5-160

Disassembly.. .....................

5-25a

5-158

Inspection.. .........................

5-25c 5-160

Repair.. ...............................

5-25d

5-162

Cylinder head replacement:

Installation.. .......................

4-12b

4-122

Removal ..............................

4 - 1 2 a 4 - 1 2 0

Cylinder head, rocker levers, push rods, and, replacement:

Cylinder head installation.. 4-41c 4-286

Cylinder head removal.. ......

4-4 lb

4-282

Rocker levers and push rods installation.. .............

4-41d

4-289

Rocker levers and push rods removal.. ...................

4-41a 4-280

Cylinder liners and block maintenance:


5-7c

5-38

Cylinder liners installation. 5-7d

5-46

Disassembly.. .....................

5-7b

5-36

Removal.. ............................

5-7a

5-34

Index 16

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Cylinder liners and block maintenance:

Cylinder liner and engine block cleaning and inspection .........................

5-28d 5-190

Cylinder liner inspection.. ... 5-28a 5-184

Cylinder liner installation ... 5-28f 5-194

Cylinder liner removal.. ....... 5-28b 5-186

Engine block assembly.. ......

5-288 5-192

Engine block disassembly ... 5 - 2 8 c 5 - 1 8 8

Cylinder packing, boom elevating, replacement:

Installation.. .......................

5-103b 5-610

Removal ..............................

5-103a 5-610

Cylinder, boom elevating, repair:

Assembly.. ..........................

5-102c 5-608


5-102b 5-608

Disassembly.. .....................

5-102a 5-606

Cylinder, boom elevating, replacement:

Installation.. .......................

4-193b 4-911

Removal.. ............................

4-193a 4-910

Cylinder, boom extension, repair:

Assembly ............................

5-106c 5-628


5-10b 5-628

Disassembly.. .....................

5-106a 5-626

Cylinder, boom extension, replacement:

Installation.. .......................

4-196b 4-920

Removal ..............................

4-196a 4-920

Cylinder, dump hoist, maintenance:

Assembly.. ..........................

5-105d 5-620


Disassembly.. .....................

5-105b 5-616

Installation.. .......................

5-105e 5-623

Removal.. ............................

5-105a 5-614

Cylinder, power steering assist, repair:

Assembly.. ..........................

4-121c 4-656


4-121b 4-656

Disassembly.. .....................

4-121a 4-654

Cylinder, steering assist, replacement:

Assembly.. ..........................

3-233c 3-664

Disassembly.. ..................... 3-233b 3-664

Installation.. .......................

3-233d 3-666

Removal ..............................

3-233a 3-662

Travel adjustment .............. 3-233e 3-666

Para Page

D

Damper, crankshaft vibration and, replacement:

Inspection .......................

4-14c 4-128

Installation . . . . .. . . . . . . . . . . . . .. 4-14d 4-128

Removal . . . . . . . . . . . . . . . . . . . . . . 4-14b

4-126

Runout and wobble check... 4-14a 4-126

Damper, vibration, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . .

4-42b 4-290

Installation . . . . . . . . . . . . . . . . . . . . 4-42c 4-290

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-42a 4-290

Dash control valve, spring brake, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-195b 3-532

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-195a 3-532

Data plates, description of . . . . . .

1-17

1-24

Data, equipment . . . . . . . . . . . . . . . . .

1-16

1-22

Davit and pulley, swing, van, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-265b 3-726

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-265a 3-726

Davit chain and wire rope, van, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-264b 3-724

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-264a 3-724

Davit winch (M934A1/A21, van, replacement:

Installation . . . . . . . . . . . . . . . . . . .

3-266b 3-728

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-266a 3-728

Deck plate, fifth wheel, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-251b 3-700

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-251a 3-700

Deck plate, forward, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-392b 3-964

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-392a 3-964

Decontamination (M13) apparatus mounting bracket kit replacement:

Installation (M923/A1/A2,

M925/A1/A2, M927/A1/A2,

M928/A1/A2).................... 3-419h 3-1076


M930/A1/A2, M931/A1/A2,

M932/A1/A2) . . . . . . . . . . . . . . . 3-419b 3-1074

Installation (M934/A1/A2).. 3-419d 3-1074

Installation (M936/A1/A2).. 3-419f 3-1076

Removal (M923/A1/A2,

M925/A1/A2, M9271A1/A2,

M928/A1/A2).................

3-419g 3-1076

Index 17

TM 9-2320-272-24-4


M930/A1/A2, M931/A1/A2,

M932/A1/A2). ...................

3-419a 3-1074

Removal (M934/A1/A2)....... 3-419c 3-1074

Removal (M936/A1/A2)....... 3-419e 3-1076

Deepwater fording air pressure hose replacement:

Installation (M939/A1). ......

4-227d 4-1038

Installation (M939A2)........ 4-227c 4-1034

Removal (M939/A1)............ 4-227a 4-1034

Removal (M939A2)............. 4-227b 4-1036

Deepwater fording control replacement:

Installation.. .......................

4-225b 4-1026

Removal.. ............................

4-225a 4-1026

Deepwater fording pressurization valve replacement:

Installation (M939/A1)....... 4-226b 4-1032

Installation (M939A2)........ 4-226c 4-1030

Removal (M939/A1)............ 4-226a 4-1028

Removal (M939A2)............. 4-226b 4-1030

Deepwater fording regulator valve replacement:

Installation.. .......................

4-228b 4-1040

Removal.. ............................

4-228a 4-1040

Deflector, ceiling and registers, replacement:

Installation.. .......................

5-83b 5-542

Removal.. ............................

5-83a 5-542

Defrost and heat controls replacement:

Installation.. .......................

3-294b 3-786

Removal.. ............................

3-294a 3-786

Description and data index, equipment.. ..........................

1-12 1-5

Description of data plates.. .....

1-17 1-24

Description of major components, location and.. ....

1-14 1-16

Destruction of Army materiel to prevent enemy use.. ..............

1-3 1-2

Differences between models ....

1-15 1-20

Differential and differential carrier repair:

Assembly and adjustment.. .....................

5-64c 5-44

Cleaning, inspection, and repair.. ..............................

5-64b 5-439

Disassembly.. .....................

5-64a 5-432

Differential oil seal, front, replacement:

Installation.. .......................

4-102b 4-574

Removal.. ............................

4-102a 4-574

Para

Page

INDEX (Contd)

Para Page

Differential oil seal, rear, replacement:

Installation.. .......................

Removal ..............................

Differential, front and rear axle carrier, maintenance:


Installation.. .......................

Removal.. ............................

Diode, transfer case transorb, replacement:

Installation.. .......................

Removal ..............................

Dipstick, dipstick tube, transmission, maintenance:

Installation.. .......................

Inspection.. .........................

Removal ..............................

Direct and general support mechanical troubleshooting symptom index ...................

Direct and general support mechanical troubleshooting...

Disassembly, general.. ............

Diverter assembly replacement:

Installation.. .......................

Removal ..............................

Door catch, cab, replacement:

Installation.. .......................

Removal ..............................

Door checks replacement:

Installation.. .......................

Removal ..............................

Door handle and lock replacement:

Installation.. .......................

Removal.. ............................

Door handle, outside, replacement:

Installation.. .......................

Removal ..............................

Door hinge and seal replacement:

Installation.. .......................

Removal ..............................

Door hinge, cab, replacement:

Installation.. .......................

Removal ..............................

Door regulator assembly, cab, replacement:

Installation.. .......................

Removal.. ............................

4-103b 4-576

4-103a 4-576

4-100b 4-564

4-100c 4-565

4-100a 4-564

4 - 9 2 b 4 - 5 2 4

4 - 9 2 a 4 - 5 2 4

3-134c 3-362

3-134b 3-362

3-134a 3-362

4-2 4-2

4-1 4-1

2-17

2-58

3-295b 3-788

3-295a 3-788

3-321b 3-821

3-321a 3-821

3-365b 3-906

3-365a 3-906

3-364b 3-905

3-364a 3-905

3-307b 3-806

3-307a 3-806

3-362b 3-902

3-362a 3-902

3-320b 3-820

3-320a 3-820

3-317b 3-816

3-317a 3-816

Index 18

TM 9-2320-272-24-4

Para

Page

INDEX (Contd)

Door, bonnet, maintenance:

Assembly.. ..........................

5-87d 5-560


5 - 8 7 c 5 - 5 5 8

Disassembly.. .....................

5-87b 5-556

Installation.. .......................

5-87e 5-562

Removal.. ............................

5-87a 5-554

Door, cab, replacement:

Installation.. .......................

3-319b 3-318

Removal.. ............................

3-319a 3-818

Door, check rod, cab, replacement:

Installation.. .......................

3-318b 3-817

Removal.. ............................

3-318a 3-817

Door, rear, maintenance:

Assembly.. ..........................

4-154d 4-758


Disassembly.. .....................

4-154b 4-756

Installation.. .......................

4-154e 4-760

Removal..............................

4-154a 4-756

Doors, side, maintenance:

Assembly.. ..........................

5-70d 5-480


5 - 7 0 c 5 - 4 8 0

Disassembly.. .....................

5-70b 5-480

Installation.. .......................

5-70e 5-482

Removal.. ............................

5-70a 5-478

Doublecheck valve No. 1 replacement:

Installation.. .......................

3-212b 3-602

Removal.. ............................

3-212a 3-602

Doublecheck valve No. 2


Installation.. .......................

3-214b, 3-606

Removal.. ............................

3-214a 3-606

Doublecheck valve No. 2 replacement:

Installation.. .......................

3-213b 3-604

Removal.. ............................

3-213a 3-604

Doublecheck valve No. 5

(M931/A1/A2,M932/A1/A2) replacement:

Installation.. .......................

3-215b 3-608

Removal.. ............................

3-215a 3-608

Doublecheck valves No. 3,

No. 4, and quick-release valve replacement:

Installation.. .......................

3-216b 3-612

. Removal.. ............................ 3-216a 3-610

Dovetail wedge, cab door, replacement:

Installation.. .......................

3-309b 3-808

Removal.. ............................

3-309a 3-808

Dovetail, cab door, replacement:

Installation.. .......................

3-310b 3-809

Removal.. ............................

3-310a 3-809

Para Page

Drag link replacement:

Installation .........................

3-229b 3-655

Removal.. ............................

3-229a 3-655

Drain kit, hydraulic reservoir, replacement:

Installation.. .......................

3-444b 3-1152

Removal.. ............................

3-444a 3-1152

Drain tube, air conditioner, replacement:

Installation.. .......................

3-382b 3-938

Removal.. ............................

3-382a 3-938

Drainvalves, air reservoir, replacement:

Installation.. .......................

3-205b 3-572

Removal.. ............................

3-205a 3-572

Drive flange, front axle, maintenance:

Inspection.. .........................

3-156b 4-432

Installation.. .......................

3-156c 4-432

Removal.. ............................

3-156a 3-432

Drive gear and driven shaft, transfer case speedometer, replacement:

Installation.. .......................

4-89b 4-518

Removal.. ............................

4-89a 4-518

Drive, tachometer, maintenance:


4 - 5 1 b 4 - 3 1 3

Installation.. .......................

4-51c 4-313

Removal.. ............................

4-51a 4-313

Drivebelt (M939/A1), water pump, maintenance:

Adjustment.. .......................

3-67a 3-196

Inspection.. .........................

3-67c 3-198

Installation.. .......................

3-67d 3-198

Removal.. ............................

3-67b 3-198

Drivebelt and drivebelt tensioner (M939A2), fan, replacement:

Installation.. .......................

3-71b 3-206

Removal.. ............................

3-71a 3-206

Drivebelt tensioner (M939A2), fan drivebelt and, replacement:

Installation.. .......................

3-7 lb 3-206

Removal.. ............................

3-71a 3-206

Drivebelts (M939A1), fan, maintenance:

Adjustment.. .......................

3-70a 3-204

Inspection.. .........................

3-70c 3-205

Installation.. .......................

3-70d 3-205

Removal.. ............................

3-70b 3-204

Index 19

TM 9-2320-272-24-4

Drivebelts, alternator

(M939/A1), maintenance:

Inspection.. .........................

3-78b 3-222


3-78c 3-222

Removal.. ............................

3-78a 3-222

Drivebelts, steering pump, maintenance (M939/A1):

Adjustment.. .......................

3-230a 3-656

Inspection.. .........................

3-230c 3-656

Installation.. .......................

3-230d 3-657

Removal.. ............................

3-230a 3-656

Driver’s seat cushion, backrest cushion, and frame replacement:

Installation.. .......................

3-285b 3-768

Removal ..............................

3-285a 3-768

Driver’s seat frame and base maintenance:


3-284b 3-766

Installation.. .......................

3-284c 3-766

Removal.. ............................

3-284a 3-764

Driver’s seat replacement:

Installation.. .......................

3-283b 3-762

Removal.. ............................

3-283a 3-762

Driveshaft (M939/A1), tachometer maintenance:

Installation.. .......................

3-89b 3-256

Removal.. ............................

3-89a 3-256

Driveshaft, speedometer maintenance:

Inspection.. .........................

3-90b 3-260

Installation.. .......................

3-90c 3-260

Removal.. ............................

3-90a 3-258

Drum (M939/A1), front hub and, maintenance:


Installation.. .......................

3-223d 3-640

Lubrication.. .......................

3-223c 3-640

Removal.. ............................

3-223a 3-638

Drum (M939/A1), rear hub and, maintenance:


Installation.. .......................

3-224d 3-646

Lubrication.. .......................

3-224c 3-644

Removal.. ............................

3-224a 3-642

Ducting, cab heat and defrost, air, replacement:

Installation.. .......................

3-297b 3-791

Removal.. ............................

3-297a 3-791

Ducting, fresh air inlet, replacement:

Installation.. .......................

3-296b 3-790

Removal.. ............................

3-296a 3-790

Para Page

INDEX (Contd)

Para

Page

Ducts, ceiling air, replacement:

Installation.. .......................

5-81b 5-536

Removal.. ............................

5-81a 5-536

Dump and tractor spare tire carrier access step replacement:

Installation .........................

3-255b 3-711

Removal.. ............................

3-255a 3-710

Dump body hydraulic hose replacement:

Installation.. .......................

4-147b 4-736

Removal.. ............................

4-147a 4-734

Dump body maintenance:

Installation.. .......................

4-144c 4-728


4-144b 4-727

Removal.. ............................

4-144a 4-726

Dump cab protector shield maintenance:


4-146b 4-732

Installation.. .......................

4-146c 4-732

Removal.. ............................

4-146a 4-731

Dump hoist cylinder maintenance:

Assembly.. ..........................

5-105d 5-620


5-105c 5-618

Disassembly.. .....................

5-105b 5-616

Installation.. .......................

5-105e 5-623

Removal.. ............................

5-105a 5-614

Dump hydraulic pump replacement.. ........................

4-150 4-748

Dump roller arm maintenance:

Assembly.. ..........................

5-104d 5-613

Disassembly .......................

5-104b 5-612


5-104c 5-612

Installation.. .......................

5-104e 5-613

Removal.. ............................

5-104a 5-612

Dump safety brace installation:

Installation.. .......................

4-145b 4-730

Removal.. ............................

4-145a 4-730

Dump spare tire carrier (M929,

M930) replacement:

Installation.. .......................

3-256b 3-712

Removal.. ............................

3-256a 3-712

Dump spare tire carrier

(M929A1/A2, M930A1/A2) replacement:

Installation.. .......................

3-257b 3-714

Removal.. ............................

3-257a 3-713

Dump subframe replacement:

Installation.. .......................

4-149b 4-746

Removal. .............................

4-149a 4-742

Dump tailgate assembly replacement:

Installation.. .......................

3-348b 3-882

Removal.. ............................

3-348a 3-882

Index 20

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Dump tailgate control linkage replacement:

Installation . . . . . .. . . . . . . . . . . . . .

3-349b 3-886

Removal . . . . . . . . . . . . . . . . . . . . . 3-349a 3-884

Dustcover, parking brakedrum, replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-177b 3-494

Removal . . . . . . . . . .. . . . . . . . . . .

3-177a 3-494

Dustcovers, wheel brakedrum, replacement:

Front wheel dustcovers installation . . . . . . . . . . . . . . . . . 3-178c 3-496

Front wheel dustcovers removal . . . . . . . . . . . . . . . . . . . 3-178a 3-496

Rear wheel dustcovers installation.................

3-178d 3-496

Rear wheel dustcovers removal . . . . . . . .. . . . . . . . . . .

3-178b 3-496

E

Electric heater (10 kw) wiring harness replacement:

Installation . . . . . . . . . . . . . . . . .

5-92b 5-578

Removal . . . . . .. . . . . . . . . . . . . 5-92a

5-578

Electrical box maintenance:

Inspection . . . . . . . . . . . . . . . 4-162b 4-790

Installation . . . . . . . . . . . . . . . . . . 4-162c 4-790

Removal . . . . . . . . . . . . . . . . . . .

4-162a 4-790

Electrical gauges replacement:

Installation . . . . . . .. . . . . . . . . . . 3-86b

3-250

Removal . . . . . . . . . . . . . . . . . . . . 3-86a 3-250

Electrical junction box replacement:

Installation . . . . . . . . . . . . . . . . . . 4-163b 4-792

Removal . . . . . . . . . . . . . . . . . . . . 4-163a 4-792

Electrical load center box maintenance:

Assembly . . . . . . . . . . . . . . . . . . 4-161c 4-782

Disassembly . . . . . . . . . . . . . . . .

4-161b 4-782

Installation . . . . . . .. . . . . . . . . . .

4-161d 4-784

Removal . . . . . . . . . . . . . . . . . . . .

4-161a 4-776

Electrical load center conduit replacement:

Installation . . . . . . . . . . . . . . . 4-170b 4-806

Removal . . . . . . . . . . .. . . . . . . 4-170a 4-806

Electrical switches replacement:

Accessory switches installation . . . . . . . . . . . . . . . 3-107b 3-292

Accessory switches removal . . . . . . . . . . . . . . . . . . 3-107a 3-292

Battery and starter switch installation . . . . . . . . 3-107d 3-293

Battery and starter switch removal . . . . . . . . . . . . 3-107c 3-292

Para Page

Electrical system troubleshooting . . . . . . . . . . . . . . 2-22 2-92

Electrical systems operation . . .

1-22

1-45

Electronic Control Unit (ECU) replacement:

Installation . . . . . . . . . . . . .. . . 3-468b 3-1282

Removal . . . . . . . . . . . .. . . . . . . 3-468a 3-1282

Emergency and trailer coupling hoses (M931/A1/A2,

M932/A1/A2) replacement:

Installation . . . . . . . . . . . . . . .

3-209b 3-596

Removal . . . . . . . . . . . . . . . . . . 3-209a 3-596

Emergency lamp wiring harness replacement:

Installation . . . . . . . . . . . . . .

5-94b 5-584

Removal . . . . . . . . .. . . . . . . 5-94a

5-582

Emergency spring brake

(supply tank) air reservoir replacement:

Installation . . . . . . . . . . . . . 3-204b 3-570

Removal . . . . . . . . . .. . . . . . 3-204a 3-570

Emergency stop control cable maintenance:

Inspection . . . . . . . . . . . . 3-44b

3-132

Installation . . . . . . . . . . . . . 3-44c 3-132

Removal . . . . . . . .. . . . . . . . . 3-44a

3-130

Emergency/blackout light lamp and lens replacement:

Installation . . . . . . . . . . . . . .

3-372b 3-915

Removal . . . . . . . . . . .. . . . .

3-372a 3-915

End panel, hinged, maintenance:

Assembly . . . . . . . . . . . . . . .

4-155d 4-764


Disassembly . . . . . . . . . . . . . 4-155b 4-762

Installation . . . . . . . . . . . . . . . . 4-155e 4-764

Removal . . . . . . . . . . . . . . . . . . 4-155a 4-762

Engine access cover (in-cab) replacement:

Installation . . . . . . . . . . . . . . 4-140b 4-712

Removal . . . . . . . . . . . . . . . . .

4-140a 4-712

Engine accessory drive and pulley maintenance:

Accessory drive assembly . . . . 4-26e

4-190

Accessory drive cleaning and inspection ... . . . . . . . .. . . . . . 4-26d

4-188

Accessory drive disassembly.. . . . . . . . . .. . . . 4-26c

4-188

Accessory drive installation. 4-27f 4-190

Accessory drive pulley installation . . . . . . . . . . . . .. . . . 4-26g

4-192

Accessory drive pulley removal . . . . . . . . . . . . . . . . . . . .

4-26a 4-186

Accessory drive removal . . . . . 4-26b

4-186

Index 21

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Engine air intake manifold maintenance:

Assembly.. ..........................

4-24d 4-180


Disassembly.. .....................

4-24b 4-180

Installation.. .......................

4-24e 4-182

Removal.. ............................

4-24a 4-178

Engine and container replacement:

Installation.. .......................

4-6b

4-88

Removal ..............................

4-6a 4-86

Engine AOAP valve maintenance:

Installation.. .......................

3-10c 3-40

Oil sampling.. .....................

3-10a 3-38

Removal

................................. 3 - 1 0 b 3 - 4 0

Engine coolant battery box heater pad replacement:

Installation.. .......................

3-404b 3-994

Removal.. ............................

3-404a 3-994

Engine coolant heater control box replacement:

Installation.. .......................

3-399b 3-978

Removal.. ............................

3-399a 3-978

Engine coolant heater harness


Installation.. .......................

3-400b 3-980

Removal.. ............................

3-400a 3-980

Engine coolant heater harness


Installation.. .......................

3-401b 3-982

Removal.. ............................

3-401a 3-982

Engine coolant heater hose replacement:

Installation.. .......................

3-403b 3-990

Removal.. ............................

3-403a 3-986

Engine coolant heater pump replacement:

Installation.. .......................

3-398b 3-976

Removal.. ............................

3-398a 3-976

Engine coolant heater replacement:

Installation.. .......................

3-397b 3-974

Removal.. ............................

3-397a 3-974

Engine coolant oil pan shroud and exhaust tube replacement:

Installation.. .......................

4-402b 3-984

Removal.. ............................

4-402a 3-984

Engine exhaust brake modification kit (M939/A1) replacement:

Installation.. .......................

3-447b 3-1194

Removal.. ............................

3-447a 3-1186

Para Page

Engine exhaust brake modification kit (M939A2) replacement:

Installation.. .......................

3-448b 3-1214

Removal ..............................

3-448a 3-1204

Engine exhaust manifold maintenance:

Installation.. .......................

4-25b 4-184

Removal.. ............................

4-25a 4-184

Engine hood maintenance:

Adjustment.. .......................

3-275c 3-746

Installation.. .......................

3-275b 3-744

Removal.. ............................

3-275a 3-742

Engine injector timing instructions:

Fuel injectors installation ...

4 - 3 2 h 4 - 2 4 2

Fuel injectors removal.. .......

4-32d 4-238

General instructions.. ......... 4-32e 4-238

Injector timing.. ..................

4-32g 4-240

Rocker lever housing covers installation.. .....................

4-32k 4-246

Rocker lever housing covers removal.. ...........................

4-32a 4-236

Rocker lever housing and push tubes removal .......... 4-32b 4-236

Rocker lever housing and push tubes installation .....

4-32j 4-244

Timing tool setup.. ..............

4-32f 4-240

Valve crossheads installation and adjustment.. .....................

4-323

4-244

Valve crossheads removal ... 4-32c 4-238

Engine lift eyes replacement:

Installation.. .......................

4 - l l b 4-118

Removal.. ............................

4 - l l a 4-118

Engine lifting brackets replacement:

Installation.. .......................

4-40b 4-278

Removal.. ............................

4-40a 4-278

Engine mounting brackets and isolators replacement:

Installation.. .......................

4-39b 4-274

Removal.. ............................

4-39a 4-272

Engine mounting on repair stand:

Installation (M939/A1). ...... 4-9a

4-100

Installation (M939A2). .......

4-9b 4-106

Removal (M9391A1). ........... 4-9d

4-110

Removal (M939A2) ............. 4-9c

4-108

Engine oil cooler (M939A2) maintenance:

Assembly.. ..........................

3-4d 3-14


3-4c 3-14

Disassembly.. .....................

3-4b 3-14

Installation.. .......................

3-4e 3-16

Removal.. ............................

3-4a 3-12

Index 22

TM 9-2320-272-24-4

Engine oil cooler maintenance:

Assembly ............................

4-23d

Cleaning and inspection ...... 4-23c

Disassembly.. .....................

4-23b

Installation .........................

4-23e

Removal.. ............................

4-23a

Engine oil filter maintenance:


3-5d

Draining oil.. .......................

3-5a

Filter shell and bolt assembly (M939/A1). ........

3-5e

Filter shell and bolt disassembly (M939/A1). ... 3-5c

Oil filter installation.. ......... 3-5f

Oil filter removal .................

3-5b

Engine oil pan maintenance:

Assembly.. ..........................

4-22d


4-22c

Disassembly.. .....................

4-22b

Installation.. .......................

4-22e

Removal.. ............................

4-22a

Engine oil pump repair:

Assembly.. ..........................

5-11d


5-11b

Disassembly.. .....................

5-11a

Repair.. ...............................

5-11c

Engine oil pump replacement:

Gear backlash test.. ........... 4-21a

Installation.. .......................

4-21c

Removal.. ............................

4-2 lb

Engine run-in test and idle speed adjustment:

Engine run-in test.. .............

4-54a

Idle speed adjustment.. ......

4-54b

Engine water manifold maintenance:

Assembly.. ..........................

4-27d


4-27c

Disassembly.. .....................

4-27b

Installation.. .......................

4-27e

Removal.. ............................

4-27a

Entrance receptacle 220V

3-phase wiring harness maintenance:

Installation.. .......................

4-159c

Removal.. ............................

4-159a

Repair.. ...............................

4-159b

Equipment characteristics, capabilities, and features.. ...

1-13

Equipment data.. ...................

1-16

Equipment description and data index ............................

1-12

Ether atomizer (M939/A1) replacement:

Installation.. .......................

3-37b

Removal.. ............................

3-37a

4-176

4-176

4-174

4-176

4-174

3-20

3-18

3-20

3-20

3-21

3-20

4-170

4-170

4-170

4-172

4-168

5-88

5-84

5-78

5-86

4-164

4-166

4-164

4-328

4-328

4-196

4-196

4-194

4-196

4-194

4-772

4-772

4-772

1-5

1-22

1-5

3-117

3-117

Para Page

INDEX (Contd)

Para Page

Ether atomizer and temperature sensor (M939A2) replacement:

Installation . . . . . . . . . . . . . . . . 3-38b 3-118

Removal . . . . . . . . . . . . . . . . . . 3-38a 3-118

Ether cylinder and valve replacement:

Ether cylinder installation... 3-35d 3-115

Ether cylinder removal . . .. . . 3-35a 3-114

Ether valve installation . . . . 3-35c 3-115

Ether valve removal . . . . . . . . 3-35b

3-114

Ether start fuel pressure switch (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . 3-34b 3-113

Removal . . . . . . . . . . . . . . . . . . . . 3-34a

3-113

Ether start switch replacement:

Installation . . . . . . . .. . . . . . . . . .

3-33b 3-112

Removal . . . . . .. . . . . . . . . . . . . 3-33a 3-112

Ether thermal close valve and bushing replacement:

Installation . . . . . . . . . . . . . . . . . . 3-36b 3-116

Removal . . . . . . . . . . . . . . . . . . . 3-36a

3-116

Ether tubing replacement:

Installation. . . . . . . . . . . . . . .

3-39b 3-120

Removal........................

3-39a 3-120

Ether, atomizer (M939/A1), replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-37b

3-117

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-37a 3-117

Ether, atomizer and temperature sensor

(M939A2), replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-38b 3-118

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-38a

3-118

European mini-lighting kit replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-439b 3-1132

Removal . . . . . . . . . . . . . . . . . . . . . .

3-439a 3-1132

Evaporator, alcohol, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-211b 3-600

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-211a 3-600

Exhaust heat shield accessory kit replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-449b 3-1224

Removal.........................

3-449a 3-1224

Exhaust manifold replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-50b 4-312

Removal..........................

4-50a 4-312

Exhaust manifold, engine, maintenance:

Installation........................

4-25b 4-184

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-25a 4-184

Index 23

TM 9-2320-272-24-4

Exhaust stack replacement:

Installation . . . . . . . . . . . . . . . 3-48b 3-140

Removal . . . . . . . . . . . . . . . . . . 3-48a 3-140

Expanding and retracting mechanism locks replacement:

Installation . . . . . . . . . . . . . . . . .

