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MAINTENANCE
MANUAL
FOR
COMMANDO
MODEL V-150
DIESEL/AUTOMATIC
VEHICLE SIN
40034 I
MANUFACTURED BY
CADILLAC GAGE COMPANY
WARREN.MICHIGAN
U.S.A.
MANUAL NO. 114101
, { ~ 1979 CADillAC GAGE COMPANY
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MAINTENANCE
MANUAL
FOR
COMMANDO
MODEL V-150
DIESEL/AUTOMATIC
VEHICLE SIN
40034
MANUFACTURED BY
CADILLAC GAGE COMPANY
WARREN,MICHIGAN
U.S.A.
MANUAL NO. 114101
; I'D 1979 CADILLAC GAGE COMPANY
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NOTICE
The information contained
in this manual is proprie-
tary to Cadillac Gage Com-
pany. It is provided to you
only for your use in order
to operate, maintain or
order parts for the Com-
mando V-150 Vehicle in an
efficient manner. Any oth-
er use is expressly unaut-
horized.
Cadillac Gage Company
I
VEHICLE
TABLE OF CONTENTS
Description Page Number
CHAPTER I INTRODUCTION ........... 1
Section 1 GENERAL ................ 1
1-1. Scope ...................... 1
1-2. Description of Coverage ........ 1
Section II DESCRIPTION AND DATA ... 2
1-3. Description .................. 2
1-4. Tabulated Data .............. .4
CHAPTER 2 OPERATION .............. 9
Section 1 SERVICE UPON RECEIPT
OF MATERIAL .................. 9
2-1. General ..................... 9
2-2. Preliminary Services ........... 9
2-3. I nstruments and Controls ....... 9
CHAPTER 3 CLEANING, INSPECTION
AND REPAIR ..................... 11
Section 1 PROCEDURES ............ 11
3-1. General .................... 11
3-2. Cleaning ................... 11
3-3. Inspection .................. 12
3-4. Repair Procedures ............ 13
CHAPTER 4 MAINTENANCE SERVICES.15
Section 1 PARTS, TOOLS AND
EQUiPMENT ................... 15
4-1. Parts ...................... 15
4-2. Tools and Equipment ......... 15
Section II LUBRICATION AND
PAINTING ..................... 16
4-3. General .................... 16
4-4. Lubrication After Unusual
Operating Conditions ......... 16
4-5. Lubricants .................. 16
4-6. Lubrication Equipment. ....... 21
4-7. Points of Lubrication ......... 21
4-8. Painting .................... 30
Section III PREVENTIVE
MAINTENANCE ................ 31
4-9. General .................... 31
4-10. Daily Preventive Maintenance .. 32
4-11. Quarterly, Semi-annual and
Annual Preventive Maintenance.33
4-12. General Procedures .......... 33
4-13. Specific Procedures .......... 33
Section IV TROUBLESHOOTING ..... 41
4-14. Scope ................... .41
4-15. Procedures .. , ............. 41
Description Page Number
CHAPTER 5 MAINTENANCE
INSTRUCTION .................... 67
Section 1 GENERAL ............... 67
5-1. Scope ..................... 67
5-2. Techniques ................. 67
5-3. Special Torque Requirements ... 67
5-4. Cleaning, Inspection and Repair .67
CHAPTER 6 LIMITED VEHICLE
................... 71
Section I HULL ITEMS .............. 71
6-1. Engine Exhaust System ........ 71
6-2. Hull Drain Plugs ............. 72
6-3. Hydraulic Reservoir.' .......... 72
Section II ENGINE INJECTORS
AND VALVES .................. 74
6-4. Injector; Valve and Crosshead
Adjustment. ................ 74
Section III ENGINE LUBRICATION
SYSTEM ....................... 77
6- 5. Replacement of Oil Filter ...... 77
Section IV FUEL SYSTEM ........... 78
6-6. Fuel Requirements ........... 78
6-7. Fuel Pump .................. 79
6-8. Injectors ................... 80
6-9. Fuel Filters ................. 81
6-10. Fuel Selector Valve .......... 82
6-11. Fuel Gage ................. 83
6-12. Fuel Shut-Down Valve ....... 83
Section V AI R INTAKE SYSTEM ..... 85
6-13. Air Cleaner ................ 85
6-14. Air Restriction Indicator ...... 86
Section VI COOLING SYSTEM ....... 87
6-15. Service .................... B7
6-16. Radiator Cap ............... 88
6-17. Water Filter ................ 88
6-18. Fan ...................... 89
6-19. Shroud Ring ........ " ..... 89
6-20. Fan Belts .................. 90
Section VII TRANSMiSSiON ......... 92
6-21. Shift Control Cable
Adjustment ................ 92
6-22. Neutral Starter Switch ........ 92
6-23. Mechanical Actuator
Adjustment ................ 87
6-24. Oil Pressure Checking
Procedure ................. 88
VEHICLE
TABLE OF CONTENTS
Description Page Number Description Page Number
6
0
25. Four Wheel Drive Shift
Section VII DRIVER'S AND
Linkage Adjustment ........ 96
OBSERVER'S HATCHES ......... 115
6
0
26. Range Shift Linkage
7-15. Removal ................. 115
Adjustment ............... 97
7-16. Installation ............... 115
Section VIII TIRES AND WHEELS .... 98 Section VIII DHIVER & OBSERVER'S
6
0
27. Tires and Wheels ........... 98
HATCH PIVOT TYPE ........ , ... 117
Section IX SERVICE BRAKES ...... 101
7-17. Removal ................. 117
6
0
28. Minor Adjustment .......... 101
7-18. Installation ............... 117
6
0
29. Pedal Adjustment .......... 101
Section IX SIDE DOORS ........ , .. 119
Section X PARKING BRAKES ...... 102
7-19. Removal ................. 119
6
0
30. Lever Adjustment .......... 102
7-20. Installation ............... 119
Section XI STEERING SYSTEM .... 102
Section X REAR DOOR ............ 121
6-31. Front Wheel Alignment ...... 102
7-21. Removal ................. 121
Section XII ELECTRICAL .......... 104
7-22. Installation ............... 121
6-32. Starting System ............ 104
7-23. Adjustment ............... 121
6-33. Batteries ................. l 04
Section XI TROOP HATCH ......... 123
6-34. Headlamp ................ 105
7-24. Removal ................. 123
6-35. Taillamp ................. 105
7-25. Installation ............... 124
6-36. Directional Signal Lamp ..... 106
Section XII WINCH HATCH ......... 124
CHAPTER 7 HULL ITEMS ............ 109
7-26. Removal ................. 124
GENERAL
7-27. Installation ............... 124
Section I INTERIOR PANELS &
Section XIII ENGINE HATCHES ..... 125
COVERS ...................... 110 7-28. Removal ................. 125
7-1. Tool Box Cover. ........ , ... 110 7-29. Installation ............... 125
7-2. Tunnel Covers .............. 110 Section XIV ENGINE DOOR ........ 126
7-3. Engine Compartment Wall 7-30. Removal ................. 126
& Covers .. , ............... 110 7-31. Installation ............... 126
7-4. Battery Heat Shield .......... 110 Section XV GUN PORT COVERS .... 127
Section II INTERIOR PADS ......... 111
7-32. Removal ................. 127
7-5. Removal .................. 111
7-33. Inspection ................ 127
7-6. Installation ................ 111
7-34. Installation ............... 127
Section III VIEW BLOCKS AND Section XVI RING MOUNT ......... 128
CRASH PADS .................. 112 7-35. Removal ................. 128
7-7. Removal .................. 112 7-36. Disassembly ............... 128
7-8. Installation............ . .. 112 7-37. Assembly ............. , ... 128
Section IV DRIVER'S SEAT ........ 113
7-9. Removal .................. 113
7-10. Disassembly ............... 113
7-11. Assembly ................. 113
7-12. Installation ............... 113
Section V OBSERVER'S SEAT ...... 114
7-13. Removal ................. 114
7-14. Installation ............... 114
7-38. Installation ............... 12B
Section XVII EXHAUST GRILLE .... 130
7-39. Removal ................. 130
7-40. Installation ............... 130
Section XVIII FUEL FILLER
AND COVER ........ , ......... 131
7-41. Removal ................. 131
7-42. Installation ............... 131
Section VI SIDE AND REAR SEATS .. 115
ii
VEHICLE
TABLE OF CONTENTS
Description Page Number Description Page Number
Section XIX TOWING PINTLE CHAPTER 8 POWER PLANT
AND SHACKLE ................ 132
AND ENGINE ................. 143
7-43. Removal ................. 132
Section I POWER PLANT ........... 143
7 -44. Installation ............... 132
81. Preliminary Instructions ..... 143
Section XX REAR VIEW MIRROR ... 132
8-2. Disconnect Procedures ...... 143
7-45. Removal ................. 132
8-3. Removal ................. 146
7 -46. Installation ............... 132
8-4. Installation ............... 146
Section XXI HYDRAU LlC
Section II ENG INE ................ 148
RESERVOIR .................. 133
8-5. Preparation of Engine ....... 148
7-47. Removal ................. 133
8-6. Engine Disassembly ......... 148
7 -48. Installation ............... 133
8-7. Mount Engine on Engine
Section XXII DOOR AND HATCH
LATCH HANDLES .............. 133
7-49. Removal ................. 133
750. Installation ............... 133
7-51. Adjustment ............... 133
Section XXIII HOLD OPEN
LATCHES ..................... 124
7-52. Removal ................. 134
7-53. Installation ............... 134
Section XXIV DOOR AND HATCH
WEATHERSTRIP SEALS ......... 134
7-54. Removal ................. 134
7-55. Installation ............... 134
Section XXV DOOR AND HATCH
CRASH PADS .................. 135
7-56. Removal ................. 135
7-57. Installation ............... 135
Stand .................... 148
8-8. Cylinder Heads ............ 151
8-9. Flywheel ................. 151
8-10. Connecting Rod and Piston
Assemblies ................ 152
8-11. Camshaft and Main Bearings .. 153
8-12. Cylinder Liners ............ 153
8-13. Cleaning ................. 154
8-14. Cylinder Block ............ 155
8-15. Camshaft Bushings ......... 162
8-16. Cylinder Liner Lower Bore ... 162
8-17. Main Bearing Caps .......... 162
8-18. Water Passages ............. 163
8-19. Tappet Bores .............. 163
8-20. Camshaft Bushings ......... 163
8-21. Main Bearing Cap .......... 163
8-22. Top Surface Refinishing ..... 164
Section XXVI FIXED FIRE
8-23. Machine Lower Bore
EXTINGUiSHER ............... 136
Entry Chamfer ............ 164
7-58. Service After Use ........... 136
Section XXVII HULL REPAIR ....... 139
7-59. General .................. 139
7-60. Method of Repair .......... 139
7-61. Preparation & Repair ........ 139
7-62. Repair Accessible from
Both Sides of Plate ......... 140
7-63. Repair Accessible from Only
One Side of Plate ........... 140
7-64. Patches & Back-Up Plates .... 140
Section XXVIII FUEL TANK
RESEALING ................... 142
7-65. Procedure ................ 142
8- 24. Cylinder Liners ............ 164
8-25. Crankshaft ................ 165
8-26. Bearings, Main and Rod ...... 166
8-27. Crankshaft Thrust Bearings ... 167
8-28. Vibration Damper .......... 167
8-29. Connecting Rods ........... 168
8-30. Piston Rings .............. 170
8-31. Pistons ................... 170
8-32. Camshaft. ................ 171
8-33. Cylinder Head ............. 171
8-34. Disassembly and Testing ..... 171
8-35. Inspection ................ 173
8-36. Rebuilding ................ 178
iii
VEHICLE
TABLE OF CONTENTS
Description Page Number
8-37. Assembly ................. 182
8-38. Rocker Lever and Shaft ...... 183
8-39. Rocker Lever Cover ......... 186
8-40. Crankcase ................ 186
8-41. Tappets .................. 186
8-42. Push Rods ................ 189
8-43. Lu brication System ......... 190
8-44. Oil Pump ................. 190
8-45. Oil Pan .................. 194
8-46.0ilFilter ................. 195
8-47. Full-Flow Paper
Element Filter ............. 195
8-48. Oil Lines ........ , ........ 196
8-49. Oil Cooler ................ 197
8-50. Water Pump .............. 198
8-51. Fan Hub ................. 200
8-52. Cooling (Radiator) Fan ...... 202
8-53. Thermostat & Housing ...... 202
8-54. Water Filter ............... 203
8-55. Vacuum Pump ............. 203
8-56. Engine Assembly -
All Units ................. 204
8-57. Crankshaft & Main
Bearings .................. 204
8-58. Cylinder Liners ............ 206
8-59. Connecting Rods and
Pistons ................... 206
8-60. Gear Housing
Spacer Plate ............... 208
8-61. Camshaft ................. 208
8-62. Tappets .................. 210
8-63. Cylinder Heads ............ 210
8-64. Injection Timing ........... 210
8-65. Injectors ................. 212
8-66. Crossheads ................ 213
8-67. Push Rods and
Rocker Lever Assemblies ..... 213
8-68. Torque Cylinder Head
Cap Screws ............... 213
8-69. Gear Housing .............. 213
8-70. Flywheel Housing .......... 214
8-71. Flywheel Housing Bore ...... 215
8-72. Flywheel Housing Face ...... 215
iv
Description Page Number
8-73. Oil Pump. _ ............... 216
8-74. Front Cover ............... 216
8-75. Oil Pan .................. 217
8-76. Crankshaft Adaptor ......... 217
8-77. Flywheel ................. 218
8-78. Adapter - Flexible
Plate .................... 218
8-79. Vacuum Pump ............. 219
8-80. Fuel Pump ................ 219
8-81. Air Intake Manifolds ........ 219
8-82. Water Crossover Pipe,
Water Connection and
Rear Engine Lifting Eye ..... 219
8-83. Fuel Lines ................ 219
8-84. Air Manifold Crossover ...... 220
8-85. Water Pump ............... 220
8-86. Cylinder Block Water
Header Cover Plate ......... 220
8-87. Camshaft Cover Plate ....... 220
8-88. Front Engine Support ....... 220
8-89. Crankshaft Pulley/
Vibration Damper .......... 220
8-90. Thermostat Housing and
Front Water Crossover. ...... 221
8-91. Front Engine Lifting Eye and/
or Alternator Bracket/
Water Cover Plate .......... 221
8-92. Fan, Fan Hub & Belts ....... 222
8-93. Remove Engine from
Engine Stand .............. 223
8-94. Engine Water Header
Cover Plate ............... 223
8-95. Oil Coller. ................ 223
8-96. Oil Filter & Bracket ......... 223
8-97. Dipstick Tube & Dipstick .... 223
8-98. Exhaust Manifolds .......... 223
8-99. FuelOil Filter and
Bracket .................. 223
8-100. Alternator ............... 224
8-101. Starter Motor ............ 224
8-102. Water Filter .............. 224
8-103. Adjust Crossheads, Injectors
and Valves .............. .224
,-
l
VEHICLE
TABLE OF CONTENTS
Description Page Number
8-104. Electric Connections ....... 228
8-105. Engine Testing ............ 228
8-106. Test Procedure ........... 229
8-107. Break-In Run ............. 229
8-108. Power Check ............. 230
8109. Checks During Run-I n
Test .................... 230
8-110. Paint Engine ............. 232
8111. Engine Storage ........... 232
8112. Preparing a Stored Engine
for Service ............... 234
CHAPTER 9 FUEL SYSTEM .......... 235
Section I F U E L PUMP ............. 235
9-1. Removal ................. 235
9-2. Installation ............... 235
Section II FUEL PUMP DRIVE ...... 236
9-3. Fuel Pump Drive ........... 236
9-4. Oil Seal .................. 236
9-5. Bores in Housing ........... 236
96. Disassembly ............... 236
9 7. Inspection ................ 236
9-8. Assembly ................. 237
99. Drive Pulleys .............. 237
Section II INJECTORS ............. 144
9-3. Removal .................. 144
9-4. Installation ................ 145
Section III AIR INTAKE SYSTEM .... 145
CHAPTE R 10 COO LING SYSTEM ...... 241
Section I ENGINE COOLANT
THERMOSTAT ................. 241
10-1. Removal ......... , ....... 241
10-2. Inspection ................ 241
103. Installation ............... 241
Section II COOLANT HOSES
AND TUBES ................... 242
10-4. Removal ................. 242
10-5. Installation ............... 242
Section III ENGINE COOLANT
PUMP ........................ 243
10-6. Removal ................. 243
10-7. Disassembly ............... 243
10-8. I nspection and Repair ....... 243
10-9. Assembly ................. 244
10-10. Installation .............. 245
v
Description Page Number
Section IV TANDEM HEAT
EXCHANG E R .................. 246
10-11. Removal ................ 246
1012. Installation .............. 246
Section V RADIATOR ............. 246
10-13. Cleaning ................ 246
10-14. Removal ................ 247
1015. Repair .................. 248
1016. Installation .............. 248
CHAPTER 11 POWER TRAIN ......... 249
Section I TRANSMISSION .......... 249
11-1. Removal ................. 249
11-2. Installation ............... 250
Section II GENERAL OVERHAUL
INFORMATION ................ 252
113. Tools and Equipment ....... 252
11-4. Replacement Parts .......... 254
11-5. Careful Handling ........... 259
11-6. Cleaning, Inspection ........ 259
11-7. Wear Limits ............... 263
11-8. Spring Specifications ........ 263
11-9. Torque Specifications ....... 263
Section III DISASSEMBLY OF
TRANSMISSION INTO
SUBASSEMBLIES .............. 264
11-10. Preparation of
Transmission ............. 264
11-11. Removal of Exterior Parts ... 264
11-12. Removal of Control
Valve Body .............. 267
11-13. Removal of Oil Pump
and Forward Clutch ....... 269
11-14. Removal of Fourth and
Third Clutches ............ 270
11-15. Removal of Center
Support Assembly
and Gears ............... 270
11-16. Removal of Second and
First and Reverse
Clutches ................ 272
1117. Removal of Output Shaft
Seal and Bearing .......... 273
VEHICLE
TABLE OF CONTENTS
Description
Section IV INSPECTION AND
REBUILD OF
Page Number
SUBASSEMBLIES .. '" ......... 275
11-18. General Information for
Subassembly Rebuild ...... 275
11-19. Torque Converter
Inspection ............... 275
11-20. Governor Inspection ....... 276
11-21. Control Valve Body ........ 277
11-22. Oil Pump Assembly-
Rebuild ................. 277
11-23. Forward Clutch and
Turbine Shaft - Rebuild .... 281
11-24. Fourth Clutch-
Rebuild ................. 288
11-25. Center Support Assembly-
Rebuild ................. 293
11-26. Planetary Gears and
Shafts - Rebuild .......... 295
11-27. Transmission Case-
Rebuild ................. 304
Section V ASSEMBLY OF
TRANSMISSION FROM
SU8ASSEMBLIES .............. 307
11-28. Selective Components ...... 307
11-29. Installation of First-and-
Reverse Clutch & 8earing ... 309
11-30. Installation of Second
Clutch & Center Support .... 313
11-31. Installation of Rear Bearing
Spacer & Fourth Clutch .... 316
11-32. Installation of Third and
Forward Clutches ......... 319
11-33. Installation of Oil
Pump Assembly ........... 322
11-34. Installation of Output Shaft
Oil Seal ................. 326
11-35. Installation of Valve Body,
Oil Filter and Oil Pan ...... 326
11-36. Installation of Governor,
Mechan ical Actuator and
Torque Converter ......... 330
11-37. Installation of External
Selector Lever ............ 333
11-38. Removal of Rear Bearing .... 333
Section VI PREVENTIVE
MAINTENANCE ................ 333
11-39. Inspection and Care ........ 333
vi
Description Page Number
11-40. Checking Oil Level ........ 334
11-41. Keep Oil Clean ........... 335
11-42. Oil Specifications ......... 335
11-43. Oil, Governor and Screen
and Oil Filter Change
Intervals ................ 335
11-44. Oil, Governor and Screen
and Oil Filter Change
Procedures ............... 335
11-45. Oil Contamination ......... 336
11-46. Breather ................ 337
11-47. Linkage ................. 337
11-48. Shift Speed Adjustments .... 338
11-49. External Lines and
Oil Cooler ............... 341
11-50. Transmission Stall Test ..... 342
11-51. Preservation & Storage ..... 342
11-52. Troubleshooting - Before
Removal for Operation ..... 345
11-53. Troubleshooting --, Before
Removal and During
Operation ............... 345
11-54. Troubleshooting-
Transmission Removed
from Vehicle ............. 345
11-55. Troubleshooting Chart ..... 345
11-56. Oil Pressure Checking
Procedures ............... 345
Section VII SPECIFICATIONS,
DATA CHART ................. 352
11-57. Transmission Oil Filter
Replacement ............. 354
11-58. Governor Filter Screen
Replacement ............. 355