3-378b 3-926

Removal . . . . . . . . . . . . . . . . . 3-378a 3-926

Exterior side panel maintenance:

Assembly . . . . . . . . . . . . . . . . . .

5-73c 5-494


Disassembly . . . . . . . . . . . . . .

5-73a 5-490

F

Fabrication of air lines.. . . . . . . . 3-452 3-1232

Failsafe warning module replacement:

Installation.. .......................

3-106b 3-290

Removal.. ............................

3-106a 3-290

Fan actuator (M939A2), fan clutch and, maintenance:

Cleaning and inspection ...... 3 - 7 4 b 3 - 2 1 2

Installation.. .......................

3-74c 3-213

Removal ..............................

3 - 7 4 a 3 - 2 1 2

Fan and fan shroud (M939A2) maintenance:

Inspection.. .........................

3-64b 3-188

Installation.. .......................

3-64c

3-188

Removal.. ............................

3-64a 3-188

Fan blade, radiator,


Installation.. .......................

3-72b 3-208

Removal.. ............................

3-72a 3-208

Fan clutch and fan actuator



Installation.. .......................

3-74c 3-213

Removal..............................

3 - 7 4 a 3 - 2 1 2

Fan drive clutch (M939/A1) maintenance:

Assembly.. ..........................

4-61c 4-364


4-61b 4-363

Disassembly.. .....................

4-61a 4-356

Fan drive clutch operation check .................

4 - 6 1 d 4 - 3 6 8

Fan drive clutch (M939/A1) replacement:

Installation.. .......................

3-75b 3-214

Removal.. ............................

3-75a 3-214

Fan drive clutch actuator


Inspection.. .........................

3-73b 3-210

Installation.. .......................

3-73c 3-210

Removal.. ............................

3-73a 3-210

Para Page

INDEX (Contd)

Para Page

Fan drive clutch maintenance

(M939A2):

Assembly.. ..........................

4-62c 4-374


4 - 6 2 b 4 - 3 7 2

Disassembly.. .....................

4-62a 4-370

Fan drivebelt and drivebelt tensioner (M939A2) replacement:

Installation.. .......................

3-7 lb 3-206

Removal.. ............................

3-71a 3-206

Fan drivebelts (M939A1) maintenance:

Adjustment.. .......................

3-70a 3-204

Inspection.. .........................

3-70c 3-205

Installation.. .......................

3-70d 3-205

Removal.. ............................

3-70b 3-204

Fan shroud (M939/A1), radiator, replacement:

Installation.. .......................

3-63b 3-186

Removal.. ............................

3-63a 3-186

Fan shroud (M939A2), fan and, maintenance:

Inspection.. .........................

3-64b 3-188

Installation.. .......................

3-64c

3-188

Removal.. ............................

3-64a 3-188

Fender extension, front, replacement:

Installation.. .......................

3-300b 3-794

Removal.. ............................

3-300a 3-794

Fender, front, replacement:

Installation.. .......................

4-135b 4-698

Removal.. ............................

4-135a 4-698

Fifth wheel approach plates replacement:

Installation.. .......................

3-249b 3-698

Removal.. ............................

3-249a 3-698

Fifth wheel deck plate replacement:

Installation.. .......................

3-251b 3-700

Removal.. ............................

3-25 la 3-700

Fifth wheel maintenance:

Assembly ............................

4-130c 4-688


Disassembly.. .....................

4-130a 4-682

Fifth wheel spacers replacement:

Installation.. .......................

3-252b 3-701

Removal.. ............................

3-252a 3-701

Fifth wheel, tractor, replacement:

Installation.. .......................

3-248b 3-696

Removal.. ............................

3-248a 3-696

Filer, air dryer, replacement:

Installation.. .......................

3-465b 3-1276

Removal.. ............................

3-465a 3-1276

Index 24

TM 9-2320-272-24-4

Filler cap and spout, fuel tank, replacement:

Installation.. .......................

3-25b 3-78

Removal.. ............................

3-25a 3-78

Filter, AFC fuel pump, replacement:

Installation.. .......................

3-31b 3-108

Removal.. ............................

3-31a 3-108

Filter, crane hydraulic, maintenance:

Assembly.. ..........................

3-391d 3-962


3-391c 3-962

Disassembly.. .....................

3-391b 3-960

Installation.. .......................

3-391e 3-962

Removal.. ............................

3-391a 3-960

Filter, power steering pump

(M939A2), maintenance:

Cleaning.. ...........................

3-237c 3-674

Filter installation.. ............. 3-237e 3-674

Filter removal.. ...................

3-237a 3-674

Reservoir installation.. ........

3-237d 3-674

Reservoir removal ...............

3-237b 3-674

Filter, wheel valve, replacement:

Installation.. .......................

3-458b 3-1248

Removal.. ............................

3-458a 3-1248

Filter, winch hydraulic oil reservoir, replacement:

Installation.. .......................

3-336b 3-858

Removal.. ............................

3-336a 3-858

Fire extinguisher mounting bracket kit replacement:

Installation.. .......................

3-416b 3-1056

Removal.. ............................

3-416a 3-1056

First clutch maintenance:


5-53b 5-358


5 - 5 3 d 5 - 3 6 0

Installation.. .......................

5-53c 5-360

Removal.. ............................

5-53a 5-358

Flasher, turn signal, replacement:

Installation.. .......................

3-114b 3-303

Removal.. ............................

3-114a 3-303

Flex hose, fuel selector valve, replacement:

Installation.. .......................

3-23b 3-74

Removal.. ............................

3-23a 3-74

Flexible converter wiring harness maintenance:

Installation.. .......................

4-160c 4-774

Removal.. ............................

4-160a 4-774

Repair.. ...............................

4-160b 4-774

Para

Page

INDEX (Contd)

Para

Page

Flexplate and flywheel housing maintenance:

Assembly.. ..........................

4-43d 4-294


4 - 4 3 c 4 - 2 9 3

Disassembly .......................

4 - 4 3 b 4 - 2 9 2

Installation .........................

4 - 4 3 e 4 - 2 9 4

Removal.. ............................

4-43a 4-292

Floodlight control switch maintenance:

Assembly.. ..........................

3-120d 3-324

Disassembly.. .....................

3-120b 3-324

Inspection.. .........................

3-120c 3-324

Installation.. .......................

3-120e 3-325

Removal.. ............................

3-120a 3-324

Floodlight maintenance:

Assembly.. ..........................

3-121c 3-328

Disassembly.. .....................

3-121b 3-326

Installation.. .......................

3-121d 3-328

Removal.. ............................

3-121a 3-326

Floodlight sealed beam lamp and door (M936/A1/A2) replacement:

Installation.. .......................

3-119b 3-322

Removal.. ............................

3-119a 3-322

Floor, hinged, maintenance:

Assembly.. ..........................

5-72d 5-488


5 - 7 2 c 5 - 4 8 8

Disassembly.. .....................

5-72b 5-487

Installation.. .......................

5-72e 5-488

Removal ..............................

5 - 7 2 a 5 - 4 8 6

Flow test, injector:

Adjusting and measuring fuel delivery ......................

5-23c 5-150

Setting up test stand .......... 5-23a 5-148

Testing check ball seating ... 5 - 2 3 b 5 - 1 4 8

Fluorescent light fixtures maintenance:

Assembly.. ..........................

4-168d 4-802

Disassembly.. .....................

4-168b 4-802

Inspection.. .........................

4-168c 4-802

Installation.. .......................

4-168e 4-803

Removal.. ............................

4-168a 4-802

Fluorescent light tube replacement:

Installation.. .......................

3-371b 3-914

Removal.. ............................

3-37 la 3-914

Flywheel housing maintenance:


Installation.. .......................

4-16c 4-132

Removal.. ............................

4-16a 4-130

Index 25

TM 9-2320-272-24-4

Flywheel housing, flexplate and, maintenance:

Assembly.. ..........................

4-43d 4-294


4-43c 4-293

Disassembly.. .....................

4-43b 4-292

Installation.. .......................

4-43e 4-294

Removal.. ............................

4-43a 4-292

Flywheel ring gear maintenance:

Installation.. .......................

4-15b 4-129

Removal.. ............................

4-15a 4-129

Fording control, deepwater, replacement:

Installation.. .......................

4-225b 4-1026

Removal.. ............................

4-225a 4-1026

Forward clutch maintenance:

Assembly ............................

5 - 4 7 d 5 - 3 2 8


5 - 4 7 c 5 - 3 2 6

Disassembly.. .....................

5-47b 5-322

Installation.. .......................

5-47e 5-331

Removal.. ............................

5-47a 5-322

Forward deck plate replacement:

Installation.. .......................

3-392b 3-964

Removal.. ............................

3-392a 3-964

Forward-rear and rear-rear axle replacement:

Installation.. .......................

4-101b 4-570

Removal.. ............................

4-101a 4-566

Forward-rear to rear-rear propeller shaft replacement:

Installation.. .......................

3-151b 3-420

Removal.. ............................

3-151a 3-420

Fourth clutch maintenance:

Assembly ............................

5-48d 5-336


5-48c 5-334

Disassembly.. .....................

5-48b 5-332

Installation.. .......................

5-48e 5-336

Removal.. ............................

5-48a 5-332

Frame assembly, outer, windshield and, replacement:

Installation.. .......................

3-278b 3-752

Removal.. ............................

3-278a 3-752

Frame assembly, windshield, replacement:

Installation.. .......................

3-279b 3-754

Removal.. ............................

3-279a 3-754

Frame extension, winch, replacement:

Installation.. .......................

3-245b 3-692

Removal.. ............................

3-245a 3-692

Frame parts, bonnet, replacement:

Installation.. .......................

5-85b 5-546

Removal.. ............................

5-85a 5-544

Frame repair ..........................

4-129 4-681

Para Page

INDEX (Contd)

Para Page

Frame, ceiling and, maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . 5-76c 5-514

Removal . . . . . . . . . . . . . . . . . . . . . . .

5-76a 5-508

Frame, under-, parts, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

5-71b 5-484

Removal . . . . . . . . . . . . . . . . . . . . . . .

5-71a 5-484

Fresh air inlet ducting replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-296b 3-790

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-296a 3-790

Fresh air vent control assembly replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-293b 3-784

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-293a 3-784

Front and rear axle breather replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-159b 3-438

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-159a 3-438

Front and rear axle carrier differential maintenance:


4-100b 4-564

Installation.......................

4-100c 4-565

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-100a 4-564

Front and rear composite light and bracket replacement:

Composite light lamp installation . . . . . . . . . . . . . . . . . . .

3-118n 3-320

Composite light lamp removal . . . . . . . . . . . . . . . . . . . . . . 3-118m 3-320

Front composite light installation . . . . . . . . . . . . . . . . . . .

3-118b 3-311

Front composite light removal . . . . . . . . . . . . . . . . . . . . . . . 3-118a 3-310

Installation (M923/A1/A2)..

3-118d 3-312


3-118h 3-314


3-118j 3-316


3-1181 3-318


3-118f 3-313

Removal (M923/A1/A2).......

3-118c 3-312

Removal (M929/A1/A2).......

3-118g 3-314

Removal (M931/A1/A2).......

3-118i 3-316

Removal (M934/A1/A2).......

3-118k 3-318

Removal (M936/A1/A2).......

3-118e 3-313

Front and rear field chock anchors (M936/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-244b 3-690

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-244a 3-690

Front and rear lifting shackle and bracket replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-24 lb 3-684

Removal . . . . . . . . . . . . . . . . . . . . . .

3-24 la 3-684

Index 26

TM 9-2320-272-24-4

Front and rear winch control valve (M930/A1/A2) replacement:

Installation.. .......................

4-179b 4-856

Removal.. ............................

4-179a 4-856

Front and rear winch control valve replacement:

Installation.. .......................

4-178b 4-854

Removal.. ............................

4-178a 4-854

Front and rear winch level wind maintenance:

Assembly.. ..........................

4-174d 4-839

Cleaning, inspection, and repair.........................

4-174c 4-836

Disassembly.. .....................

4-174b 4-832

Installation.. .......................

4-174e 4-841

Removal.. ............................

4-174a 4-832

Front axle drive flange maintenance:

Inspection.. .........................

3-156b 4-432

Installation.. .......................

3-156c 4-432

Removal ..............................

3-156a 3-432

Front axle replacement:

Installation.. .......................

4-99b 4-560

Removal.. ............................

4-99a 4-558

Front axle seal replacement:

Installation.. .......................

3-160b 3-439

Removal.. ............................

3-160a 3-439

Front axle shaft and universal joint maintenance:


Installation.. .......................

3-154e 3-429

Removal.. ............................

3-154a 3-426

Universal joint assembly.... 3-154d 3-428

Universal joint disassembly 3-154c 3-428

Front brake actuator repair:

Adjustable actuator assembly ..........................

4-112e 4-598

Adjustable actuator disassembly.. .....................

4-112a 4-596


4-112c 4-596

Stationary actuator assembly.. ........................

4-112d 4-598

Stationary actuator disassembly.. ....................

4-112b 4-596

Front brake spider replacement:

Installation.. .......................

3-183b 3-508

Removal.. ............................

3-183a 3-508

Front bumper and plates replacement:

Installation.. .......................

3-243b 3-688

Removal.. ............................

3-243a 3-688

Front cab mount replacement:

Installation.. .......................

3-304b 3-800

Removal.. ............................

3-304a 3-800

Para

Page

INDEX (Contd)

Para Page

Front differential oil seal replacement:

Installation.. .......................

Removal ..............................

Front exhaust pipe replacement:

Installation.. .......................

Removal..............................

Front fender extension replacement:

Installation.. .......................

Removal ..............................

Front fender replacement:

Installation.. .......................

Removal ..............................

Front gearcase cover and oil seal maintenance:


Installation.. .......................

Removal.. ............................

Front gearcase cover maintenance:

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Front gearcase housing and timing pin maintenance:


Front gearcase housing installation.. .....................

Front gearcase housing removal .............................

Timing pin installation.. .....

Timing pin removal.. ...........

Front hub and drum



Installation.. .......................

Lubrication.. .......................

Removal ..............................

Front hub and drum



Installation.. .......................

Lubrication.. .......................

Removal.. ............................

Front hubs repair:


Installation.. .......................

Removal ..............................

Repair.. ...............................

4-102b 4-574

4-102a 4-574

3 - 5 0 b 3 - 1 4 4

3 - 5 0 a 3 - 1 4 4

3-300b 3-794

3-300a 3-794

4-135b 4-698

4-135a 4-698

4 - 4 8 b 4 - 3 0 6

4 - 4 8 c 4 - 3 0 6

4 - 4 8 a 4 - 3 0 6

4-18d

4-18c

4-18b 4-138

4-18e 4-142

4-18a

4-140

4-140

4-138

4 - 4 6 c 4 - 3 0 0

4 - 4 6 e 4 - 3 0 2

4 - 4 6 a 4 - 3 0 0

4 - 4 6 d 4 - 3 0 2

4 - 4 6 b 4 - 3 0 0

3-223b 3-640

3-223d 3-640

3-223c 3-640

3-223a 3-638

3-223b 3-640

3-223d 3-640

3-223c 3-640

3-223a 3-638

3-460b 3-1253

3-460d 3-1256

3-460a 3-1252

3-460c 3-1254

Index 27

TM 9-2320-272-24-4

Front lights cable assembly


Installation.. .......................

4-65b 4-390

Removal.. ............................

4-65a 4-388

Front limiting valve replacement:

Installation.. .......................

3-190b 3-522

Removal..............................

3-190a 3-522

Front relay valve replacement:

Installation.. .......................

3-187b 3-516

Removal..............................

3-187a 3-516

Front spring and main leaf replacement:

Front spring main leaf installation .......................

3-161c 3-443

Front spring main leaf removal .............................

3-161b 3-443

Front spring installation ..... 3-161d 3-444

Front spring removal .......... 3-161a 3-440

Front spring bumper replacement:

Installation.. .......................

3-164b 3-450

Removal.. ............................

3-164a 3-450

Front spring bushing maintenance:

Inspection.. .........................

3-163a 3-448

Installation.. .......................

3-163c 3-448

Removal.. ............................

3-163b 3-448

Front spring shackle replacement:

Installation.. .......................

3-162b 3-446

Removal.. ............................

3-162a 3-446

Front sump tube maintenance:

Inspection.. .........................

3-9b 3-36

Installation.. .......................

3-9c 3-36

Removal ..............................

3 - 9 a 3-36

Front wall registers replacement:

Installation.. .......................

5-78b 5-531

Removal ..............................

5 - 7 8 a 5 - 5 3 1

Front wheel valve maintenance:


3-456b 3-1244

Installation.. .......................

3-456c 3-1245

Removal.. ............................

3-456a 3-1244

Front winch automatic brake adjustment:

Adjustment .........................

3-323b 3-826

Testing.. .............................

3-323a 3-824

Front winch cable chain and hook replacement:

Installation.. .......................

3-325b 3-830

Removal ..............................

3-325a 3-830

Front winch cable replacement:

Installation.. .......................

3-327b 3-834

Removal.. ............................

3-327a 3-834

Para Page

INDEX (Contd)

Para Page

Front winch cable tensioner maintenance:

Assembly.. ..........................

4-173d 4-829


4-173c 4-827

Disassembly.. .....................

4-173b 4-825

Installation.. .......................

4-173e 4-830

Removal.. ............................

4-173a 4-825

Front winch control valve cable replacement:

Installation.. .......................

4-177b 4-851

Removal.. ............................

4-177a 4-850

Front winch drag brake adjustment:

Adjustment.. .......................

3-324b 3-828

Testing.. .............................

3-324a 3-828

Front winch hydraulic hose and tube replacement:

Installation.. .......................

4-180b 4-861

Removal ..............................

4-180a 4-858

Front winch hydraulic pump replacement:

Installation.. .......................

4-176b 4-848

Removal.. ............................

4-176a 4-848

Front winch motor replacement:

Installation.. .......................

3-328b 3-838

Removal.. ............................

3-328a 3-836

Front winch repair:

Assembly of subassemblies.. ..................

4-172d 4-819

Assembly of winch.. ............ 4-172e 4-823


4-172c 4-816

Disassembly into subassemblies.. ................

4-172a 4-810

Disassembly of subassemblies.. ................

4-172b 4-812

Front winch replacement:

Installation.. .......................

3-329b 3-842

Removal.. ............................

3-329a 3-840

Front winch roller assembly maintenance:

Assembly.. ..........................

4-175d 4-845


4-175c 4-844

Disassembly.. .....................

4-175b 4-843

Installation.. .......................

4-175e 4-847

Removal.. ............................

4-175a 4-842

Front wiring harness


Installation.. .......................

4-66b 4-408

Removal.. ............................

4-66a 4-394

Front wiring harness (M939A2) replacement:

Installation.. .......................

4-67b 4-434

Removal ..............................

4 - 6 7 a 4 - 4 2 2

Index 28

TM 9-2320-272-24-4

Para

Page

INDEX (Contd)

Front, axle, seal, replacement:

Installation.. .......................

3-160b 3-439

Removal.. ............................

3-160a 3-439

Front-wheel drive lock-in switch replacement:

Installation.. .......................

3-101b 3-280

Removal.. ............................

3-101a 3-280

Fuel can bracket replacement:

Installation.. .......................

4-187b 4-896

Removal.. ............................

4-187a 4-896

Fuel crossover connectors and crossheads replacement:

Inspection.. .........................

4-30b 4-210


4-30c 4-212

Removal.. ............................

4-30a 4-210

Fuel drain and bypass tubing


Installation.. .......................

3-17b 3-58

Removal.. ............................

3-17a 3-56

Fuel filter and cover maintenance:


3-106

Installation (M939/A1)........ 3-30d 3-106

Installation (M939A2). ........ 3-30e 3-107

Removal (M939/A1). ............ 3-30b 3-105

Removal (M939A2). ............. 3-30a 3-104

Fuel injection pump calibration:

Cylinder phasing (timing) .... 5 - 3 7 b 5 - 2 6 6

External stop setting.. ........

5-37m 5-278

Fuel breakaway test.. ......... 5-37j

5-277

Fuel delivery test.. ..............

5-37i

5-276

Full load delivery.. ..............

5-37g 5-274

High-speed fuel delivery test.. .................................

5-37d 5-270

Lock timing.. .......................

5-37c 5-268

Low idle fuel delivery test ... 5-371 5-278

Low-speed fuel delivery test.. .................................

5-37e 5-270

Manifold pressure compensator test.. ............

5-37h 5-275

Prestroke and rack travel ................................

5 - 3 7 a 5 - 2 6 2

Rated speed test.. ...............

5-37f 5-272

Starting fuel delivery test.... 5-37k

5-277

Fuel injection pump maintenance:

Adjustment.. .......................

4-57c 4-345

Installation.. .......................

4-57b 4-342

Removal.. ............................

4-57a 4-338

Para Page

Fuel injection pump maintenance:

Barrel and control rack removal.. ...........................

5-36c

Camshaft installation.. .......

5-36i

Camshaft removal ..............

5-36a


5-36d

Delivery valve and barrel installation.. ........... 5-36f

Leakage test.. .....................

5-36e

Plunger and control rack installation.. .....................

5-36g

Tappet and plunger removal.. ...........................

5-36b

Tappet and spring installation.. .....................

5-36h

Fuel injection pump pretest:

Cylinder phasing (timing) .... 5-32b

Fuel breakaway test.. ......... 5-32j


5-32i


5-32f


5-32c

Low idle fuel delivery test ...

5-321

Low speed fuel delivery test.. .................................

5-32d

Manifold pressure compensator test ..............

5-32g

Prestroke and rack travel.. ..............................

5-32a


5-32e

Starting cut out test.. .......... 5-32h


Fuel injection pump, mounting to test stand:

Mounting fuel injection pump to test stand.. .........

5-31a

Removing fuel injection pump from test stand.. .....

5-31b

Fuel injector calibration:

Leakage test.. .....................

4-56b

Opening pressure test.. .......

4-56a

Spray pattern test.. ............

4-56c

Fuel injector maintenance:

Assembly.. ..........................

4-55d


4-55c

Disassembly.. .....................

4-55b

Installation.. .......................

4-55e

Removal.. ............................

4-55a

Fuel injector repair:

Inspection.. .........................

5-19c

Non-top stop injector assembly ..........................

5-19d

5-246

5-258

5-240

5-248

5-252

5-250

5-254

5-244

5-256

5-216

5-222

5-220

5-220

5-218

5-222

5-218

5-220

5-214

5-218

5-220

5-222

5-210

5-212

4-336

4-336

4-337

4-334

4-332

4-330

4-334

4-330

5-19c

5-19d

Index 29

TM 9-2320-272-24-4

Para

Non-top stop injector disassembly.. ....................

5-19a

Top stop injector assembly. 5-19e

Top stop injector disassembly.. ....................

5-19b

Fuel injector sleeve maintenance:

Bead cutting.. .....................

5-6b

Check and test.. ..................

5-6e

Fitting and forming.. ........... 5-6d

Installation.. .......................

5-6c

Removal..............................

5-6a

Fuel injector tube (M939A2) maintenance:

Cleaning and inspection ...... 3-19b

Installation.. .......................

3-19c

Removal ..............................

3-19a

Fuel level sending unit replacement:

Installation.. .......................

3-92b

Removal.. ............................

3-92a

Fuel pressure switch, ether start, (M939/A1) replacement: 3-34b

Installation.. .......................

3-34a

Removal..............................

Fuel pressure transducer


Installation.. .......................

3-96b

Removal.. ............................

3-96a

Fuel primer pump (M939/A1) replacement:

Installation.. .......................

3-40b

Removal ..............................

3-40a

Fuel pump filter, AFC, replacement:

Installation.. .......................

3-3 lb

Removal.. ............................

3-3 la

Fuel pump housing maintenance:

Assembly ............................

5-15c

Disassembly.. .....................

5-15a

Inspection.. .........................

5-15b

Fuel pump replacement:

Installation.. .......................

4-35b

On-engine adjustments....... 4-35c

Removal.. ............................

4-35a

Fuel pump setup and calibration:

Checking and adjusting governor weight pressure.. 5-181

Checking and adjusting throttle lever travel.. ......... 5-18h

Fuel pump run-in.. ..............

5-18c

5-122

5-132

5-126

5-28

5-32

5-30

5-28

5-26

3-64

3-64

3-62

3-264

3-264

3-113

3-113

3-271

3-271

3-122

3-122

3-108

3-108

5-96

5-96

5-96

4-262

4-264

4-260

5-116

5-114

5-108

Page

INDEX (Contd)

Para Page

Mounting pump to test stand . . . . . . . . . . . . . . . . . . . .

Shutdown and removal from test stand . . . . . . . . . . . . . . . . .

Testing and adjusting fuel pressure . . . . . . . . . . . . . . . .

Testing and adjusting governor fuel pressure . . . . . . .

Testing and adjusting idle speed (VS governor only).. . . . . . . . . . . . . . . . . . . . . . . . .

Testing and adjusting idle speed . . . . . . . . . . . . . . . . . . . .

Testing and adjusting pump main pressure . . . . . . . . .

Testing and adjusting throttle leakage . . . . . . . . . . . . .

Testing governor cutoff . . . . . . . .

Testing pump seals for leaks . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle shaft cover removal. . . . . . . . . . . . . . . . . . . . . .

Fuel pump shutoff valve

(M936) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel pump shutoff valve replacement:

Fuel pump shutoff valve installation . . . . . . . . . . . . . . . . . . .

Fuel pump shutoff valve removal... . . . . . . . . . . . . . . . . . . . .

Manual shutoff valve installation . . . . . . . . . . . . . . . . . . .

Manual shutoff valve removal... . . . . . . . . . . . . . . . . . . . . .

Fuel pump with VS governor filter replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel selector valve flex hose replacement:

Installation . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel selector valve switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Fuel selector valve, mounting bracket, and indicator plate maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . .

5-18b

5-18n

5-18j

5-18k

5-18m

5-18g

5-18i

5-18f

5-18e

5-18d

5-18a

4-37b

4-37a

4-36c

4-36b

4-36d

4-36a

3-32b

3-32a

5-106

5-119

5-116

5-116

5-118

5-112

5-114

5-112

5-110

5-110

5-104

4-268

4-268

4-266

4-266

4-266

4-266

3-110

3-110

3-23b 3-74

3-23a 3-74

3-109b 3-296

3-109a 3-296

3-24b

3-76

3-24c

3-77

3-24a

3-76

Index 30

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Fuel system (M939A2), priming:

Priming.. .............................

3-22 3-72

Fuel tank (M936/A1/A2) maintenance:

Draining.. ...........................

3-27a 3-84

Inspection.. .........................

3-27c 3-88

Installation.. .......................

3-27d

3-88

Removal.. ............................

3-27a

3-84

Fuel tank filler cap and spout replacement:

Installation.. .......................

3-25b 3-78

Removal.. ............................

3-25a 3-78

Fuel tank hangers and retaining straps maintenance:

Inspection.. .........................

3-28b 3-94

Installation.. .......................

3-28c 3-94

Removal.. ............................

3-28a

3-92

Fuel tank lines (M939A2) replacement:

Installation.. .......................

3-29b 3-100

Removal.. ............................

3-29a

3-96

Fuel tank maintenance:

Draining.. ...........................

3-26a 3-80

Inspection.. .........................

3-26c 3-82

Installation.. .......................

3-26d

3-82

Removal.. ............................

3-26b

3-80

Fuel tank vent system kit, atmospheric, replacement:

Installation .........................

3-441b 3-1141

Removal.. ............................

3-441a 3-1140

Fuel transfer pump and supply lines (M939A2) maintenance:

Cleaning and inspection ...... 3 - 2 0 b 3 - 6 6

Installation.. .......................

3-20c 3-67

Removal.. ............................

3-20a 3-66

G

Gauge, air, replacement:

Installation . . . . . . . . . . . . . . . . 3-87b 3-252

Removal . . . . . . . . . . . . . . . . . . . 3-87a 3-252

Gauges, electlrical replacement:

Installation . . . . . . . . . . . . . . . . .

3-86b 3-250

Removal . . . . . . . . . . . . . . . . . . . . 3-86a 3-250

Gear (on-vehicle), power steering, adjustment:

Sector shaft adjustment...... 4-125a 4-668

Wormshaft adjustment....... 4-125b 4-668

Para Page

Gear (Ross), steering, repair:

Assembly.. ..........................

Cleaning, inspection and repair.. .......................

Disassembly.. .....................

Final adjustment.. ..............

Gear (Sheppard), steering, repair:

Assembly.. ..........................


Disassembly.. .....................