11-59. Parkinq Broke ............ 356
Section VIII FLEXIBLE GEAR
COUPLING .................... 357
11-60. Removal ................ 357
11-61. Installation .............. 357
Section IX TRANSFER ............ 358
11-62. Seal Replacement ......... 358
11-63. Lubricant Reservoir. ....... 360
11-64. Lubricant Pump .......... 360
11-65. Transfer Removal ......... 360
11-66. Disassembly .............. 361
11-67. Inspection and Repair ...... 364
11-68. Assembly ................ 364
11-69. Installation .............. 367
I
VEHICLE
TABLE OF CONTENTS
Description Page Number
Section X PROPELLER SHAFTS ..... 368
1 no. Removal ................ 368
1171. Cleaning ................ 370
1172. Inspection and Repair ...... 370
1173. Installation .............. 370
CHAPTER 12 SUSPENSION .......... 373
Section I SHOCK ABSORBERS,
SPRINGS, AND JOUNCE
BUMPE RS ..................... 373
121. Front Shock Absorber. ..... 373
122. Rear Shock Absorber ....... 374
123. Front Springs ............. 376
12-4. Rear Springs .............. 376
125. Jounce Bumpers ........... 377
Section II AXLE HUBS AND
BEARINGS .................... 378
126. Removal ................. 378
127. Repacking Front Axle
Bearings .................. 378
128. Installation ............... 378
Section III FRONT AXLE .......... 381
129. Removal ................. 381
1210. Disassembly .............. 381
1211. Inspection ............... 383
1212. Assembly ................ 384
1213. Installation .............. 385
1214. Removal ................ 386
1215. Disassembly ............. 386
1216. Inspection ............... 386
1217. Assembly ................ 386
1218. Removal ................ 388
1219. Disassembly .............. 388
1220. Inspection & Repair ....... 392
1221. Assembly ................ 393
1222. Installation .............. 399
CHAPTER 13 BRAKES ............. 0401
Section I PEDAL ASSEMBLY ...... 0401
131. Removal ................ 0401
132. Disassembly .............. 0401
133. Repair .................. 0401
13-4. Assembly ................ 0404
135. Installation .............. 0404
Section II LINES & HOSES ........ 0404
136. Inspection ............... 0404
13 7. Repair .................. 0404
Description Page Number
Section III WHEEL BRAKES ........ 406
138. Removal ................ .406
139. Disassembly .............. .406
1310. Inspection & Repair ...... .406
1311. Assembly ............... 0408
1312. Installation ............. 0408
1313. Major Adjustment ...... ' .. 0409
Section IV BRAKE VACUUM
BOOSTE RS ................... 0410
1314. Removal ............... .410
1315. Inspection .............. .41 0
1316. Installation ............. 0410
Section V VACUUM PUMP ......... All
1317. Removal ............... All
1318. Disassembly .............. 412
1319. Cleaning ............... 0413
1320. Inspection & Repair ...... 0413
1321. Assembly ............... 0417
1322. Bench Test ............. -418
1323. Troubleshooting ......... -419
1324. Installation ............. -419
Section VI PARKING BRAKE ...... -420
1325. Removal ............... -420
1326. Inspection & Repair ...... -420
1327. Installation ............. 0422
1328. Adjustment ............. 0422
CHAPTER 14 STEERING ........... .423
Section I STEERING WHEEL ....... .423
141. Removal ................ .423
142. Installation .............. .423
Section II PITMAN ARM .......... .425
143. Removal ................ .425
14-4. Installation .............. .425
Section III STEERING GEAR ...... .426
145. Removal ............... .426
146. Disassembly .............. .426
147. Cleaning, Inspection & Repair.429
148. Assembly ................ .429
149. Installation .............. .433
1410. Adjustment ............. 433
Section IV HYDRAULIC PUMP
STEERING AND WINCH ........ .434
1411. Removal " .... " .... " .. 434
1412. Disassembly ............. .435
1413. Inspection & Repair ...... .435
vii
VEHICLE
TABLE OF CONTENTS
Descri ption Page Number Description Page Number
14-14. Assembly ............... .437 1527. Repair ................. .465
14-15. Installation ............. .437 15-28. Assembly ............... .466
Section V TIE ROD .............. .438 1529. Testing ................ .467
14-16. Removal ............... .438 15-30. Installation ............. .467
14-17. Installation ............. .438
Section VII HEAOLAMP .......... .468
Section VI DRAG LINK ........... .439 15-31. Removal ............... .468
1418. Removal ............... .439 15-32. Installation ............. .468
14-19. Disassembly ............. .439 Section VI" TAl LLAMP ........... .468
14-20. Assembly ............... .439 15-33. Removal ............... .468
14-21. Installation ............. .439 1534. Installation ............. .468
14-22. Adjustment ............. .440 Section IX DI RECTIONAL
CHAPTER 15 ELECTRICAL ......... .441 SIGNAL LAMP ................ .468
Section I GENERAL. ............. .441 15-35. Removal ............... .468
Section" INSTRUMENT PANEL ... .444 15-36. I nsta lIation ............. .468
15-1. Removal ................ .444
Section X DI RECTIONAL
15-2. Disassembly .............. .444
SIGNAL F LASHE R ............. 469
15-3. Assembly ................ .444
15-37. Removal ............... .469
15.4. Installation .............. .444 15-38. Installation ............. .469
Section "I MASTER SWITCH AND Section XI 01 RECTIONAL
SLAVE RECEPTACLE .......... .446 SIGNAL CONTROL ............ .469
15-5. Removal ................ .446
15-39. Removal ............... .469
15-6. Installation .............. .446
15.40. Installation ............. .469
Section IV BATTERIES ....... '" . .447 Section XII HORN ............... .469
15-7. Removal ................ .447 15.41. Removal ............... .469
15-8. Installation .............. .447 15.42. Installation ............. .469
15-9. Servicing Batteries ......... .448 Section XIII .... DOME AND MAP
Section V STARTER ............. .452 LIGHT ...................... .470
15-10. Removal ............... .452 15.43. Removal ............... .470
15-11. Troubleshooting ... : ..... .452 15.44. Disassembly ............. .470
15-12. Testing ................ .452 15.45. Assembly ............... .470
15-13. Disassembly ............. .454 15.46. Installation ............. .470
15-14. Cleaning ............... .456 Section XIV CIRCUIT BREAKERS .. .472
15-15. Brushes and Holders' ...... .456 15.47. Removal ............... .472
15-16. Armature Servicing ....... .456 15.48. Installation .............. 472
15-17. Assembly ............... .457 Section XV BILGE PUMP .......... .472
15-18. Lubrication ............. .457 15.49. Removal ............... .472
15-19. Pinion Clearance ......... .458 15-50. Disassembly ............. .472
. 15-20. Installation ............. .458 15-51. Assembly ............... .473
Section VI ALTERNATOR ......... .459 1552. Installation ............. .473
15-21. Adjustment ............. .459 Section XVI 01 L PRESSURE
15-22. Removal ............... .460 SENDING UNIT ............... .474
15-23. Troubleshooting ......... .460 1553. Test. .................. .474
15-24. Disassembly ............. .461 15-54. Removal ................ 474
15-25. Cleaning ............... .463 15-55. Inspection .............. .474
15-26. Inspection .............. .464 15-56. Installation ............. .474
viii
VEHICLE
TABLE OF CONTENTS
Description.
Page Number Description
Page Number
Section XVII COOLANT TEM-
16-7. Installation .............. .486
PERATUR SENDING UNIT ...... .475
Section III WI NCH ............... .487
15-57. Test ................... .475
16-8. Removal ................ .487
15-58. Removal ............... .475
16-9. Disassembly .............. .487
15-59. Inspection .............. .4 76
16-10. Inspection .............. .489
15-60. Installation .............. 476
16-11. Assembly ............... .489
Section XVIII PARKING BRAKE
16-12. Installation ............. .491
WARNING LIGHT SWITCH ...... .477 CHAPTER 17 WEAR LIMITS ......... .493
15-61. Removal ............... ,477 Section I ENGINE WEAR LIMITS
15-62. Installation & Adjustment. .. 477 AND SPECIFICATIONS ......... .493
Section XIX WIRING HARNESS .... .478
17-1. Lubricating Oil ........... .499
15-63. Repair .................. 479 17-2. Oil Performance
15-64. Troubleshooting .......... 478 Specifications ............ .499
Section XX CABLE CONNECTORS .. .481 17-3. Break-In Oils ............. .499
15-65. Male Cable Connector ...... 481 17-4. Viscosity
15-66. Female Cable Connector ... ,481 Recommendations ......... .499
15-67. Electrical Receptacle ...... .481 17-5. Grease ................... 500
15-68. Receptacle Connector ..... .481 17-6. Fuel Oil. ................. 500
CHAPTER 16 WINCH SYSTEM ....... .483 17-7. Coolant .................. 501
Section I WINCH CONTROL Section II TRANSMISSION WEAR
VALVE ...................... .483 LIMITS AND SPRING DATA ...... 502
16-1. Removal ................ .483 17-8. Wear Limits Data ........... 502
16-2. Installation .............. .483 17-9. Spring Data ............... 502
Section II WINCH HYDRAULIC 17-10. Transmission Wear
MOTOR ...................... 485 Limits Chart ............. 503
16-3. Removal ................. 485 17-11. Spring Chart ............. 504
16-4. Disassembly ............... 485 17-12. Clutch Plate Wear ......... 504
16-5. Inspection ................ 485 17-13. English-to-Metric
16-6. Assemb Iy ................ .486 Conversions .............. 504
INDEX ........................ 507
ix
11. SCOPE
VEHICLE
CHAPTER 1
Introduction
Section I - GENERAL
This manual is for the information and guidance of personnel maintaining the V150 Com
mando Diesel/Automatic Armored Vehicle. Personnel selected for maintenance functions must be
thoroughly versed in their respective fields as well as with the V150 Commando Diesel/Automatic
Vehicle, and will utilize this manual as a supplement to their prior training and experience.
12. DESCRIPTION OF COVERAGE
This manual contains a brief description of the basic vehicle and each of its major compon
ents, pertinent data and specifications, lubrication services, troubleshooting charts and instructions
for removal, installation and repair of major components.
The vehicle and component orientation terms used in this manual, such as "right", "left",
"front," and "rear", designate the area, side, or location on which items or components are in
stalled. These location terms apply when viewing the vehicle from the rear and facing the driver's
compartment, with the exception of the power plant, which is in reverse position; that is, the engine
fan being the front, and the flywheel the rear of the engine.
1
VEHICLE
Section II - DESCfllPTION AND DATA
13. DESCRIPTION
A. General. The Commando V -150 Diesel! Automatic Armored Car is a maneuverable am-
phibious "four wheel drive vehicle. It is capable of bulldozing barricades or trees, climbing 60 percent
grades, travel cross-country over terrain passable only with highly specialized vehicles and traverse
deep mud, snow or water with equal ease. The Commando can travel over stumps, throu(Jh ditches
and climb vertical wall obstacles up to 24 inches in height. The vehicle's combination of diesel
engine and automatic transmission provides exceptional reliability, low maintenance requirements
and reduced driver training time. The vehicle's run-flat combat tires allow continued mobility even
after being punctured by hostile fire.
-: .'."
B. Hull. The hull is constructed of welded, homogeneous armor plate that provides complete
protection against small arms fire, grenades and anti-personnel mines. All exposed surfaces are
angled for maximum ballistic ricochet. The power plant is completely enclosed in the hull with air
intake and exhaust openings protected by a ballistic pod and grille to allow free air passage. Vision
blocks are located around the sides of the hull. All vision blocks are interchangeable and provide
ballistic protection comparable to the armor. The vehicle has three two-piece doors, one on each
side of the hull and one in the rear. The top half of the doors swing outward and the bottom half of
the doors open downward to provide a step for entering the vehicle. Five hatches are located on the
hull roof, three for personnel and two to gain access to the power plant. The driver's seat can be
adjusted fore, aft, up and down. The vertical adjustment is provided so that the driver can control
the vehicle either with the hatch open and viewing from above, or with the hatch closed and viewing
through the vision blocks. The observer's seat, located to the right of the driver's seat is self-storing
and adjusts to two positions.
C. Engine. Power is supplied by a rear-mounted 504 cubic-inch displacement 4-cycle diesel
engine rated at 202 horsepower. Outside access to the engine and mounted accessories is through
two hatches in the hull roof and one access door in the left side of the hull. Inside access is accom-
plished by removal of engine compartment panels. An hour meter attached to the engine records
hours of engine operation.
D. Transmission. An automatic transmission with four forward speed ranges and one re-
verse range is mounted directly to the engine. Fully automatic shifting in all forward ranges mini-
mizes driver training requirements. Built-in inhibitors prevent harmful downshifts or reverse shifts
unless the vehicle speed is within an acceptable range. A three-element torque convertor provides
smooth, shock-free operation. Rugged planetary gearing and wear-compensating clutches are de-
signed for strength and long life. An external oil cooler is provided.
E. Transfer. The two-speed transfer case, mounted on the hull floor behind the transmis-
sion, is coupled to the transmission output shaft. Output of the transfer drives the front and rear
axles through individual propeller shafts. Transfer is manually controlled by the driver with two
selector levers to the right of the driver's seat. The near lever is for HI!LOW range selection. The
furthermost lever shifts the vehicle IN and OUT of 4-wheel drive. A pump, reservoir and heat
exchanger are provided for lubricant cooling. .
F. Differential. The front and rear carrier drive units are, double-reduction, single speed
units, top mounted over banjo-type differential housings. The differential assemblies are of the
silent locking type providing positive drive to all wheeeis while allowing differential action. The
differential carrier assemblies of the front and rear axles are interchangeable.
2
VEHICLE
G. Axles & Suspension. The front axle has constant velocity universal joints at its steering
knuckles permitting vehicle steering in the conventional manner. The front axle uoiversaljoints are
permanently lubricated. The front axle has boots to prevent water and dirt from entering the
steering knuckle universal joints. The vehicle suspension consists of four semielliptic leaf springs
mounted to the hull. The front and rear axle housings are secured to their respective springs by
U-bolts. A high-control direct-acting shock absorber is used at each wheel.
H. Service Brake System. The vehicle has dual four-wheel, vacuum-assisted, hydraulically
actuated brakes. The dual master cylinder is operated by the brake pedal to actuate the'vacuum-
powered brake boosters which in turn applies hydraulic pressure to the individual brake-shoes
through the wheel hydraulic cylinder. Vacuum to operate the power boosters is supplied by an
engine driven vacuum pump.
I. Parking Brake. The parking brake is hand lever operated and cable actuated. The brake
shoes, backing plate and brake drum are mounted on the rear of the transmission.
"
J. Propeller Shafts. All the drive train propeller shafts have universal joints at each end. In,
addition, each shaft has a sl ip joint that permits telescopic action of the shaft during either oper-
ation or maintenance. The universal joints permit angular movement of shaft during rotation.
Seals on journal bearings prevent loss of lubricant or entry of dirt, water or other foreign matter.
1-' '. ': - . '"
K. Tires. The four 14.50 x 21 tubeless tires used on this/vehicle are self-cleaning, cross-
country type of a special run-flat combat design. At zero these tires will operate up to 50
miles (BOkm) while traveling at moderate speeds and still provide maximum traction under extreme
conditions of both load and temperature. Sidewall construction of the tires is unique in that the tire
will not collapse without air pressure, thereby preventing fold-under and slippage on the rim.
):;',",-..t,, \',,,J.
L. Hydraulic System. An engine-driven dual pump supplies hydraulic pressure for operation
of the winch and power steering system. The pump draws oil from a 5-gallon reservoir tank. The
reservoir fill port is accessible through the engine hatch in the hull roof. A reservoir fluid level sight
gage, replaceable element oil filter and drain valve are accessible through the hatch on the left rear
side of the vehicle.
1. Power Steering. The steering gear assembly with integral power assist is mounted inside
the vehicle hull directly below the steering wheel. Steering inputs are transmitted to the
front steering axle through a pitman arm and drag link assembly. If hydraulic pressure is
lost, the steering gear can be operated manually.
2. Winch. The winch is a worm-geared, jaw-clutch, drum type. Pressurized hydraulic fluid is
constantly cycled from the engine-driven dual hydraulic pump through the winch control
valve and back to the hydraulic reservoir. When the winch control lever is actuated,
hydraulic pressure is applied to the winch motor. A snatch block is furnished, which
doubles line pull for heavy winching requirements.
M. Electrical System. Two 12-volt batteries connected in series supply 24-volt power to the
vehicle. Battery charge is maintained by a 60-ampere belt driven alternator, that is radio frequency
suppressed and is mounted on the left side of the engine. The master electrical ground disconnect
switch and emergency slave receptacle are located inside the vehicle on the right side of the engine
compartment enclosure.
3
VEHICLE
N. Fuel System. The fuel system consists of twin 40-gallon (150 liters) fuel tanks, tank
selector valve and filter assembly mounted in the forward section of the vehicle plus an engine-
driven fuel [Jump and injector system. Fuel tanks are in the front Jeft and right cornersof the
vehicle, all around. Each tank has a fuel level gauge visir,ie from the driver's seat. The fuel
tank selector valve is mounted on the forward compartment wall to the right of the driver. A re-
placeable element fuel filter and water separator assembly is mounted just forward of the fuel
selector valve. Fuel supply and return hoses to the engine are routed down the right side of the
vehicle under the tunnel panels. A check valve is provided in the fuel return line at the engine to
prevent reverse fuel flow.
O. Cooling System. The cooling system consists of a radiator and shroud, belt-driven water
pump, thermostat, cooling fan and shroud, tandem heat ex'Cilanger, coolant filter, plus required
coolant tubes, flexible hoses, fittings and clamps. Outside air is pulled through the top-mounted
radiator and over the engine by the engine-driven fan. Air is exhausted through the air outlet duct