Gear unit and main shaft maintenance:

Assembly ............................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Gear, camshaft and, maintenance:

Assembly.. ..........................

Check backlash.. .................


Disassembly.. .....................

Installation.. .......................

Removal.. ............................

Gear, camshaft and, maintenance:

Assembly.. ..........................


Check backlash and end play.. ..........................

Disassembly.. .....................

Installation.. .......................

Removal ..............................

Gear, crankshaft and, maintenance:

Assembly.. ..........................

Check end play ...................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Gearcase cover, front, maintenance:

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

4-119c 4-631

4-119b 4-630

4-119a 4-624

4-119d 4-638

4-120c 4-648

4-120b 4-645

4-120a 4-640

5-51d

5-51c 5-350

5-51b 5-348

5-51e 5-353

5-51a

5-9e

5-9b

5-62

5-9a 5-58

5-9d 5-60

5-9c 5-60

5-9f 5-62

5-58

5 - 2 7 e 5 - 1 8 0

5 - 2 7 d 5 - 1 7 8

5 - 2 7 a 5 - 1 7 4

5 - 2 7 c 5 - 1 7 6

5 - 2 7 f 5 - 1 8 1

5 - 2 7 b 5 - 1 7 6

5-29e

5-29a

5-29d

5-29c

5-29f

5-29b

5-351

5-348

5-202

5-196

5-199

5-198

5-202

5-197

4 - 1 8 d 4 - 1 4 0

4 - 1 8 c 4 - 1 4 0

4 - 1 8 b 4 - 1 3 8

4 - 1 8 e 4 - 1 4 2

4 - 1 8 a 4 - 1 3 8

Index 31

TM 9-2320-272-24-4

Gearcase, crane swinger, repair:

Assembly.. ..........................


Disassembly.. .....................

Gearcase, crane swinger, replacement:

Installation.. .......................

Removal.. ............................

General ...................................

General assembly.. .................

General cleaning.. ...................

General disassembly ..............

General information ................

General inspection.. ................

General inspection and servicing instructions ............

General maintenance instructions.. .........................

General repair ........................

General service upon receipt ...

Generator, speed signal, replacement:

Installation.. .......................

Removal ..............................

Glass, cab door, maintenance:

Adjustment.. .......................

Installation.. .......................

Removal..............................

Glass, cab door, repair:

Assembly.. ..........................

Disassembly.. .....................

Glossary .................................

Gondola replacement:

Installation.. .......................

Removal ..............................

Governor piping and capacitor maintenance:

Inspection.. .........................

Installation.. .......................

Removal ..............................

Governor spring pack maintenance:

Inspection.. .........................

Installation .........................

Removal ..............................

Governor weight maintenance:

Inspection.. .........................

Installation.. .......................

Removal ..............................

Governor, air, maintenance:

Adjustment.. .......................

Installation.. .......................

Removal ..............................

Testing ...............................

5-107c

5-107b

5-107a

4-200b

4-200a

4-70

2-18

2-14

2-17

4-115

2-15

2-6

5-39

2-16

2-5

4-936

4-936

4-465

2-58

2-54

2-58

4-605

2-56

3-47 l b 3-1288

3-47 l a 3-1288

3-314c 3-813

3-314b 3-813

3-314a 3-813

4-137b

4-137a

1-11

4-202b

4-202a

3-135b

3-135c

3-135a

5-14b

5-14c 5-95

5-14a 5-94

5-17b

5-634

5-632

5-630

2-2

5-281

2-57

2-1

4-706

4-706

1-3

4-944

4-942

3-366

3-368

3-364

5-94

5-102

5-17c 5-102

5-17a 5-102

3-207d 3-582

3-207b 3-580

3-207a 3-580

3-207c 3-582

Para Page

INDEX (Contd)

Para Page

Governor, air, maintenance:

Adjustment . . . . . . . . . . . . . . . . .

3-207d 3-582

Installation . . . . . . . .. . . . . . . . . 3-207b 3-580

Removal . . . . . . . . . . . . . . . . . . . . 3-207a 3-580

Testing . . . . . . . . .. . . . . . . . . . . . 3-207c

3-582

Governor, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . 5-54b 5-362

Removal . . . . . . . . . . . . . . . . . . . 5-54a 5-362

Grab handle, cab, replacement:

Installation . . . . . . . . . . . . . . . . 3-288b 3-773

Removal . . . . . . . . . . . . . . . . . . . 3-288a 3-773

Grab handle, hood, replacement:

Installation . . . . . . . . . . . . . . . . .

3-271b 3-737

Removal . . . . . . .. . . . . . . . . . . . . . 3-271a 3-737

Ground cable, battery, maintenance:

Connection . . . . . . . . . . . . . . . . .

3-126b 3-338

Disconnection . . . . . . . . . . . . . .

3-126a 3-338

Ground strap replacement:

Ground strap (M939/A1) installation . . . . . . . . . . . .. . . . . 3-129b 3-344

Ground strap (M939A2) installation . . . . . . . . . . . . . . . . 3-129d 3-346

Ground strap (M939/A1) removal . . . . . . . . . . . . . . . . . . . 3-129a 3-344

Ground strap (M939A2) removal . . . . . . . . . . . . . . . . . . . 3-129c

3-346

H

Hand airbrake air supply valve replacement:

Installation . . . . . . . . . . . . . . . . .

3-422b 3-1084

Removal . . . . . . .. . . . . . . . . . . . .

3-422a 3-1084

Hand airbrake controller valve replacement:

Installation . . . . . . . . . . . . . . . . . 3-423b 3-1086

Removal . . . . . .. . . . . . . . . . . . . .

3-423a 3-1086

Hand airbrake doublecheck valves replacement:

Installation (forward-rear axle doublecheck valve)..... 3-424b 3-1088

Installation (rear-rear axle doublecheck valve)..... 3-424d 3-1090

Removal (forward-rear axle doublecheck valve)..... 3-424a 3-1088

Removal (rear-rear axle doublecheck valve) . . . . . . . . . . 3-424c 3-1090

Hand airbrake tractor protection valve replacement:

Installation . . . . . . . . . . . . . . . . 3-425b 3-1092

Removal . . . . . . . . . . . . . . . . . . 3-425a 3-1092

Index 32

TM 9-2320-272-24-4

Hand control valve

(M931/A1/A2, M932/A1/A2), trailer airbrake, replacement:

Installation . . . . . . . .. . . . . . . . . .

3-210b 3-598

Removal . . . . . . . . . . . . . . . . . . . 3-210a 3-598

Handle, and control rod, bonnet, replacement:

Installation . . . . . . . . . . . . . . . . 3-36 lb 3-900

Removal . . . . . . . . .. . . . . . . . . . 3-36 la 3-900

Handle, and lock, door, replacement:

Installation . . . . . . . . . . . . . . . . 3-364b 3-905

Removal . . . . . . . . . . . . . . . . . . 3-364a 3-905

Handle, inside door, window regulator and, replacement:

Installation . . . . . . . . . . . . . . .

3-308b 3-807

Removal . . . . . . . . . . . . . . . . . 3-308a 3-807

Handrail modification kit,

(M934/A1/A2), van, replacement:

Door check spacer installation . . . . . . . . . . . . .. . .

3-450h 3-1229

Door check spacer r e m o v a l . . . . . . . . . . . . . . . .

3-450g 3-1229

Ladder handrail guide installation . . . . . . . . . . . . . . 3-450b 3-1225

Ladder handrail guide removal . . . . . . . . . . . . . . . . . . 3-450a 3-1225

Ladder handrail hangers installation . . . . . . . . . . . . . .

3-450d 3-1226

Ladder handrail hangers removal . . . . . . . . . .. . . . . . . . .

3-450c 3-1226

Van door grab handles installation . . . . . . . . . . . . . . 3-450f 3-1228

Van door grab handles removal . . . . . . . . . . . . . . . 3-450e 3-1228

Hangers and retaining straps, fuel tank, maintenance:

Inspection . . . . . . .. . . . . . . . . . 3-28b

3-94

Installation . . . . . . . .. . . . . . . . 3-28c 3-94

Removal . . . . . . . . . . . . . . . . . . 3-28a 3-92

Hard top kit replacement:

Installation . . . . . . . . . . . . . . . . 3-396b 3-972

Removal . . . . . . . . . . . . . . . . . . . 3-396a 3-972

Harness (M939/A1), engine coolant heater, replacement:

Installation . . . . . . . . . .. . . . . . . 3-400b 3-980

Removal . . . . . . . . . . . . . . . . . 3-400a 3-980

Harness (M939A2), engine coolant heater, replacement:

Installation . . . . . . . . . . . . . . . 3-401b 3-982

Removal . . . . . . . . . . . . . . . . . . 3-401a 3-982

Harness conduit, 400 Hz converter, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . . . . .

4-164b 4-794

Removal . . . . . . . . . . . . . . . . . . 4-164a 4-794

Para Page

INDEX (Contd)

Para Page

Harness, 100-amp alternator, replacement:

Installation.. .......................

Removal ..............................

Harness, circuit breaker and, circuit breaker maintenance:

Circuit breaker harness installation.. .....................

Circuit breaker harness removal.. ...........................

Circuit breaker installation.. .....................

Circuit breaker removal.. ....

Repair.................................

Harness, convoy warning light

(M929/A1/A2, M930/A1/A2), replacement:

Installation.. .......................

Removal ..............................

Harness, convoy warning light, replacement:

Installation.. .......................

Removal.. ............................

Harness, instrument cluster, replacement:

Installation.. .......................

Removal.. ............................

Harness, right and left side blackout, maintenance:

Installation.. .......................

Removal.. ............................

Repair.................................

Harness, right and left side blackout, maintenance:

Installation.. .......................

Removal ..............................

Repair .................................

Harness, swingfire heater, replacement:

Installation.. .......................

Removal.. ............................

Harness, wiring, repair:

Female cable connector

(with sleeve). .....................

Male cable connector.. .........

Plug assembly ....................

Receptacle assembly.. .........

Terminal-type cable connector.. .........................

Head, cylinder, replacement:

Installation.. .......................

Removal ..............................

3-427b 3-1098

3-427a 3-1096

4-158e 4-770

4-158a 4-770

4-158d 4-770

4-158b 4-770

4-158c 4-770

3-434b 3-1118

3-434a 3-1116

3-433b 3-1114

3-433a 3-1114

3-130b 3-348

3-130a 3-348

4-157c 4-768

4-157a 4-768

4-157b 4-768

5 - 9 8 c 5 - 6 0 0

5 - 9 8 a 5 - 5 9 8

5 - 9 8 b 5 - 6 0 0

3-408b 3-1012

3-408a 3-1010

3-131c 3-350

3-131b 3-350

3-131d 3-350

3-131e 3-350

3-131a 3-349

4 - 1 2 b 4 - 1 2 2

4 - 1 2 a 4 - 1 2 0

Index 33

TM 9-2320-272-24-4

Head, oil cooler filter, transmission, replacement:

Oil cooler filter installation . . . . . . . . . . . . . . 3-139d 3-377

Oil cooler filter head installation . . . . . . . . . . . . . .

3-139c 3-377

Oil cooler filter head removal . . . . . . . . . . . . . . . . . 3-139b 3-376

Oil cooler filter removal....... 3-139a 3-376

Header plates, water, replacement:

Installation . . . . . . . . . . . . . . . . 4-28b 4-198

Removal . . . . . . . . . . . . . . . . . 4-28a 4-198

Headlight maintenance:

Alignment . . . . . . . . . . . . . . 3-116c 3-306

Installation . . . . . .. . . . . . . 3-116b 3-306

Removal . . . . . . . . .. . . . . . . .

3-116a 3-306

Heat shield accessroy, exhaust, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . . . . 3-449b 3-1224

Removal . . . . . . . . . . . . . . . .. . . . 3-449a 3-1224

Heater (M933/A1), personnel fuel burning, replacement:

Installation . . . . . . . . . . . . . . .

4-215b 4-1004

Removal . . . . . . . . . . . . . . .

4-215a 4-1004

Heater and exhaust, van, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . . . . 3-379b 3-930

Removal . . . . . . . . . . . . . . .

3-379a 3-928

Heater control box, engine coolant, replacement:

Installation . . . . . . . . . . . . . . . . 3-399b 3-978

Removal . . . . . . . . . . . . . . . . .

3-399a 3-978

Heater exhaust tube

(M939/A1), personnel fuel burning, replacement:

Installation . . . . .. . . . . . . . . .

4-222b 4-1020

Removal . . . . . . . . . . . . . . . . .

4-222a 4-1020

Heater exhaust tube (M939A21, personnel fuel burning, replacement:

Installation . . . . . . . . . . 4-223b 4-1022

Removal . . . . . . . . . . . . . . . . . . 4-223a 4-1022

Heater fuel pump

(M934A1/A2), van, replacement:

Installation (M934) . . . . . . . .

3-381d 3-936

Installation (M934A1/A2)... 3-381b 3-934

Removal (M934). . . . . . . . . .. . 3-381c 3-936

Removal (M934A1/A2)......

3-381a 3-934

Heater fuel pump wiring harness maintenance:

Installation . . . . . . . . . . .. . . . .

4-156c 4-766

Removal . . . . . . . . . . . . . . . . 4-156a 4-766

Repair . . . . . . . . . . . . . . . . . . . . .

4-156b 4-766

Para Page

INDEX (Contd)

Para Page

Heater pad, swingfire heater battery box, replacement:

Installation . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . .

Heater pump, engine coolant, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . .

Removal.. . . . . . .. . . . . . . . .

Heater thermostat and 10 kW heater thermostat replacement:

10 kW heater thermostat installation . . . . . . . . . . . . .

10 kW heater thermostat removal . . . . . . . . . . . . . . . . .

Heater thermostat installation . . . . . . . . . . . . . . .

Heater thermostat removal. . . . . . . . . . .

Heater, circuit breaker, personnel fuel burning, replacement:

Installation . . . . . . . . .. .

Removal . . . . . . . . . . . . . . . .

Heater, electric fuel pump

3-410b 3-1018

3-410a 3-1018

3-398b 3-976

3-398a 3-976

4-165d 4-796

4-165b 4-796

4-165c 4-796

4-165a 4-796

4-224b 4-1024

4-224a 4-1024

(M939A1), personnel fuel burning, replacement:

Installation . . . . . . . . . . . . .. . .

Removal.. . . . . . . . . . . . . . . . .

Heater, electric fuel pump

(M939A2), personnel fuel burning, replacement:

I n s t a l l a t i o n . . . . . . . . . . . . .

Removal. . . . . . . . . . . . . . . . .

Heater, electrical components, swingtire, replacement:

Circuit breaker installation . . . . . . . . . . . . . .

4-218b 4-1010

4-218a 4-1010

4-219b 4-1012

4-219a 4-1012

Circuit breaker removal . . . .

Electrical connecter installation . . . . . . . . . . . . .

Electrical connector removal . . . . . . . . . . . . . . . . .

Relay installation . . . . . .. . .

Relay removal . . . . . . . . . . . .

Thermal switch

3-407f 3-1006

3-407c 3-1006

3-407h 3-1008

3-407a 3-1004

3-407g 3-1008

3-407b 3-1004 installation . . . . . . . . . . . . .. .

Thermal switch removal . . . .

Heater, fuel shutoff valve, personnel fuel burning,

3-407e 3-1006

3-407d 3-1006 replacement:

Installation . . . . . . . . . . . . . .

4-220b 4-1014

Removal.. . . . . . . . . . . . . . . . . . 4-220a 4-1014

Index 34

TM 9-2320-272-24-4

Heater, mounting bracket and swingtire, replacement:

Installation.. .......................

3-406b 3-1002

Removal.. ............................

3-406a 3-1000

Heater, personnel, hot water, replacement:

Installation.. .......................

3-292b 3-782

Removal.. ............................

3-292a 3-782

Heater, wiring harness, personnel fuel burning, replacement:

Installation.. .......................

4-221b 4-1018

Removal.. ............................

4-221a 4-1016

High-beam selector switch replacement:

Installation.. .......................

3-112b 3-301

Removal.. ............................

3-112a 3-301

Hinge, and seal, door, replacement:

Installation.. .......................

3-362b 3-902

Removal.. ............................

3-362a 3-902

Hinge, hood, replacement:

Installation.. .......................

4-133b 4-694

Removal.. ............................

4-133a 4-694

Hinged end panel maintenance:

Assembly.. ..........................

4-155d 4-764


4-155c 4-763

Disassembly.. .....................

4-155b 4-762

Installation.. .......................

4-155e 4-764

Removal.. ............................

4-155a 4-762

Hinged floor maintenance:

Assembly.. ..........................

5-72d 5-488


5 - 7 2 c 5 - 4 8 8

Disassembly.. .....................

5-72b 5-487

Installation.. .......................

5-72e 5-488

Removal.. ............................

5-72a 5-486

Hinged roof and floor counterbalance cable maintenance:

Cable adjustment.. .............

3-356c 3-895

Installation.. .......................

3-356b 3-894

Removal.. ............................

3-356a 3-894

Hinged roof maintenance:

Assembly.. ..........................

5-77d 5-526


5 - 7 7 c 5 - 5 2 4

Disassembly.. .....................

5-77b 5-520

Installation.. .......................

5-77e 5-530

Removal.. ............................

5-77a 5-518

Hinged roof-operated blackout circuit plungers replacement:

Installation.. .......................

3-377b 3-924

Removal.. ............................

3-377a 3-924

Para

Page

INDEX (Contd)

Para

Page

Hoist level wind maintenance:

Assembly.. ..........................

4-191c 4-906

Disassembly.. .....................

4-191b 4-906

Installation.. .......................

4-191d 4-906

Removal.. ............................

4-191a 4-906

Hoist winch cable replacement:

Installation.. .......................

3-384b 3-944

Removal.. ............................

3-384a 3-942

Hoist winch replacement:

Installation.. .......................

4-192b 4-908

Removal.. ............................

4-192a 4-908

Holding future, mounting fuel pump to:

Installation.. .......................

5-12b 5-92

Removal.. ............................

5-12a 5-92

Holding fixture, transmission mounting to:

Installation.. .......................

5-40a 5-284

Removal.. ............................

5-40b 5-282

Hood bumper replacement:

Installation.. .......................

3-274b 3-741

Removal ..............................

3-274a 3-741

Hood crossmember bracket maintenance:


4-132b 4-692

Installation.. .......................

4-132c 4-692

Removal.. ............................

4-132a 4-692

Hood grab handle replacement:

Installation.. .......................

3-27 lb 3-737

Removal.. ............................

3-271a 3-737

Hood hinge replacement:

Installation.. .......................

4-133b 4-694

Removal.. ............................

4-133a 4-694

Hood latch and bracket replacement:

Installation.. .......................

3-268b 3-732

Removal.. ............................

3-268a 3-732

Hood retaining bracket replacement:

Installation.. .......................

3-247b 3-695

Removal.. ............................

3-247a 3-695

Hood stop bracket, cab, replacement:

Installation.. .......................

3-273b 3-740

Removal.. ............................

3-273a 3-740

Hood stop cables replacement:

Installation.. .......................

3-270b 3-736

Removal.. ............................

3-270a 3-736

Hood support bar and bracket replacement:

Installation.. .......................

3-269b 3-734

Removal.. ............................

3-269a 3-734

Hood, engine, maintenance:

Adjustment.. .......................

3-275c 3-746

Installation.. .......................

3-275b 3-744

Removal ..............................

3-275a 3-742

Index 35

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Hook, pintle, maintenance:

Assembly.. ..........................

3-242d 3-687


3-242c 3-686

Disassembly.. .....................

3-242b 3-686

Installation.. .......................

3-242e 3-687

Removal.. ............................

3-242a 3-686

Hook, side panel roof swivel, replacement:

Installation.. .......................

3-359b 3-898

Removal.. ............................

3-359a 3-898

Horn contact brush replacement:

Installation.. .......................

3-102b 3-282

Removal.. ............................

3-102a 3-282

Horn switch replacement:

Installation.. .......................

3-104b 3-286

Removal.. ............................

3-104a 3-286

Horn, solenoid, and bracket replacement:

Installation.. .......................

3-103b 3-285

Removal.. ............................

3-103a 3-284

Hose (M939A2), air cleaner, maintenance:

Assembly.. ..........................

3-13d 3-48

Disassembly.. .....................

3-13b 3-48

Inspection.. .........................

3-13c 3-48

Installation.. .......................

3-13e 3-49

Removal.. ............................

3-13a 3-48

Hose chafe guard kit, hydraulic, replacement:

Installation.. .......................

3-443b 3-1150

Removal.. ............................

3-443a 3-1148

Hose, deepwater fording air pressure, replacement:

Installation (M939/A1)....... 4-227d 4-1038


4-227c 4-1034

Removal (M9391A1). ........... 4-227a 4-1034

Removal (M939A2). ............ 4-227b 4-1036

Hose, heater inlet and outlet, personnel, replacement:

Installation.. .......................

3-291b 3-780

Removal.. ............................

3-291a 3-780

Hose, heater, engine coolant, replacement:

Installation.. .......................

3-403b 3-990

Removal.. ............................

3-403a 3-986

Hoses and brackets (M939A2), upper radiator, replacement:

Installation.. .......................

3-58b 3-170

Removal.. ............................

3-58a 3-170

Hoses and lines (M939A2), coolant, replacement:

Installation.. .......................

3-56b 3-166

Removal.. ............................

3-56a 3-164

Para Page

Hoses and tubes (M939/A1), coolant, replacement:

Radiator inlet hoses and tube installation . . . . . . . . . . . 3-54j 3-158

Radiator inlet hoses and tube removal . . . . . . . . . . . . . . 3-54a 3-154

Radiator outlet hoses and tee installation . .. . . . . . . . . 3-54g 3-156

Radiator outlet hoses and tee removal . . . . . . . . . . . . . . . 3-54d 3-156



Thermostat housing hose, radiator bypass tube, and hose installation . . . . . . . . . . 3-54i

3-158

Thermostat housing hose, radiator bypass tube, and hose removal . . . . . . . . . . . . . 3-54b 3-154

Transmission oil cooler hoses and tube installation 3-54f 3-156

Transmission oil cooler hoses and tube removal.... 3-54e 3-156

Hoses, oil cooler, transmission, replacement:

Installation . . . . . . . . . . . . . . . . 3-142b 3-388

Removal . . . . . . . . . . . . . . . . . . .

3-142a 3-384

Hoses, power steering pump pressure and return, replacement (Ross):

Installation . . . . . . . . . . . . . . . . . 3-234b 3-668

Removal . . . . . .. . . . . . . . . . . . . .

3-234a 3-668

Hoses, power steering pump pressure and return, replacement (Sheppard):

Installation . . . . . . . . . . . . . . . . . . 3-235b 3-670

Removal . . . . . . . . . . . . . . . . . . 3-235a 3-670

Hoses, steering assist cylinder, replacement:

Installation . . . . . . . . . . . . . . . . . 3-232b 3-660

Removal . . . . . . . . . . . . . . . . . . . .

3-232a 3-660

Housing (M939A2), thermostats and, maintenance:


Installation (external bypass) . . . . . . . . . . . . . . . . . . . 3-66e

3-194

Installation (internal bypass) . . . . . . . . . . . . . . . . . . . . . . . 3-66c

3-193

Removal (external bypass)..

3-66d 3-194

Removal (internal bypass)..

3-66a 3-192

Housing assembly cover replacement:

Installation . . . . . . . . . . . . . . . . . . 3-333b 3-852

Removal . . . . . . . . . . . . . . . . . . . 3-333a 3-852

Index 36

TM 9-2320-272-24-4

Housing, adapter and first cluth piston, maintenance:

Assembly ............................

5-57d 5-380


5-57c 5-380

Disassembly.. .....................

5-57b 5-378

Removal.. ............................

5-57a 5-378

Housing, cam follower, maintenance:

Assembly.. ..........................

4-19d 4-150


4-19c 4-148

Disassembly.. .....................

4-19b 4-146

Installation.. .......................

4-19e 4-152

Removal.. ............................

4-19a 4-144

Housing, flywheel, maintenance:


4-16b 4-130

Installation.. .......................

4-16c 4-132

Removal.. ............................

4-16a 4-130

Housing, fuel pump, maintenance:

Assembly.. ..........................

5-15c 5-96

Disassembly.. .....................

5-15a 5-96

Inspection.. .........................

5-15b 5-96

Housing, hydraulicoil filter, replacement:

Installation.. .......................

4-186b 4-894

Removal.. ............................

4-186a 4-894

Housing, transmission, maintenance:

Assembly.. ..........................

5-59c 5-384


5-59b 5-384

Disassembly.. .....................

5-59a 5-384

Hub air seal leak test:

Front hub leak test.. ........... 3-462a 3-1264

Rear hub leak test.. ............

3-462b 3-1266

Hub and drum (M939/A1), front, maintenance:


Installation.. .......................

3-223d 3-640

Lubrication.. .......................

3-223c 3-640

Removal.. ............................

3-223a 3-638

Hub and drum (M939/A1), rear, maintenance:


Installation.. .......................

3-224d 3-646

Lubrication .........................

3-224c 3-644

Removal.. ............................

3-224a 3-642

Hubs, front, repair:


3-460b 3-1253

Installation.. .......................

3-460d 3-1256

Removal ..............................

3-460a 3-1252

Repair.. ...............................

3-460c 3-1254

Para Page

INDEX (Contd)

Para Page

Hubs, rear, repair:

Cleaning and inspection. . . . . .

3-461b 3-1260

Installation . . . . . . . . . . . . . . . . 3-461d 3-1262

Removal . . . . . . . . . . . . . . . . . . .

3-461a 3-1258

Repair. . . . . . . . . . . . . . . . . . . 3-461c 3-1260

Hydraulic hoist winch motor and lines replacement:

Installation . . . . . . . . . . . . . . . . . . 4-190b 4-904

Removal . . . . . . . . . . . . . . . . . . . . 4-190a 4-904

Hydraulic hose chafe guard kit replacement:

Installation . . . . . . . . . . . . . . . . . 3-443b 3-1150

Removal . . . . . . . . . . . . . . . . . . . . . 3-443a 3-1148

Hydraulic oil filter housing replacement:

Installation . . . . . . . . . . . . . . . . 4-186b 4-894

Removal . . . . . . . . . .. . . . . . . . . .

4-186a 4-894

Hydraulic oil reservoir brackets and straps replacement:

Installation . . . . . . . . . . . . . . . . . . 4-189b 4-902

Removal . . . . . . . . . . . . .. . . . . . . 4-189a 4-902

Hydraulic oil reservoir maintenance:

Assembly . . . . . . . . . . . . . . . . . . . 4-188d 4-900

Cleaning, inspection, and repair . . . . . .. . . . . . . . . . . .

4-188c 4-900

Disassembly . . . . . . . . . . . . . . . . 4-188b 4-898

Installation . . . . . . . . . . . . . . . . . . 4-188e 4-900

Removal . . . . . . . . . . . . . . . . . . . . 4-188a 4-898

Hydraulic reservoir drain kit replacement:

Installation . . . . . . . . . . . . . . . . 3-444b 3-1152

Removal . . . . . . . . . . . . . . . . . .

3-444a 3-1152

Hydraulic reservoir shutoff modification kit replacement:

Installation . . . . . . . . . . . . . . .

3-445b 3-1156

Removal . . . . . . . . . . . . . . . . . . . 3-445a 3-1154

Hydraulic system operation..... 1-24 1-71

I

Idle speed, engine run-in test and, adjustment:

Engine run-in test . . . . . . . . . . . 4-54a 4-328

Idle speed adjustment . .. . . . . 4-54b 4-328

Indicator lamp, turn signal control and, replacement:

Installation . . . . . . . . . . . . . . . . . 3-113b 3-302

Removal . . . . . . . . . . . . . . . . . . . . 3-113a 3-302

Indicator panel light and lamp replacement:

Lamp installation . . . . . . . . . . . . 3-84d 3-246

Lamp removal . . . . . . . . . . . . . . 3-84c 3-246

Light assembly installation. 3-84b 3-246

Light assembly removal...... 3-84a 3-246

Index 37

TM 9-2320-272-24-4

Indicator plate, fuel selector valve, mounting bracket, and, maintenance:

Inspection.. .........................

3-24b

Installation.. .......................

3-24c

Removal.. ............................

3-24a

Information, general ...............

4-115

Injection pump, fuel, maintenance:

Adjustment.. .......................

4-57c

Installation.. .......................

4-57b

Removal.. ............................

4-57a

Injector (dial indicator method), valve and, adjustment:

Checking plunger free travel.. ..............................

4-33a

Injector and valve adjustments.. ...................