and grille at the rear of the vehicle. The radiator has an integral surge tank for fluid expansion and
keeping the radiator top tank full. To eliminate coolant loss from "after-boil", a tube is connected
from the surge tank to the inlet side of the water pump. This provides a static head on the pump
suction side which relieves excessive pressure caused by high engine temperatures. Coolant flows
from the radiator through a tandem heat exchanger and then into the engine. The heat exchanger,
positioned on the floor of the engine compartment, provides cooling for the transmission and
transfer case lubricants. The water filter by-passes a small amount of coolant through a filtering
and treating element that controls acidity, removes impurities and helps check rust and corrosion
in the cooling system. The spin-on filter element must be replaced periodically.
P. Exhaust System. The exhaust system consists of two exhaust pipes and two mufflers. The
exhaust pipes are mounted directly to the exhaust manifolds. The mufflers are concealed in the air
outlet and clamped securely to the hull.
Q. Bilge Pumps. Two electrically powered bilge pumps are installed within the Commando to
f expel any water that may enter the vehicle during water operations. One bilge pump is located in
the transmission well; the other is located in the engine well. Each pump is capable of pumping 50
gallons (189 liters) per minute. The pumps are controlled by a manual switch located on the in-
strument panel.
R. Pintle, Shackles and Lifting Eyes. Each Commando has a towing pintle, four
towing shackles and four lifting eyes. The towing pintle is mounted to the rear of the hull two
towing shackles are mounted at the front of the vehicle and two towing shackles are located at the
rear of the vehicle next to the spring hanger brackets. A lifting eye is located at each corner of the
vehicle.
S. Fixed Fire Extinguisher System. The dry chemical type fire extinguisher cylinder is
mounted inside the vehicle above the left rear wheel. A double nozzle outlet is mounted in the
engine compartment and connected to the cylinder via a flexible hose. A remove activating control
is mounted to the left of the driver. Once the system is activated, the entire contents of the cylinder
are expended.
1-4. TABULATED DATA
A. Tires:
Type ..................................... Commando Special "run-flat" combat tubeless
Size .................................................................. 14:50 x 21
Ground contact pressure .. __ ..................... 11.5 psi @ 3 inch (7.6 em) soil penetration
21 psi on hard surfaces
Tire pressure ............ _ ................ _ ................. _ ......... normal 45 psi
4
VEHICLE
B. Weight:
Basic Vehicle
Curb (with driver & fuel) ........................................ 16,000 Ibs (7200 kg)
Payload ...................................................... 6,000 Ibs (2700 kg)
Weight distribution - Loaded (GVW)
Front ....................................................... 10,000 Ibs (4500 kg)
Rear ....................................................... 12,000 Ibs (5400 kg)
GVW ....................................................... 22,000 Ibs (9900 kg)
C. Dimensions:
Wheelbase ......... " ........................................... 105 inches (2.67m)
Tread .......................................................... 76.5 inches (1.90m)
Overall length ................................................... 224 inches (5.69m)
Overall width ..................................................... 89 inches (2.26m)
Height over turret ................................................ 110 inches (2.79m)
Height over hull. .................................................. 78 inches (1.95m)
Ground clearance (under hull) ...................................... 25.5 inches (64.8cm)
(under differential) ...................................... ' ........ 15 inches (38.1cm)
Angle of approach ............................................................. 55
0
"
Angle of departure .. ,'::; ...................................................... 53
0
Center of gravity (above floor) ....................................... 18 inches (45.7cm)
(behind front axle) .............................................. 54 inches (1.37m)
D. Performance:
Land
Maximum speed ........................... , ...................... 56 mph (89.6 kph)
Maximum gradient climbable ................................................... 60%
Maximum Side Slope Operation ................................................. 30%
Maximum vertical obstacle ........................................... 36 inches (91cm)
Turning radius ....................................................... 26 feet (7.8m)
Operating range:
Road ....................... " ................................ 500 miles (812km)
Crosscountry .................................................. 400 miles (644km)
Fuel Consumption:
Road ........................................................ 6 mpg (2.5km/liter)
Cross-country ......... , ....................................... 5 mpg (2.1km/liter)
Minimum braking distance:
20-0 mph (32,0 kph) ................................................ 30 feet (9.1 m)
Amphibious:
Maximum speed .................................................. 3 mph (4.8kph)
Turning radius ..................................................... 29 feet (8.8m)
E. Engine:
Type ............................................ 4Cycle Diesel V8, naturally aspirated
Bore ........................................................ 4.625 inches (117mm)
Stroke ......................................................... 3.75 inches (95mm)
Displacement .............................................. 504 cubic inches (8.3 liters)
5
VEHICLE
Compression Ratio ......................................................... 17.0: 1
Gross Horsepower .......................................... 202 @ 3300 rpm (governed)
Gross Torque ......................................... 387 ft. Ibs. (525 Nm) @ 1900 rpm
Idle Speed ............................................................... 650 rpm
Governed Speed ......................................................... 3300 rpm
810ck Type ............................................ 90
0
Vee, replaceable wetsleeve
cylinder liners
Valves ............................................... 2 intake, 2 exhaust per cylinder,
overhead, push rod actuated
Firing Order ........................................................ 1-5-4-8-6-3-7-2
Fuel requirements ...................................................... No.2 Diesel
F. Engine Luhrication System:
Type .................................................... Wet sump (pressurized feed)
Capacity, including filter ...................................... 6 U.S. gallons (22.7 liters)
Oil pump ............................................................... Gear type
Oil filter ................................................ Full flow replaceable element
Remote mount.
G. Engine Cooling System:
Capacity ...................................................... 32 quarts (30.3 liters)
Circulation ....................................................... Centrifugal pump
Fan ................................ _ 19.375 inch diameter (49.2cm) 6 bladed pusher type
Cooling control ....................................... Thermostat 170-185
0
F (77-85
0
C)
Pressure cap ............................................ , ...... 15 psi (1.06kg/sq. cm)
H. Fuel System:
Type ..................................................... PT (pressure time) System
Pump ............................................ Low pressure gear type, engine driven
Injection ................................................. Camshaft actuated injectors
Throttle ....................................................... Fuel pressure control
Governor .... _ .................................... Mechanical (fly-ball type, controls idle
speed, maximllm rpm)
Tanks ......................................................... 2 integral with body
Capacity ..................... _ ............................. 40 gals. (150 liters) each;
80 gals. (300 liters) total
Gages ................................................... 1 each tank; mechanical float
Filter. ................ _ ................. _ ........... Dual, in-line (fuel filter and water
separator) replaceable element
I. Service Brakes:
Type ............. _ ......................................... .4-wheel dual hydraulic
Assist ............................................. _ Vacuum brake booster front & rear
Drum size ............................................................ 16.5" x 5.5"
Lining material ............................ _ ............................... Organic
Master cylinder ................................. Dual (60/40) 1.75-inch (4.45cm) diameter
Wheel cylinder (front) ...................................... 1.75-inch (4.45cm) diameter
Wheel cylinder (rear) ........................................ 2.0-inch (5.08cm) diameter
6
VEHICLE
J. Parking Brake:
Type ............................... Pull handle control, cable actuated brake shoes & drum
Location ............................................ Rear output flange of transmission
1<: Transmission:
Type ........................................................... Automatic 4,speed
Ratios:
First .................................................................... 3.45
Second .................................................................. 2.25
Third .................................................................... 1.41
Fourth ................................................................... 1.00
Reverse .................................................................. 5.02
L. Transfer:
Type ............................................ Two-speed with an in-out engagement
clutch for front axle drive
Ratios ..................... ' ........................ _ ................... 1.75/0.98
M. Axles:
Type ............................................. _ .... Double reduction, .. single speed
Gears ......................... _ ................. _ ............... hypoid and helical
8earings ............................................................. tapered roller
Ratio .................................................................... 8:4.3.1
Maximum Governed Road Speeds:
Transmission Gear Maximum Governed Speed Transfer Range
HI LOW
First (25.6 kph) 16 mph (14.4 kph) 9 mph
Second (40.0 kph) 25 mph (22.4 kph) 14 mph
Third (64.0 kph) 40 mph (35.2 kph) 22 mph
Fourth (89.6 kph) 56 mph (49.6 kph) 31 mph
Reverse (17.6 kph) 11 mph ( 9.6 kph) 6 mph
N. Electrical System:
Waterproof 24 volts, complete radio suppression.
Batteries .................................................. 2 @ 12 volts each in series
Designation ............................................................... 6TN
Amp-hr rating Maximum ........ , ....... , ..................................... 100
Alternator capacity ........................................... Heavy duty unit 60 amps
Charge at engine idle speed (650 rpm) .......................................... 25 amps
Minimum engine rpm for full charge ................................. , ............ 1000
7
VEHICLE
O. Capacities:
Engine lubrication system ..................................... 6 U.S. gallons (22.7 liters)
Engine cooling system ............................................ 32 quarts (30.3 liters)
Fuel. tanks (2) ............................................. .40 gallons (150 liters) each
Transmission ............................. 15 quarts (14.12 liters) excluding external circuit
Transfer case ................................. 7 quarts (6.6 liters) inclUding external circuit
Axles (2) ................................................... 11 quarts (9.9 liters) each
Winch ....................................................... H/4 pints (0.6 liters)
Hydraulic reservoir .............................................. 28 quarts (22.8 liters)
Air cleaner ............................................................... Ory type
P. Winch:
Drive .................................................................. Hydraulic
Gearing ............................................................... 31: 1 worm
Drum size ............................ 3-1/2 inch (8.9cm) diameter; 10 inch (25.4cm) length
Maximum rated !lull (bottom layer) ........................... 10,000 Ibs (4536kg) nominal
Line speed (bottom layer) ............................ 12 feet per minute (3.6m per minute)
Cable ..................................... 3/8" dia high strength steel core swedged cable
Length ......................................................... 160 feet (40.6m)
Q. Steering:
Type ................................................. Rack and pinion, integral power
~ " I h e e l limit .................. _ ......................................... 3-3/4 turns
Pump (flow & pressure relief) ................................. 6 gallons/minute (22.7 liters
per minute) at 1750 psi (86.0 kg
per sq. em) relief
Steering wheel diameter ................. _ ......................... 18 inches (45.7 cm)
Filter (common to winch system) ................................. 25-micron, spin-on type
R. Suspension:
Type ...................................... Solid axles with semi-elliptic multi-leaf springs
with direct acting shock absorbers
S. Bilge Pumps:
Type ..................... __ .... _ .......... _ ............................. Electric
Capacity rating ..................... .46 gpm (174.0 liters per minute) at 6 feet (1.83 m) head
T. Fire Extinguisher:
Operation ................. _ ..... _ ........... : ............ _ ....... Remote actuator
Location ........... _ .......................................... Engine compartment
8
VEHICLE
CHAPTER 2
Operation
Section I - SERVICE UPON RECEIPT OF MATERIAL
2-1. GENERAL
When a new, used or reconditioned vehicle is first received by the using unit it is necessary to
determine whether the vehicle has been properly prepared for service by the supplying organization
and to assure that it is in condition to perform its mission. The services to be performed by the
operator or user are designated in the following paragraph.
2-2 PRELIMINARY SERVICES
NOTE: If vehicle has been driven to the using unit, most of the following procedures should
have been performed.
A. General Procedures.
1. Before attempting to start the engine, it must be checked for seizure of internal
components. To check, first make sure the engine fuel is shut off, then using the starter turn the
engine over several times. If engine turns freely, it may be started. If engine fails to turn over
immediately notify maintenance personnel.
CAUTION: Do not attempt further starting procedure until maintenance personnel have
corrected the malfunction.
2. If any exterior surfaces of the vehicle are coated with rust-preventive compound,
remove it with dry-cleaning solvent or mineral spirits paint thinner, then rinse thoroughly and dry.
B. Specific Services.
1. Lubricate the vehicle in accordance with the Lubrication Chart. Check processing tag
or shipping documents for engine oil and viscosity. If tag states that oil is suitable for 800 km (500
miles) of operation and is of the proper viscosity for local operation, check level but do not change
oil. Lubricate all points regardless of interval.
2. Perform a road test of at least 80 km (50 miles) on all new or reconditioned vehicles.
If the vehicle was driven to using unit, make the road test only long enough for the usual observa-
tion, stopping at least every mile to make observations around the vehicle. Check particularly for
overheated wheel hubs, drive-train components, loose parts and oil leaks.
C. Service After 1600 km (1,000 Miles). When the vehicle has been driven 1600 km (1,000
miles), it will be placed on the preventive-maintenance schedule and will be given the first regular
quarterly preventive-maintenance service.
2-3. INSTRUMENTS AND CONTROLS
Vehicle instruments and controls are illustrated in Vehicle Operator's Manual.
9
VEHICLE
NOTES
10
I
,
1_
,
VEHICLE
CHAPTER 3
Cleaning, Inspection and Repair
Section I - PROCEDURES
31. GENERAL
A. The cleaning, inspection and repair coverage in this manual is limited to normal or com
mon conditions. The procedures listed will be the same for a large percentage of the parts and
components. To avoid repetition of instructions, the general procedures are detailed below. Any
cleaning, inspection and repair procedures which are peculiar to a specific part or component are
covered in the paragraph relating to that item.
B. Parts susceptible to rust, whether new or used, are to be lightly coated with preservative
oil immediately after cleaning, inspection or repair and prior to their assembly.
32. CLEANING
A. Before Disassembly.
1. Preliminary instructions. Before attempting to repair the engine or other large assem
blies, be sure unit is properly supported to prevent tipping or falling. Cover all openings to prevent
entrance of foreign matter into working parts of the assembly.
2. Cleaning instructions. All dirt and grease shall be removed from the assembly prior to
removal of accessories and other components that are attached.
a. Wash using water under pressure to remove as much mud and dirt as possible.
b. Remove grease or oil from all parts of the assembly, using a stiff brush and cleaning
solvent or mineral spirits paint thinner.
c. After the assembly is clean, rinse with water and dry thoroughly with compressed
air. Apply a thin coat of preservative oil to exposed metal surfaces to prevent rusting.
3. General precautions in cleaning.
a. Cleaning solvent or mineral spirits paint thinner is flammable and should not be
used near an open flame. Fire extinguishers should be provided when these materials are used.
WARNING: When using cleaning solvent or mineral spirits paint thinner, the room or area
must be well ventilated.
b. These cleaners have a drying effect on the skin and if used without gloves may
cause cracking, irritation, or inflammation of the skin.
c. Do not allow cleaning solvent, engine fuels, or lubricants to contact rubber cover
ings as they cause deterioration.
d. The use of gasoline, benzene (benzol) or diesel fuel oil for cleaning is strictly
prohibited.
11
VEHICLE
B. After Disassembly.
1. Clean all detail components thoroughly.
2. Clean and prepare for use all ball bearings and roller bearings by soaking the bear-
ings for a period of time in medium hot oil. This will loosen and remove all the old grease along
with accumulated contaminates. After the oil bath rinse bearings in kerosene. Use a wire mesh
basket for soaking and rinsing. After cleaning coat bearings with lubricant and wrap tightly in oiled
or waxed paper pending inspection and assembly.
NOTE: Do not spin bearings with compressed air.
3. Remove all gaskets or parts of gaskets from mating surfaces, using a putty knife or
suitable scraper. Be careful to avoid scratching or gouging the surface metal when removing gaskets.
4. Clean all inner and outer surfaces of castings and all areas subject to oil and grease
with dry-cleaning solvent or mineral spirits paint thinner. Remove sludge and gum deposits, using
a stiff brush. Blowout all tapped holes with compressed air. After cleaning, dry, using compressed
air.
WARNING: Particles blown by compressed air are hazardous. Make certain the air stream
is directed away from the user and other persons in the area.
5. Clean all oil seals, electrical cables, and flexible hoses with soap and water.
CAUTION: Do not allow dry-cleaning solvent or mineral spirits paint thinner to come in
contact with seals, cables, or flexible hoses. These cleaners cause leather, rubber, and syn-
thetic materials to dry out and lose flexibility.
6. Clean all oil and air passages with a wire or probe to break up sludge or gum deposits.
Clean the passages by flushing with dry-cleaning solvent or mineral spirits paint thinner. After clean-
ing, dry the passages with compressed air.
7. Clean all parts that have been repaired.
8. Protect all parts from accumulation of dust and grit after cleaning.
3-3. INSPECTION
A. General. Engine, transmission, transfer unit and axle components must be thoroughly
examined to determine if they are in a serviceable condition. Such expressions as "adjust if neces-
sary" or "replace if necessary" are not used in the specific procedures. It is understood that when-
ever inspection reveals the need of adjustments, repairs or replacements, the necessary action will
be taken. General inspection and repair procedures are listed in the following paragraphs.
B. Castings. Inspect all castings for cracks, giving particular attention to areas adjacent to
studs, and pipe plugs. Look for local discoloration on mating surfaces as it often indicates persis-
tent oil, fuel or exhaust leaks. Test all mating flanges with a straightedge or surface plate. Remove
all burrs or raised metal. Replace any part if cracks are evident or mating surface is warped. If
damage is suspected, inspect all ferrous (cast iron, steel, etc.) castings for cracks with magnaflux
equipment and all non-ferrous (aluminum) castings for cracks, using a magnifying glass and a strong
light. Inspect machine surfaces for nicks, burrs or raised metal. Mark any damaged areas for repairs.
12
VEHICLE
C. Studs, Screws and Nuts. Inspect all studs, screws and nuts for damaged threads. Minor
damage to threads may be corrected with a standard thread chaser and/or tap. I f severe damage is
evident, replace the affected part. Bent or loose stud or studs showing any evidence of stretch must
be replaced.
D. Tapped Holes. Inspect all tapped holes for damaged threads. Clean up threads with a tap.
E. Ball Bearings. Inspect ball bearings for smoothness of operation, flat spots, brinnelling of
the race and corrosion.
F. Gears.
NOTE: Clean and protect pending inspection. Good judgment is required to determine need
for replacement.
1. Inspect all gears, using magnaflux equipment. When such equipment is not available
use die penetrant, a magnifying glass and a strong light.
2. Inspect all gear teeth for wear due to improper meshing, sharp fins, burrs and galled
or pitted surfaces.
G. Bushing-type Bearings.
1. Check all bushings and bearings for secure fit in their respective casting or mating part
and for evidence of heating indicated by discoloration of the bushing or bearing surface.
2. Inspect bUshings and bearings for wear, burrs, nicks or outof-round condition.
3. Check for dirt in lubrication holes or grooves of bushings and bearings. Holes and
grooves must be clean and free from damage to insure proper lUbrication.
4. Inspect thrust faces of bearings for wear and damage. Wear can be determined by
temporarily assembling mating parts and checking end play with a feeler gage inserted between
the thrust faces.
3-4. REPAIR PROCEDURES
NOTE: Upon completion of any repairs, clean and protect parts in accordance with para-
graph 3-2.
A. All repairs must be of highest quality. Makeshift or temporary repairs are not permitted,
except in extreme emergencies. Reference should be made to specific components for detailed
repair instructions.
B. The principal purpose of repairs is to salvage parts which would otherwise be scrapped.
The decision as to whether a part is to be repaired or not rests upon the following three factors:
1. Practicality of the repair. If the part cannot be repaired and returned to an equal-to-
new condition, repair should not be attempted.
2. Cost of the repair. Compare the cost of the repair with that of a replacement part.
If the repair cost factor does not favor the repair, the part should be discarded.
13
VEHICLE
3. Availability of replacement parts. If service parts are not available or in short supply,
every effort should be made to salvage as many parts as possible, disregarding any of the other
governing factors.
C. General.
1. Studs. Correct minor damage with a standard thread chaser. Studs with stripped
threads, bent or loose studs, or studs showing any evidence of stretching must be replaced.
2. Tapped holes. If there is any indication of stripped or damaged threads, or if stud has
been removed for looseness, tap hole to the next larger oversize stud if available. Helli-coil or thread
inserts may be used to repair permanently damaged internal screw threads in cast iron, steel alumi-
num, magnesium, and plastic.
3. Brackets and supports. Brackets and supports that are cracked, excessively bent, or
collapsed should be discarded.
4. Gasket "0" rings and seals. Gasket 0 rings, seals and/or packings that have been re-
moved, deteriorated, worn, torn or damaged must be replaced.
5. Welding. Welding is permitted where properties are retained and the part is not
weakened.
14
4-1_ PARTS
VEHICLE
CHAPTER 4-
Maintenance Services
Section I - PARTS, TOOLS AND EQUIPMENT
Maintenance parts are listed in the Commando V-150 Diesel/Automatic Parts Manual Part
Number 114102.
4-2. TOOLS AND EQUIPMENT
Common tools carried on the Commando V-150 Diesel/Automatic are listed in Table 4-1.
Special tools are listed in Tables 4-2 and 11-1.
Table 4-1. ON VEHICLE TOOL LIST
PART NO.
110281-1
110258-1
101258-8
101258-9
101258-11
101260
101267-1
110420
109803
109805
109806
111154
111155
110298
111156
111157
111386
112250
Tool Kit
Consisting of
DESCRIPTION
Wrench Set Open End (1/4" to 1-1/4")
Grease Gun with Extension and Adaptor
Tire Pressure Gage (4 to 50 PSI)
Hinge Handle, 1/2" Square Drive
Lug Wrench, Wheel (1-1/2")
Tool 8ag, Canvas
Jack, Hydraulic - 8 Ton Capacity
Breaker Bar - 54.0 in. long
Screwdriver Set
Hex, Key Set (.050 to 3/16")
Oil Can
Pliers, Cutter (6 ")
Trouble Light Assy.
Extension 1/2" Drive 10" Long
Auto Wrench 9" Long
Spout, Flexible
Kit, Repair Tubeless Tire
15
PART NO.
206824
206825
206572
200995
200990
206826
206827
201165
206828
206829
200979
206830
206831
206832
200965
206833
206834
206835
200983
200985
RC150A
206836
206837
206838
206839
206840
206841
200989
200988
203681
200969
201180
206842
206843
206844
206845
200970
206846
206847
206848
206849
206850
200980
206851
206852
200977
206853
206854
206855
206856
VEHICLE
Table 42. SPECIAL TOOLS (ENGINE)
DESCRIPTION
Kit, Valve Seat Insert
Set, Valve Seat Cutter
Compressor, Valve Spring
Block, Gauge
Gauge, Piston Groove Wear
Fixture, Rod Checking
Fixture, Head Holding
Puller, Standard
Mandrel, Water Pump
Tester, Spray Angle
Adaptor, Torque Wrench
Machine, Valve Facing
Machine, Valve Seat Grinding
Set, Block and Mandrel
Tool Kit, Maintenance
Tool, Burnishing
Tool, Ball Seating
Mandrel, Oil Seal
Kit, Mechanics Hand Tool
Kit, Torque Wrench
Compressor, Ring
Test Stand, Injector
Spacer, Crosshead
Gauge, Connecting Rod Bushing
Reamer, Valve Guide
Mandrel, Locating
Arbor Set, Valve Guide
Expander, Piston Ring
Fixture, Injecting Timing
Puller, Flywheel Adaptor
Wrench, Fan Hub
Plate, Head Lifting
Driver, Cup Plug
Driver, Valve Guide Seal
Brush, Fuel Passage
Expander, Injector Sleeve
Wrench, Fan Hub
Gauge, Rod Ring
Cutter, Injector Seat
Driver, Front Cover Seal
Driver, Gear Cover Seal
Tool, Protrusion Checking
Tool, Fuel Pump Adjusting
Detector, Injector Leak
Kit, Chromate Water
Sight Glass, Fuel Tube
Repair Kit, Water Hole
Tester, Hydrostatic
Clamp, Hydrostatic Tester
Stand, Valve Spring Compressor
16
PART NO.
206857
206858
206859
206860
206861
206862
206863
206864
206865
206866
206867
206868
200966
200984
206869
203668
206870
201170
206871
206872
206873
206874
206875
206876
203675
200994
200993
206877
206878
206879
206880
206571
200998
200992
206881
206882
201169
206883
206692
206884
206559
206885
206886
206887
200974
201179
206888
206889
201167
206890
VEHICLE
Table 42. SPECIAL TOOLS (ENGINE) - Continued
DESCRIPTION
Driver, Tachometer Seal
Plate, Hydrostatic Tester
Cutter, Counterbore
Wrench, Crowfoot
Extension, Plunger
Wrench, Torque
Plate, Valve Spring Compressor
Driver, Valve Seat Staking
Tool, Valve Seat Staking
Kit, Flowmeter
Extractor, Dowel Pin
Filter, Oil Sampling
Gauge, Belt Tension
Tool, Injector Torquing
Tool, Lube Hose Assembly
Detector, Magnaflux Crack
Bore Bar, Main Bearing
Puller, Main Bearing Cap
Holding Tool, Injector Sleeve
Driver, Oil Seal Wear Sleeve
Driver, Connecting Rod Bushing
Kit, Etching
Fixture, Tappet Roller Pin
Driver, Rocker Shaft Plug
Clamp, Cylinder Liner
Bridge, Liner Puller
Puller, Lines
Driver, Valve Guide
Mandrel, Lube Cooler
Mandrel, Thermostat Seal
Driver, Injector Sleeve
Driver Set, Crankshaft Bushing
Driver, Cylinder Liner
Sleeve, Piston Ring Compressor
Puller, Injector Sleeve
Socket, Impact
Puller, Coupling Half
Gauge, Concentricity
Counterbore, Liner
Tester, Valve Vacuum
Fixture, Engine Lifting
Extractor, Valve Seat
Boring Tool, Lower Liner
Puller, Injector
Wrench, Torque
Wrench, Torque
Kit, Convertible Tool Holder
Tool, Chamfer
Attachment, Dial Gauge
Puller, Tachometer Drive
17
PART NO.
206891
2068'2
201177
200987
200986
200972
200996
206893
206894
206895
201174
206896
206897
201173
200971
206898
206899
206900
206901
206902
206903
206904
206905
206906
206907
VEHICLE
Table 4-2_ SPECIAL TOOLS (ENGINE) - Continued
DESCR IPTION
Plate, Engine Stand Adaptor
Gauge, Orifice
Kit, Torque Wrench
Kit, Torque Wrench
Kit, Torque Wrench
Wrench, Oil Filter
Kit, Dial Bore Gauge
Puller, Crankshaft Gear
Stand, Injector Assembly
Wrench, Air Compressor
Puller, Injector
Tester, Valve Spring
Kit, Injector Stand Audit
Stand, Engine Rebuild
Kit, DCA Coolant
Tool, Injector Testing
Set, Fillet Gauge
Puller, Water Pump Impeller
Kit, Pressure
Cutter, Tube
Spanner, Ratchet
Mandrel, Water Pump Bearing
Separator, Water Pump Bearing
Adaptor, Injector Sleeve
Mandrel, Water Pump Seal
18
VEHICLE
Section II - LUBRICATION AND PAINTING
4-3. GENERAL
This section prescribes lubrication procedures as to locations, intervals, and proper materials
to be used when servicing the vehicle. Refer to Figure 4-1 for specific lubrication instructions.
A. Service Intervals. Reduce service intervals specified on the lubrication order by lubricat-
ing more frequently to compensate for abnormal conditions, extreme temperatures, prolonged
periods of high-speed operation, continuous operation in sand or dust, operation in water or mud.
Anyone of these conditions may cause contamination and destroy the protective qualities of the
lubricants.
B. Changing Grades of Lubricants. Lubricants are prescribed according to temperature
ranges. Change the grade of lubricants whenever weather forecasts indicate air temperature will be
consistently in the next higher or lower temperature range.
4-4. LUBRICATION AFTER UNUSUAL OPERATING CONDITIONS
A. Lubrication After Water Operations.
1. Immediately after the vehicle emerges from the water continue to operate the engine
so as to drive out any water which may have entered the system. At the end of the operating day
return vehicle to organizational maintenance for inspection of components to determine if lubri-
cants have been contaminated. Check the axle oil levels. Drain and change the oil if the presence of
water is detected.
2. Lubricate all external chassis points to cleanse bearings of water and grit.
B. Lubrication After Operation Under Dusty and Sandy Conditions.
After operation under dusty or sandy conditions, clean and inspect all external lubrication
points for fouled lubricants and relubricate as necessary.
CAUTION: A lubricant contaminated by dust or sand becomes an abrasive mixture that
causes rapid wear of parts.
4-5. LUBRICANTS
A. An engine lubricating oil (OE) that conforms to American Petroleum Institute (API)
classification CC (MIL-L-2104) is recommended for the Commando diesel engine. API classifica-
tions CC/SC and CC/CD are also satisfactory. The maximum sulphated ash content of any oil
used must not exceed 1.85%.
1. Viscosity Recommendations - Engine
Ambient Temperatures
-10 to 30
0
F (-23 to _10 C)
20 to 60
0
F (-7 to 16
0
C)
40
0
F (4
0
C) and above
19
Viscosity
lOW
20-20W
30
VEHICLE
NOTE: For operation in areas where ambient temperatures are consistently below 10
0
F
(-23
0
C) and there is no provision for keeping engines warm during shutdown, SAE multi-
viscosity grades 10W-20, 10W-30 or 10W-40 may be used. Multigraded lubricating oils may
be used where there are wide variations in ambient temperatures if they meet the API per-
formance specifications and ash content limits shown above.
B. Transmission Fluid. MiI-L-2104 Grade 10 (OE-10) to latest specification is recommended
when prevailing ambient temperatures are above -10
0
F (-23
0
C). Hydraulic Transmission Fluid
Type C3 or Dexron Transmission Fluid are acceptable substitutes. When prevailing ambient temper-
atures are from 0
0
F to -65
0
F (-18
0
C to -54
0
C) MIL-L-10295 to latest specification is recom-
mended.
NOTE: If auxiliary preheating equipment is available and the sump temperature can be
raised to -10
0
F (-23
0
C), it is recommended that MI L-L-2104 Grade 10 oil be used. When
changing to oil of different grade, thoroughly flush system with grade oil to be used before
refilling.
CAUTION: DO NOT use MIL-L-10295 when the ambient temperature is consistently above
-10
0
F (-23
0
C).
C. 8rake Fluid (HB), heavy duty type fluid conforming to SAE 70R-1 or SAE 70R-3 speci-
fications.
1. Wagner Lockheed 21 B.
2. Shell Donax B.
3. Texaco Super Heavy Duty 8970.
4. Caltex Brake Fluid J1703.
D. Gear oil (GO), multi-purpose gear lubricant for API service G L-4 SAE 90 or SAE 90-140.
1. Elco 28 SAE 90.
2. Shell Spirax HD90 or EP 90.
3. Esso Gear Oil LC.
4. Texaco Gear Lube HD 90 952.
5. MIL-L-2105.
E. Lubricating Oil, General Purpose (PL), conforming to MI L-L-3150 for oil can lubrication
points.
F. Chassis Grease (GAA), a high-quality, multi-purpose grease that can also be used in the
wheel bearings when necessary.
1. Mobile Grease Special.
2. Shell Retinax AM.
3. Texaco Marfak All Purpose 1917
20
VEHICLE
4. Shell Darina AX.
5. Shell Retinax H (wheel bearing grease).
NOTE: Do not mix lubricants of different makes.
G. The lubrication charts contain lubrication points, intervals and proper lubricants (Figure
41 ).
H. Lubricate vehicle more frequently than specified if vehicle is used in extreme conditions
of mud, sand, dust, moisture, temperature and prolonged periods of operation.
I. After fording or amphibious operations, lubricate all external chassis points, winch cable
and inspect axles for water.
J. Oil Can Lubricating Points. Every 1,000 miles, 1,600 kilometers, monthly or as operating
conditions require, lubricate door and hatch hinges and latches, control clevises and pins, control
levers, linkages, cables and seat moving parts.
46. LUBRICATION EQUIPMENT
Clean lubrication equipment before and after using. Operate the lubricating guns and equip-
ment carefully and in such a manner as to insure proper distribution of lubricant.
4-7. POINTS OF APPLICATION
Lubricants, fittings, level plugs, oilers, and oil holes are shown in Figures 4-1 and 4-2. Wipe
clean all fittings, plugs, oilers, etc., and their surrounding surfaces, both before and after lubricant
is applied.
21
VEHICLE
ITEM LUBRICANT CAPACITY PROCEOURE
INTERVAL
(whichever occurs first)
-
FLUIDS
A-WINCH GO-gO 1% Pts. CHECK AND FILL
MONTHLY or 1600 KM 11,000 MILES)
(0.6 Liter) DRAIN AND REFILL
ANNUALLY or 19200 KM 112,000 MILES)
WINCH CABLE OE.30 CLEAN AND COAT
SEMI-ANNUAL or 9600 KM 16,000 MILES)
8-BRAKE MASTER HB A/R CHECK AND FILL
QUARTERLY or 4800 KM 13,000 MILES)
CYLINDER
AXLE GO-90 OR 22 Pts. CHECK AND FILL
MONTHLY or 1600 KM (1,000 MILES)
GO-140 (10.4 Liters) DRAIN AND REFILL
ANNUALLY or 19200 KM 112,000 MILES)
D-TRANSFER GO-90 70ts. CHECK AND FILL MONTHLY or 1600 KM 11,000 MILES)
(6.7 Liters) DRAIN AND REFILL
ANNUALLY or 19200 KM 112,000 MILES)
E-REAR AXLE GO-90 22 Pts. CHECK AND FILL
MONTHLY or 1600 KM 11,000 MILES)
GO-140 10.4 Litersl DRAIN AND REFILL ANNUALLY or 19200 KM 112,000 MILES)
F-ENGINE OE 6 Gal. CHECK AND FILL
DAILY
122.8 Liters) DRAIN QUARTERLY or 4800 KM 13,000 MILES
AND REFILL
or 200 HOURS
OE-lO 220ts. CHECK AND FILL MONTHLY or 1600 KM 11,000 MILES)
RESERVOIR (26.6 Liters) ANNUALLY or 19200 KM (12,000 MILES)
H-TRANSMISSION OE-lO or 11 Ots. CHECK AND FILL MONTHLY or 1600 KM 11,000 MILES)
Type C-3 or
(10.5 Liters) DRAIN AND REFILL ANNUALLY or 40000 KM 125,000 MILES)
Dexron
Figure 4-1, Lubrication Chart (1 of 3)
22
VEHICLE
ITEM PROCEDURE INTERVAL
(Whichevp.r Occurs First)
FILTERS
J-ENGINE AIR CHECK AIR CLEANER RESTRICTlON- QUARTERLY or 9600 KM (6,000 MILES)
SERVICE ELEMENT AS REQUIRED. OR WHEN INDICATQR IS RED
KENGINE OIL CHANGE ELEMENT QUARTERLY or 9600 KM (6,000 MILES)
or 200 HOURS
L-WATER CHANGE ELEMENT QUARTERLY or 9600 KM (6,000 MILES)
or 200 HOURS
M-FUEL FUEL FILTER - DRAIN AS REQUIRED BY WEATHER
(DUAL ELEMENT)
ACCUMULATED WATER AT CONDITIONS AND AMOUNT OF
BOTTOM PLUG WATER USUALLY ENCOUNTERED
DRAIN & CHANGE ELEMENT QUARTERLY or 9600 KM (6,000 MILES)
or 200 HOURS
WATER SEPARATOR - DRAIN AS REQUIRED BY WEATHER
ACCUMULATED WATER AT CONDITIONS AND AMOUNT OF
BOTTOM PLUG WATER USUALLY ENCOUNTERED
DRAIN & CHANGE ELEMENT SEMIANNUALLY or 19200 KM (12,000
MILES) or 400 HOURS
N-TRANSMISSION OIL - CHANGE ELEMENT AND ANNUALLY or 40000 KM (25,000 MILES)
INTAKE PIPE SEAL RING
GOVERNOR SCREEN - CLEAN
ANNUALLY or 40000 KM (25,000 MILES)
OR REPLACE
O-HYDRAULIC CHANGE ELEMENT
ANNUALLY or 19200 KM (12,000 MILES)
RESERVOIR
A c o
L
K
M
B
"
N G 0
Figure 41, Lubrication Chart Fluids and Filters (2 of 3)
23
VEHICLE
ITEM LUORICANT NUMBER OF FITTINGS
INTERVAL
(Whichever Occurs First)
GREASE
A-WINCH GAA 2 MONTHLY or 1600 KM 11.000 MILES)
WINCH DRUM GAA 2 SEMIANNUAL or 9600 KM 16.000 MILES)
B-FRONT SPRINGS GAA 6 MONTHLY or 1600 KM 11.000 MILES)
C-FRONT WHEEL BEARII,GS GAA CLEAN AND REPACK ANNUALLY or 19200 KM 112.000 MILES)
AND STEERING KNUCKLES
D-PROPELLER SHAFTS AND GAA 11 MONTHLY or 1600 KM 11.000 MILES)
UNIVERSAL JOINTS
E-TRANSFER CASE COUPLER GAA 4 SEMIANNUAL or 9600 KM 16.000 MILES)
F-REAR SPRINGS GAA 6 MONTHLY or 1600 KM 11.000 MILES)
G-TOWING PINTLE GAA 2 MONTHLY or 1600 KM 11.000 MILES)
H-TIE ROD GAA 2 MONTHLY or 1600 KM 11.000 MILES)
J-STEERING KINGPINS GAA 6 MONTHLY or 1600 KM 11.000 MILES)
AN D KNUCKLES
K-DRAG LINK GAA 2 MONTHLY or 1600 KM 11.000 MILES)
L-STEERING GEAR GAA
ANNUALLY or 19200 KM 112.000 MILES)
BEARING CAP
A B c
"
o o
F
G
K
"
Figure 4-1. Lubrication Chart - Grease (3 of 3)
24
VEHICLE
ENGINE Oil DIPSTICK ~
ENGINE
ENGINE Oil LEVEL DIPSTICK
Oil DRAIN
PLUG
ENGINE Oil FilTER
FRONT
WATER SHUT-OFF
VALVE (HIDDEN)
ENGINE OIL Fill
ENGINE FUEl FIL TERS
ACCESS COVER
eNGINE WATER FILTER TRANSMISSION
Figure 42. Lubrication Points (1 of 5)
25
TRANSMISSION
DIPSTICK
VEHICLE