4-33b

Injector flow test:

Adjusting and measuring fuel delivery ......................

5-23c

Setting up test stand.. ........

5-23a

Testing check ball seating... 5-23b

Injector leak test:

Setting up injector leakage detector.. ...........................

5-20a

Testing injector plunger and seat.. .........................

5-20b

Injector plunger and valve adjustments (torque method):

Injector and valve adjustment.. .....................

4-34b

Pre-adjustment setup ......... 4-34a

Injector spray pattern test:

Setting up spray pattern tester.. .................

5-21a

Testing spray pattern .........

5-21b

Injector test stand calibration:

Setting up injector tester.....

5-22a

Test stand calibration ........

5-22b

Injector, fuel, calibration:

Leakage test.. .....................

4-56b

Opening pressure test.. .......

4-56a

Spray pattern test.. ............ 4-56c

Injector, fuel, maintenance:

Assembly.. ..........................

4-55d


4-55c

Disassembly.. .....................

4-55b

Installation.. .......................

4-55e

Removal.. ............................

4-55a

Injector, fuel, repair:

Inspection.. .........................

5-19c

Non-top stop injector assembly ..........................

5-19d

3-76

3-77

3-76

4-605

4-345

4-342

4-338

4-248

4-248

5-150

5-148

5-148

5-136

5-138

4-256

4-254

5-140

5-140

5-142

5-146

4-336

4-336

4-337

4-334

4-332

4-330

4-334

4-330

5-128

5-129

Para Page

INDEX (Contd)

Para

Page

Non-top stop injector disassembly.. ....................

5-19a 5-122

Top stop injector assembly. 5-19e 5-132

Top stop injector disassembly.. ....................

5-19b 5-126

Inner boom replacement:

Installation.. .......................

4-195b 4-918

Removal.. ............................

4-195a 4-916

Inserts, valve seat, maintenance:

Cleaning .............................

5-5d

5-24

Counterboring.. ...................

5-5c

5-24

Gauging.. ............................

5-5b

5-22

Installation.. .......................

5-5e 5-24

Removal.. ............................

5-5a

5-22

Inside telephone jack post replacement:

Installation.. .......................

3-374b 3-918

Removal.. ............................

3-374a 3-918

Inspection and servicing instructions, general ............. 2-6

2-2

Inspection and servicing instructions, specific.............. 2-7

2-2

Inspection in limited storage... 6-11

6-3

Inspection, general .................. 2-15

2-56

Instrument cluster harness replacement:

Installation.. .......................

3-130b 3-348

Removal.. ............................

3-130a 3-348

Instrument cluster maintenance:

Assembly.. ..........................

3-83c

3-242

Disassembly.. .....................

3-83b 3-242

Installation.. .......................

3-83d 3-244

Removal.. ............................

3-83a 3-238

Instrument panel replacement:

Installation.. .......................

3-85b 3-248

Removal.. ............................

3-85a 3-248

Insulation, cab, replacement:

Installation.. .......................

3-306b 3-804

Removal.. ............................

3-306a 3-804

Intake and exhaust valves refacing:

Cleaning after refacing.. ......

5-4c

5-20

Grinding or refacing valves ...............................

5-4b

5-20

Valve specifications.. ........... 5-4a

5-18

Intake pipe (M939/A1), air cleaner, maintenance:

Inspection.. .........................

3-14b 3-50

Installation.. .......................

3-14c 3-50

Removal.. ............................

3-14a 3-50

Interior side panels and latches replacement:

Installation.. .......................

5-75b 5-504

Removal.. ............................

5-75a 5-500

Index 38

TM 9-2320-272-24-4

Isolator (M939A2), transmission mounting bracket replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

K

3-137b 3-373

3-137a 3-373

Kit, A-frame, maintenance:

Inspection.. .........................

Installation.. .......................

Removal ..............................

Kit, air dryer (M923/A1/A2,

M925/A1/A2, M927/A1/A2,


Installation.. .......................

Removal ..............................

Kit, air dryer (M929/A1/A2,

M930/A1/A2, M931/A1/A2,


Installation.. .......................

Removal ..............................

Kit, hardtop, replacement:

Installation.. .......................

Removal ..............................

Kit, mud guard (M931/A1/A2,

M932/A1/A2), replacement:

Installation.. .......................

Removal ..............................

Kit, troop seat and siderack

(M929/A1/A2, M930/A1/A2) maintenance:

Siderack assembly.. ............

Siderack disassembly.. .......

Troop seat assembly.. .........

Troop seat disassembly ......

Knuckle, steering, maintenance:


End play test.. ....................

Installation.. .......................

Removal ..............................

3-414b 3-1048

3-414c 3-1048

3-414a 3-1046

3-412b 3-1026

3-412a 3-1022

3-413b 3-1039

3-413a 3-1032

3-396b 3-972

3-396a 3-972

3-420b 3-1078

3-420a 3-1078

3-429c 3-1102

3-429b 3-1102

3-429d 3-1102

3-429a 3-1102

4 - 9 8 b 4 - 5 5 2

4 - 9 8 d 4 - 5 5 6

4 - 9 8 c 4 - 5 5 4

4 - 9 8 a 4 - 5 5 0

L

Ladder locking clamp replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Ladder rack bumpers replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . .

3-360b 3-899

3-360a 3-899

3-366b 3-907

3-366a 3-907

Para Page

INDEX (Contd)

Para Page

Lamp and door (M936/A1/A2), floodlight, sealed beam, replacement:

Installation.. .......................

3-119b 3-322

Removal.. ............................

3-119a 3-322

Lamp and lens, emergency/ blackout light, replacement:

Installation.. .......................

3-372b 3-915

Removal.. ............................

3-372a 3-915

Latch and bracket, hood, replacement:

Installation.. .......................

3-268b 3-732

Removal.. ............................

3-268a 3-732

Leak test, injector:

Setting up injector leakage detector.. ...........................

5-20a 5-136

Testing injector plunger and seat.. .........................

5-20b 5-138

Leakage, axle, test:

Corrective action .................

4-106b 4-582

Test.. ..................................

4-106a 4-582

Level wind, hoist, maintenance:

Assembly.. ..........................

4-191c 4-906

Disassembly.. .....................

4-191b 4-906

Installation.. .......................

4-191d 4-906

Removal.. ............................

4-191a 4-906

Lift eyes, engine, replacement:

Installation.. .......................

4-11b 4-118

Removal.. ............................

4-11a 4-118

Lifting shackle and bracket, front and rear, replacement:

Installation .........................

3-24 lb 3-684

Removal.. ............................

3-24 la 3-684

Light fixtures, blackout and emergency, replacement:

Installation.. .......................

4-166b 4-798

Removal.. ............................

4-166a 4-798

Light fixtures, flourescent, maintenance:

Assembly.. ..........................

4-168d 4-802

Disassembly.. .....................

4-168b 4-802

Inspection.. .........................

4-168c 4-802

Installation.. .......................

4-168e 4-803

Removal.. ............................

4-168a 4-802

Light switch, main, replacement:

Installation.. .......................

3-108b 3-294

Removal.. ............................

3-108a 3-294

Light tube, fluorescent, replacement:

Installation.. .......................

3-371b 3-914

Removal.. ............................

3-371a 3-914

Index 39

TM 9-2320-272-24-4

Light, blackout, maintenance:

Assembly.. ..........................

3-117c 3-308

Disassembly.. .....................

3-117b 3-308

Installation.. .......................

3-117d 3-308

Removal.. ............................

3-117a 3-308

Light, head-, maintenance:

Alignment.. .........................

3-116c 3-306

Installation.. .......................

3-116b 3-306

Removal.. ............................

3-116a 3-306

Lights, bracket and side marker, replacement:

Lamp installation.. ............. 3-122d 3-330

Lamp removal.. ..................

3-122a 3-330

Light installation.. .............. 3-122c 3-330

Light removal.. ...................

3-122b 3-330

Lightweight weapon station modification kit maintenance:

Assembly.. ..........................

3-446c 3-1170

Disassembly.. .....................

3-446b 3-1168

Installation.. .......................

3-446d 3-1174

Removal..............................

3-446a 3-1160

Limited storage instructions ... 6-10 6-2

Limited storage, inspection in. 6-11 6-3

Limited storage, removal from 6-12 6-3

Limiting valve, front, replacement:

Installation .........................

3-190b 3-522

Removal.. ............................

3-190a 3-522

Lines (M939A2), air compressor and, replacement:

Installation.. .......................

3-206b 3-576

Removal.. ............................

3-206a 3-574

Lines (M939A2), fuel tank, replacement:

Installation.. .......................

3-29b 3-100

Removal.. ............................

3-29a 3-96

Link, drag, replacement:

Installation.. .......................

3-229b 3-655

Removal.. ............................

3-229a 3-655

Linkage (M939/A1), accelerator, maintenance:

Adjustment.. .......................

3-42c 3-124

Installation.. .......................

3-42b 3-124

Removal.. ............................

3-42a 3-124

Linkage (M939A2), accelerator, maintenance:

Adjustment.. .......................

3-43f 3-128

Assembly.. ..........................

3-43d 3-128


Disassembly.. .....................

3-43b 3-126

Installation .........................

3-43e 3-128

Removal.. ............................

3-43a 3-126

List of abbreviations.. .............

l-10

1-3

Loading and movement .......... 6-8 6-2

Location and description of major components.. ...............

1-14 1-16

Para Page

INDEX (Contd)

Para

Page

Lock, cab door, replacement:

Installation . . . . .. . . . . . . . . . . . . 3-313b 3-812

Removal . . . . . . . . . .. . . . . . . . . .

3-313a 3-812

Lock, rear, side panel, replacement:

Installation . . . . . . . . .. . . . . . . . .

3-368b 3-910

Removal . . . . . . . .. . . . . . . . . . . 3-368a 3-909

Lock, side panel exterior, replacement:

Installation . . . . . .. . . . . . . . . . . 3-370b 3-912

Removal . . . . . . . . . . . . . . . . . . .

3-370a 3-912

Lock, side panel front and hinged-type roof, replacement:

Installation . . . . . . . . . . . . . . . . . . 3-369b 3-911

R e m o v a l . . . . . . . . . . . . . . . . . . . . .

3-369a 3-911

Lock-in control valve, transfer case front axle, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-147b 3-404

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-147a 3-404

Lock-in switch, front wheel, replacement:

Installation . . . . . . . . . . . . . . . . 3-101b 3-280

Removal . . . . . . . . . . .. . . . . . . . 3-101a 3-280

Locks, expanding and retracting mechanism, replacement:

Installation . . . . . . . . . . . . . .

3-378b 3-926

Removal . . . . . . . . . . . . . . . . . . 3-378a 3-926

Low clutch removal and clearance:


Establishing clearance........ 5-56c 5-376

Removal . . . . . . . . . . . . . . .. . . . . . 5-56a 5-374

Lower torque rod, upper and, maintenance:

Assembly . . . . . . . . . . . . . . . . . .

3-170e 3-472


Diassembly. . . . . . . . . . . . . .. . . . . 3-170d 3-470

Lower torque rod installation. . . . . . . . . . . . . . . . 3-170h 3-474

Lower torque rod removal... 3-170b 3-470

Setting preload for upper torque rod . . . . . . . . . . . . . . . . . 3-170f 3-472

Upper torque rod installation . . . . .. . . . . . . . . . . 3-170g 3-474

Upper torque rod removal... 3-170a 3-468

Lubrication, general preparation of vehicle for shipment . . . . . . . . . . . . . . . . . . . 6-3

6-1

Index 40

TM 9-2320-272-24-4

M

Machine gun mounting kit maintenance:

Assembly ............................

Disassembly.. .....................

Installation.. .......................

Removal ..............................

Main leaf, front spring and, replacement:

Front spring main leaf installation.. .....................

Front spring main leaf removal.. ...........................

Front spring installation .....

Front spring removal ..........

Main light switch replacement:

Installation.. .......................

Removal ..............................

Main shaft, gear unit and, maintenance:

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Main wiring harness replacement:

Installation.. .......................

Removal ..............................

Maintenance forms, records, and reports.. .........................

Maintenance instructions, general ..................................

Manifold pressure compensator maintenance:

Assembly.. ..........................


Installation. ........................

Disassembly .......................

Removal ..............................

Manifold return hose

(M939/A1), surge tank, radiator vent hose and, replacement:

Radiator vent and manifold return hoses installation ...

Radiator vent and manifold return hoses removal ........

Surge tank installation.. .....

Surge tank removal .............

3-418c 3-1070

3-418b 3-1068

3-418d 3-1072

3-418a 3-1066

3-161c 3-443

3-161b 3-443

3-161d 3-444

3-161a 3-440

3-108b 3-294

3-108a 3-294

5-51d

5-51c

5-51b

5-51e

5-353

5-51a

5-348

5-89b

5-89a

1-2

5-39

5-33d

5-33a

3-61d

5-351

5-350

5-348

5-568

5-568

1-1

5-281

5-226

5-33c

5-226

5-33e 5-226

5-33b 5-224

5-224

3-182

3-61a 3-180

3-61c 3-182

3-61b 3-180

Para Page

INDEX (Contd)

Para

Page

Manifold, engine air intake, maintenance:

Assembly.. ..........................

4-24d 4-180


4-24c 4-180

Disassembly.. .....................

4-24b 4-180

Installation.. .......................

4-24e 4-182

Removal ..............................

4-24a 4-178

Manifold, engine water, maintenance:

Assembly.. ..........................

4-27d 4-196


4-27c 4-196

Disassembly.. .....................

4-27b 4-194

Installation.. .......................

4-27e 4-196

Removal.. ............................

4-27a 4-194

Manifold, exhaust, replacement:

Installation.. .......................

4-50b 4-312

Removal.. ............................

4-50a 4-312

Manual selector shaft, transmission, replacement:

Installation.. .......................

5-45b 5-308

Removal.. ............................

5-45a 5-308

Map compartment replacement:

Installation.. .......................

3-287b 3-772

Removal.. ............................

3-287a 3-772

Mechanical troubleshooting, direct and general support symptom index ................... 4-2 4-2

Mechanical troubleshooting, unit level.. .............................

2-21

2-61

Mini-lighting kit, European, replacement:

Installation.. .......................

3-439b 3-1132

Removal.. ............................

3-439a 3-1132

Mirror, brace and, rearview, replacement:

Installation.. .......................

3-290b 3-779

Removal.. ............................

3-290a 3-778

Models, differences between .... 1-15

1-20

Modulate lockup valve, low trimmer valve, and low shift valve replacement:

Installation.. .......................

5-43b 5-304

Removal.. ............................

5-43a 5-304

Modulator, transmission, maintenance:

Adjustment.. .......................

5-61b 5-394

Testing.. .............................

5-61a 5-394

Motor, crane hydraulic swinger, replacement:

Installation.. .......................

4-199b 4-934

Removal.. ............................

4-199a 4-934

Index 41

TM 9-2320-272-24-4

Mount (M939/A1), oil cooler, transmission, replacement:

Oil cooler installation . . . . . . . . . . 3-140d 3-379

Oil cooler mount installation . . . . . . . . . . . . . . . . .

3-140c 3-378

Oil cooler mount removal . . . .

3-140b 3-378

Oil cooler removal . . . . . . . . . . . . .

3-140a 3-378

Mount (M939A2), oil cooler, transmission, replacement:

Installation . . . . . .. . . . . . . . . . .

3-14 lb 3-382

Removal . . . . . . . . . . . . . . . . . . .

3-14 la 3-380

Mount, convoy warning light

(M929/A1/A2, M930/A1/A2), replacement:

Installation . . . . . . . . . . . . . . . . .

3-432b 3-1112

Removal . . . . . .. . . . . . . . . . . . . . 3-432a 3-1112

Mount, convoy warning light

(M934/A1/A2), replacement:

Installation . . . . . . . . . . . . . . . . 3-431b 3-1110

Removal . . . . . .. . . . . . . . . . . . . . 3-431a 3-1108

Mount, convoy warning light, replacement:

Installation . . . . . . . . . . . . . . . . 3-430b 3-1106

Removal . . . . . . . . . . . . . . . . . . . 3-430a 3-1104

Mounting bracket kit, chemical agent alarm, replacement:

Chemical alarm wiring harness installation . . . . . . . . 3-417d 3-1064

Chemical alarm wiring harness removal . . . . . . . . . . . 3-417a 3-1058

Detector and alarm bracket installation . . . . . . . . . . . . . . . .

3-417c 3-1062

Detector and alarm bracket removal . . . . . . . . . . . . . . . . . . . 3-417b 3-1060

Mounting bracket kit, decontamination (M13) apparatus, replacement:


M925/A1/A2, M9271A1/A2,

M928/A1/A2) . . . . . . . . . . . .

3-419h 3-1076


M930/A1/A2, M931/A1/A2,

M932/A1/A2) . . . . . . . . . . . .

3-419b 3-1074


3-419d 3-1074


3-419f 3-1076


M925/A1/A2, M927/A1/A2,

M928/A1/A2).............. 3-419g 3-1076


M930/A1/A2, M931/A1/A2,

M932/A1/A2) . . . . . . . . . . . .

3-419a 3-1074

Removal (M934/A1/A2)....... 3-419c 3-1074

Removal (M936/A1/A2)....... 3-419e 3-1076

Para Page

INDEX (Contd)

Para

Page

Mounting bracket kit, fire extinguisher, replacement:

Installation . . . . . . . . . . . . . . . . . .

3-416b 3-1056

Removal . . . . . . . . . . . . . . . . . . . . .

3-416a 3-1056

Mounting bracket, air cleaner assembly and, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . 3-15b 3-52

Installation . . . . . . . . . . . . . . . . .

3-15c 3-54

Removal . . . . . . . . . . . . . . . . . . . . . .3-15a 3-52

Mounting bracket, alernator, pulley (M939A2) maintenance:

Adjustment . . . . . . . . . . . . . . . . . . 3-80e 3-230

Alternator and mounting bracket installation . . . . . . . . . . 3-80d 3-230

Alternator and mounting bracket removal . . . . . . . . . . . . . . 3-80a 3-228

Pulley installation . . . . . . . . . . . . . . 3-80c 3-230

Pulley removal . . . . . . . . . . . . . . . . . 3-80b

3-229

Mounting bracket, alternator

(M939/A1) and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-79b 3-226

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-79a 3-224

Mounting bracket, fuel selector valve, and indicator plate maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-24b

3-76

Installation . . . . . . . . . . . . . . . . . . . . .

3-24e 3-77

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-24a 3-76

Mounting bracket, pioneer tool kit, replacement:

Bracket installation (M923,

M925, M927, M928) . . . . . . . . . 3-415b 3-1052


M930)...........................

3-415f 3-1054

Bracket installation

(M929A1, M930A1) . . . . . . . . . 3-415h 3-1054


M932) . . . . . . . . . . . . . . . . .

3-415d 3-1052

Bracket removal (M923,

M925, M927, M928) . . . . . . . . 3-415a 3-1052


M930). . . . . . . . . . . . . . . . . . . .

3-415e 3-1054

Bracket removal (M929A1,

M930A1). . . . . . . . .. . . . . . . . . 3-415g 3-1054


M932) . . . . . . . . . . . .. . . . . . . . . 3-415c 3-1052

Mounting brackets and isolators, engine, replacement:

Installation . . . . . . .. . . . . . . . . . .

4-39b 4-274

Removal . . . . . . . . . . . . . . . . . . . 4-39a 4-272

Index 42

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Mounting fuel injection pump to test stand:

Mounting fuel injection pump to test stand.. .........

5-31a

5-210

Removing fuel injection pump from test stand.. ..... 5-31b

5-212

Mounting fuel pump to holding fixture:

Installation.. .......................

5-12b

5-92

Removal ..............................

5 - 1 2 a 5 - 9 2

Mounting kit, machine gun, maintenance:

Assembly.. ..........................

3-418c 3-1070

Disassembly.. .....................

3-418b 3-1068

Installation.. .......................

3-418d 3-1072

Removal ..............................

3-418a 3-1066

Mounting kit, rifle, replacement:

Installation on left door.. .... 3-421c 3-1082

Installation on dash and floor.. .........................

3-42ld 3-1083

Removal from dash and floor ...........................

3-421b 3-1081

Removal from left door ........ 3-421a 3-1080

Mounting pins, shock absorber and, replacement:

Installation.. .......................

3-166b 3-452

Removal ..............................

3-166a 3-452

Mounting plate (M936/Al/A2), wet air reservoir (supply tank) and, replacement:

Installation.. .......................

3-201b 3-558

Removal.. ............................

3-201a 3-556

Movement, loading and ........... 6-8

Mud guard kit (M931/A1/A2,

6-2


Installation.. .......................

3-420b 3-1078

Removal.. ............................

3-420a 3-1078

Muffler and shield maintenance:

Inspection ...........................

3 - 5 1 b 3 - 1 4 6

Installation.. .......................

3-51c

3-146

. Removal.. ............................

3-51a 3-146

N

Neutral start switch, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-98b

3-273

Removal. . . . . . . . . . . . . . . . . . . . . . . . 3-98a 3-273

Para Page

O

Official nomenclature.. ............

1-5

Oil cooler, engine, maintenance:

1-2

Assembly.. ..........................

4-23d 4-176


4-23c 4-176

Disassembly.. .....................

4-23b 4-174

Installation.. .......................

4-23e 4-176

Removal.. ............................

4-23a 4-174

Oil dipstick tube maintenance:

Inspection ...........................

3-3c 3-8

Installation (M939/A1). ......

3-3d

3-10


3-3e 3-10

Removal (M939/A1).. .......... 3-3a 3-8

Removal (M939A2). ............ 3-3b

3-8

Oil pan and filter, transmission, maintenance:


5 - 4 2 b 5 - 3 0 0

Installation.. .......................

5-42c 5-302

Removal.. ............................

5-42a 5-300

Oil pan and oil suction tube maintenance:


4 - 4 7 c 4 - 3 0 4

Oil pan installation ............ 4-47e

4-305

Oil pan removal.. ................

4-47a 4-304

Oil suction tube 4 - 4 7 d 4 - 3 0 4 installation.. .....................

Oil suction tube removal ..... 4 - 4 7 b 4 - 3 0 4

Oil pan shroud and exhaust tube, engine coolant replacement:

Installation.. .......................

4-402b 3-984

Removal.. ............................

4-402a 3-984

Oil pan shroud and exhaust tube, swingfire heater, replacement:

Installation.. .......................

3-409b 3-1016

Removal ..............................

3-409a 3-1016

Oil pan, engine, maintenance:

Assembly ............................

4 - 2 2 d 4 - 1 7 0


4 - 2 2 c 4 - 1 7 0

Disassembly.. .....................

4-22b 4-170

Installation.. .......................

4-22e 4-172

Removal.. ............................

4-22a 4-168

Oil pressure sending unit replacement:

Installation.. .......................

3-91b 3-262

Removal.. ............................

3-91a 3-262

Oil pressure, transmission, testing:

Automatic shift speed test.. 5-60c

5-392

Main pressure and governor pressure test.......

5 - 6 0 b 5 - 3 9 0

Oil cooler pressure test.. ..... 5-60a

5-386

Index 43

TM 9-2320-272-24-4

Oil pump and front support, transmission, maintenance:

Assembly.. ..........................

5-46d 5-316


5-46c 5-314

Disassembly.. .....................

5-46b 5-312

Installation.. .......................

5-46e 5-320

Removal.. ............................

5-46a 5-310

Oil pump maintenance:


4-49c 4-310

Gear backlash test.. ........... 4-49a 4-308

Installation.. .......................

4-49d 4-310

Removal.. ............................

4-49b 4-308

Oil pump pickup hose maintenance:

Inspection.. .........................

3-7b

3-32

Installation.. .......................

3-7c 3-32

Removal.. ............................

3-7a

3-32

Oil pump return hose maintenance:

Inspection.. .........................

3-8b

3-34

Installation.. .......................

3-8c 3-34

Removal ................................ 3-8a

3-34

Oil pump, engine, replacement:

Gear backlash test.. ........... 4-21a 4-164

Installation.. .......................

4-21c 4-166

Removal.. ............................

4-21b 4-164

Oil reservoir (M932/A1/A2), tractor winch hydraulic, replacement:

Installation.. .......................

3-338b 3-866

Removal.. ............................

3-338a 3-864

Oil reservoir brackets and straps, hydraulic, replacement:

Installation.. .......................

4-189b 4-902

Removal.. ............................

4-189a 4-902

Oil reservoir, hydraulic, maintenance:

Assembly.. ..........................

4-188d 4-900


4-188c 4-900

Disassembly.. .....................

4-188b 4-898

Installation.. .......................

4-188e 4-900

Removal.. ............................

4-188a 4-898

Oil reservoir, winch hydraulic, replacement:

Installation.. .......................

3-337b 3-862

Removal.. ............................

3-337a 3-860

Oil seal (in vehicle), rear, maintenance:


4-45b 4-298

Installation .........................

4 - 4 5 c 4 - 2 9 8

Removal.. ............................

4-45a 4-298

Para

Page

INDEX (Contd)

Para

Page

Oil seal, front gearcase cover and, maintenance:


4 - 4 8 b 4 - 3 0 6

Installation.. .......................

4-48c 4-306

Removal ..............................

4 - 4 8 a 4 - 3 0 6

Oil seal, rear cover and, maintenance:


4 - 4 4 b 4 - 2 9 6

Installation.. .......................

4-44c 4-296

Removal ..............................

4 - 4 4 a 4 - 2 9 6

Oil seal, transmission output shaft yoke and, replacement:

Installation.. .......................

4-78b 4-494

Removal.. ............................

4-78a 4-494

Oil section tube, oil pan and, maintenance:


4 - 4 7 c 4 - 3 0 4

Oil pan installation ............ 4-47e 4-305

Oil pan removal ..................

4 - 4 7 a 4 - 3 0 4

Oil suction tube

4 - 4 7 d 4 - 3 0 4 installation.. .....................

Oil suction tube removal .....

4 - 4 7 b 4 - 3 0 4

Oil service, transmission, instructions:

Draining oil.. .......................

3-133a 3-354

Governor filter installation.. .....................

3-133e 3-358

Governor filter removal.. ..... 3-133d 3-358

Oil filter installation.. .........

3-133c 3-356

Oil filter removal.. ...............

3-133b 3-356

Replenishing oil ..................

3-133f 3-360

One-way check valve, air reservoir, replacement:

Installation.. .......................

3-186b 3-514

Removal.. ............................

3-186a 3-514

Operation reference index, principles of.. ........................

1-19

1-25

Operation, general, principles of ..........................................

1-18

1-25

Operation:

Central tire inflation system

(CTIS) operation ...............

1-25

1-78

Compressed air and brake system.. ............................

1-23 1-25

Control system.. ....................

1-20

1-25

Electrical systems.. ...............

1-22

1-45

Hydraulic system ..................

1-24

1-71

Power system.. .....................

1-21

1-34

Outside door handle replacement:

Installation.. .......................

3-307b 3-806

Removal.. ............................

3-307a 3-806

Outside telephone jack post replacement:

Installation.. .......................

3-375b 3-920

Removal.. ............................

3-375a 3-920

Index 44

TM 9-2320-272-24-4

P

Packaging, general preparation of vehicle for shipment . . . . . . . . . . 6-5

Packing, general preparation of vehicle for shipment.. ............ 6-6

6-2

6-2

Panel light and lamp, indicator replacement:

Lamp installation.. ............. 3-84d

3-246

Lamp removal ....................

3-84c 3-246

Light assembly installation. 3-84b

3-246

Light assembly removal ...... 3-84a 3-246

Panel seals replacement:

Installation.. .......................

3-363b 3-904

Removal.. ............................

3-363a 3-904

Panel, exterior side, maintenance:

Assembly.. ..........................

5-73c 5-494


5-73b 5-494

Disassembly.. .....................

5-73a 5-490

Panel, instrument replacement:

Installation.. .......................

3-85b 3-248

Removal.. ............................

3-85a 3-248

Panels, ceiling filler and side, replacement:

Installation .........................

5-79b 5-532

Removal.. ............................

5-79a 5-532

Panels, latches, side panels and, replacement:

Installation.. .......................

5-7513 5-504

Removal.. ............................

5-75a 5-500

Panels, rear wall interior replacement:

Installation.. .......................

5-74b

5-498

Removal.. ............................

5-74a

5-498

Parking and service brakedrum repair:

Cleaning .............................

4-110a 4-592

Inspection ...........................

4-110b 4-592

Parking and service brakeshoe repair:

Inspection.. .........................

4-111c 4-595

Parking brakeshoe assembly ..........................