GQVERNOH SCREEN (\ -=-':01:t17<fJ.@
{REMOVE OIL PAN ---t kJ./;4'I

ilL - '9
7
74
.., OIL FILTER
(RfMOVE OIL PAN)
DRAIN PLUG
TRANSMISSION
TRANSFER
DRIVE SHAFT
fITTINGS
FRONT AND REAR DRIVE SHAFTS
\11//
fl{M
GREASE FITTINGS \ @
(REMOVE PLUG _ D'
EACH SLEEVEI

'W..,, ___ @

TRANSMISSION COUPLER
TRANSFER CASE
DRAIN PLUG {HIDDEN!
TRANSFER
INTERMEDIATE DRIVE SHAFT
Figure 4-2. Lubrication Points (2 of 5)
26
VEHICLE

FRONT AXLE
KINGPIN

\ --- '\
INSTAll LUBE fiTTING "" { \


REMOVE
PLUGS
'-."
FRONT AXLE JOINTS
SPRING
FIllI NG -'---IOi'l.-IJ
'
\
,
STEERING
KNUCKLE
______
- :-----.. -- ---
--------
- -
AXLE Fill ............
AND LEVEl ...........
AXLE
DRAIN
FRONT AND REAR AXLE
FRONT WHEEL BEARINGS
SPRING
REAR FITTINGS
SPRING BUSHINGS, FRONT SPRING BUSHINGS, REAR
Figure 4-2. Lubrication Points (3 of 5)
27

WHEEl
BEARING
VEHICLE


STEERING
HYDRAULIC SYSTEM (STEERING AND WINCH)
:7 --r======;--r==l\
F,lllER PLUG @ ({lb

lie /LEVEL
=
WINCH
-CABLE -------'(1
WINCH
BRAKE MASTER CYLH>JDER
RESERVOIR FILL
AND DIPSTICK
HYDRAULIC SYSTEM (STEERING AND WINCH)
-- --
-
WINCH DRUM
FITTINGS
-
C)