4-111e 4-595

Parking brakeshoe disassembly ......................

4-111a 4-594

Service brakeshoe assembly ..........................

4-111d 4-595

Service brakeshoe disassembly.. ....................

4-11 lb 4-594

Para Page

INDEX (Contd)

Para Page

Parking brake adjustment:

Lever arm adjustment........ 3-172d 3-480

Major adjustment . . . . . . . . . . . . . . . 3-172c 3-480

Minor adjustment . . . . . . . . . . . . . . . 3-172b 3-478

T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172a 3-478

Parking brake cable and bracket replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-175b 3-488

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-175a 3-486

Parking brake lever and switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-174b 3-484

Removal . . . . . . . . . . . . . . . . . . . . . 3-174a 3-484

Parking brakedrum dustcover replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-177b 3-494

Removal . . . . . . . . . . . . . . . . . . . . . 3-177a 3-494

Parking brakeshoes replacement:

Installation . . . . . . . . . . . . . . . . . 3-176b 3-492

Removal . . . . . . . . . . . . . . . . . . . . . .

3-176a 3-490

Pedal, brake, maintenance:

Adjustment . . . . . . . . . . . . . . . . . . .

3-196c 3-534

Installation . . . . . . . . . . . . . . . . . . . . 3-196b 3-534

Removal . . . . . . . . . . . . . . . . . . . . . .

3-196a 3-534

Personnel fuel burning heater


Installation... . . . . . . . . . . . . . . . . . . .

4-215b 4-1004

Removal ............................

4-215a 4-1004

Personnel fuel burning heater and mounting bracket


Installation . . . . . . . . . . . . . . . . . . . . .

4-217b 4-1008

Removal . . . . . . . . . . . . . . . . . . . . .

4-217a 4-1008

Personnel fuel burning heater circuit breaker replacement:

Installation........................

4-224b 4-1024

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-224a 4-1024

Personnel fuel burning heater control box replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-214b 4-1003

Removal.. . . . . . . . . . . . . . . . . . . . . .

4-214a 4-1002

Personnel fuel burning heater electric fuel pump (M939A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-219b 4-1012

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-219a 4-1012

Personnel fuel burning heater exhaust tube (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-222b 4-1020

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-222a 4-1020

Index 45

TM 9-2320-272-24-4

Personnel fuel burning heater exhaust tube (M939A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-223b 4-1022

Removal . . . . . . . . . . . . . . . . . . . . . . 4-223a 4-1022

Personnel fuel burning heater fuel pump (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-218b 4-1010

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-218a 4-1010

Personnel fuel burning heater fuel shutoff valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-220b 4-1014

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-220a 4-1014

Personnel fuel burning heater mounting bracket (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-216b 4-1006

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-216a 4-1006

Personnel fuel burning heater wiring harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-221b 4-1018

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-221a 4-1016

Personnel heater inlet and outlet hose replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-291b 3-780

Removal . . . . . . . . . . . . . . . . . . . . . .

3-291a 3-780

Personnel hot water heater replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-292b 3-782

Removal . . . . . . . . . . . . . . . . . . . . . .

3-292a 3-782

Pintle hook maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . .

3-242d 3-687


Disassembly . . . . . . . . . . . . . . . . . .

3-242b 3-686

Installation . . . . . . . . . . . . . . . . . . . . 3-242e 3-687

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-242a 3-686

Pioneer tool kit mounting bracket replacement:


M925, M927, M928) . . . . . . . . . 3-415b 3-1052


M930) . . . . . . . . . . . . . . . . . . . . . .

3-415f 3-1054

Bracket installation

(M929A1, M930A1) . . . . . . . 3-415h 3-1054


M932). . . . . . . . . . . . . . . . . . . . . . . . .

3-415d 3-1052


M925, M927, M928) . . . . . . . . . 3-415a 3-1052


M930). . . . . . . . . . . . . . . . . . . . . . . . 3-415e 3-1054

Bracket removal (M929A1,

M930A1) . . . . . . . . . . . . . . . . . . . . .

3-415g 3-1054


M932) . . . . . . . . . . . . . . . . . . . . . . .

3-415c 3-1052

Para Page

INDEX (Contd)

Para

Page

Pipe, front exhaust, replacement:

Installation.. .......................

Removal.. .............................

Piston and connecting rod maintenance:

Assembly.. ..........................


Connecting rod side clearance check .................

Disassembly.. .....................

Installation.. .......................

Removal ..............................

Piston and connecting rod maintenance:

Assembly ............................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Piston, first clutch, adapter housing, maintenance:

Assembly ............................


Disassembly.. .....................

Removal ..............................

Pitman arm replacement

(Ross):

Installation.. .......................

Removal ..............................

Pitman arm replacement

(Sheppard):

Installation.. .......................

Removal ..............................

Pitman, arm, replacement

(Ross):

Installation .........................

Removal ..............................

Pitman, arm, replacement

(Sheppard):

Installation.. .......................

Removal ..............................

Planetary carrier, adapter housing, low clutch, and rear cover, low, installation:

Installation.. .......................

Planetary carrier, rear cover and, maintenance:

Assembly.. ..........................


Disassembly.. .....................

Removal ..............................

Platel, rear splice, replacement:

Installation.. .......................

Removal ..............................

3-50b 3-144

.3-50a 3-144

5-10e

5-10d

5-10a

5-10c

5-10f

5-10b

5-26d

5-26c

5-26b 5-166

5-26e 5-172

5-26a

5-57d 5-380

5-57c 5-380

5-57b

5-57a

3-227b

3-227a

3-228b

3-228a

3-227b

3-227a

3-228b

3-228a

5-58

5-55d

5-74

5-68

5-64

5-68

5-76

5-66

5-170

5-168

5-166

5-370

5-55c 5-368

5-55b 5-366

5-55a 5-364

5-84b

5-84a

5-378

5-378

3-653

3-653

3-654

3-654

3-653

3-653

3-654

3-654

5-382

5-543

5-543

Index 46

TM 9-2320-272-24-4

Para

Plates, front bumper and, replacement:

Installation.. .......................

3-243b 3-688

Removal.. ............................

3-243a 3-688

Pneumatic controller and relief valve maintenance:

Assembly.. ..........................

3-454d 3-1238


3-454c 3-1238

Disassembly.. .....................

3-454b 3-1236

Installation.. .......................

3-454e 3-1239

Removal.. ............................

3-454a 3-1236

Power cable reel (M934A1/A2), van, replacement:

Installation.. .......................

3-380b 3-932

Removal.. ............................

3-380a 3-932

Power plant (M939/A1) replacement:

Installation.. .......................

4-4c 4-53

Preliminary disconnections. 4-4a 4-36

Removal.. ............................

4-4b 4-49

Power plant (M939A2) replacement:

Installation.. .......................

4-5c

4-76

Preliminary disconnections. 4-5a 4-67

Removal.. ............................

4-5b 4-75

Power steering gear adjustment (on-vehicle):

Sector shaft adjustment......

4-125a 4-668

Wormshaft adjustment.......

4-125b 4-668

Power steering pump


Assembly.. ..........................

3-236c 3-672

Disassembly .......................

3-236b 3-672

Installation.. .......................

3-236d 3-673

Removal.. ............................

3-236a 3-672

Power steering pump

(M939A2) repair:

Assembly.. ..........................

4-127c 4-676


4-127b 4-676

Disassembly.. .....................

4-127a 4-674

Power steering pump and reservoir (M939/A1) repair:

Assembly.. ..........................

4-126d 4-672


4-126c 4-672

Disassembly.. .....................

4-126b 4-670

Installation.. .......................

4-126e 4-672

Removal.. ............................

4-126a 4-670

Power steering pump filter


Cleaning.. ...........................

3-237c

3-674

Filter installation.. ............. 3-237e 3-674

Filter removal.. ...................

3-237a 3-674

Reservoir installation.. ........

3-237d 3-674

Reservoir removal ............... 3-237b 3-674

Page

INDEX (Contd)

Para Page

Power steering pump filter and reservoir (M939A2) maintenance:

Cleaning . . . . . . . . . . . . . . . . . . . . . . .

3-237c 3-674

Filter installation . . . . . . . . . . . . . . .

3-237e 3-674

Filter removal . . . . . . . . . . . . . . 3-237a 3-674

Reservoir installation . . . . . . . . . . 3-237d 3-674

Reservoir removal . . . . . . . . . . . . .

3-237b 3-674

Power steering pump maintenance:

Assembly . . . . . . . . . . . . . . . . . .

3-236c 3-673

Disassembly . . . . . . . . . . . . . . . . . . .

3-236b 3-672

Installation . . . . . . . . . . . . . . . . . . . . .

3-236d 3-673

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-236a 3-672

Power steering pump pressure and return hoses replacement

(Ross):

Installation . . . . . . . . . . . . . . . . . . . . .

3-234b 3-668

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-234a 3-668

Power steering pump pressure and return hoses replacement

(Sheppard):

Installation . . . . . . . . . . . . . . . . . . . . .

3-235b 3-670

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-235a 3-670

Power steering pump test equipment setup:

Installation . . . . . . . . . . . . . . . . . . . . .

4-122a 4-658

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-122b 4-658

Power steering tests and adjustment (Ross):

Poppet adjustment . . . . . . . . . . . . .

4-123d 4-662

Steering gear internal leakage test . . . . . . . . . . . . . . . . . . 4-123c 4-662

Steering pump flow test...... 4-123b 4-661

Steering pump pressure test..............................

4-123a 4-660

Power steering tests and adjustment (Sheppard):

Plunger adjustment . . . . . . . . . . . . 4-124d 4-666

Steering gear internal leakage test . . . . . . . . . . . . . . . . . . .

4-124c 4-664

Steering pump flow test . . . . . . 4-124b 4-664

Steering pump pressure test . . . . . . . . . . . . . . . . . . . . . . . . 4-124a 4-664

Power system operation . . . . . . . . . .

1-21 1-34

Power Takeoff (PTO) control cable (M939A2), transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-210b 4-980

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-210a 4-978

Power Takeoff (PTO) control cable, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-209b 4-976

Removal . . . . . . . . . . . . . . . . . . . . . .

4-209a 4-976

Index 47

TM 9-2320-272-24-4

Power Takeoff (PTO) crossshaft (control lever), transfer case, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-206b 4-956

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-206a 4-956

Power Takeoff (PTO), transfer case, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . .

4-208c 4-970


4-208b 4-968

Disassembly . . . . . . . . . . . . . . . . . . .

4-208a 4-962

Power Takeoff (PTO), transfer case, replacement:

Installation .. . . . . . . . . . . . . . . . . . . . 4-207b 4-960

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-207a 4-958

Power Takeoff (PTO), transmission, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . .

4-212c 4-996


4-212b 4-994

Disassembly . . . . . . . . . . . . . . . . . . 4-212a 4-988

Power Takeoff (PTO), transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-211b 4-986

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-211a 4-982

Preparation for storage or shipment . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2

Preparing replacement engine for installation in vehicle:

Installation . . . . . . . . . . . . . . . . . . 4-7b

4-92

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-7a 4-91

Preservation, general preparation of vehicle for shipment . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Pressure gear pump removal:

6-2

Removal . . . . . . . . . . . . . . . . . . . . . .

5-13 5-93

Pressure lines, steering gearto-assist cylinder replacement:

Installation. . . . . . . . . . . . . . . . . . . . .

3-239b 3-680

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-239a 3-678

Pressure relief valve maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . .

3-389b 3-956

Testing . . . . . . . . . . . . . . . . . . . . . . . . . 3-389a 3-956

Pressure switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-467b 3-1280

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-467a 3-1280

Pressure switch, 5th gear lockup, transmission replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-138b 3-374

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-138a 3-374

Pressure switch, spring brake, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-100b 3-278

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-100a 3-278

Para Page

INDEX

(Contd)

Para

Page

Pressure transducer replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-453b 3-1234

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-453a 3-1232

Preventive Maintenance

Checks and Services (PMCS), unit:

General . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Intervals . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-2

2-2

Reporting repairs . . . . . . . . . . . . . . 2-10

2-3

General service and inspection procedures.. . . . . . . 2-11

2-3

Specific PMCS procedures. . . 2-12

2-3

Primary air reservoir (supply tank) replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-202b 3-564

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-202a 3-562

Primary and secondary low air pressure switch replacement:

Primary switch installation . . . . . . . . . . . . . . . . . .

3-99b 3-274

Primary switch removal . . . . . . . . . . . . . . . . . . . . . . 3-99a 3-274

Secondary switch installation . . . . . . . . . . . . . . . . . . . 3-99d 3-276

Secondary switch removal . . . . . . . . . . . . . . . . . . . . . . 3-99c 3-276

Primary, air reservoir (supply tank), replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-202b 3-564

Removal...........................

3-202a 3-562

Primer pump (M939/A1), fuel, replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-40b 3-122

Removal . . . . . . . . . . . . . . . . . . . . . .

3-40a 3-122

Priming fuel system (M939A2):

Priming...............................

3-22

3-72

Principles of operation reference index . . . . . . . . . . . . . . . . .

1-19 1-25

Principles of operation, general 1-18

1-25

Propeller shaft, forward-rear to rear-rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-151b 3-420

Removal . . . . . . . . . . . . . . . . . . . . . .

3-151a 3-420

Propeller shaft, PTO-tohydraulic pump, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-334b 3-853

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-334a 3-853

Propeller shaft, transfer case to forward-rear axle, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . .

3-150d 3-416

Index 48

TM 9-2320-272-24-4


Disassembly.. .....................

3-150b 3-414

Installation.. .......................

3-150e 3-416

Removal.. ............................

3-150a 3-412

Propeller shaft, transfer caseto-front axle, replacement:

Installation.. .......................

3-149b 3-410

Removal.. ............................

3-149a 3-410

Propeller shaft, transmissionto-transfer case, maintenance:

Assembly ............................

3-148c 3-408

Disassembly.. .....................

3-148b 3-408

Installation.. .......................

3-148d 3-408

Removal.. ............................

3-148a 3-406

Proportioning valve, brake, replacement:

Installation.. .......................

3-199b 3-546

Removal.. ............................

3-199a 3-546

Protective control box replacement:

Installation.. .......................

3-115b 3-304

Removal.. ............................

3-115a 3-304

PTO-to-hydraulic pump propeller shaft, transfer, replacement:

Installation.. .......................

3-393b 3-966

Removal.. ............................

3-393a 3-966

Pulley (M939/A1), alternator, replacement:

Installation.. .......................

3-81b 3-232

Removal.. ............................

3-81a 3-232

Pulse sensor (M939/A1), tachometer replacement:

Installation.. .......................

3-94b 3-268

Removal.. ............................

3-94a

3-268

Pulse sensor (M939A2), tachometer replacement:

Installation.. .......................

3-95b 3-270

Removal.. ............................

3-95a

3-270

Pump (M939/A1), power steering, maintenance:

Assembly.. ..........................

3-236c 3-672

Disassembly.. .....................

3-236b 3-672

Installation.. .......................

3-236d 3-673

Removal..............................

3-236a 3-672

Pump (M939/A1), water maintenance:

Assembly ............................

4-63c 4-384


4-381

Disassembly.. .....................

4-63a 4-378

Pump (M939/A1), water, replacement:

Installation.. .......................

3-68b 3-200

Removal.. ............................

3-68a 3-200

Para Page

INDEX (Contd)

Para Page

Pump (M939A2), power steering, repair:

Assembly.. ..........................

4-127c 4-676


Disassembly.. .....................

4-127a 4-674

Pump (M939A2), water, maintenance:


Installation.. .......................

3-69c 3-202

Removal.. ............................

3-69a 3-202

Pump, engine oil, repair:

Assembly.. ..........................

5-11d 5-88


Disassembly.. .....................

5-11a 5-78

Repair.. ...............................

5-11c 5-86

Pump, fuel injection, calibration:

Cylinder phasing (timing).... 5-37b

5-266

External stop setting.. ........ 5-37m

Fuel breakaway test..

.........

5-37j

5-278

5-277

Fuel delivery test.. .............. 5-37i 5-276


5-37g 5-274

High-speed fuel delivery test ...................................

5-37d 5-270

Lock timing.. .......................

5-37c 5-268

Low idle fuel delivery test ... 5-371

5-278

Low-speed fuel delivery test.. .................................

5-37e 5-270

Manifold pressure compensator test.. ............ 5-37h

5-275


5-37a 5-262


5-37f 5-272


5-277

Pump, fuel injection, maintenance:

Barrel and control rack removal.. ...........................

5-36c 5-246

Camshaft installation.. ....... 5-36i

5-258

Camshaft removal ..............

5-36a 5-240


5-36d 5-248

Delivery valve and barrel installation.. ........... 5-36f 5-252

Leakage test.. .....................

5-36e 5-250

Plunger and control rack installation.. .....................

5-36g 5-254

Tappet and plunger removal.. ...........................

5-36b 5-244

Tappet and spring installation.. .....................

5-36h 5-256

Pump, fuel injection, pretest:

Cylinder phasing (timing).... 5-32b

5-216

Fuel breakaway test.. ......... 5-32j 5-222


5-323

5-220


5-32f 5-220

Index 49

TM 9-2320-272-24-4


5-32c 5-218

Low idle fuel delivery test ... 5-321 5-222

Low speed fuel delivery test.. .................................

5-32d 5-218

Manifold pressure compensator test.. ............ 5-32g 5-220


5-32a 5-214


5-32e 5-218

Starting cut out test.. .......... 5-32h

5-220

Starting fuel delivery test.... 5-32k 5-222

Pump, fuel, replacement:

Installation.. .......................

4-35b 4-262

On-engine adjustments .......

4-35c 4-264

Removal.. ............................

4-35a 4-260

Pump, oil, maintenance:

Cleaning and inspection ...... 4 - 4 9 c 4 - 3 1 0

Gear backlash test.. ........... 4-49a

4-308

Installation.. .......................

4-49d 4-310

Removal.. ............................

4-49b 4-308

Pump, pressure gear, removal:

Removal..............................

5-13 5-93

Pump, steering, drivebelts, maintenance (M939/A1):

Adjustment.. .......................

3-230b 3-656

Inspection.. .........................

3-230c 3-656

Installation.. .......................

3-230d 3-657

Removal..............................

3-230a 3-656

Pump, swingtire heater, replacement:

Installation.. .......................

3-405b 3-998

Removal.. ............................

3-405a 3-996

Pump, transfer case oil, replacement:

Installation.. .......................

4-93b 4-526

Removal.. ............................

4-93a 4-526

Pump, water, maintenance:

Assembly.. ..........................

4-29d 4-206


4 - 2 9 c 4 - 2 0 4

Disassembly.. .....................

4-29b 4-202

Installation.. .......................

4-29e 4-208

Removal.. ............................

4-29a 4-200

Pump, wrecker crane hydraulic, replacement:

Installation.. .......................

3-388b 3-954

Removal.. ............................

3-388a 3-954

Push rods, rocker levers and, maintenance:

Assembly.. ..........................

5-30c 5-208


5-30b 5-206

Disassembly.. .....................

5-30a 5-206

Para Page

INDEX (Contd)

Para Page

Push tubes, rocker lever housing and, maintenance:

Assembly.... . . . . . . . . . . . . . . . . .


Disassembly . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . .

Pushrods, rocker levers, cylinder head and, replacement:

Cylinder head installation ..

Cylinder head removal . . . . . .

Rocker levers and push rods installation . . . . . . . . . . . . .

Rocker levers and push rods removal . . . . . . . . . . . . . . . . . . . . .

4-20d

4-160

4-20c 4-156

4-20b 4-156

4-20e

4-160

4-20a

4-154

4-41c

4-286

4-41b

4-282

4-41d

4-289

4-41a 4-280

R

R.Q.V. governor cover maintenance:

Adjustment .........................

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

R.Q.V. governor housing maintenance:

Adjustment.. .......................

Assembly.. ..........................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Radiator (M9391A1) replacement:

Installation.. .......................

Removal ..............................

Radiator (M939A2) maintenance:


Installation.. .......................

Removal.. ............................

Radiator baffles, seals, and plates replacement:

Installation .........................

Removal ..............................

Radiator brushguard maintenance:


Installation.. .......................

Removal ..............................

5-34e

5-34d

5-34c

5-34b

5-34f

5-34a

5-35f

5-35d

5-35c

5-35b

5-35c

5-35a

5-230

5-230

5-228

5-228

5-230

5-228

5-238

5-234

5-234

5-234

5-236

5-232

3-59b 3-174

3-59a 3-172

3-60b 3-177

3-60c

3-178

3-60a

3-176

3-272b 3-738

3-272a 3-738

4-136b 4-702

4-136c 4-704

4-136a 4-700

Index 50

TM 9-2320-272-24-4

Radiator cover kit replacement:

Installation.. .......................

3-395b 3-970

Removal.. ............................

3-395a 3-970

Radiator fan blade (M939/A1) replacement:

Installation.. .......................

3-72b 3-208

Removal.. ............................

3-72a 3-208

Radiator fan shroud (M939/A1) replacement:

Installation.. .......................

3-63b 3-186

Removal.. ............................

3-63a 3-186

Radiator hoses and brackets

(M939A2), upper, replacement:

Installation.. .......................

3-58b 3-170

Removal.. ............................

3-58a 3-170

Radiator maintenance:

Assembly.. ..........................

4-60c 4-354


4-60b 4-354

Disassembly.. .....................

4-60a 4-352

Radiator vent hose, manifold return hose, and surge tank,


Radiator vent and manifold return hoses installation ... 3-61d 3-182

Radiator vent and manifold return hoses removal ........

3-61a 3-180

Surge tank installation ....... 3-61c 3-182

Surge tank removal.. ........... 3-6 lb 3-180

Rail sill, cargo body frame, maintenance:

Fabrication.. .......................

4-143c 4-723

Inspection.. .........................

4-143b 4-722

Installation.. .......................

4-143d 4-725

Removal.. ............................

4-143a 4-722

Rear axle air manifold maintenance:


3-463b 3-1268

Installation.. .......................

3-463c 3-1268

Removal.. ............................

3-463a 3-1268

Rear axle shaft maintenance:

Inspection.. .........................

3-157b 3-433

Installation.. .......................

3-157c 3-433

Removal.. ............................

3-157a 3-433

Rear axles spring seat wear pads and upper bracket maintenance:

Inspection.. .........................

3-168b 3-462

Installation.. .......................

3-168c 3-462

Removal.. ............................

3-168a 3-460

Rear brake actuator repair:

Assembly.. ..........................

4-113c 4-602


4-113b 4-600

Disassembly.. .....................

4-113a 4-600

Para Page

INDEX (Contd)

Para Page

Rear brake spider replacement:

Installation.. .......................

Removal ..............................

Rear cab mount replacement:

Installation.. .......................

Removal.. ............................

Rear cover and low planetary carrier maintenance:

Assembly.. ..........................


Disassembly.. .....................

Removal ..............................

Rear cover and oil seal maintenance:


Installation.. .......................

Removal ..............................

Rear differential oil seal replacement:

Installation.. .......................

Removal ..............................

Rear door maintenance:

Assembly ............................


Disassembly.. .....................

Installation.. .......................

Removal ..............................

Rear exhaust pipe, support bracket, and cab heat shield maintenance:

Inspection.. .........................

Installation.. .......................

Removal ..............................

Rear hub and drum (M939/A1) maintenance:


Installation.. .......................

Lubrication.. .......................

Removal.. ............................

Rear hubs repair:


Installation.. .......................

Removal ..............................

Repair.. ...............................

Rear oil seal (in vehicle) maintenance:


Installation.. .......................

Removal., ............................

Rear relay valve replacement:

Installation.. .......................

Removal ..............................

Rear splice plate replacement:

Installation.. .......................

Removal ..............................

3-184b

3-184a

3-305b

3-305a

5-55d

5-55c

5-55b

5-55a

4-44b

4-44c

4-44a

4-103b

4-103a

4-154d 4-758

4-154c 4-758

4-154b 4-756

4-154e 4-760

4-154a 4-756

3-49b

4-296

4-296

4-296

3-142

3-49c 3-142

3-49a 3-142

3-224b 3-644

3-224d 3-646

3-224c 3-644

3-224a 3-642

3-461b

3-461d

3-461a

3-461c

4-45b

3-1260

3-1262

3-1258

3-1260

4-298

4-45c 4-298

4-45a 4-298

3-188b 3-518

3-188a 3-518

5-84b

5-84a

3-510

3-510

3-802

3-802

5-370

5-368

5-366

5-364

4-576

4-576

5-543

5-543

Index 51

TM 9-2320-272-24-4

Rear spring bumper replacement:

Installation.. .......................

3-165b 3-451

Removal.. ............................

3-165a 3-451

Rear spring replacement:

Installation.. .......................

3-167b 3-458

Removal.. ............................

3-167a 3-454

Rear spring seat maintenance:

Adjustment.. .......................

3-169e 3-466


Installation.. .......................

3-169d 3-466

Lubrication.. .......................

3-169c 3-466

Removal.. ............................

3-169a 3-464

Rear wall interior panels replacement:

Installation.. .......................

5-74b 5-498

Removal.. ............................

5-74a

5-498

Rear wheel valve maintenance:


3-457b 3-1246

Installation.. .......................

3-457c

3-1247

Removal.. ............................

3-457a 3-1246

Rear winch adjustment:

Cable tensioner adjustment.. .....................

3-330b 3-844

Cable tensioner check.. ...............................

3-330a 3-844

Rear winch cable replacement:

Installation.. .......................

3-331b 3-846

Removal.. ............................

3-331a 3-846

Rear winch cable tensioner repair:

Assembly.. ..........................

4-182c 4-882


4-182b 4-880

Disassembly.. .....................

4-182a 4-878

Rear winch hydraulic motor replacement:

Installation.. .......................

4-185b 4-890

Removal.. ............................

4-185a 4-888

Rear winch repair:

Assembly.. ..........................

4-181c 4-872


4-181b 4-870

Disassembly.. .....................

4-181a 4-864

Rear winch replacement:

Installation.. .......................

3-332b 3-848

Removal.. ............................

3-332a 3-847

Rear winch roller repair:


4-153c 5-754

Side roller assembly.. .......... 4-153e 4-754

Side roller disassembly ....... 4-153a 4-752

Top and bottom roller assembly.. ........................

4-153d 4-754

Top and bottom roller disassembly.. ....................

4-153b 4-752

Para Page

INDEX (Contd)

Para

Page

Rear winch side roller repair:

Assembly.. ..........................

4-183c 4-885


4-183b 4-884

Disassembly.. .....................

4-183a 4-884

Rear winch top and bottom roller repair:

Assembly.. ..........................

4-184c 4-887


4-184b 4-886

Disassembly.. .....................

4-184a 4-886

Rear wiring harness replacement:

Installation.. .......................

4-68b 4-454

Removal.. ............................

4-68a 4-446

Rear, axle, shaft, maintenance:

Inspection.. .........................

3-157b 3-433

Installation.. .......................

3-157c 3-433

Removal.. ............................

3-157a 3-433

Rearview mirror and brace replacement:

Installation.. .......................

3-290b 3-779

Removal.. ............................

3-290a 3-778

Receptacle (M936/A1/A2), auxiliary outlet socket and, replacement:

Installation.. ....................... 3-110b 3-298

Removal.. ............................

3-110a 3-298

Receptacle 220v 3-phase wiring harness, entrance, maintenance:

Installation.. .......................

4-159c 4-772

Removal.. ............................

4-159a 4-772

Repair.. ...............................

4-159b 4-772

Receptacle 220v 3-phase wiring harness, entrance, maintenance:

Installation.. .......................

4-159c 4-772

Removal.. ............................

4-159a 4-772

Repair.................................

4-159b 4-772

Receptacle, slave, replacement:

Installation.. .......................

3-127b 3-340

Removal.. ............................

3-127a 3-340

Reflectors replacement:

Installation.. .......................

3-345b 3-879

Removal.. ............................

3-345a 3-879

Registers, front wall, replacement:

Installation.. .......................

5-78b 5-531

Removal.. ............................

5-78a 5-531

Relay valve repair:

Assembly.. ..........................

4-109c 4-590


4-109b 4-590

Disassembly.. .....................

4-109a 4-590

Relay valve, front, replacement:

Installation.. .......................

3-187b 3-516

Removal.. ............................

3-187a 3-516

Index 52

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Relay valve, rear, replacement:

Installation.. .......................

3-188b 3-518

Removal.. ............................

3-188a 3-518

Relief safety valve maintenance:

Assembly.. ..........................

3-455d 3-1242


3-455c 3-1242

Disassembly.. .....................