\
lJ
\
WINCH
Figure 4-2. Lubrication Points (4 of 5)
28
TOWING
PINTlE
FITTINGS
VEHICLE
WINCH
PINTlE
WINCH DHAIN
c.
1--__ 1
ENGINE AlA CLEANER
Figure 42. Lubrication Points (5 of 5)
29
VEHICLE
4-8. PAINTING
NOTE: The upper surface of the vehicle is painted with a non-skid paint. If this paint is not
available, clean sand can be sprinkled onto fresh paint and allowed to dry. After a second
coat of paint is applied over the sand, the surface will have the same characteristics as no-
skid paint.
A. Painted surfaces showing evidence of peeling, cracking, blistering, checking, scaling or
after welding of the vehicle shall be stripped and refinished.
CAUTION: Never use acid preparations in removing old paint or cleaning rusted areas. High
hardness armor used in the construction of the vehicle will become prone to cracking when
exposed to acid even for short periods of time. All surface preparation should be done by use
of mechanical means (sanding or wire brush) or with an alkaline solution.
B. All surface requiring paint shall be finished with an appearance indicative of good work-
manship (e.g., free from runs and sags). Luster and color shall be uniform.
C. The inner side of all door and hatches or parts of the vehicle that open outward shall be
painted the same color as the exterior of the vehicle hull.
D. All interior surfaces not exposed to outside view shall be painted with a non-reflective
type paint.
E. All walk and foot surfaces shall be covered with a non-skid type paint.
F. There should not be any overspray on glass, plastic, canvas or informational items such as
decals or data plates. Rubber or resilient items may be oversprayed unless the paint interferes with
the proper function of the item or if the paint is detrimental to the material.
G. Battery boxes and associated parts shall be painted with black acid proof paint.
H. The interior surface of electrical components shall be coated with glyptol varnish.
I. Electrical cable and harness assemblies may be painted except for quick-disconnect fit-
tings, plug assemblies, receptacle assemblies, connector assemblies and terminals. Components
where paint will interfere with the successful functioning must be kept free from paint. Radio
wiring or equipment will not be painted.
30
VEHICLE
Section III - PREVENTIVE MAINTENANCE
49. GENERAL
The pu rpose of preventivemaintenance services are to detect first signs of electrical and
mechanical failures of assemblies in the vehicle, and to ensure that appropriate corrective action is
taken before expensive and timeconsuming repairs or replacements are required. Preventivemain
tenance services are based on frequent inspections and services accomplished by the driver and/or
maintenance personnel. All services listed in Tables 43 through 4-4 are general in nature and can
only isolate the unit that requires further maintenance. When a malfunction is detected, it will be
necessary to refer to the appropriate section of the troubleshooting table to locate and correct
individual component failure.
A. The following general procedures apply to preventivemaintenance services and to all
inspections, and are just as important as the specific procedures.
B. Inspection to see if items are in good condition, correctly assembled or stored, secure,
not excessively worn, not leaking, and adequately lubricated apply to most items irJthe preventive
maintenance and inspection procedures. All checks that are pertinent to an item (including support
ing, attaching, or connecting members) will be performed automatically as general procedures in
addition to any specifics given.
1. Good condition. I nspection for good condition is usually a visual inspection to deter
mine if the unit is safe or serviceable. Good condition is explained further as meaning: Not bent
or twisted, not chafed or burned, not broken or cracked, not bare or frayed, not dented or collap
sed, not torn or cut, not deteriorated.
2. Correctly assembled. Inspection of a unit to see if it is correctly assembled or stored
is usually a visual inspection to see if the unit is in its normal position in the vehicle and if all its
parts are present and in their correct relative positions.
3. Excessively worn. Excessively worn is understood to mean worn beyond serviceable
limits or likely to fail, if not replaced before the next scheduled inspection. Excessive wear of mat
ing parts or linkage connections is usually evidenced by too much play (lash or lost motion). It
includes illegibility as applied to markings, data and caution plates, and printed matter.
C. Where the instruction "tighten" appears in the procedures, it means tighten with a
wrench, even if the item appears to be secure (using the correct torque when quoted).
D. Such expressions as "adjust if necessary" or "replace if necessary" are not used in the
specific procedures. It is understood that whenever inspection reveals the need of adjustments
repairs or replacements the necessary action will be taken.
E. Any special cleaning instructions required for specific mechanisms or parts are contained
in the pertinent section. General instructions are as follows:
1. Use drycleaning solvent or mineral spirits paint thinner to clean or wash grease or oil
from all parts of the vehicle.
2. A solution of one part greasecleaning compound to four parts of drycleaning solvent
or mineral spirits paint thinner may be used for dissolving grease and oil from engine blocks, chassis,
and other parts. Use cold water to rinse off any solution which remains after cleaning.
31
VEHICLE
3. After the parts are cleaned, rinse and dry them thoroughly. Apply a lightgrade oil to
all polished metal surfaces to prevent rusting.
4. When authorized to install new parts, remove any preservative materials, such as rust
preventive compound, protective grease, etc.; prepare parts as required (oil seals, etc.); and for those
parts requiring lubrication, apply the lubricant prescribed in the lubrication order.
F. General precautions in cleaning are as follows:
WARNING: Drycleaning solvent or mineral spirits paint thinner is flammable and should
not be used near any open flame. Fire extinguishers should be provided when this material is
used. Use only in well-ventilated places. The battery ground cable should be disconnected and
taped.
NOTE: This cleaner evaporates quickly and has a drying effect on the skin. If used without
gloves, it may cause cracks in the skin and, in the case of some individuals, a mild irritation
or inflammation.
CAUTION: Avoid getting petroleum products, such as dry-cleaning solvent or mineral
spirits paint thinner, engine fuels, or lubricants on rubber parts; they will deteriorate the
rubber.
WARNING: The use of diesel fuel oil, gasoline, or benzene (benzol) for cleaning is pro-
hibited.
4-10. DAILY PREVENTIVE MAINTENANCE
A. Responsibility. Maintenance performed by the user, driver, or crew of the equipment
includes care, cleaning, preservation and lubrication. Those services listed in Tables 4-3, 4-4 and 4-5
require the services of a trained mechanic and must not be attempted by the driver or crew without
prior authorization.
B. Daily Services. Each vehicle will be inspected and serviced by its assigned driver each day
it is operated. This service is divided into three parts:
1. Beforeoperation service. This is a brief service to determine if the vehicle is ready for
operation. Essentially, it is a check to see if conditions affecting the vehicle's readiness have changed
since the last after-operation service.
2. During-operation service. This service consists of observing any unsatisfactory per-
formance. While driving, the operator should be alert for any unusual noises or odors, abnormal
instrument readings, steering irregularities, or any other indications of malfunction of the vehicle.
All malfunctions detected while driving should be investigated and corrected, if possible, or report-
ed to supporting maintenance personnel.
3. After-operation service. The purpose of the after-operation service is to prepare the
vehicle to operate immediately when its use is required again. This is a basic daily service for all
vehicles. Afteroperation service is particularly important because, at this time, the driver should
inspect the vehicle thoroughly to detect any malfunctions that may have developed during opera-
tion. Components that require inspection or service, while they are still at operating temperatures,
should be checked as soon as possible after parking the vehicle. Operational defects that have occur-
red during the day must be corrected. Malfunctions on which the driver is not authorized to per-
form maintenance, must be reported to the maintenance personnel.
32
VEHICLE
NOTE: Refer to Daily Preventive-Maintenance Chart outlined in the operator's manual.
4-11. QUARTERLY, SEMIANNUAL AND ANNUAL PREVENTIVE MAINTENANCE
A. Purpose. The preventive-maintenance services ensure the correct adjustment, securing,
and assembly of all components of the vehicle. Necessary replacement, cleaning, lubrication and
protection of parts and/or assemblies will be accomplished by the organizational mechanics as
required, to give reasonable assurance of troublefree operation until the next preventive-mainten
ance service is performed.
B. Intervals. The mileage that a vehicle travels is the principal criterion for the frequency of
preventive-maintenance service. Operation under adverse conditions, such as extreme temperature,
dust, or mud, may require preventive-maintenance services to be performed more frequently. Per-
form all preventive-maintenance services more frequently when environmental and atmospheric
conditions indicate the need. The quarterly preventivemaintenance services are performed every 3
months or at every 4800 km (3,000 miles) whichever occurs first. The semlannual preventive
maintenance services are performed every 6 months or at every 9,600 km (6,000 miles), whichever
occurs first. The annual preventive-maintenance services are performed every 12 months or at every
19,200 km (12,000 miles), whichever occurs first. Certain engine preventive-maintenance services
are based on number of hours of engine operation as well as time and mileage intervals. A meter
attached to the engine records the number of hours of engine operation.
412. GENERAL PROCEDURES
A. Automatically Applied. All of the general procedures given will be followed. Mechanics
should be so thoroughly trained in these procedures that they will apply them automatically at all
times in the performance of their duties.
B. Operator's Participation. The driver or crew usually accompanies the vehicle and assists
the maintenance mechanics in the performance of these services.
C. Unwashed Vehicle. The driver or crew should present the vehicle for a scheduled pre
ventive-maintenance service in a reasonably clean condition. However, washing of the vehicle should
be avoided immediately prior to an inspection, since certain types of defects as loose parts and oil
leaks may not be evident immediately after washing.
413. SPECIFIC PROCEDURES
Specific procedures for performing each item in the quarterly, semiannual and annual pre
ventive-maintenance services on the vehicle are given in Tables 4-3, 4-4 and 45 in accordance with
procedures outl ined.
33
VEHICLE
Table 4-3. QUARTERLY PREVENTIVE-MAINTENANCE CHECKS AND SERVICES
(performed in addition to the DAILY PREVENTIVE-MAINTENANCE CHECKS
AND SERVICES listed in the Operator's Manual)
Sequence No. Item to be Inspected
1 Transmission
2 Transfer
3 Brakes (service and park)
4 Steering assembly
34
Procedure
PRIOR TO ROAD TEST
Note: When the tactical situation does
not permit a full road test, check those
items which require little or no movement of
vehicle.
ROAD TEST
Test neutral starter switch by observing
that starter engages only when trans-
mission is in neutral. Observe that selec-
tor lever moves easily and gives a crisp
feel in each gear range. Operate vehicle
through normal speed range and note
that transmission upshifts and downshifts
smoothly through all gears. Check for
unusual noises, excessive slippage or
abnormal transmission oil operating
temperature.
Operate transfer in H I and LOW range and IN
and OUT of four-wheel drive. Observe any
unusual stiffness of shifting levers, tenden-
cy to slip out of gear, unusual noise, or
excessive vibration. Excessive vibration of
shifting levers may indicate loose mount-
ings.
Check braking effect, feel, side pull, noise,
chatter, pedal travel, hand control and
effort necessary to apply. Make service
stops noting other unusual conditions
Notice if vacuum assist is operating
satisfactorily. Release parking brake
and check to see that brake band is free
and completely released. Stop vehicle on
an approximate 30% grade or 15 incline
and apply parking brake to see if it
holds the vehicle.
With vehicle moving straight ahead, steering
wheel free play should not exceed 1
inch. Notice if there is any tendency to
wander, shimmy, or pull to one side.
Turn steering wheel through its entire
range and note proper operation of power
assist and absence of binding.
VEHICLE
Table 4-3. QUARTERLY PREVENTIVEMAINTENANCE CHECKS AND SERVICES - Continued
Sequence No.
5
6
7
8
Item to be Inspected
Steering knuckles
Power train, wheels
and hull
Hubs drums, axles, power
train
Leaks
35
Procedure
Inspect steering knuckle boots to see that
they are not cut or torn. I f a boot is
torn, replace boot. When replacing a torn
boot, clean, inspect, and lubricate all
affected components.
While operating the vehicle notice if it has
normal power and acceleration in each
speed. Listen for any unusual noise when
engine is under load. Speed up vehicle in
any driving gear to see if it will reach,
but not exceed, governed speed specified
for that gear. At all times during road
test, be alert for unusual or excessive
noise that may indicate looseness,
defects or deficient lubrication in
these components.
AFTER ROAD TEST
I mmediately after road test, feel accessible
units cautiously. An overheated wheel hub
and brakedrum indicate an improperly
adjusted, defective, or dry wheel bearing
or a dragging brake. An abnormally cool
condition ind icates an inoperative brake.
An overheated gearcase indicates internal
maladjustment, damage, or lack of
lubrication. Cautiously: feel each axle
differential and carrier, transmission,
and transfer for overheating. Drain plugs
of the front and rear axle differential
housings should be loosened and the
housings checked for water.
I f water is found, the housing should be
drained of water and refilled to proper
level with specified gear lubricant.
Check propeller shafts for universal
joint wear, missing weights or other
irregularities. Check four-wheel drive
linkage for proper adjustment, full
engagement, and full disengagement.
Check engine oil, fuel and cooling systems,
transmission, transfer case and all
other components carrying fluids, oil,
or grease. Make general observations in
the engine compartment and hull for oil,
water, fuel and exhaust leaks.
VEHICLE
Table QUARTER L Y CHECKS AND SERVICES - Continued
Sequence No.
9
10
11
12
13
14
15
I tern to be Inspected
Battery specific gravity
Battery voltage and alter-
nator regulator
Engine fuel injectors
and valves
Throttle linkage
R ad iator and cap
Manifold
Exhaust manifolds,
pipes and mufflers
36
Procedure
Make hydrometer test of electrolyte in each
cell (para.
Check batteries for damaged case, terminals,
or cell cover plates. Check for
short circuit. If any of these
conditions are noted, replace batteries.
Test battery voltage using
circuit tester (para. 15-9).
Test alternator-regulator with low-voltage
circuit tester (para. 15-24). Battery
condition and charging system may be
checked by referring to these values and
verified at Battery Generator Indicator.
Adjust fuel injectors and valves after first
3 months or 6,000 miles or 200 hours of
engine operation; thereafter at annual,
30,000 mi Ie or 1,000 hour intervals.
Inspect linkage for proper operation and
absence of excessive wear. Check travel
to be sure linkage operates throttle from
stop to full throttle.
Inspect core, shell, hoses, cap and gasket,
and surge tank, noticing particularly if
the radiator is blocked with foreign
material or if fins are bent. Test oper-
ation of filler cap (para. 6-16). Observe
coolant level and examine for oil
temination. Test coolant with a hydro-
meter to see if it contains sufficient
antifreeze (-25
0
F) during cold weather.
If need is indicated, drain radiator and
block, clean, flush, refill, and add inhibitor
unless antifreeze which contains inhibitor
is used. Check security of radiator
ings and hose connections.
Inspect; look particularly for signs of
leakage at pipe
connection.
Inspect; listen for excessive or unusual
noises and look for exhaust leaks.
Tighten mountings.
VEHICLE
Table 4-3. QUARTERLY PREVENTIVE-MAINTENANCE CHECKS AND SERVICES - C.ontinued
Sequence No.
16
17
18
19
20
21
22
23
24
I tem to be Inspected
Air cleaner
Crankcase
Oil filter
Water filter
Water pump, fan, pulleys,
and belts
Oil pressure
Fuel tanks
Fuel filters
Service brakeshoes,
linkage, anchor pins, and
cylinders
37
Procedure
Remove air cleaner. Remove wraparound outer
element. Inspect inner element for
damage or contamination. For extremely
dusty operations, clean as often as
required. If renovating a sunk vehicle,
replace both elements.
Drain only when hot after operation. Refill
with OE crankcase grade to full mark on
dipstick, Run engine a few minutes and
recheck oil level.
While crankcase is drained, remove oil filter
elenlent, clean inside of case and install