3-455b 3-1241

Installation.. .......................

3-455e 3-1242

Removal.. ............................

3-455a 3-1240

Removal from limited storage. 6-12

6-3

Repair, general.. .....................

2-16 2-57

Reporting Equipment

Improvement

Recommendations (EIRs); reporting of errors and recommending improvements.. .....................

1-6

Reservoif shutoff modification

1-2 kit, hydraulic, replacement:

Installation.. .......................

3-445b 3-1156

Removal.. ............................

3-4453 3-1154

Reservoir (M939/A1), power steering pump and, repair:

Assembly ............................

4-126d 4-672


4-126c 4-672

Disassembly.. .....................

4-126b 4-670

Installation.. .......................

4-126e 4-672

Removal.. ............................

4-126a 4-670

Reservoir (supply tank) and bracket, wet air, replacement:

Installation.. .......................

3-200b 3-552

Removal.. ............................

3-200a 3-548

Reservoir (supply tank) and mounting plate, wet air,


Installation.. .......................

3-201b 3-558

Removal.. ............................

3-201a 3-556

Reservoir, jet, and control, windshield wiper, replacement:

Installation.. .......................

3-28 lb 3-758

Removal.. ............................

3-281a 3-758

Resistor, convoy warning light, leads and, replacement:

Installation.. .......................

3-436b 3-1126

Removal.. ............................

3-436a 3-1124

Retaining bracket, hood, replacement:

Installation.. .......................

3-247b 3-695

Removal.. ............................

3-247a 3-695

Retaining straps, fuel tank hangers and, maintenance:

Inspection.. .........................

3-28b 3-94

Installation.. .......................

3-28c 3-94

Removal.. ............................

3-28a 3-92

Para Page

Retractable beam drive shaft and lock maintenance:


5-68b 5-472

Installation.. .......................

5-68c 5-472

Removal.. ............................

5-68a 5-470

Retractable beam replacement:

Installation.. .......................

5-67b 5-468

Removal.. ............................

5-67a 5-468

Retractable beam rollers replacement:

End roller installation.. .......

5-69d 5-476

End roller removal .............. 5-69c 5-476

Support roller installation ... 5 - 6 9 b 5 - 4 7 4

Support roller removal ........

5-69a 5-474

Retractable window glass and van door window glass replacement:

Installation.. .......................

4-139b 4-710

Removal.. ............................

4-139a 4-710

Retractable window regulator replacement:

Installation.. .......................

3-354b 3-892

Removal.. ............................

3-354a 3-892

Retractable window replacement:

Installation.. .......................

3-351b 3-889

Removal.. ............................

3-35 la 3-889

Return tubes (M939/A1), air compressor coolant supply and, maintenance:

Inspection.. .........................

3-55c 3-161

Return tube installation ..... 3-55e 3-163

Return tube removal.. .........

3-55b 3-161

Supply tube installation.. ... 3-55d 3-162

Supply tube removal.. .........

3-55a 3-160

Rifle mounting kit replacement:

Installation on left door.. .... 3-421c 3-1082

Installation on dash and floor.. .........................

3-421d 3-1083

Removal from dash and floor.. .........................

3-421b 3-1081

Removal from left door ........

3-421a 3-1080

Right and left side blackout harness maintenance:

Installation.. .......................

4-157c 4-768

Removal.. ............................

4-157a 4-768

Repair.. ...............................

4-157b 4-768

Right and left side blackout harness maintenance:

Installation.. .......................

5-98c 5-600

Removal.. ............................

5-98a 5-598

Repair.. ...............................

5-98b 5-600

Index 53

TM 9-2320-272-24-4

Ring gear, flywheel, maintenance:

Installation.. .......................

4-15b 4-129

Removal.. ............................

4-15a 4-129

Rocker lever housing and push tubes maintenance:

Assembly.. ..........................

4-20d 4-160


4-156

Disassembly.. .....................

4-20b 4-156

Installation.. .......................

4-20e 4-160

Removal.. ............................

4-20a 4-154

Rocker levers and push rods maintenance:

Assembly.. ..........................

5-30c 5-208


5-30b 5-206

Disassembly.. .....................

5-30a 5-206

Rocker levers, push rods, and cylinder head replacement:

Cylinder head installation.. 4-41c 4-286

Cylinder head removal ........

4-41b 4-282

Rocker levers and push rods installation.. .............

4-41d 4-289

Rocker levers and push rods removal.. ...................

4-41a 4-280

Rod, connecting, piston, and, maintenance:

Assembly.. ..........................

5-26d 5-170


5-26c 5-168

Disassembly.. .....................

5-26b 5-166

Installation.. .......................

5-26e 5-172

Removal.. ............................

5-26a 5-166

Rod, piston and connecting, maintenance:

Assembly.. ..........................

5-10e 5-74


5-10d 5-68

Connecting rod side clearance check .................

5-10a 5-64

Disassembly.. .....................

5-10c 5-68

Installation.. .......................

5-10f 5-76

Removal.. ............................

5-10b 5-66

Rod, stopscrew, accelerator pedal, bracket and, replacement:

Installation.. .......................

3-41b 3-123

Removal.. ............................

3-41a 3-123

Rod, tie, maintenance:

Inspection.. .........................

3-153b 3-424

Installation.. .......................

3-153c 3-424

Removal.. ............................

3-153a 3-424

Roller, boom, maintenance:

Assembly.. ..........................

4-197d 4-924


4-197c 4-924

Disassembly.. .....................

4-197b 4-922

Installation.. .......................

4-197e 4-924

Removal.. ............................

4-197a 4-922

Para Page

INDEX (Contd)

Para

Page

Roof, hinged, maintenance:

Assembly.. ..........................

5-77d 5-526


5-77c 5-524

Disassembly.. .....................

5-77b

5-520

Installation.. .......................

5-77e 5-530

Removal.. ............................

5-77a

5-518

Rotation, wheel and, tire

(M939):

Front wheel installation.. ... 3-218f 3-621

Inner rear wheel installation.. .....................

3-218d 3-619

Wheel and tire removal ....... 3-218b

3-616

Inspection.. .........................

3-218e 3-620

Outer rear wheel installation.. .....................

3-218a

3-616

Wheel and tire rotation ....... 3-218c 3-618

Rotation, wheel and, tire

(M939A1/A2):

Front wheel installation.. ... 3-219e 3-625

Inspection.. .........................

3-219b 3-622

Rear wheel installation ....... 3-219d 3-624

Wheel and tire removal ....... 3-219a 3-622

Wheel and tire rotation ....... 3-219c 3-624

S

Safety valve, wet reservoir

(supply tank), replacement:

Installation.. .......................

3-185b 3-512

Removal.. ............................

3-185a 3-512

Scope.. ....................................

1-1

1-1

Scope, general preparation of vehicle for shipment.. ............ 6-1

Scope, limited storage.. ........... 6-9

Screen, window, replacement:

6-1

6-2

Installation.. .......................

3-353b 3-891

Removal.. ............................

3-353a 3-891

Seal and retainer, cab top, replacement:

Installation .........................

3-316b 3-815

Removal.. ............................

3-316a 3-815

Seal, front, axle, replacement:

Installation.. .......................

3-160b 3-439

Removal.. ............................

3-160a 3-439

Seals, panel, replacement:

Installation.. .......................

3-363b 3-904

Removal.. ............................

3-363a 3-904

Seat frame and base, driver’s, maintenance:


3-284b 3-766

Installation.. .......................

3-284c 3-766

Removal.. ............................

3-284a 3-764

Seat, driver’s, replacement:

Installation.. .......................

3-283b 3-762

Removal.. ............................

3-283a 3-762

Index 54

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Seatbelt replacement:

Companion seatbelts installation . . . . . . . . . . . . . . . . . . 3-289d 3-776

Companion seatbelts removal . . . . . . . . . . . . . . . . . . . . 3-289c 3-776

Driver’s seatbelt installation . . . . . . . . . . . . . . . . . .

3-289b 3-774

Driver’s seatbelt removal . . . . . . . . . . . . . . . . . . . . . . . 3-289a 3-774

Second clutch maintenance:


Establishing clearance........ 5-52d 5-356

Installation . . . . . . . . . . . . . . . . . . . .

5-52c 5-356

Removal . . . . . . . . . . . . . . . . . . . . . . . 5-52a 5-354

Secondary air reservoir (supply tank) replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-203b 3-568

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-203a 3-566

Secondary low air pressure switch, primary and, replacement:

Primary switch installation . . . . . . . . . . . . . . . . . . . 3-99b 3-274

Primary switch removal . . . . . . . . . . . . . . . . . . . . . . . 3-99a 3-274

Secondary switch installation . . . . . . . . . . . . . . . . . . . 3-99d 3-276

Secondary switch removal . . . . . . . . . . . . . . . . . . . . 3-99c

3-276

Secondary, air reservoir (supply tank), replacement:

Installation . . . . . . . . . . . . . . . . . . . .

3-203b 3-568

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-203a 3-566

Select lever, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-73b 4-482

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-73a 4-482

Selector switch, high-beam, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-112b 3-301

Removal . . . . . . . . . . . . . . . . . . . . . . 3-112a 3-301

Sending unit, fuel level, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-92b 3-264

Removal . . . . . . . . . . . . . . . . . . . . . 3-92a 3-264

Sending unit, oil pressure, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-91b 3-262

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-91a 3-262

Sending unit, water temperature, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-93b 3-266

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-93a 3-266

Para Page

Separator, water, maintenance:

Assembly.. ..........................

3-466d 3-1278


3-466c 3-1278

Disassembly.. .....................

3-466b 3-1278

Installation.. .......................

3-466e 3-1279

Removal..............................

3-466a 3-1278

Service brake chamber replacement:

Installation.. .......................

3-181b 3-504

Removal.. ............................

3-181a 3-504

Service brake chamber, combination spring

(emergency) and, replacement:

Installation. ........................

3-182b 3-506

Removal.. ............................

3-182a 3-506

Service upon receipt, general ... 2-5 2-1

Shackle, front spring, replacement:

Installation.. .......................

3-162b 3-446

Removal.. ............................

3-162a 3-446

Shaft oil seal, transmission selector, replacement:

Installation .........................

4-76b 4-490

Removal.. ............................

4-76a 4-489

Shaft, rear, axle, maintenance:

Inspection.. .........................

3-157b 3-433

Installation.. .......................

3-157c 3-433

Removal.. ............................

3-157a 3-433

Shaft, throttle cover and, maintenance:

Assembly.. ..........................

5-16c 5-100

Disassembly.. .....................

5-16a 5-98

Inspection.. .........................

5-16b 5-98

Shield, muffler and, maintenance:

Inspection ...........................

3-51b 3-146

Installation.. .......................

3-51c 3-146

Removal.. ............................

3-51a 3-146

Shift cable, transmission, maintenance:

Adjustment.. .......................

4-75c 4-488

Installation.. .......................

4-75b 4-486

Removal.. ............................

4-75a 4-486

Shift lever shift rod, transfer case, maintenance:

Adjustment.. .......................

4-86b 4-512

Installation.. .......................

4-86c 4-512

Removal.. ............................

4-86a 4-512

Shift lever, dump valve cable and, replacement:


4-148b 4-740

Removal ..............................

4-148a 4-738

Index 55

TM 9-2320-272-24-4

Shift lever, transfer case, maintenance:

Cleaning, inspection, and repair . . . . . . . . . . . . . . . . . . . . . . . 4-85b 4-510

Installation . . . . . . . . . . . . . . . . . . . . 4-85c 4-510

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-85a

4-510

Shift rod, transfer case, maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . .

4-88c 4-517

Cleaning, inspection, and repair a...............................

4-88b 4-516

Installation . . . . . . . . . . . . . . . . . . . . .

4-88d 4-517

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-88a 4-516

Shift tower, transmission, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-74b 4-484

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-74a 4-484

Shipment of Army documents . . . . . . . . . . . . . . . . . . . . . . 6-7

Shock absorber and mounting

6-2 pins replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-166b 3-452

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-166a 3-452

Shroud (M939/A1), radiator fan, replacement:

Installation......................

3-63b 3-186

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-63a 3-186

Shutoff valve (M936), fuel pump, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-37b 4-268

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-37a 4-268

Shutoff valve, fuel pump, replacement:

Fuel pump shutoff valve installation . . . . . . . . . . . . . . . . . . . 4-36c 4-266

Fuel pump shutoff valve removal . . . . . . . . . . . . . . . . . . . . . . . 4-36b 4-266

Manual shutoff valve installation . . . . . . . . . . . . . . . . . . .

4-36d 4-266

Manual shutoff valve removal . . . . . . . . . . . . . . . . . . . . . . . 4-36a

4-266

Side and rear door blackout light switch maintenance:

Installation . . . . . . . . . . . . . . . . . . . . .

3-376b 3-922

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-376a 3-922

Side cover gasket, carrier differential top cover gasket and, replacement:

Side cover gasket installation . . . . . . . . . . . . . . . . . . .

3-158d 3-437

Side cover gasket removal... 3-158c 3-437

Top cover gasket installation . . . . . . . . . . . . . . . . . . . 3-158b 3-436

Top cover gasket removal.... 3-158a 3-434

Para Page

INDEX (Contd)

Para Page

Side doors maintenance:

Assembly ............................

5-70d 5-480


5-70c 5-480

Disassembly.. .....................

5-70b 5-480

Installation.. .......................

5-70e 5-482

Removal ..............................

5-70a 5-478

Side locking pin retaining clip replacement:

Installation.. .......................

3-344b 3-878

Removal.. ............................

3-344a 3-878

Side marker lights and bracket replacement:

Lamp installation.. ............. 3-122d 3-330

Lamp removal .................... 3-122a 3-330

Light installation.. .............. 3-122c 3-330

Light removal .....................

3-122b 3-330

Side panel exterior lock replacement:

Installation.. .......................

3-370b 3-912

Removal.. ............................

3-370a 3-912

Side panel front lock and hinged-type roof lock replacement:

Installation.. .......................

3-369b 3-911

Removal.. ............................

3-369a 3-911

Side panel rear lock replacement:

Installation.. .......................

3-368b 3-910

Removal.. ............................

3-368a 3-909

Side panel roof swivel hook replacement:

Installation.. .......................

3-359b 3-898

Removal ..............................

3-359a 3-898

Side panel rubber bumpers replacement:

Installation.. .......................

3-367b 3-908

Removal.. ............................

3-367a 3-908

Side panel-to-roof toggle clamp replacement:

Installation.. .......................

3-357b 3-896

Removal.. ............................

3-357a 3-896

Slave receptacle replacement:

Installation.. .......................

3-127b 3-340

Removal.. ............................

3-127a 3-340

Sleeve, fuel injector, maintenance:

Bead cutting .......................

5-6b

5-28

Check and test.. ..................

5-6e

5-32

Fitting and forming.. ........... 5-6d

5-30

Installation.. .......................

5-6c

5-28

Removal.. ............................

5-6a

5-26

Snubber valve assembly replacement:

Installation.. .......................

3-390b 3-958

Removal ..............................

3-390a 3-958

Index 56

TM 9-2320-272-24-4

Solenoid (M939A2), throttle control, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-46b 3-138

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-46a 3-138

Solenoid, bracket, horn and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-103b 3-285

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-103a 3-284

Solenoid, transmission fifth gear lock-in, replacement:

Installation.....................

4-80b 4-502

Removal . . . . . . . . . . . . . . . . . . . . . . 4-80a 4-500

Spacers, fifth wheel, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-252b 3-701

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-252a 3-701

Spare tire carrier (M923,

M925, M927, M928), cargo, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-258b 3-716

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-258a 3-716

Spare tire carrier

(M923A1/A2,M925A1/A2,

M927A1/A2, M928A1/A2), cargo, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-259b 3-718

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-259a 3-718


M930), dump, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-256b 3-712

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-256a 3-712

Spare tire carrier (M929A1/A2,

M930A1/A2), dump, replacement:

Installation . . . . . . . . . . . . . . . . . . . .

3-257b 3-714

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-257a 3-713


M932), tractor, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-253b 3-702

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-253a 3-702

Spare tire carrier (M931A1/A2,

M932A1/A2), tractor, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-254b 3-706

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-254a 3-704

Spare tire carrier (M934), van, replacement . . . . . . . . . . . . . . . . . . . 3-262 3-722

Spare tire carrier (M934A1/A2), van, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-263b 3-722

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-263a 3-722

Specific inspection and servicing instructions . . . . . . . . . . . . 2-7 2-2

Para Page

INDEX (Contd)

Para Page

Speed signal generator replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-471b 3-1288

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-471a 3-1288

Speedometer and tachometer replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-88b 3-254

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-88a 3-254

Speedometer driveshaft maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . .

3-90b 3-260

Installation. . . . . . . . . . . . . . . . . . . . . 3-90c 3-260

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-90a 3-258

Spindle bearing sleeve replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-97b 4-549

Removal . . . . . . . . . . . . . . . . . . . . . . . 4-97a 4-548

Splash guard, cargo upper and lower wheel, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-342b 3-874

Removal...........................

3-342a 3-874

Splash shield, fender, replacement:

Installation........................

3-301b 3-795

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-301a 3-795

Spout, fuel tank, filler cap and, replacement:

Installation........................

3-25b 3-78

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-25a 3-78

Spray pattern test, injector:

Setting up spray pattern tester . . . . . . . . . . . . . . . . . 5-21a

5-140

Testing spray pattern . . . . . . . . .

5-21b 5-140

Spring (emergency) and service brake chamber, combination, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-182b 3-506

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-182a 3-506

Spring (emergency) brake chamber maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . .

3-193c 3-528

Disassembly . . . . . . . . . . . . . . . . . . .

3-193a 3-528

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-193b 3-528

Spring and main leaf, front, replacement:

Front spring main leaf installation . . . . . . . . . . . . . . . . . . . .

3-161c 3-443

Front spring main leaf removal . . . . . . . . . . . . . . . . . . . . . . 3-161b 3-443

Front spring installation..... 3-161d 3-444

Front spring removal . . . . . . . . . . 3-161a 3-440

Spring brake (supply tank), emergency, air reservoir, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-204b 3-570

Removal............................

3-204a 3-570

Index 57

TM 9-2320-272-24-4

Spring brake dash control valve replacement:

Installation.. .......................

3-195b 3-532

Removal.. ............................

3-195a 3-532

Spring brake pressure switch replacement:

Installation.. .......................

3-100b 3-278

Removal.. ............................

3-100a 3-278

Spring brake valve maintenance:

Adjustment.. .......................

3-173b 3-482

Installation.. .......................

3-173c 3-482

Removal.. ............................

3-173a 3-482

Spring bumper, front, replacement:

Installation.. .......................

3-164b 3-450

Removal.. ............................

3-164a 3-450

Spring bumper, rear, replacement:

Installation.. .......................

3-165b 3-451

Removal.. ............................

3-165a 3-451

Spring bushing, front, maintenance:

Inspection.. .........................

3-163a 3-448

Installation.. .......................

3-163c 3-448

Removal.. ............................

3-163b 3-448

Spring pack, governor, maintenance:

Inspection.. .........................

5-14b 5-94

Installation.. .......................

5-14c 5-95

Removal.. ............................

5-14a 5-94

Spring parking brake valve replacement:

Installation.. .......................

3-194b 3-530

Removal.. ............................

3-194a 3-530

Spring seat wear pads and upper bracket, rear axles, maintenance:

Inspection.. .........................

3-168b 3-462

Installation.. .......................

3-168c 3-462

Removal.. ............................

3-168a 3-460

Spring seat, rear, maintenance:

Adjustment.. .......................

3-169e 3-466


Installation.. .......................

3-169d 3-466

Lubrication.. .......................

3-169c 3-466

Removal.. ............................

3-169a 3-464

Spring shackle, front, replacement:

Installation.. .......................

3-162b 3-446

Removal.. ............................

3-162a 3-446

Spring, rear, replacement:

Installation.. .......................

3-167b 3-458

Removal.. ............................

3-167a 3-454

Para Page

INDEX (Contd)

Para Page

Stack, exhaust, replacement:

Installation.. .......................

3-48b 3-140

Removal.. ............................

3-48a 3-140

Stall test, transmission converter:

Forward stall test.. .............

5-62

5-396

Start switch, ether, replacement:

Installation .........................

3-33b 3-112

Removal.. ............................

3-33a 3-112

Starter replacement:

Installation.. .......................

3-82b 3-236

Removal.. ............................

3-82a 3-234

Starting repaired or replacement engine:

In-chassis run-in.. ...............

4-8c

4-96

Out-of-chassis run-in

(M939/A1) ........................

4-8b

4-96

Priming lubrication system (M939/A1). ............ 4-8a

4-95

STE/ICE troubleshooting.. ...... 2-24

2-219

Steering assist cylinder hoses replacement:

Installation.. .......................

3-232b 3-660

Removal.. ............................

3-232a 3-660

Steering assist cylinder replacement:

Assembly.. ..........................

3-233c 3-664

Disassembly.. .....................

3-233b 3-664

Installation.. .......................

3-233d 3-666

Removal.. ............................

3-233a 3-662


Steering assist cylinder stone shield replacement:

Installation.. .......................

3-231b 3-658

Removal.. ............................

3-231a 3-658

Steering column, upper and lower, maintenance:


4-116c 4-608

Disassembly.. .....................

4-116b 4-608

Installation.. .......................

4-116e 4-612

Reassembly.. ......................

4-116d 4-610

Removal.. ............................

4-116a 4-606

Steering gear (Ross) and mounting bracket replacement:

Installation.. .......................

4-117b 4-616

Removal.. ............................

4-117a 4-614

Steering gear (Ross) repair:

Assembly.. ..........................

4-119c 4-631

Cleaning, inspection and repair.. .......................

4-119b 4-630

Disassembly.. .....................

4-119a 4-624

Final adjustment.. ..............

4-119d 4-638

Index 58

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Steering gear (Sheppard) and mounting bracket replacement:

Installation.. .......................

4-118b 4-620

Removal.. ............................

4-118a 4-618

Steering gear (Sheppard) repair:

Assembly.. ..........................

4-120c 4-648


4-120b 4-645

Disassembly.. .....................

4-120a 4-640

Steering gear stone shield replacement:

Installation.. .......................

3-238b 3-676

Removal.. ............................

3-238a 3-676

Steering gear-to-assist cylinder pressure lines replacement:

Installation.. .......................

3-239b 3-680

Removal.. ............................

3-239a 3-678

Steering knuckle boot maintenance:


Installation.. .......................

3-155c 3-430

Removal.. ............................

3-155a 3-430

Steering knuckle maintenance:


4-552

End play test.. ....................

4-98d 4-556

Installation.. .......................

4-98c

4-554

Removal.. ............................

4-98a

4-550

Steering pump drivebelts maintenance (M939/Al):

Adjustment.. .......................

3-230b 3-656

Inspection.. .........................

3-230c

3-656

Installation.. .......................

3-230d 3-657

Removal.. ............................

3-230a 3-656

Steering stop adjustment:

Check.. ................................

4-105a 4-580

Turning angle adjustment.. 4-105b 4-580

Steering wheel replacement:

Installation.. .......................

3-226b 3-652

Removal ..............................

3-226a 3-651

Steering, assist cylinder, replacement:

Assembly.. ..........................

3-233c 3-664

Disassembly.. .....................

3-233b 3-664

Installation.. .......................

3-233d 3-666

Removal.. ............................

3-233a 3-662


Step, tailgate personnel, replacement:

Installation.. .......................

3-347b 3-881

Removal.. ............................

3-347a 3-881

Steps, toolbox and, replacement:

Installation.. .......................

3-302b 3-796

Removal.. ............................

3-302n 3-796

Para Page

Stone shield, steering assist cylinder, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-231b 3-658

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-231a 3-658

Stone shield, steering gear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-238b 3-676

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-238a 3-676

Stop bracket and latch, windshield, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-276b 3-747

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-276a 3-747

Stop cables, hood, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-270b 3-736

Removal.........................

3-270a 3-736

Stop control cable, emergency, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-44b

3-132

Installation . . . . . . . . . . . . . . . . . . . . .

3-44c 3-132

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-44a

3-130

Stop, steering, adjustment::

Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105a 4-580

Turning angle adjustment.. 4-105b 4-580

Stoplight switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-111b 3-300

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-111a 3-300

Stopscrew, accelerator pedal, bracket, rod and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-41b 3-123

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-41a

3-123

Stowage, box cargo, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-346b 3-880

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-346a 3-880

Strap, ground, replacement:

Ground strap (M939/A1) installation . . . . . . . . . . . . . . . . . . .

3-129b 3-344

Ground strap (M939A2) installation . . . . . . . . . . . . . . . . . . .

3-129d 3-346

Ground strap (M939/A1) removal . . . . . . . . . . . . . . . . . . . . . . . 3-129a 3-344

Ground strap (M939A2) removal . . . . . . . . . . . . . . . . . . . . . . . 3-129c 3-346

Stud, wheel rim, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-222b 3-636

Removal.............................

3-222a 3-636

Subframe, dump, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-149b 4-746

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-149a 4-742

Supply and return tubes

(M939/A1), air compressor coolant, maintenance:

Inspection. . . . . . . . . . . . . . . . . . . . . .

3-55c 3-161

Return tube installation . . . . . 3-55e 3-163

Index 59

TM 9-2320-272-24-4

Return tube removal . . . . . . . . . . . 3-55b 3-161



Supply lines (M939A2), fuel transfer pump and, maintenance:


3-20b 3-66

Installation . . . . . . . . . . . . . . . . . . . . 3-20c 3-67

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-20a 3-66

Support bar and bracket, hood, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-269b 3-734

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-269a 3-734

Support, center, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . .

5-50d 5-344


Disassembly . . . . . . . . . . . . . . . . . .

5-50b 5-342

Installation . . . . . . . . . . . . . . . . . . . . 5-50e 5-346

Removal . . . . . . . . . . . . . . . . . . . . . . . 5-50a 5-340

Surge tank and bracket


Installation . . . . . . . . . . . . . . . . . . . . 3-62b 3-184

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-62a 3-184

Surge tank, radiator vent hose, and manifold return hose


Radiator vent and manifold return hoses installation... 3-61d 3-182

Radiator vent and manifold return hoses removal . . . . . . . . 3-61a 3-180

Surge tank installation....... 3-61c 3-182

Surge tank removal . . . . . . . . . . . . . 3-61b 3-180

Swingfire heater and mounting bracket replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-406b 3-1002

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-406a 3-1000

Swingfire heater battery box heater pad replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-410b 3-1018

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-410a 3-1018

Swing-fire heater electrical components replacement:

Circuit breaker installation . . . . . . . . . . . . . . . . . . . 3-407f 3-1006

Circuit breaker removal . . . . . . 3-407c 3-1006

Electrical connector installation . . . . . . . . . . . . . . . . . . .

3-407h 3-1008

Electrical connector removal . . . . . . . . . . . . . . . . . . . . . .

3-407a 3-1004

Relay installation . . . . . . . . . . . . . 3-407g 3-1008

Relay removal . . . . . . . . . . . . . . . . .

3-406b 3-1004

Thermal switch installation . . . . . . . . . . . . . . . . . . .

3-407e 3-1006

Thermal switch removal . . . . . 3-407d 3-1006

Para Page

INDEX (Contd)

Para Page

Swingfire heater harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-408b 3-1012

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-408a 3-1010

Swingfire heater oil pan shroud and exhaust tube replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-409b 3-1016

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-409a 3-1016

Swingfire heater pump replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-405b 3-998

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-405a 3-996

Swingfire heater water jacket replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-411b 3-1020

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-411a 3-1020

Switch, blackout light,

100-volt, receptacle, and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-373b 3-916

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-373a 3-916

Switch, convoy warning light, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-438b 3-1130

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-438a 3-1130

Switch, horn, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-104b 3-286

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-104a 3-286

Switch, parking brake lever and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-174b 3-484

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-174a 3-484

Switch, pressure, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-467b 3-1280

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-467a 3-1280

Switch, stoplight, replacement:

Installation . . . . . . . . . . . . . . . . . . . 3-111b 3-300

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-111a 3-300

Switch, transfer case, replacement:

Installation........................

4-90b 4-520

Removal . . . . . . . . . . . . . . . . . . . . . .

4-90a 4-520

Switches, air conditioner manual starter, replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

4-167b 4-800

Removal . . . . . . . . . . . . . . . . . . . . . . .