new element.
Close water shutoff valves at both ends of
engine. Replace water filter element. Open
both shut-off valves.
Inspect pulleys and fan for alignment, fan
for even tip clearance and belts for
tension. Check water pump for leaks.
Operate engine until it reaches normal oper-
ating temperature. Reduce engine speed
to idle and record oil pressure. A compar-
ison of pressure at idling speed with
previous readings will give an indication
of progressive wear of oil pump, bearings,
shafts, etc. These readings are more
accurate and reliable when taken immedi-
ately after an oil change.
I nspect fuel and vent lines and connections.
Loosen (approximately 7 turns) but do
not remove drain plugs from bottom of
fuel tank to let condensation drip from
tanks.
Remove fuel filter elements, clean inside
of container and reassemble using new
elements.
Test brake for freedom of action. Inspect
brake lines, master cylinder and vacuum
hydraulic booster. Adjust brakes.
VEHICLE
Table 4-3. QUARTERLY PREVENTIVE-MAINTENANCE CHECKS AND SERVICES ~ Continued
Sequence No.
25
26
27
28
29
30
Item to be Inspected
Tires
Springs and shock
absorbers
Lubrication
Hull
Pintle and shackles
Winch
38
Procedure
Rotate and match tires according to degree of
wear. All wheel nuts, rims and side rings
should be in serviceable condition and
secure. Check that wheel turning stops
are secure.
Inspect suspension springs, jounce bumpers,
and shock absorbers for damage and
security. Shock absorbers should be warm
to medium hot after use.
Lubricate vehicle in accordance with the
lubrication instructions of Figure 4-1.
Inspect entire hull for general condition and
security. Test operation of all operable
items.
Inspect pintle and towing shackles. Test
operation of pintle assembly and note if
it locks securely.
Inspect winch, hydraulic motor, winch
drum, wire rope and hydraulic lines.
Test operation of winch.
VEHICLE
Table 44. SEMIANNUAL PREVENTIVEMAINTENANCE CHECKS AND SERVICES
(performed in addition to the DAILY and QUARTERL Y PREVENTlVEMAINTENANCE).
Sequence No.
2
3
4
5
6
7
8
Item to be Inspected
Lubrication Points
Winch Cable
Winch Drum
Fuel Filter
Transfer Coupler
Hull
Hull Drain Plugs
Transmission air
breather
Procedure
Perform all lubrication procedures of
Figure 4-1.
Clean and coat with OE-3D.
Lube with GAA Lube.
Drain and Change element.
Lube with GAA Lube.
Inspect entire hull for general condition
and paint as necessary (Refer Para 4-8).
Remove, clean threads, grease and replace.
Remove and replace.
J9
VEHICLE
Table 4-5. ANNUAL PREVENTIVE-MAINTENANCE CHECKS AND SERVICES
(performed in addition to the QUARTERLY and SEMIANNUAL PREVENTIVE MAINTENANCE)
Sequence No.
2
3
4
5
6
Item to be Inspected
Air cleaner
Front wheel bearings
Propeller shaft center
bearing
Front wheel universal
joints
Alternator
Starter
Procedure
Perform all before operation checks and
services listed in Operator's Manual and all
quarterly and semiannual
preventive-maintenance services.
Remove air cleaner. Replace both the
wraparound outer and inner elements.
Disassemble wheel bearings, clean, dry,
repack and assemble.
Disassemble propeller shaft center bearing,
clean, dry, repack and reassemble.
Remove the front axle shaft assemblies from
the axle housing. Clean and inspect the
axle assemblies and steering knuckles.
Recoat the U-joints with grease and
reassemble.
I nspect terminals for corrosion and loose
connections and wiring for frayed
insulation. Check mounting bolts for
tightness and drive belt for proper align-
ment and wear. Check shaft for looseness
which indicates excessive bearing wear.
Check brushes for wear. Replace as
necessary.
Inspect wiring terminals for corrosion and
loose connections and mounting bolts
for tightness. I nspect brushes and com-
mutator for wear. Repair or replace
as necessary.
40
VEHICLE
Section IV - TROUBLESHOOTING
4-14. SCOPE
A. This section contains troubleshooting information and tests for locating and correcting
some of th troubles that may develop in the vehicle. Each symptom of trouble or malfunction
given for an individual unit or system is followed by a list of probable causes of the trouble and
corrective actions necessary to remedy the malfunction. Refer to the index for specific component
maintenance and repair procedures. Item numbers in the corrective action column refer to mal
function numbers within the troubleshooting table.
B. This technical manual cannot cover all possible troubles and deficiencies that may occur
under the many conditions of operation. If a specific malfunction is not covered herein, proceed to
isolate the system in which the trouble occurs and then locate the defective component. Use all the
senses to observe and locate troubles. Do not neglect the use of any test instruments such as ohm
meter, voltmeter, ammeter, test lamp, hydrometer, and pressure and vacuum gages that are avail
able. Standard automotive theories and principles of operation apply in troubleshooting the vehicle.
The troubleshooting procedures contained herein will be performed by a trained mechanic with the
assistance of the vehicle operator. The mechanic will question the vehicle operator to obtain the
maximum number of observed symptoms. The greater the number of symptoms of trouble that can
be evaluated, the easier will be the isolation of the primary cause or defect. Since the operator of
the vehicle, in most instances, can describe malfunctions only in terms of unsatisfactory vehicle
performance, trained personnel should be capable of analyzing the operational symptoms to deter
mine the primary cause of the malfunction.
C. Good operational trouble analysis depends on logical follow through from effect or major
malfunction to the primary cause before corrective measures (remedies) may be applied. This sec
tion has been arranged to assist personnel in systematic followthrough to isolate the primary causes
of malfunction. The test and remedies provided herein are governed by the scope and level of main
tenance available to the using organization.
415. PROCEDURES
A. General. Table 46 lists possible malfunctions that may be experienced during the oper
ation of this vehicle or its components. Each malfunction is followed by a list of probable causes
that may be considered in determining the action necessary to correct the malfunction. Probable
causes are listed in their order of probability and should be considered in that manner during
troubleshooting.
B. Operator/Crew Performance. The troubleshooting malfunctions, detection of probable
causes, and corrective actions that may be performed by the operator and/or crew are designated
by a circled letter ( 0 ' ' () , etc.) in the appropriate columns. Should these steps, when
taken, fail to correct the malfunction, maintenance personnel must be notified.
CAUTION: The operator will perform only those checks and corrective actions circled.
All other checks must be performed by a trained mechanic "assisted" by the operator.
C. Maintenance Mechanic Performance. All troubleshooting diagnoses listed in Table 46
may be performed by the maintenance mechanic. However, the operator should have performed
all pertinent circled items prior to requesting assistance; therefore, the mechanic is responsible only
for the uncircled items. The electrical schematics will assist the maintenance personnel in determin-
ing the probable causes of a malfunction with a particular electrical circuit of the vehicle.
41
VEHICLE
Table 4-6. TROUBLESHOOTING
Item
No. Malfunction Probable Causes Corrective Action
ENGINE
1 . Engine fails to a. Master switch off.
G
Turn master switch on.
crank when
starter switch b. Loose battery cables or
CD
Tighten battery cables and/or
is held on. wiring connections. wiring terminals.
c. Batteries discharged.
@
Recharge or replace batteries.
d. Defective starting
@
Troubleshoot starting system
system. (item 20) for inoperative
starter.
e. Mechanical seizure of e. If starting system (d above)
parts or hydrostatic is in satisfactory
lock.
operating condition,
trouble may be caused by
mechanical seizure of
parts or hydrostatic lock.
Find and correct cause of
seizure or lock.
2.
Engine cranks, a. Fuel tanks empty.
G
Fill fuel tanks.
but is hard to
start or fails b. I mproper setting of
@
Set fuel tank selector valve on
to start. fuel tank selector
tank having fuel.
valve.
c. Restricted air intake. c. Check and service air cleaner.
d. Water in fuel d. Check for presence of water
at water separator and fuel
filter. Drain water and
replace filter elements.
e. Poor quality fuel.
G
Provide fuel of known quality.
f. Air leaks in fuel f. Check suction lines for leaks.
suction lines.
Tighten fittings, repair or
replace lines.
g. Restricted fuel lines;
@
Check fuel I ines for restric-
stuck drain valve.
tions. Check operation of
drain valve.
h. I ncorrect valve and/or h. Adjust valves and/or injectors.
injector adjustment.
i. Plugged injector spray i. Repair or replace injector.
holes.
42
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Callses Corrective Action
j. Long idle periods.
CD
Do not idle engine excessively.
Shut engine down when
vehicle is stopped for long
periods.
k. Defective fuel pump. k. Check output pressure of
pump. Replace if required.
I. Worn engine internal
CD
Check engine for signs of wear:
parts, (high mileage oil consumption, no oil
vehicles). pressure at idle, noise oper-
ation, piston blow-by.
Blowby can be detected by
running engine with oil
filler cap removed. Distinct
puffs of vapor indicate
blow-by. I s usually accom-
panied by high oil
comsumption.
3. Engine starts, a. I mproper setting of fuel
0
Refer to Item 2b.
but stalls
tank selector valve.
immediately
after starting. b. Water in fuel. b. Refer to Item 2d.
c. Poor quality fuel.
@
Refer to Item 2e.
d. Air leaks in fuel d. Refer to Item 2f.
suction lines.
e. External or internal e. Check fuel pressure lines,
fuel leaks. injectors for signs of leak-
age. Replace leaking
components.
f. Defective fuel pump. f. Refer to Item 2k.
g. Throttle linkage in- g. Inspect linkage for proper
operative or out operation. Adjust linkage.
of adjustment.
h. Defective governor. h. Inspect governor for proper
assembly of components.
Replace.
43
VEHICLE
Table TROUBLESHOOTING - Continued
Item
No. Mqlfunction Probable Causes Corrective Action
4. Engine misses. a. Water in fuel. a. Refer to Item 2d.
b. Poor quality fuel. b. Refer to Item
c. Air leaks in fuel c. Refer to Item 2f.
suction lines.
d. Restricted fuel lines d. Refer to Item 2g.
stuck drain valve.
e. Injectors out of e. Refer to Items 2h & 2i.
ment or spray holes
plugged.
f. Long idle periods.
CD
Refer to Item 2j.
g. I ntake or exhaust
@
Check engine for signs of
valves leaking; internal wear or damage.
worn or broken See Item 21.
piston rings.
5. Excessive exhaust a. Restricted fuel lines:
G
Refer to Step 2g.
smoke at idle. stuck drain valve.
b. Faulty injectors. b. Check injectors for plugged
spray holes, incorrect
injector cups, cracked
injector body or cup.
Repair or replace faulty
injectors.
c. Long id Ie periods.
8
Refer to Item 2j.
d. I ncorrect va Ive andl d. Adjust valves andlor
or injector timing. injectors.
e. Worn internal engine
0
Refer to Item 21.
parts--piston rings
cylinder liners,
blown head gasket.
Excessive exhaust a. Restricted air intake. a. Refer to Item 2c.
smoke under
@
load. b. High exhaust back Check exhaust system for
pressure. restrictions.
c. Poor quality fuel.
8
Refer to Item 2e.
44
VEHICLE
Table 4-6_ TROUBLESHOOTING Contlflued
Item
No. MalfunctlOll
Probable Causes Corrective Action
d. Restricted fuel lines:
@
Refer to Item 2g.
stuck drain valve.
e. Faulty injectors. e. Refer to Item 5b.
t. Long idle periods.
CD
Refer to Item 2j.
g. High altitude and/or
CD
Operate vehicle in lower gear
hot weather range as needed to avoid
operation. smoke.
h. Incorrect valve and/ h. Refer to Item 2h.
or injector adjustment.
i. Worn internal engine
CD
Check engine for signs of
parts .. piston rings, cylinder wear or damage.
cylinder liners, Refer to Item 21.
blown head gasket.
7. Low power or a.
Poor quality fuel.
0
Refer to Item 2e.
loss of power.
b.
Restricted air intake. b. Refer to Item 2c.
c. Engine oil level
(0
Reduce oil to proper level.
too high.
d. Dirty fuel fi Iters. d. Inspect filter elements and
replace as required.
e. Air leaks in fuel e. Refer to Item 2f.
suction lines.
t. Restricted fuel lines;
CD
Refer to Item 2g.
stuck drain valve.
g. External or internal g. Refer to Item 3e.
fuel leaks.
h. Faulty injectors. h. Refer to Item 5b.
i. Scored or worn I. Replace fuel pump.
fuel pump gears.
j. Throttle linkage j. Refer to Item 3g.
inoperative or out
of adjustment.
45
VEHICLE
Table 46. TROUBLESHOOTING - Contll1l1cd
Item
No. Malfunction Probable Causes Corrective Action
k. Incorrect governor k. Adjust governor high speed
setting. setting.
I. Long idle periods.
CD
Refer to Item 2j.
rn. I ncorrect valve andl rn. Refer to Item 2h.
or injector
adjustment.
n. Worn engine internal
8
Check engine for signs of
parts. internal wear. Refer to
I tern 21.
8. Engine does a. Water in fuel. a. Refer to Item 2d.
not reach
governed rpm. b. Throttle linkage out b. Refer to I tern 3g.
of adjustment.
c. Restricted fuel lines;
8
Refer to Item 2g.
stuck drain valve.
d. I ncorrect governor d. Refer to Item 7k.
setting.
9. Excessive fuel a. Restricted air intake. a. Refer to Item 2c.
consumption.
@
b. Poor quality fuel. Refer to Item 2e.
c. Engine oil level too
8
Refer to Item 7c.
high.
d. Restricted fuel lines;
@
Refer to Item 2!1.
stuck drain valve.
e. Injectors defective or e. Check injectors for adjust
out of adjustment. ment, plugUed spray holes,
incorrect injector cups,
cracked injector hody or
cup, damf.lued Clip "0"
ring.
/. External or internal
[ . Refnf to
[uclleaks.
46
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
I telll
No. Malfunction Probable Causes Corrective Action
g. Vehicle overloaded
CD
Check operational use of
or operated vehicle.
improperly.
h, Worn engine internal
@
Refer to Item 21.
parts.
i. Transmission malfunction i. Refer ahead to Item 39.
(overheating) .
10. Erratic idle a. Air leaks in fuel a. Refer to Item 2f.
speeds. suction lines.
b. Throttle linkage b. Refer to Item 3g.
inoperative or out
of adjustment.
11. Engine surges a. Air leaks in fuel a. Refer to Item 2f.
governed rpm. suction lines.
b. Throttle linkage in- b. Refer to Item 3g.
operative or out
of adjustment.
12. Excessive lube a. Oil leaks.
0
Check engine for visible
oil consumption.
signs of oil leakage.
b. Oil level too high.
@
Refer to Item 7c.
c. Wrong grade of oil
0)
Follow lube oil recommen-
for weather dati ons in paragraph
conditions. 4-5.
d. Worn engine internal d. Refer to Item 21.
components.
13. Sludge in engine a. Dirty oil filter. a. Inspect oil filter. Change
oil pan.
element as needed.
b. Oil needs changing.
@
Check maintenance records
to be sure oil change
recommendations are being
followed. Change oil if
required.
c. Long idle periods.
0)
Refer to Item 2j.
d. Engine operating
@
Check coolant temperature
temperature too high.
gauge during normal
veh icle operation.
47
Item
No. Malfunction
14. Oil dilution a.
b.
c.
d.
e.
15. Low lubricating a.
oil pressure.
b.
c.
d.
e.
f.
16. Engine a.
overheats.
b.
c.
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Probable Causes
External or internal
fuel leaks.
Oil leaks.
Long idle periods.
Engine operating
temperature too
low.
Faulty injectors.
Crankcase low or
out of oil.
Wrong grade of oil for
weather conditions.
Dirty oil filter.
Engine operating
temperature too
high.
Clogged oil cooler.
Worn engine internal
parts.
Low radiator coolant
level.
Engine hatches and/or
access doors open.
Leaks in engine
compartment walls.
48
Corrective Action
a. Refer to Item 3e.
@ Refer to Item 12a.
8 Refer to Item 2j.
@ Refer to Item 13d.
e. Refer to Item 5b.
0
Check level. Add oil as
required.
@
Follow lube oil recommen-
dation in paragraph
4-5.
c. Refer to Item 13a.
@
Check coolant temperature
gauge during normal vehicle
operation. If temperature is
beyond normal range,
inspect cooling system for
leakage, faulty thermostat,
loose fan belts, faulty water
pump, low coolant level.
e. Clean oil cooler.
CD
Refer to Item 21.
0
Fill radiator with 50/50
solution of coolant.
@
Close hatches and access
doors securely.
8
Check all panels and walls
for secure attachment.
VEHICLE
Table 46. TROUBLESHOOTING ~ Continued
Item
No. Malfunction Probable Causes Corrective Action
d. Loose or broken drive
@
Check fan and water pump
belts. drive belts. Check for
correct tension. Adjust
or replace belts.
e. Defective thermostat. e. Remove thermostat and
inspect for corrosion or
sticking valve.
f. Crankcase low or out
CD
Refer to Item 15a.
of oil.
g. Oil contamination.
@
Check for dilution of oil
that would prevent proper
lubrication.
h. Coolant leaks. h. Inspect cooling system for
leaks. Tighten loose
assembly bolts or clamps.
Replace leaking radiator,
hoses or water pump.
i. Clogged cooling I. Clean radiator and flush cool-
system. ing system. Install new
water filter element. Do not
use antifreeze containing
anti-leak additive as this
may clog the water filter.
J.
Defective water pump. j. Replace water pump.
17. Fuel knock a. Poor quality fuel.
0
Refer to Item 2e.
b. Air leaks in fuel b. Refer to Item 2f.
suction lines.
c. I ncorrect valve and/or c. Refer to Item 2h.
injector adjustment.
d. Coolant temperature d. Remove and inspect thermo-
too low. stat for proper operation.
18. Mechanical a. Loose or damaged
0
Check condition of damper
knock or vibration damper. and tighten attaching
vibration. hardware.
b. Loose engine