4-167a 4-799

Switches, electrical, replacement:

Accessory switches installation . . . . . . . . . . . . . . . . . . 3-107b 3-292

Accessory switches removal . . . . . . . . . . . . . . . . . . . . . . 3-107a 3-292

Index 60

TM 9-2320-272-24-4

Battery and starter switch installation . . . . . . . . . . . . 3-107d 3-293

Battery and starter switch removal . . . . . . . . . . . . . . . . . . 3-107c 3-292

T

Tachometer drive maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-51c 4-313

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-51a 4-313

Tachometer driveshaft


Installation...........................

3 - 8 9 b 3 - 2 5 6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-89a 3-256

Tachometer pulse sensor


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-94b 3-268

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-94a 3-268

Tachometer pulse sensor


Installation.... . . . . . . . . . . . . . . . . . . . . . .

3-95b 3-270

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-95a 3-270

Tachometer, speedometer and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-88b 3-254

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-88a 3-254

Tailgate assembly, dump replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-348b 3-882

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-348a 3-882

Tailgate bumpers replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-261b 3-721

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-261a 3-721

Tailgate control linkage, dump, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-349b 3-886

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-349a 3-884

Tailgate personnel step replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-347b 3-881

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-347a 3-881

Tailgate, cargo, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-343b 3-876

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-343a 3-876

Tank and bracket (M939A2), surge, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-62b 3-184

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-62a 3-184

Telephone jack post, inside, vreplacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-374b 3-918

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-374a 3-918

Para Page

INDEX (Contd)

Para Page

Telephone jack post, outside, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-375b 3-920

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-375a 3-920

Telephone post wiring harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-99b 5-602

Removal ...............................

5 - 9 9 a 5 - 6 0 2

Temperature sensor (M939A2), ether atomizer and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-38b 3-118

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-38a 3-118

Tensioner, front winch cable, maintenance:

Assembly ............................

4-173d 4-829


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-173b 4-825

Installation ........................

4-173e 4-830

Removal ..............................

4-173a 4-825

Terminal adapter, battery cable and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-124b 3-334

Removal ..............................

3-124a 3-334

Test equipment setup, power steering setup:

Installation ........................

4-122a 4-658

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-122b 4-658

Test stand, injector, calibration:

Setting up injector tester..... 5-22a 5-142

Test stand calibration ............ 5-22b 5-146

Tests, and adjustment (Ross), power steering:

Poppet adjustment . . . . . . . . . . . . .

4-123d 4-662

Steering gear internal leakage test . . . . . . . . . . . . . . . . . . . . . .

4-123c 4-662

Steering pump flow test...... 4-123b 4-661

Steering pump pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123a 4-660

Tests, and adjustment

(Sheppard), power steering:

Plunger adjustment . . . . . . . . . . . . 4-124d 4-666

Steering gear internal leakage test . . . . . . . . . . . . . . . . . . . . . .

4-124c 4-664

Steering pump flow test......

4-124b 4-664

Steering pump pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124a 4-664

Thermal close valve and bushing, ether, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-36b 3-116

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-36a 3-116

Index 61

TM 9-2320-272-24-4

Para

Thermostat (M939/A1) maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-65c 3-190

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-65a 3-190

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-65b 3-190

Thermostat, heater and 10 kW thermostat heater, replacement:

10 kW heater thermostat installation . . . . . . . . . . . . . . . . . . . . . . .

4-165d 4-796

10 kW heater thermostat removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-165b 4-796

Heater thermostat installation . . . . . . . . . . . . . . . . . . . . . . .

4-165c 4-796

Heater thermostat removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-165a 4-796

Thermostats and housing



Installation (external bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-66e 3-194

Installation (internal bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-66c

3-193

Removal (external bypass). . 3-66d 3-194

Removal (internal bypass) . . 3-66a

3-192

Third clutch maintenance:


Installation ......................... 5 - 4 9 c 5 - 3 3 9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-49a 5-338

Throttle control cable maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45b 3-136

Installation . . . . . . . . . . . . . . . . . . . . . . . .

3-45c 3-136

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-45a 3-134

Throttle control solenoid


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-46b 3-138

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-46a 3-138

Throttle cover and shaft maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16c 5-100

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

5-16a 5-98

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16b 5-98

Throttle kit (M936/A1), automatic, replacement:

Installation ........................

3-440b 3-1136

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-440a 3-1134

Tie rod maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153b 3-424

Installation ......................

3-153c 3-424

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-153a 3-424

Tiedown kit, vehicle, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-442b 3-1146

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-442a 3-1146

Page

INDEX (Contd)

Para Page

Timing pin, front gearcase cover and, maintenance:


4 - 4 6 c 4 - 3 0 0

Front gearcase housing installation . . . . . . . . . . . . . . . . . . . . . . .

4-46e

4-302

Front gearcase housing removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-46a 4-300

Timing pin installation....... 4-46d 4-302

Timing pin removal . . . . . . . . . . . . . 4-46b 4-300

Timing, engine injector, instructions:

Fuel injectors installation . . . 4 - 3 2 h 4 - 2 4 2

Fuel injectors removal . . . . . . . . .

4-32d 4-238

General instructions . . . . . . . . . . . 4-32e 4-238

Injector timing . . . . . . . . . . . . . . . . . . . .

4-32g

4-240

Rocker lever housing covers installation . . . . . . . . . . . . . . . . . . . . . . .

4-32k 4-246

Rocker lever housing covers removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-32a 4-236

Rocker lever housing and push tubes removal . . . . . . . . . .

4-32b 4-236

Rocker lever housing and push tubes installation..... 4-32j 4-244

Timing tool setup . . . . . . . . . . . . . . . .

4-32f

4-240

Valve crossheads installation and adjustment . . . . . . . . . . . . . . . . . . . . . . .

4-32i

4-244

Valve crossheads removal... 4-32c 4-238

Tire and tube (M939) maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-220b 3-628

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-220c 3-628

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-220a 3-626

Tire and wheel (M939A1/A2) maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-221b 3-634

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-221a 3-630

Tire, wheel and, rotation

(M939):

Front wheel installation . . . . . 3-218f 3-621

Inner rear wheel installation . . . . . . . . . . . . . . . . . . . . . . 3-218d 3-619

Wheel and tire removal....... 3-218b 3-616

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-218e 3-620

Outer rear wheel installation . . . . . . . . . . . . . . . . . . . . . . 3-218a 3-616

Wheel and tire rotation....... 3-218c 3-618

Tire, wheel and, rotation

(M939A1/A2):

Front wheel installation . . . . .

3-219e 3-625

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-219b

3-622

Rear wheel installation.......

3-219d 3-624

Wheel and tire removal....... 3-219a 3-622


Index 62

TM 9-2320-272-24-4

Toe-in check and adjustment:

Toe-in adjustment . . . . . . . . . . . . . . 3-152b 3-422

Toe-in check . . . . . . . . . . . . . . . . . . . . . . . . 3-152a 3-422

Toggle clamp anchor post replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-358b 3-897

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-358a 3-897

Toggle clamp, side panel-toroof, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-357b 3-896

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-357a 3-896

Toolbox and steps replacement: 3-302b 3-796

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-302a 3-796

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toolbox, spare tire carrier, tractor, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-250b 3-699

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-250a 3-699

Top cover gasket and side cover gasket, carrier differential, replacement:

Side cover gasket installation . . . . . . . . . . . . . . . . . . . . . . . 3-158d 3-437

Side cover gasket removal...

3-158c 3-437

Top cover gasket installation ............................. 3-158b 3-436

Top cover gasket removal.... 3-158a 3-434

Torque converter, transmission, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41d 5-291


5-41c 5-290

Disassembly . . . . . . . . . . . . . . . . . . . . . 5-41b 5-288

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-41e 5-298

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-41a 5-286

Torque rod, upper and lower, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-170e 3-472


Diassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-170d 3-470

Lower torque rod installation . . . . . . . . . . . . . . . . . . . . . . . 3-170h 3-474

Lower torque rod removal....... 3-170b 3-470

Setting preload for upper torque rod . . . . . . . . . . . . . . . . . . . . . . . . . 3-170f 3-472

Upper torque rod installation . . . . . . . . . . . . . . . . . . . . . . . 3-170g 3-474

Upper torque rod removal 3-170a 3-468

Torsion bars and crossmembers replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-134b 4-696

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-134a 4-696

Tractor fifth wheel replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-248b 3-696

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-248a 3-696

Para Page

INDEX (Contd)

Para Page

Tractor spare tire carrier

(M931, M932) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor spare tire carrier

(M931A1/A2, M932A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-253b 3-702

3-253a 3-702

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor spare tire carrier toolbox replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor winch hydraulic oil reservoir (M932/A1/A2) replacement:

Installation ..........................

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer airbrake hand control valve (M931/A1/A2,


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . .

Trailer coupling hoses

(M931/A1/A2, M932/A1/A2), emergency and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transducer (M939/A1), fuel pressure, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transducer, pressure, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-254b 3-706

3-254a 3-704

3-250b 3-699

3-250a 3-699

3-338b 3-866

3-338a 3-864

3-210b 3-598

3-210a 3-598

3-209b 3-596

3-209a 3-596

3 - 9 6 b 3 - 2 7 1

3 - 9 6 a 3 - 2 7 1

3-453b 3-1234

3-453a 3-1232

Transfer case (M936/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer case capacitor replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 9 5 b 4 - 5 4 2

4 - 9 5 a 4 - 5 3 7

4-91b 4-522

4 - 9 1 a 4 - 5 2 2

Transfer case cross shaft replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 8 7 b 4 - 5 1 4

4 - 8 7 a 4 - 5 1 4

Transfer case front axle engagement air cylinder replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 8 4 b 4 - 5 0 8

Removal . . . . . . . . . . . . . . . . . . . . . . .

4 - 8 4 a 4 - 5 0 8

Index 63

TM 9-2320-272-24-4

Transfer case front axle engagement control valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-144b 3-396

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-144a 3-396

Transfer case front axle lock-in control valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-147b 3-404

Removal. . . . . . . . . . . . . . . . . . . . 3-147a 3-404

Transfer case interlock air cylinder replacement:

Installation .........................

4-83b 4-506

Removal . . . . . . . . . . . . . . . . . . . . . . .

4 - 8 3 a 4 - 5 0 6

Transfer case interlock valve


Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-82b 4-504

Removal . . . . . . . . . . . . . . . . . . . . . .

4-82a 4-504

Transfer case interlock valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-143b 3-394

Removal . . . . . . . . . . . . . . .. . . . . . . 3-143a 3-392

Transfer case oil pump replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-93b 4-526

Removal . . . . . . . . . . . . . . . . . . . . . . 4-93a 4-526

Transfer case Power Takeoff

(PTO) control cable replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-205b 4-954

Removal . . . . . . . . . . . . . .. . . . . . . . .

4-205a 4-954


(PTO) cross shaft (control lever) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-206b 4-956

Removal . . . . . . . . . . . . . . . . . . . . . .

4-206a 4-956


(PTO) maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . 4-208c 4-970


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-208a 4-962


(PTO) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-207b 4-960

Removal . . . . . . . . . . . . . . . . . . . . . .

4-207a 4-958

Transfer case repair:

Assembly and adjustment . . . . . . . . . . . . . . . . . . . . . . .

5-63c 5-412

Cleaning and inspection...... 5 - 6 3 b 5 - 4 0 8

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

5-63a 5-398

Transfer case replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-94b 4-532

Removal . . . . . . . . . . . . . . . . . . . . . .

4-94a 4-528

Para Page

INDEX (Contd)

Para

Page

Transfer case shift lever maintenance:


4-85b 4-510

Installation.. .......................

4-85c 4-510

Removal.. ............................

4-85a 4-510

Transfer case shift lever shift rod maintenance:

Adjustment.. .......................

4-86b 4-512

Installation.. .......................

4-86c 4-512

Removal.. ............................

4-86a 4-512

Transfer case shift rod maintenance:

Adjustment.. .......................

4-88c 4-517


4-88b 4-516

Installation.........................

4-88d 4-517

Removal..............................

4-88a 4-516

Transfer case speedometer drive gear and driven shaft replacement:

Installation.........................

4-89b 4-518

Removal..............................

4-89a 4-518

Transfer case switch replacement:

Installation.........................

4-90b 4-520

Removal..............................

4-90a 4-520

Transfer case to forward-rear axle propeller shaft maintenance:

Assembly............................

3-150d 3-416


Disassembly.......................

3-150b 3-414

Installation.........................

3-150e 3-416

Removal..............................

3-150a 3-412

Transfer case transorb diode replacement:

Installation.. .......................

4-92b 4-524

Removal.. ............................

4-92a 4-524

Transfer case-to-front axle propeller shaft replacement:

Installation.. .......................

3-149b 3-410

Removal.. ............................

3-149a 3-410

Transfer PTO-to-hydraulic pump propeller shaft replacement:

Installation.. .......................

3-393b 3-966

Removal.. ............................

3-393a 3-966

Transition, ceiling, maintenance:

Assembly.. ..........................

5-82c 5-540

Disassembly.. .....................

5-82b 5-538

Installation.. .......................

5-82d 5-540

Removal.. ............................

5-82a 5-538

Index 64

TM 9-2320-272-24-4

Transmission 5th gear lock-up pressure switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-138b 3-374

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-138a 3-374

Transmission breather replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-136b 3-372

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-136a 3-372

Transmission control valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-44b 5-306

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-44a 5-306

Transmission converter stall test:

Forward stall test . . . . . . . . . . . . . . . 5-62 5-397

Transmission converter stall test:

Forward stall test . . . . . . . . . . . . . . . 5-62 5-396

Transmission dipstick tube and dipstick maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-134c 3-362

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134b 3-362

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-134a 3-362

Transmission fifth gear lock-in solenoid replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-80b 4-502

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-80a 4-500

Transmission governor replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-54b 5-362

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-54a 5-362

Transmission housing maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59c 5-384


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

5-59a 5-384

Transmission lubrication valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-79b 4-498

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-79a 4-496

Transmission manual selector shaft replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-45b 5-308

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-45a 5-308

Transmission modulator and cable maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-145c 3-400

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-145b 3-400

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-145a 3-398

Transmission modulator maintenance:

Adjustment............................

5-6lb 5-394

Testing . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 5 - 6 1 a 5 - 3 9 4

Para Page

INDEX (Contd)

Para Page

Transmission mount bushing replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-77b 4-492

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 7 a 4 - 4 9 2

Transmission mounting bracket and isolator


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-137b 3-373

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-137a 3-373

Transmission mounting to holding fixture:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-40a 5-284

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 - 4 0 b 5 - 2 8 2

Transmission neutral start switch replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-98b 3-273

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-98a 3-273

Transmission oil cooler and mount (M939/A1) replacement:

Oil cooler installation . . . . . . . . . . 3-140d 3-379

Oil cooler mount installation . . . . . . . . . . . . . . . . . . . . . . .

3-140c 3-378

Oil cooler mount removal . . . . 3-140b 3-378

Oil cooler removal . . . . . . . . . . . . . . . 3-140a 3-378

Transmission oil cooler and mount (M939A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-14lb 3-382

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14la 3-380

Transmission oil cooler filter and head replacement:

Oil cooler filter installation . . . . . . . . . . . . . . . . . . . . . . .

3-139d 3-377

Oil cooler filter head installation . . . . . . . . . . . . . . . . . . . . . . .

3-139c 3-377

Oil cooler filter head removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-139b 3-376

Oil cooler filter removal....... 3-139a 3-376

Transmission oil cooler hoses replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-142b 3-388

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-142a 3-384

Transmission oil pan and filter maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-42c 5-302

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-42a 5-300

Transmission oil pressure testing:

Automatic shift speed test...... 5-60c 5-392

Main pressure and governor pressure test....... 5-60b 5-390

Oil cooler pressure test . . . . . . . 5-60a 5-386

Index 65

TM 9-2320-272-24-4

Transmission oil pump and front support maintenance:

Assembly ............................

5 - 4 6 d 5 - 3 1 6


5 - 4 6 c 5 - 3 1 4

Disassembly.. .....................

5-46b 5-312

Installation.. .......................

5-46e 5-320

Removal.. ............................

5-46a 5-310

Transmission oil service instructions:

Draining oil.. .......................

3-133a 3-354

Governor filter installation.. .....................

3-133e 3-358

Governor filter removal....... 3-133d 3-358

Oil filter installation.. ......... 3-133c 3-356

Oil filter removal.. ...............

3-133b 3-356

Replenishing oil ..................

3-133f 3-360

Transmission output shaft yoke and oil seal replacement:

Installation.. .......................

4-78b 4-494

Removal.. ............................

4-78a 4-494

Transmission Power Takeoff

(PTO) control cable (M939A2) replacement:

Installation.. .......................

4-210b 4-980

Removal.. ............................

4-210a 4-978


(PTO) control cable replacement:

Installation.. .......................

4-209b 4-976

Removal.. ............................

4-209a 4-976


(PTO) maintenance:

Assembly ............................

4-212c 4-996


4-212b 4-994

Disassembly.. .....................

4-212a 4-988


(PTO) replacement:

Installation.. .......................

4-211b 4-986

Removal.. ............................

4-211a 4-982

Transmission PTO-to-hydraulic pump propeller shaft replacement:

Installation.. .......................

3-334b 3-853

Removal.. ............................

3-334a 3-853

Transmission PTO-to-hydraulic pump propeller shaft universal joint maintenance:

Assembly.. ..........................

3-335c 3-856

Disassembly.. .....................

3-335a 3-854

Inspection.. .........................

3-335b 3-854

Transmission replacement (invehicle):

Installation.. .......................

4-71b 4-470

Removal.. ............................

4-71a 4-466

Para Page

INDEX (Contd)

Para Page

Transmission replacement

(out-of-vehicle):

Installation.. .......................

4-72b 4-478

Removal.. ............................

4-72a 4-476

Transmission select lever replacement:

Installation.. .......................

4-73b 4-482

Removal.. ............................

4-73a 4-482

Transmission selector shaft oil seal replacement:

Installation.. .......................

4-76b 4-490

Removal.. ............................

4-76a 4-489

Transmission shift cable maintenance:

Adjustment.. .......................

4-75c 4-488

Installation.. .......................

4-75b 4-486

Removal.. ............................

4-75a 4-486

Transmission shift tower replacement:

Installation.. .......................

4-74b 4-484

Removal.. ............................

4-74a 4-484

Transmission temperature transmitter replacement:

Installation.. .......................

3-97b 3-272

Removal.. ............................

3-97a 3-272

Transmission torque converter maintenance:

Assembly.. ..........................

5-41d 5-291


5-41c 5-290

Disassembly.. .....................

5-41b 5-288

Installation.. .......................

5-41e 5-298

Removal.. ............................

5-41a 5-286

Transmission-to-transfer case propeller shaft maintenance:

Assembly.. ..........................

3-148c 3-408

Disassembly.. .....................

3-148b 3-408

Installation.. .......................

3-148d 3-408

Removal.. ............................

3-148a 3-406

Transmitter, transmission temperature, replacement:

Installation.. .......................

3-97b 3-272

Removal.. ............................

3-97a 3-272

Troop seat and siderack kit

(M929/A1/A2, M930/A1/A2) maintenance:

Siderack assembly.. ............ 3-429c 3-1102

Siderack disassembly.. .......

3-429b 3-1102

Troop seat assembly.. .........

3-429d 3-1102

Troop seat disassembly ......

3-429a 3-1102

Troop seat, cargo, replacement:

Installation.. .......................

3-340b 3-870

Removal.. ............................

3-340a 3-870

Troubleshooting, Central Tire

Inflation System (CTIS) ........

2-25

2-267

Troubleshooting, compressed air and brake system.. ..........

2-23

2-177

Index 66

TM 9-2320-272-24-4

Troubleshooting, direct and general support, mechanical symptom index . . . . . . . . . . . . . . . . . . . 4-2

Troubleshooting, electrical

4-2 system . . . . . . . . . . . . . . . . . . . . . . . . .

2-22 2-92

Troubleshooting, mechanical, unit level . . . . . . . . . . . . . . . . . . . . . . .

2-21 2-61

Troubleshooting, STE/ICE symptom index . . . . . . . . . . . . . . . . . . . 2-24

2-219

Tube (M939), tire and, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-220b 3-628

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-220c

3-628

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-220a 3-626

Tube (M939A2) Air Fuel

Control (AFC), maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . 3-18b

3-61

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-18c 3-61

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-18a 3-61

Tube, air cleaner indicator and, maintenance:


3-12c 3-44

Installation . . . . . . . . . . . . . . . . . . . . . 3-12d 3-46

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-12b

3-44

Testing . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a 3-42

Tube, cross, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-104b 4-578

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-104a 4-578

Tubes (M939/A1), coolant hoses and, replacement:

Radiator inlet hoses and tube installation . . . . . . . . . . . . . . . 3-54j 3-158

Radiator inlet hoses and tube removal . . . . . . . . . . . . . . . . . . . . .

3-54a 3-154

Radiator outlet hoses and tee installation . . . . . . . . . . . . . . . . 3-54g 3-156

Radiator outlet hoses and tee removal . . . . . . . . . . . . . . . . . . 3-54d

3-156



Thermostat housing hose, radiator bypass tube, and hose installation . . . . . . . . . . . . . . . 3-54i 3-158

Thermostat housing hose, radiator bypass tube, and hose removal..................

3-54b

3-154

Transmission oil cooler hoses and tube installation 3-54f

3-156

Transmission oil cooler hoses and tube removal . . . . 3-54e

3-156

Tubes (M939A2), aftercooler and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . 3-76b 3-218

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-76a

3-216

Para Page

INDEX (Contd)

Para Page

Tubes (M939A2), aftercooler and, replacement:

Installation.. .......................

3-76b 3-218

Removal ..............................

3 - 7 6 a 3 - 2 1 6

Tubing, ether, replacement:

Installation.. .......................

3-39b 3-120

Removal ..............................

3 - 3 9 a 3 - 1 2 0

Turbocharger and coolant lines


Installation.. .......................

3-21b 3-70

Removal.. ............................

3-21a 3-68

Turbocharger maintenance:

Assembly.. ..........................

4-58c 4-348


4 - 5 8 b 4 - 3 4 8

Disassembly.. .....................

4-58a 4-346

Turn signal control and indicator lamp replacement:

Installation.. .......................

3-113b 3-302

Removal.. ............................

3-113a 3-302

Turn signal flasher replacement:

Installation.. .......................

3-114b 3-303

Removal.. ............................

3-114a 3-303

Turnbuttons and lashing hooks, cab, replacement:

Installation.. .......................

3-303b 3-798

Removal.. ............................

3-303a 3-798

Turntable repair:

Assembly.. ..........................

4-203d 4-948


4-203c 4-948

Disassembly.. .....................

4-203b 4-946

Installation.. .......................

4-203e 4-948

Removal.. ............................

4-203a 4-946

Underframe parts replacement:

Installation.. .......................

5-71b 5-484

Removal.. ............................

5-71a 5-484

U

Unit Preventive Maintenence

Checks and Services (PMCS):

General.. .............................

2-8 2-2

Intervals.. ...........................

2-9

2-2

Reporting repairs ................ 2-10

2-3

General service and inspection procedures ........ 2-11

2-3

Specific PMCS procedures ... 2-12

2-3

Universal joint, front axle shaft and, maintenance:


Installation.. .......................

3-154e 3-429

Removal.. ............................

3-154a 3-426

Universal joint assembly.... 3-154d 3-428

Universal joint disassembly 3-154c 3-428

Index 67

TM 9-2320-272-24-4

Para Page

INDEX (Contd)

Universal joint, PTO-tohydraulic pump propeller shaft, transmission, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-335c 3-856

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-335a 3-854

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-335b 3-854

Upper and lower steering column maintenance:

Cleaning, inspection, and repair . . . . . . . . . . . . . . . . . . . . . . . . .

4-116c 4-608

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-116b 4-608

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-116e 4-612

Reassembly . . . . . . . . . . . . . . . . . . . . . . . .

4-116d 4-610

Removal . . . . . . . . . . . . . . .. . . . . . . .

4-116a 4-606

Upper and lower torque rod maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170e 3-472


Diassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-170d 3-470

Lower torque rod installation . . . . . . . . . . . . . . . . . . . . . . . 3-170h 3-474

Lower torque rod removal...

3-170b 3-470

Setting preload for upper torque rod . . . . . . . . . . . . . . . . . . . . . 3-170f 3-472

Upper torque rod installation . . . . . . . . . . . . . . . . . . . . . . . 3-170g 3-474

Upper torque rod removal...

3-170a 3-468

Upper bracket, rear axles spring seat wear pads and, maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168b 3-462

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-168c 3-462

Removal . . . . . . . . . . . . . . . . .. . . . . .

3-168a 3-460

Upper radiator hoses and brackets (M939A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-58b

3-170

Removal . . . . . . . . . . . . . . . . . . . . .

3-58a 3-170

Use of metric system . . . . . . . . . . . . . . .

1-9

1-3

V

Valve (M936/A1/A2), brake pedal (treadle), replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-198b 3-542

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-198a 3-540

Valve (M936/A1/A2), transfer case interlock, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-82b 4-504

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-82a

4-504

Valve adjustment:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . .

4-53a 4-326

Para Page

Valve and injector adjustment

(dial indicator method):

Checking plunger free travel . . . . . . . . . . . . . . . . . . . . . . . . . 4-33a 4-248

Injector and valve adjustments . . . . . . . . . . . . . . . . . . . . . 4-33b 4-248

Valve cover (M939A2) maintenance:


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-6c

3-26

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-6a 3-22

Valve No. 1, doublecheck, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-212b 3-602

Removal . . . . . . . . . . . . . . . . . . . . . 3-212a 3-602

Valve No. 2 (M931/A1/A2,

M932/A1/A2), doublecheck, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-214b 3-606

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-214a 3-606

Valve No. 2 (M931/A1/A2,

M932/A1/A2), doublecheck, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-214b 3-606

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-214a 3-606

Valve No. 2, doublecheck,


Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-214b 3-606

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-214a 3-606

Valve No. 2, doublecheck, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-213b 3-604

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-213a 3-604

Valve No. 5, doublecheck,

(M931/A1/A2,M932/A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-215b 3-608

Removal . . . . . . . . . . . . . . . . . . . . . .

3-215a 3-608

Valve seat inserts maintenance:

Cleaning . . . . . . . . . . . . . . . . . . . . . .

5-5d

5-24

Counterboring . . . . . . . . . . . . . . . . . . . . . 5-5c 5-24

Gauging . . . . . . . . . . . . . . . . . . . . . . 5-5b

5-22

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-5e 5-24

Removal . . . . . . . .. . . . . . . . . . . . . . 5-5a

5-22

Valve switch, fuel selector, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . 3-109b 3-296

Removal . . . . . . . . .. . . . . . . . . . . . . .

3-109a 3-296

Valve, air supply, hand airbrake, replacement:

Installation ........................

3-422b 3-1084

Removal . . . . . . . . .. . . . . . . . . . . . . 3-422a 3-1084

Index 68

TM 9-2320-272-24-4

Para

Page

INDEX (Contd)

Valve, assembly, snubber, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve, brake pedal (treadle) repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valve, brake pedal (treadle), replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve, Check, air reservoir oneway, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve, crane control, repair:

Assembly . . . . . . . . . . . . . . . . . . . . . .

Cleaning, inspection, and repair . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valve, crane swivel, maintenance:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harness connection.. . . . . . . . . . . . . . . . . . . . . . . .

Wiring harness disconnection . . . . . . . . . . . . . . . . . .

Valve, deepwater fording pressurization, replacement:

Installation (M939/A1) . . . . . . .

Installation (M939A2) . . . . . . . .

Removal (M939/A1) . . . . . . . . . . .

Removal (M939A2) . . . . . . . . . . . . .

Valve, deepwater fording regulator, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . .

Valve, doublecheck,hand airbrake, replacement:

Installation (forward-rear axle doublecheck valve). . . . .

Installation (rear-rear axle doublecheck valve). . . .

Removal (forward-rear axle doublecheck valve). . . . .

Removal (rear-rear axle doublecheck valve) . . . . . . . . . . . .

Valve, ether cylinder and, replacement:

Ether cylinder installation . .

Ether cylinder removal . . . . . . . .

Ether valve installation . . . . . .

Ether valve removal . . . . . . . . . . . .

3-390b 3-958

3-390a 3-958

4-108c 4-586

4-108b 4-586

4-108a 4-584

3-197b 3-538

3-197a 3-536

3-186b 3-514

3-186a 3-514

5-108c 5-640

5-108b 5-640

5-108a 5-636

4-198c 4-930

4-198b 4-928

4-198d 4-932

4-198a 4-926

4-226b 4-1032

4-226c 4-1030

4-226a 4-1028

4-226b 4-1030

4-228b 4-1040

4-228a 4-1040

3-424b 3-1088

3-424d 3-1090

3-424a 3-1088

3-424c 3-1090

3 - 3 5 d 3 - 1 1 5

3 - 3 5 a 3 - 1 1 4

3 - 3 5 c 3 - 1 1 5

3 - 3 5 b 3 - 1 1 4

Para Page

Valve, front wheel, maintenance:


3-456b 3-1244

Installation.. .......................

3-456c 3-1245

Removal.. ............................

3-456a 3-1244

Valve, hand airbrake controller, replacement:

Installation.. .......................

3-423b 3-1086

Removal.. ............................

3-423a 3-1086

Valve, hand air-brake tractor protection, valve replacement:

Installation.. .......................

3-425b 3-1092

Removal.. ............................

3-425a 3-1092

Valve, injector plunger (torque method) and, adjustments:

Injector and valve adjustment.. .....................

4-34b 4-256

Pre-adjustment setup.. .......

4-34a 4-254

Valve, interlock, transfer case, replacement:

Installation.. .......................

3-143b 3-394

Removal.. ............................

3-143a 3-392

Valve, modulator lockup, low trimmer valve, and low shift valve, replacement:

Installation.. .......................

5-43b 5-304

Removal.. ............................

5-43a 5-304

Valve, pneumatic controller and relief, maintenance:

Assembly.. ..........................

3-454d 3-1238


3-454c 3-1238

Disassembly.. .....................

3-454b 3-1236

Installation.. .......................

3-454e 3-1239

Removal.. ............................

3-454a 3-1236

Valve, pressure relief, maintenance:

Adjustment.. .......................

3-389b 3-956

Testing.. .............................

3-389a 3-956

Valve, rear wheel, maintenance:


3-457b 3-1246

Installation.. .......................

3-457c 3-1247

Removal.. ............................

3-457a 3-1246

Valve, relay, repair:

Assembly.. ..........................

4-109c 4-590


Disassembly.. .....................

4-109a 4-590

Valve, relief safety, maintenance:

Assembly.. ..........................

3-455d 3-1242


3-455c 3-1242

Disassembly.. .....................

3-455b 3-1241

Installation.. .......................

3-455e 3-1242

Removal ..............................

3-455a 3-1240

Index 69

TM 9-2320-272-24-4

Valve, spring brake, maintenance:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . .

Valve, transmission lubrication, replacement:

Installation. . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . .

Valve, wheel, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . .

Cleaning and inspection. . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

Valves No. 3, No. 4, doublecheck and quickrelease valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . .

Valves, intake and exhaust, refacing:

Cleaning after refacing.. . . . . . .

Grinding or refacing

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

Valve specifications . . . . . . . . . . . . .

Van air conditioner wiring harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . .

Van body replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van davit chain and wire rope replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Van davit chain and wire rope replacement:

Installation. . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van davit winch (M934A1/A2) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van handrail modification kit


Door check spacer installation . . . . . . . . . . . . . . . . . . . . . . .

Door check spacer removal. . . . . . . . . . . . . . . . .. . . .

Ladder handrail guide installation . . . . . . . . . . . . . . . . .

Ladder handrail guide removal . . . . . . . . . . . . . . . . . . . . .

3-173b 3-482

3-173c 3-482

3-173a 3-482

4 - 7 9 b 4 - 4 9 8

4 - 7 9 a 4 - 4 9 6

3-459c 3-1250

3-459b 3-1250

3-459a 3-1250

3-216b 3-612

3-216a 3-610

5-4c

5-4b

5-4a

5-20

5-20

5-18

5 - 9 0 b 5 - 5 7 0

5 - 9 0 a 5 - 5 7 0

5 - 6 6 b 5 - 4 6 6

5 - 6 6 a 5 - 4 6 4

3-264b 3-724

3-264a 3-724

3-264b 3-724

3-264a 3-724

3-266b 3-728

3-266a 3-728

3-450h 3-1229

3-450g 3-1229

3-450b 3-1225

3-450a 3-1225

Para

Page

INDEX (Contd)

Para Page

Ladder handrail hangers installation . . . . . . . . . . . . . . . . . . . 3-450d 3-1226

Ladder handrail hangers removal . . . . . . . . . . . . . . . . . . . . . .

3-450c 3-1226

Van door grab handles installation . . . . . . . . . . . . . . . . . .

3-450f 3-1228

Van door grab handles removal . . . . . . . . . . . . . . . . . . . . .

3-450e 3-1228

Van heater and exhaust replacement:

Installation . . . . . . . . . . . . . . . . . . . . 3-379b 3-930

Removal . . . . . . . . . . . . . . . . . . . . . . . . . .

3-379a 3-928

Van heater fuel pump

(M934A1/A2) replacement:

Installation (M934) . . . . . . . . . . . . .

3-381d 3-936

Installation (M934A1/A2)... 3-381b 3-934

Removal (M934) . . . . . . . . . . . . . . . . . .

3-381c 3-936

Removal (M934A1/A2)........

3-381a 3-934

Van heater wiring harness replacement:

Installation . . . . . . . . . . . . . . . . . . . . 5-91b 5-574

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-91a 5-572

Van power cable reel


Installation . . . . . . . . . . . . . . . . . . . . .

3-380b 3-932

Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-380a 3-932

Van rear door and side door window replacement:

Installation ........................

3-350b 3-888

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-350a 3-888

Van spare tire carrier (M934) replacement . . . . . . . . . . . . . . . . . . . . .

3-262 3-722

Van spare tire carrier


Installation . . . . . . . . . . . . . . . . . . . . .

3-263b 3-722

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-263a 3-722

Van swing davit and pulley replacement:

Installation . . . . . . . . . . . . . . . . . . . . .

3-265b 3-726

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-265a 3-726

Vavle, crane control, replacement:

Installation . . . . . . . . . . . . . . . . . . . . 4-201b 4-940

Removal . . . . . . . . . . . . . . . . . . . . . .

4-201a 4-938

Vehicle tiedown kit replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-442b 3-1146

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-442a 3-1146

Vent door weatherseal replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-298b 3-792

Removal . . . . . . . . . . . . . . . . . . . . . . . .

3-298a 3-792

Vent, screen and door, cab cowl, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-299b 3-793

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-299a 3-793

Index 70

TM 9-2320-272-24-4

Vibration damper maintenance:

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 4 2 b 4 - 2 9 0

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-42c 4-290

Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-42a

4-290

Voltage regulator, 100-amp, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-428b 3-1100

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-428a 3-1100

VS governor filter, fuel pump with, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-32b 3-110

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-32a 3-110

W

Warning light, amber, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-469b 3-1283

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-469a 3-1283

Warning light, convoy, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-437b 3-1128

Removal . . . . . . . . . . . . . . . . . . . .. . . . 3-437a 3-1128

Warning module, failsafe, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-106b 3-290

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-106a 3-290

Warranty information . . . . . . . . . . . . .

Washer control valve

1-7 1-2 replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-191b 3-524

Removal . . . . . . . . . . . . . . . . . . . .. . . . . 3-191a 3-524

Washer hoses, windshield, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-282b 3-760

Removal . . . . . . . . . . . . . . . . . . . . . .

3-282a 3-760

Water header plates replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-28b

4-198

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28a 4-198

Water jacket, swingfire heater, replacement:

Installation ....................... 3-411b 3-1020

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-411a 3-1020

Water pump (M939/A1) maintenance:

Assembly . . . . . . . . . . . . .. . . . . . . . . .

4-63c 4-384


4-63b 4-381

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-63a 4-378

Water pump (M939/A1) replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-68b 3-200

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-68a

3-200

Para Page

INDEX (Contd)

Para Page

Water pump (M939A2) maintenance:


Installation.. .......................

3-69c 3-202

Removal.. ............................

3-69a 3-202

Water pump drivebelt


Adjustment.. .......................

3-67a 3-196

Inspection.. .........................

3-67c 3-198

Installation.. .......................

3-67d 3-198

Removal.. ............................

3-67b 3-198

Water pump maintenance:

Assembly.. ..........................

4-29d 4-206


4-29c 4-204

Disassembly.. .....................

4-29b 4-202

Installation.. .......................

4-29e 4-208

Removal.. ............................

4-29a 4-200

Water separator maintenance:

Assembly.. ..........................

3-466d 3-1278


3-466c 3-1278

Disassembly.. .....................

3-466b 3-1278

Installation.. .......................

3-466e 3-1279

Removal.. ............................

3-466a 3-1278

Water temperature sending unit replacement:

Installation.. .......................

3-93b 3-266

Removal.. ............................

3-93a 3-266

Weapon station modification kit, lightweight, maintenance:

Assembly.. ..........................

3-446c 3-1170

Disassembly.. .....................

3-446b 3-1168

Installation.. .......................

3-446d 3-1174

Removal.. ............................

3-446a 3-1160

Weatherseal, cab door, replacement:

Installation.. .......................

3-311b 3-810

Removal.. ............................

3-311a 3-810

Weatherseal, vent door, replacement:

Installation.. .......................

3-298b 3-792

Removal.. ............................

3-298a 3-792

Weatherstripping (cab door), window, replacement:

Installation.. .......................

3-315b 3-814

Removal.. ............................

3-315a 3-814

Weight, governor, maintenance:

Inspection.. .........................

5-17b 5-102

Installation.. .......................

5-17c 5-102

Removal ..............................

5 - 1 7 a 5 - 1 0 2

Wet air reservoir (supply tank) and bracket replacement:

Installation.. .......................

3-200b 3-552

Removal.. ............................

3-200a 3-548

Index 71

TM 9-2320-272-24-4

Wet air reservoir (supply tank) and mounting plate


Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-201b 3-558

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-201a 3-556

Wet reservoir (supply tank) safety valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-185b 3-512

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-185a 3-512

Wheel (M939A1/A2), tire and, maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-221b 3-634

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-221a 3-630

Wheel and tire rotation

(M939):

Front wheel installation . . . . . 3-218f 3-621

Inner rear wheel installation . . . . . . . . . . . . . . . . . 3-218d 3-619


Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .

3-218b 3-616

Outer rear wheel installation . . . . . . . . . . . . . . . . . . . . . . . 3-218e 3-620


Wheel and tire rotation

(M939A1/A2):

Front wheel installation . . . . . 3-219e 3-625

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-219b 3-622

Rear wheel installation....... 3-219d 3-624



Wheel bearing adjustment:

Front wheel bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-225a 3-648

Rear wheel bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-225b 3-650

Wheel brakedrum dustcovers replacement:

Front wheel dustcovers installation . . . . . . . . . . . . . . . . . . . . . . . 3-178c 3-496

Front wheel dustcovers removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-178a 3-496

Rear wheel dustcovers installation . . . . . . . . . . . . . . . . . . . . . . . 3-178d 3-496

Rear wheel dustcovers removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-178b 3-496

Wheel rim stud replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-222b 3-636

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-222a 3-636

Wheel valve filter replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-458b 3-1248

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-458a 3-1248

Wheel valve maintenance:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-459c 3-1250


Disassembly . . . . . . . . . . . . . . . . . . . . . . .

3-459a 3-1250

Para Page

INDEX (Contd)

Para Page

Wheel, steering, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-226b 3-652

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-226a 3-651

Winch automatic brake, front, adjustment:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-323b 3-826

Testing ............................

3-323a 3-824

Winch cable chain and hook, front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-325b 3-830

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-325a 3-830

Winch cable clevis replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-326b 3-832

Removal . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 3-326a 3-831

Winch cable tensioner, rear, repair:

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-182c 4-882

Cleaning, inspection, and repair . . . . . . . . . . . . . . . . . . . . . . . . .

4-182b 4-880

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-182a 4-878

Winch cable, front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-327b 3-834

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-327a 3-834

Winch cable, rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-33 lb 3-846

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-33 la 3-846

Winch control valve

(M930/A1/A2), front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-179b 4-856

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-179a 4-856

Winch control valve cable, front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-177b 4-851

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-177a 4-850

Winch control valve, front and rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-178b 4-854

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-178a 4-854

Winch drag brake, front, adjustment:

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

3-324b 3-828

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-324a 3-828

Winch frame extension replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-245b 3-692

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-245a 3-692

Winch hydraulic hose and tube, front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-180b 4-861

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-180a 4-858

Winch hydraulic motor, rear, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-185b 4-890

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-185a 4-888

Index 72

TM 9-2320-272-24-4

Para

Page

INDEX

(Contd)

Winch hydraulic oil reservoir replacement:

Installation.. .......................

3-337b 3-862

Removal ..............................

3-337a 3-860

Winch level wind, front and rear, maintenance:

Assembly ............................

4-174d 4-839


4-174c 4-836

Disassembly.. .....................

4-174b 4-832

Installation.. .......................

4-174e 4-841

Removal.. ............................

4-174a 4-832

Winch motor and lines, hydraulic hoist, replacement:

Installation.. .......................

4-190b 4-904

Removal.. ............................

4-190a 4-904

Winch motor, front, replacement:

Installation.. .......................

3-328b 3-838

Removal.. ............................

3-328a 3-836

Winch roller, rear, repair:


4-153c 5-754

Side roller assembly ............ 4-153e 4-754

Side roller disassembly .......

4-153a 4-752

Top and bottom roller assembly.. ........................

4-153d 4-754

Top and bottom roller disassembly.. ....................

4-153b 4-752

Winch side roller, repair:

Assembly ............................

4-183c 4-885


4-183b 4-884

Disassembly.. .....................

4-183a 4-884

Winch top and bottom roller, rear, repair:

Assembly ............................

4-184c 4-887


4-184b 4-886

Disassembly.. .....................

4-184a 4-886

Winch, front, repair:

Assembly of subassemblies.. ..................

4-172d 4-819

Assembly of winch.. ............ 4-172e 4-823


4-172c 4-816

Disassembly into subassemblies.. ................

4-172a 4-810

Disassembly of subassemblies.. ................

4-172b 4-812

Winch, front, replacement:

Installation.. .......................

3-329b 3-842

Removal.. ............................

3-329a 3-840

Winch, hoist replacement:

Installation.. .......................

4-192b 4-908

Removal ..............................

4-192a 4-908

Winch, hoist, PTO maintenance.. .......................

5-101 5-606

Para Page

Winch, hydraulic pump, front, replacement:

Installation.. .......................

4-176b 4-848

Removal ..............................

4-176a 4-848

Winch, rear, adjustment:

Cable tensioner adjustment.. .....................

3-330b 3-844

Cable tensioner check.. ...............................

3-330a 3-844

Winch, rear, repair:

Assembly.. ..........................

4-181c 4-872


4-181b 4-870

Disassembly.. .....................

4-181a 4-864

Winch, rear, replacement:

Installation.. .......................

3-332b 3-848

Removal.. ............................

3-332a 3-847

Winch, roller assembly, front, maintenance:

Assembly.. ..........................

4-175d 4-845


4-175c 4-844

Disassembly.. .....................

4-175b 4-843

Installation.. .......................

4-175e 4-847

Removal.. ............................

4-175a 4-842

Window blackout panel replacement:

Installation.. .......................

3-352b 3-890

Removal.. ............................

3-352a 3-890

Window brushguard replacement:

Installation.. .......................

3-355b 3-893

Removal.. ............................

3-355a 3-893

Window glass, retractable and van door, replacement:

Installation.. .......................

4-139b 4-710

Removal.. ............................

4-139a 4-710

Window regulator and inside door handle replacement:

Installation.. .......................

3-308b 3-807

Removal.. ............................

3-308a 3-807

Window regulator, retractable, replacement:

Installation.. .......................

3-354b 3-892

Removal.. ............................

3-354a 3-892

Window screen replacement:

Installation.. .......................

3-353b 3-891

Removal.. ............................

3-353a 3-891

Window weatherstripping (cab door) replacement:

Installation.. .......................

3-315b 3-814

Removal.. ............................

3-315a 3-814

Window, retractable, replacement:

Installation .........................

3-351b 3-889

Removal.. ............................

3-351a 3-889

Index 73

TM 9-2320-272-24-4

Window, van rear door and side door, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-350b 3-888

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-350a 3-888

Windshield and outer frame assembly replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-278b 3-752

Removal . . . . . . . . . . . . . . . . . . . . . .. . 3-278a 3-752

Windshield frame assembly replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-279b 3-754

Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-279a 3-754

Windshield hinge, cab assembly, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-280b 3-756

Removal . . . . . . . . . . . . . . . . . . . . . .

3-280a 3-756

Windshield stop bracket and latch replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-276b 3-747

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-276a 3-747

Windshield washer hoses replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-282b 3-760

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-282a 3-760

Windshield wiper control valve replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-192b 3-526

Removal . . . . . . . . . . . . . . . . . . . . . . . 3-192a 3-526

Windshield wiper reservoir, jet, and control replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-281b 3-758

Removal . . . . . . . . . . . . . . . . . . . . . . .

3-281a 3-758

Windshield, cab, repair:

Assembly . . . . . . . . . . . . . . . . . . . .

4-138b 4-708

Disassembly . . . . . . . . . . . . . . . . . . . . . . .

4-138a 4-708

Wiper motor, windshield wiper blade, wiper arm, and, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-277b 3-750

Removal . . . . . . . . . . . . . . . . . . . . . .

3-277a 3-748

Wire, boom, floodlight, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

3-385b 3-946

Removal . . . . . . . . . . . . . . . . .. . . . . . . 3-385a 3-946

Wiring harness (M939/A2), front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-66b 4-408

Removal . . . . . . . . . . . . . . . . . . . . . .

4-66a 4-394

Wiring harness (M939A2), front, replacement:

Installation . . . . . . . . . . . . . . . . . . . . . . . . .

4-67b

4-434

Removal . . . . . . . . . . . . . . . . . .. . . . . . 4-67a

4-422

Para Page

INDEX (Contd)

Para Page

Wiring harness repair:

Female cable connector

(with sleeve). .....................

3-131c 3-350

Male cable connector.. ......... 3-131b 3-350

Plug assembly.. .................. 3-131d 3-350

Receptacle assembly.. .........

3-131e 3-350

Terminal-type cable connector.. .........................

3-131a 3-349

Wiring harness, 3-phase receptacle, replacement:

Installation.. .......................

5-100b 5-604

Removal.. ............................

5-100a 5-604

Wiring harness, 400 Hz supply, replacement:

Installation.. .......................

5-96b 5-592

Removal.. ............................

5-96a

5-590

Wiring harness, air conditioner, van, replacement:

Installation.. .......................

5-90b 5-570

Removal.. ............................

5-90a 5-570

Wiring harness, blackout and clearance lights, replacement:

Installation.. .......................

5-95b 5-588

Removal.. ............................

5-95a 5-588

Wiring harness, blackout bypass, maintenance:

Installation.. .......................

5-93c

5-580

Removal.. ............................

5-93a 5-580

Repair.. ...............................

5-93b 5-580

Wiring harness, brached 400

Hz receptacle, replacement:

Installation.. .......................

5-97b

5-596

Removal.. ............................

5-97a 5-596

Wiring harness, crane, replacement:

Installation.. .......................

3-386b 3-950

Removal.. ............................

3-386a 3-948

Wiring harness, CTIS, replacement:

Installation.. .......................

3-470b 3-1286

Removal.. ............................

3-470a 3-1284

Wiring harness, electric heater

(10 kw), replacement:

Installation.. .......................

5-92b

5-578

Removal.. ............................

5-92a 5-578

Wiring harness, emergency lamp, replacement:

Installation.. .......................

5-94b 5-584

Removal.. ............................

5-94a 5-582

Index 74

Para

Page

INDEX (Contd)

Wiring harness, flexible converter, maintenance:

Installation.. .......................

Removal..............................

Repair.. ...............................

Wiring harness, heater fuel pump, maintenance:

Installation.. .......................

Removal..............................

Repair.. ...............................

Wiring harness, main, replacement:

Installation.. .......................

Removal ..............................

Wiring harness, rear, replacement:

Installation.. .......................

Removal..............................

Wiring harness, telephone post, replacement:

Installation.. .......................

Removal ..............................

Wiring harness, van heater, replacement:

Installation.. .......................

Removal ..............................

Wrecker body replacement:

Installation .........................

Removal.. ............................

Wrecker crane hydraulic hose and tube replacement:

Installation.. .......................

Removal ..............................

Wrecker crane hydraulic pump replacement:

Installation.. .......................

Removal.. ............................

4-160c 4-774

4-160a 4-774

4-160b 4-774

4-156c 4-766

4-156a 4-766

4-156b 4-766

5 - 8 9 b 5 - 5 6 8

5 - 8 9 a 5 - 5 6 8

4 - 6 8 b 4 - 4 5 4

4 - 6 8 a 4 - 4 4 6

5 - 9 9 b 5 - 6 0 2

5 - 9 9 a 5 - 6 0 2

5-91b 5-574

5 - 9 1 a 5 - 5 7 2

4-152b 4-750

4-152a 4-748

3-387b 3-952

3-387a 3-952

3-388b 3-954

3-388a 3-954

TM 9-2320-272-24-4

Index 75/(Index 76 blank)

By Order of the Secretary of the Army:

DENNIS J. REIMER

General, United States Army

Chief of Staff

Administrative Assistant to the

Secretary of the Army

04876

DISTRIBUTION:

T o b e d i s t r i b u t e d i n a c c o r d a n c e w i t h t h e i n i t i a l d i s t r i b u t i o n number (IDN) 381074 requirements for TM 9-2320-272-24-4.

*U.S. GOVERNMENT PRNITING OFFICE:1998-646-.039/80045

THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters =

0.3937 Inches

1 Meter = 100 Centimeters = 1,000 Millimeters =

39.37 Inches

1 Kilometer = 1,000 Meters = 0.621 Miles

SQUARE MEASURE

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches

1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet

1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

CUBIC MEASURE

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches

1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

LIQUID MEASURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces

1 Liter = 1,000 Milliliters = 33.82 Fluid Ounces

TEMPERATURE

5/9 (

212 o

F -32) - o

C o

Fahrenheit is equivalent to 100 o

Celsius

90 o

32 o

Fahrenheit is equivalent to 32.2

Fahrenheit is equivalent to 0

9/5 o

C +32 = o

F o o

Celsius

Celsius

WEIGHTS

1 Gram = 0.001 Kilograms = 1,000 Milligrams = 0.035 Ounces

1 Kilogram = 1,000 Grams = 2.2 Lb

1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons

APPROXIMATE CONVERSION FACTORS

TO CHANGE

Inches . . . . . . . . . . . . . . . . . . . . . . . . .

Feet . . . . . . . . . . . . . . . . . . . . . . . . . .

TO

C e n t i m e t e r s . . . . . . . . . . . . . . . . .

MULTIPLY BY

2.540

Meters . . . . . . . . . . . . . . . . . . . . .

0.305

Yards . . . . . . . . . . . . . . . . . . . . . . . . .

Meters . . . . . . . . . . . . . . . . . . . . .

Miles . . . . . . . . . . . . . . . . . . . . . . . . . .

Kilometers . . . . . . . . . . . . . . . . . .

Square Inches . . . . . . . . . . . . . . . . . .

Square Centimeters . . . . . . . . . . .

Square Feet . . . . . . . . . . . . . . . . . . . .

Square Meters . . . . . . . . . . . . . . .

Square Yards . . . . . . . . . . . . . . . . . . .

Square Meters . . . . . . . . . . . . . . .

Square Miles . . . . . . . . . . . . . . . . . . .

Square Kilometers . . . . . . . . . . . .

Acres . . . . . . . . . . . . . . . . . . . . . . . . . .

Square Hectometers . . . . . . . . . .

0.914

1.609

6.451

0.093

0.836

2.590

0.405

Cubic Feet . . . . . . . . . . . . . . . . . . . . .

Cubic Meters . . . . . . . . . . . . . . . .

Cubic Yards . . . . . . . . . . . . . . . . . . . .

Cubic Meters . . . . . . . . . . . . . . . .

0.028

0.765

Fluid Ounces . . . . . . . . . . . . . . . . . . .

Milliliters . . . . . . . . . . . . . . . . . . .

29.573

P i n t s . . . . . . . . . . . . . . . . . . . . . . . . . .

Liters . . . . . . . . . . . . . . . . . . . . . .

0.473

Quarts . . . . . . . . . . . . . . . . . . . . . . . .

Liters . . . . . . . . . . . . . . . . . . . . . .

Pound-Feet . . . . . . . . . . . . . . . . . . . . .

Newton-Meters . . . . . . . . . . . . . .

Pounds Per Square Inch . . . . . . . . . .

Kilopascals . . . . . . . . . . . . . . . . . .

0.946

G a l l o n s . . . . . . . . . . . . . . . . . . . . . . . .

Ounces . . . . . . . . . . . . . . . . . . . . . . . .

Pounds . . . . . . . . . . . . . . . . . . . . . . . .

Liters . . . . . . . . . . . . . . . . . . . . . .

Grams . . . . . . . . . . . . . . . . . . . . . .

Kilograms . . . . . . . . . . . . . . . . . . .

Short Tons . . . . . . . . . . . . . . . . . . . . .

Metric Tons . . . . . . . . . . . . . . . . .

3.735

28.349

0.454

0.907

1.356

6.895

Miles Per Gallon . . . . . . . . . . . . . . . .

Kilometers Per Liter . . . . . . . . . .

Miles Per Hour . . . . . . . . . . . . . . . . .

Kilometers Per Hour . . . . . . . . . .

0.425

1.609

TO CHANGE

TO MULTIPLY BY

Centimeters . . . . . . . . . . . . . . . . . . . .

Inches . . . . . . . . . . . . . . . . . . . . . .

Meters . . . . . . . . . . . . . . . . . . . . . . . .

Meters . . . . . . . . . . . . . . . . . . . . . . . .

Feet . . . . . . . . . . . . . . . . . . . . . . . .

Yards . . . . . . . . . . . . . . . . . . . . . .

0.394

3.280

1.094

Kilometers . . . . . . . . . . . . . . . . . . . . .

Miles . . . . . . . . . . . . . . . . . . . . . . .

Square Centimeters . . . . . . . . . . . . .

Square Inches . . . . . . . . . . . . . . .

0.621

0.155

Square Meters . . . . . . . . . . . . . . . . . .

Square Feet . . . . . . . . . . . . . . . . .

10.764

Square Meters . . . . . . . . . . . . . . . . . .

Square Yards . . . . . . . . . . . . . . . .

Square Kilometers . . . . . . . . . . . . . . .

Square Miles . . . . . . . . . . . . . . . .

Square Hectometers . . . . . . . . . . . . .

Acres . . . . . . . . . . . . . . . . . . . . . . .

1.196

0.386

2.471

Cubic Meters . . . . . . . . . . . . . . . . . . .

Cubic Feet . . . . . . . . . . . . . . . . . .

35.315

Cubic Meters . . . . . . . . . . . . . . . . . . .

Cubic Yards . . . . . . . . . . . . . . . . .

1.308

Milliliters . . . . . . . . . . . . . . . . . . . . . .

Fluid Ounces . . . . . . . . . . . . . . . .

Liters . . . . . . . . . . . . . . . . . . . . . . . . .

Pints . . . . . . . . . . . . . . . . . . . . . . .

0.034

2.113

Liters . . . . . . . . . . . . . . . . . . . . . . . . .

Liters . . . . . . . . . . . . . . . . . . . . . . . . .

Quarts . . . . . . . . . . . . . . . . . . . . .

Gallons . . . . . . . . . . . . . . . . . . . . .

G r a m s . . . . . . . . . . . . . . . . . . . . . . . . .

Ounces . . . . . . . . . . . . . . . . . . . . .

Kilograms. . . . . . . . . . . . . . . . . . . . . .

Pounds . . . . . . . . . . . . . . . . . . . . .

Metric Tons . . . . . . . . . . . . . . . . . . . .

Short Tons . . . . . . . . . . . . . . . . . .

Newton-Meters . . . . . . . . . . . . . . . . .

Pound-Feet . . . . . . . . . . . . . . . . . .

1.057

0.264

0.035

2.205

1.102

0.738

Kilopascals . . . . . . . . . . . . . . . . . . . . .

Kilometers Per Liter . . . . . . . . . . . . .

Pounds Per Square Inch . . . . . . .

Miles Per Gallon . . . . . . . . . . . . .

Kilometers Per Hour . . . . . . . . . . . . .

Miles Per Hour . . . . . . . . . . . . . .

0.145

2.354

0.621

PIN: 076652-000

TM 9-2320-272-24-4

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

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