Tighten mounting bolts.
mounting bolts.
49
Item
No. Malfunction
19. Odor of exhaust
fumes in
driver's
compartment.
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
Probable Causes Corrective Action
8 Refer to Item 21. c. Worn engine
internal parts.
EXHAUST SYSTEM
Warning: Exhaust fumes 0 Troubleshoot fan and belts for
are extremely proper operation.
dangerous and can
cause loss of life. Inform maintenance personnel.
Evacuate vehicle
if possible. If not,
ventilate vehicle
thoroughly until
evacuation can be
effected. Replace
defective parts as
soon as possible.
Note: Because of the unique cooling system of the vehicle, it is practically impossible for
exhaust fumes to enter the driver's compartment. However, if exhaust fumes enter the driver's
compartment, either the fan belts are broken (which will also cause engine overheating) or the
vehicle is being driven at a low rate of speed with wind blowing from the rear of the vehicle.
STARTING SYSTEM
20. Inoperative, a. Loose mounting bolts.
G
Tighten mounting bolts.
noisy, or
sluggish b. No electrical current

Service and test batteries
starter.
reaching starter.
and cables to be sure they
are in satisfactory
working condition, all
connections are tight and
that full power is
available.
c. Defective starter. c. Test starter by operating it
with use of starter switch.
Starter must rotate freely.
I f starter does not rotate,
or if teeth do not
contact flywheel, replace
or repair starter.
d. Defective starter drive d. Engage starter switch. If
gear or clutch. starter rotates without
drive engagement,
starter drive gear or
clutch may be damaged.
Replace or repair
starter.
50
VEHICLE
Table TROUBLESHOOTING - Continued
I telll
No. Malfunction
Probable Callses Corrective Action
e. Excessive friction due e. Operate starter Illotor
to defective bypassing solenoid.
bearings or bent I f starter does not
shaft. rotate freely, without
noise, replace or repair
starter.
CHARGING SYSTEM
21. Low or a. Loose alternator drive
0
Check drive belt and tighten.
indication on belt.
battery
alternator b. Defective b. Replace indicator gauge.
indicator alternator indicator.
when
(0
batteries c. Loose battery cables, I nspect cables and wiring
have low
and/or faulty system for shorts,
charge. wiring system. fraying, breaks, corrosion,
loose or
connections, or other
damage and test battery
wiring system.
d. Alternator voltage d. Test and adjust alternator
adjustment set to voltage setting.
low or defective Replace or repair.
alternator.
22.
a. Defective
a. Refer to Item 21b.
indication on alternator
battery- indicator.
alternator
indicator b. Alternator voltage
. b.
Hefer to Item 21 d.
when batteries adjustment set to
are fully high or defective
charged. alternator.
23.
Noisy alternator. a. Loose alternator
0
I nspect alternator mountings
mountings. and alternator mounting
brackets. Tighten if
necessary.
b. Defective alternator. b. Replace alternator or repair.
24. Discharged or a. Excessive use of
0
Recharge batteries.
low charged batteries at low
batteries. engine speeds.
b. Defective batteries. b. Replace batteries.
51
VEHICLE
Table 46. TROUBLESHOOTING- Continued
Item
No. Malfunction Probable Causes Corrective Action
c. Defective cables or
G
Check battery cables and
wiring. vehicle wiring for shorts.
d. Defective alternator d. Refer to Item 21d.
and/or improper
voltage adjustment.
25. Excessive charged a. I mproper voltage a. Refer to item 22.
batteries. adjustment.
LIGHT SYSTEM
26. Lights dim. a. Dirty lenses.
0
Clean lenses.
b. End of normal lamp life.
@
Replace lamps.
c. Defective batteries or c.
Refer to Items 24b and 24c.
battery cables.
d. Defective charging d. Troubleshoot charging system
system. (items 22 thru 251.
e. Overloaded circuit. e. Troubleshoot vehicle wiring
and components for short
circuits or highresistance
circuits.
f. Defective lamp contact.
CD
Inspect lamp contacts for
corrosion.
g. Poor grounding.
CD
Inspect grounding of light to
body or chassis. Clean and
tighten as necessary.
h. Defective circuit wiririg h. Refer to electrical
and switches. wiring diagram.
27. Light failure. a. Defective lamp.
0
Inspect lamp and, if burned
out, replace service
headlight lamp unit,
blackout headlight lamp
unit, marker light lamp,
service and blackout tail
and stoplight lamp, dome
light lamp or instrument
panel light lamp.
b. Defective battenes or
@ Refer to Items 24b and 24c.
battery cables.
52
Item
No. Malfunction
c.
d.
e.
28. Frequent lamp a.
failure.
29. Electrical a.
components of
instrument
panel
inoperative.
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Probable Causes
Corrective Action
Poor grounding.
(0
Refer to item 26g.
Defective light switch. d. Replace light switch.
Defective vehicle wiring e. Troubleshoot vehicle wiring
harness.
harness.
Alternator output a. Test alternator for proper
voltage too high. output.
INSTRUMENT PANEL GAGES, SENDING
UNITS, AND SWITCHES
Defective components or a. Troubleshoot gages, switches,
wiring circuit breakers, sending
units and wiring.
WIRING HARNESS,
CABLES AND CONNECTORS
I
Each electrical system of the vehicle is interconnected to the other electrical systems through
use of common power sources - alternator and batteries. A symptom of trouble in one system may
be caused by failure in another system as well as failure in the system itself. If failure is not located
in the system showing the symptom, systematically troubleshoot the entire electrical system until
the fault is located.
30. Circu it tracing
procedure.
31. Automatic shifts a.
at too high
speed.
TRANSMISSION
Governor valve
malfunctioning.
b. Mechanical actuator
cable kinked, broken
or not properly
adjusted.
c. Mechanical actuator
32. Automatic shifts a.
at too low
speed at full b.
throttle.
c.
malfunctioning.
Governor valve stuck.
Governor spring weak.
Mechanical actuator
cable kinked, broken
or not properly
adjusted.
53
Trace all circuits until
trouble is isolated.
a. Clean or replace governor
and governor screen.
b. Replace or repair cable.
c. Replace actuator.
a. Refer to Item 31a.
b. Replace governor.
c. Refer to Item 31b.
VEHICLE
Table 4-6_ TROUBLESHOOTING - Continued
Item
No. Malfu nction Probable Causes
Corrective Action
d. Mechanical actuator d. Replace actuator.
malfunctioning.
33. Low main a. Low oil level.
0)
Add oil to proper level.
pressure in
all ranges. b. Oil filter element b. Replace filter.
clogged.
c. Seal ring on oil c. I nstall new seal ring.
pickup tube leaking
or missing.
d. Main-pressure regulator d. Check spri ng and replace
valve spring weak.
if necessary.
e. Control valve body e.
Replace control valve
leakage.
body assembly.
f. Valves sticking.
f.
Replace control valve body
assembly.
g. Oil pump worn or
g. Replace oil pump.
damaged.
34. Low main a. First gear circuit a.
Replace control valve body.
pressure in
of control valve
first gear. body, leakage.
normal
pressure in
other forward b. Excessive leakage at b. Overhaul transmission;
ranges.
first-and-reverse
replace seals.
35. Buzzing noise a. Low oil level.
0
Refer to Item 33a.
occurring
intermittently. b. Air leak at oil b. Replace intake pipe seal
intake pipe.
and filter.
c. Clogged filter. c. Refer to Item 33b.
d. Aerated oil.
0
Check for improper oil level,
Improper or contaminated
oil.
36. Excessive creep a. i;ngine idle speed
0
Adjust to correct idle speed.
in first-and- too high.
reverse gears.
37. Low lubrication a. Oil level low.
0)
Refer to Item 33a.
pressure.
54
55
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Causes Corrective Action
b. Clutch pressure low. b. Refer to Item 33.
c. Forward clutch c. Rebuild forward clutch and
slipping (forward). replace piston seals.
d. F irst-and-reverse d.
Rebuild first-and-reverse
clutch slipping.
clutch and replace piston
0
seals.
42. Low stall a. Engine not performing
Troubleshoot engine,
speed. efficiently (may be (item 7,8).
due to high altitude).
b. Defective torque b. Refer to Item 3ge.
converter.
43. Rough
shifting. a. Manual selector a. Adjust linkage.
linkage out of adjust-
ment.
b. Control valves, sticking. b.
Replace control valve.
c. Governor valve c. Refer to Item 31a.
malfunctioning.
d. Mechanical actuator d. Refer to Item 31b.
cable kinked.
e. Mechanical actuator e. Refer to Item 31c.
malfunctioning.
f. Engine idle speed
CD
Refer to Item 36a.
too fast.
44. Engine over- a. Piston seals leaking a. Overhaul transmission.
speeds on full or clutch plates
throttle upshift. slipping in range
involved.
b. Forward clutch piston b. Overhaul forward clutch and
seals or clutch piston assembly.
plates slipping.
(all upshifts)
c. Broken seal rings on c. Replace rings.
front support hub.
d. Sticking governor d. Refer to Item 31a.
valve.
56
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
Item
No.
Malfunction
Probable Causes
Corrective Action
45. Excessive slip- a. Clutch slippage in a. Overhaul clutch.
page and clutch that range clutch.
chatter in one
range (not in b. Excessive oil leakage b. Overhaul clutch and piston
all ranges). in range piston seals. assembly.
c. Oil leakage in valve c. Overhaul control valve body
components for that assembly.
particular range.
46. Dirty oil. a. Failure to change oil a. Change oil, install new filter.
at proper interval.
b. Heat excessive. b.
Refer to transmission, item 39.
c. Clutch failure. c. Overhaul transmission.
d. Damaged oil filter. d. Replace filter.
47. Oil leak at a. Faulty or missing seal a. Install new lip-type seal in
output shaft. at output flange. rear of transmission
housing.
48. Slippage in all a. Oil level low.
0
Refer to Item 33a.
forward gears.
b. Clutch pressure low. b.
Refer to transmission, item 33.
c. Forward clutch slipping. c. Rebuild forward clutch.
49. Slippage in a. Fourth clutch slipping. a. Refer to Item 41c.
fourth and
reverse
gears. b. Broken sealrings on b. Replace seal rings.
support assembly hub.
50. Slippage in a. F irst-and-reverse a. Refer to Item 41d.
reverse and clutch slipping.
first gear; proper
function in
other forward
gears.
51. Vehicle moves a.
Range selector linkage a.
Adjust linkage properly.
forward in
out of adjustment.
neutral.
b.
Forward clutch failed b. Refer to Item 41d.
and dragging.
57
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Callses Correctivp. Action
52. Vehicle moves a. Range selector linkage a. Refer to Item 51 a.
backward out of adjustment.
in nelltral.
b. Fourth clutch failed b. Rebuild clutch assembly.
and dragging.
53. Throws oil out a. Dipstick loose.
0
Tighten cap; replace if
of trans- necessary.
mission
@
filler tube b. Oil level too high. Refer to Item 3gb.
or breather.
c. Oil level too low.
G
Refer to Item 33a.
d. Breather clogged. d. Clean or replace breather.
e. Water in oil.
e. Drain oil, replace filters
and refill.
TRANSFER
54. Hard Shifting. a. Insufficient
()
Clean and lubricate transfer
lubrication. case linkage. (Refer to
Lubrication Chart.)
55. Slips out of a. Clutch does not fully a. Adjust transfer case linkage.
gear. engage.
b. Defective transfer. b.
Repair transfer.
56. Lubricant a. Loose drain plug.
~
Tighten loose drain plug.
leakage.
b. Loosen screws, b. Tighten case screws. If
damaged gaskets leakage persists,
or oil seals. replace gaskets or oil
seals.
c. Obstructed transfer case c. Troubleshoot breather for
venting. high transfer case
pressure.
57. Overheating a. I nsufficient lube.
G
Check lube level. (Refer to
Lubrication Chart.)
b. Malfunction of internal
b. Repair transfer.
components.
58
VEHICLE
Table TROUBLESHOOTING - Continued
I telll
No. Malfunction
Probable Causes
Corrective Action
PROPELLER SHAFTS
58. Excessive noise a. Lack of lubrication.
0
Lubricate all universal
or vibration.
joints. (Refer to
Lubrication Chart.)
b. Worn universal joint b. Repair universal joint or
parts or sprung replace drive shaft.
shaft.
59. Lubricant a. Damaged oil seals a.
Replace universal joint or
leakage.
repair propeller shaft.
FRONT AXLE
60.
Hard steering. a. Tires underinflated.
0
Check air pressure, using an
accurate gage, and inflate
tires to correct
pressure.
b. Low flu id level in
@
Fill hydraulic system.
hydraulic system. (Refer to Lubrication
Chart.)
c. Lack of lubrication.
G
Lubricate front axle
steering knuckle, king
pin bearings,
ends, and drag link ends.
(Refer to Lubrication
Chart.)
d. Overadjusted, defective d. Adjust front wheel bearings
wheel bearings. or replace.
e. I mproper e. Align front end.
I. Power steering pump I.
Repair or replace power
failure.
steering pump.
61. Shimmy. a. Excessive looseness in a. Raise front wheels from
front axle steering
ground, move wheels from
knuckles.
side to side and up and
down, and note any
looseness in steering
knuckle. If knuckles are
loose, replace knuckle
bearings.
b. Loose front wheel b. Refer to item 60d.
bearings
59
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Causes Corrective Action
65. Excessive backlash a. Axle flange screws
0
Tighten screws.
in axle loose.
driving parts.
b. Ring gear and pinion b. Replace axle differential.
worn excessively.
c. First reduction gear c. Refer to Item 64d.
set worn or out of
adjustment.
SERVICE BRAKES
66. Pedal goes nearly a. No fluid in hydraulic a. Fill master cylinder reservoir
to floor. master cylinder and bleed hydraulic
reservoir. system.
b. Normal wear of linings. b. When linings become worn, it
is necessary to set shoes
closer to braked rums. Ad-
just brakes.
c. Brakes improperly c. Adjust brakes.
adjusted.
d. Brake fluid leak. d. I nspect vehicle for signs of
flu id leaks at wheel
cylinders, and brake line.
Correct leak and fill
master cylinder.
e. Air in system. e. Air in brake system will cause
spongy or rubbery action
of pedal. Bleed hydraulic
system.
f. Pedal improperly f. Brake pedal should have 1/8-
adjusted. to 1/4inch free travel
before pressure stroke
starts. Additional free
motion reduces active
travel of vacuum cylinder
which in turn, limits
amount of working fluid to
be expelled to the wheel
cylinders. Adjust brake
pedal travel.
61
VEHICLE
Table 4-6. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Causes Corrective Action
67. All brakes drag. a. Brake pedal improperly a.
Brake pedal must have approx-
adjusted.
imately 118 to 1/4inch
free travel before pressure
stroke starts. Adjust
brakepedal free travel.
b. Mineral oil in system. b. I ntroduction of mineral oil in
hydraulic brake system will
cause cylinder cups to
swell and retard or prevent
their action. Clean brake
system of improper oil and
fill with hydraulic brake
fluid. If this remedy is
not effective, to system
will have to be recon-
ditioned and all cylinder
cups replaced.
c. Defective breather and c. Troubleshoot breather and
ventilation system.
ventilation system for
obstructed vacuum and
master-cylinder venting.
68. One wheel drags. a. Brakeshoes improperly a. Adjust brake clearance between
adjusted.
shoe and brakedrum.
b. Brakeshoes seizing on b.
Lubricate brakeshoe bearing
anchor pins.
surface on anchor pins.
c. Weak brakeshoe return c.
A weak or broken shoe return
spring.
spring will prevent brake
shoes from being retracted.
Replace spring.
69. Vehicle pulls to a. Grease-soaked linings. a. Replace brakeshoe assy. or
one side when
lining.
brakes are
applied. b. I mproperly adjusted b. Refer to Item 66c.
brakeshoes.
c. Tires improperly
G
Correct tire inflation.
inflated.
70. Spongy pedal. a. Brakeshoes improperly a.
Refer to Item 66c.
adjusted.
b. Air in system. b. Refer to Item 66e.
62
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Item
No. Maifullction Probable Causes Corrective Action
71. Light pedal a. Improperly adjusted a. Refer to Item 66c.
pressure bra keshoes.
(brakes
"grab"). b. Greasesoaked lining. b. Refer to Item 69a.
72. Weak braking a. Improper brakeshoe a. Refer to Item 66c.
action from adjustment.
heavy pedal
pressure. b. Worn brake lining. b. Replace brakeshoe assembly or
lining.
c. Oil or water on lining. c. If oil, replace brakeshoes
assembly or lining. If
water, allow linings to
dry.
d. Defective brake booster. d. Replace brake booster.
PARKING BRAKE
73. Brake does not a. I mproperly adjusted a. Adjust parking brake.
hold. parking brake.
b. Broken parking brake b. Replace cable.
cable.
c. Worn parking brakeshoe c. Replace worn parking brake
lining. lining or brakeshoe assy.
d. Grease on parking brake- d. Replace parking brake lining
shoe lining. or bra ke shoe assy.
74. Brake drags or a. Brake partially applied. a. Release parking brake fully.
over heats.
b. Improperly adjusted b. Adjust parking brake.
parking brake.
c. Brakedrum out of round. c. Replace braked rum.
WHEELS, TIRES, AND HUBS
75. Wheel wobbles. a. Wheel loose on hub.
0
Tighten wheel nuts.
b. Bent wheel.
@
Replace wheel.
c. Wheel bearings out of c. Adjust wheel bearings or
adjustment or replace bearings.
damaged.
63
Item
No. Malfunction
76. Excessive or
uneven tire
wear.
77. Hard steering.
78. Wander or weaving.
79. Insufficient
flexibility.
VEHICLE
Table TROUBLESHOOTING - Continued
Probable Causes Corrective Action
a. Unequal pressur9 in
CD
Inflate tires equally using an
tires. accurate gage.
b. I mproper b. Check alignment
alignment. and correct.
c. Bent wheel.
0
Refer to Item 75b.
d. Damaged wheel bearings. d. Replace wheel bearings.
STEERING GEAR
a. Vehicle in
CD
Return to drive.
drive.
b. Lack of lubricant.

Lubricate in accordance with
Lubrication CharI.
c. Tight steering gear. c.
Move steering wheel from
one extreme to the other.
I f tightness is felt,
just steering gear.
d. Insufficient hydraulic
@
Check fluid level in reservoir.
pressure. Check pump operation.
a. Vehicle in
CD
Refer to I tern 77a.
drive.
b. Unequal rolling radius

Adjust tire pressure for equal
of rear tires.
rolling radius.
c. Tight adjustment in c. If gear is tight in midposition

or adjust
steering gear.
d. Steering drag link ends d. I nspect drag lin k ends for
loose.
proper adjustment. Adjust
drag link.
SPRINGS AND SHOCK ABSORBERS
a. Broken or weak springs. a.
Replace broken or weak springs.
b. Shock absorbers binding. b. Disconnect shock absorber and
test shock absorber action.
64
/
VEHICLE
Table 46. TROUBLESHOOTING - Continued
Item
No. Malfunction Probable Callses Corrective Action
80. Excessive a.
Lack of fluid in shock a. Replace shock absorbers.
flexibility. absorbers.
b. Shock absorbers b. Disconnect shock absorber, and
inoperative.
test operation. I f little
or no resistance is felt,
replace unit.
c. Broken spring leaves. c. Examine springs for broken
leaves, replace broken or
weak springs.
81. Excessive noise. a.
Worn spring shackles, a. Use pry bar to test for wear
shackle bolts, or
of spring shackles, bolts,
bushings.
or bushings.
b. Worn or broken shock b. I nspect shock absorber brackets
absorber brackets, for wear, damage, or
looseness,
82, Spring leaf a. Spring leaf failure at a. Replace spring.
failure,
spring eye,
b. Spring leaf failures at b. Breakage of spring leaves at
center section of
the center bolt section
spring.
is generally caused by
loose spring U-bolts.
Replace spring and tighten.
U-bolts securely.
c. Grabbing brakes. c. Grabbing brakes result in
extreme twist or strain on
springs. Adjust brakes.
WINCH
83. Winch fails to a. Drum clutch not engaged.
0
Operate front winch clutch
operate or
control lever.
operates
@
improperly. b, I nsufficient hydraulic Check fluid level in reservoir.
pressure.
Check pump operation,
c. Defective winch control c. Replace control valve.
valve.
d. Defective winch motor. d. Repair or replace motor.
65
66
51. SCOPE
VEHICLE
CHAPTER 5
Maintenance Instructions
Section I -- GENERAL
This chapter contains information for the guidance of maintenance personnel performing
general maintenance, repair, and installation of the major components of this vehicle. Generally,
the prescribed maintenance responsibilities, or practicability of maintenance functions must be
determined by the availability of repair parts.
52. TECHNIQUES
"Inspect and repair, only as necessary" is the maintenance technique whereby end items,
components, or assemblies are restored to prescribed serviceability standards after determining the
need for performing the minimum essential maintenance required. It implements the principles of
economical maintenance operations by requiring thorough diagnosis of major items and compo
nents before repair or replacement. Unwarranted disassembly and uneconomical teardown are
uncalled for if modern diagnostic equipment and tools, together with available technical inspection
procedures, are put to use. This technique does not cancel essential disassembly or teardown to
assure the proper serviceability standards for the components and/or major item involved. It does
not change or lower the required quality of maintenance or prescribed serviceability standards.
53. SPECIAL TORQUE REQUIREMENTS
During repair and maintenance of the vehicle, use Standard Torque Values as listed in Table
52 and elsewhere in the manual for all nuts, screws and threaded fittings except as specified in
Table 51.
54. CLEANING, INSPECTION AND REPAIR
Refer to Chapter 3 for general cleaning, inspection and repair procedures to be followed and
used in conjunction with specific instructions contained in the following individual repair sections.
Table 51. SPECIAL TORQUE SPECIFICATIONS
ITEM
Axle Carrier Stud Nuts
Axle Flange Screws
Axle Sleeve Plate Screw
Axle Spindle Lock Nut
Axle Spindle Stud Nuts
Axle Steering Arm Screw
Brake Shoe Anchor Pin Lock Nut
Differerential Carrier Inspection Cover Screws
Differential Through Shaft Bearing Cage to Carrier Screws
Differential Cross Shaft Bearing Cage Cover Screws - Small
Differential Cross Shaft Bearing Cage Cover Screws Large
67
Lbs. Ft.
130170
90115
105135
105135
90115
3.25-420
120150
2035
6585
6585
100-130
N.m
180235
124-159
142187
145187
124-159
450581
166207
26-47
88115
88115
136176
VEHICLE
Table 5-1_ SPECIAL TORQUE SPECIFICATIONS - Continued
-------
ITEM
Differential Spur Gear to Lock Unit Nuts
Differential Carrier to Axle Housing Nuts
Drag Link Clamp Nut
Drive Shaft Center Bearing Retainer Flange Screws
Drive Shaft U-Bolts
Drive Shaft Yoke to Carrier Companion F lange Screws
Engine Oil Pan Screws 5/16"
Engine Oil Pan Screws 3/8"
Engine Air Intake Manifold Screws
Engine Crankshaft Pulley/Vibration Damper Screws
Engine Fan Hub Locknut - Initial
Engine Fan Hub Locknut - Final
Engine Exhaust Manifolds
Engine Flexplate to Flywheel Bolts
Engine Flexplate to Transmission Torque Converter Bolts
Fuel Pump Mounting Screws
Gear Coupling & Trans_ Adapter to Brake Drum Flange Screws
Gear Coupling Sleeve Screws
Parking Brake F lange Screw
Parking Brake Drum Screws
Parking Brake Backing Plate Screws
Propeller Shaft Flange Nuts
Steering Arm Retaining Screws
Steering Gear Mounting Screws & Nuts
Steering Knuckle Plate Screws
Steering Knuckle Stud Nuts
Steering Shaft Pitman Arm Nut Locking Screw
Steering Drag Link Nut
Spring Hanger Pin Pinch Screws
Spring Shackle Pin Pinch Screws
Suspension U-Bolts
Transfer Carrier Cap to Declutch Housing Screws
Transfer Cover to Case Screws - Short
Transfer Cover to Case Screws - Long
Transfer Declutch Assembly to Transfer Case
Transfer Drain Plug
Transfer Input, Idler and Helical Gear Shaft Screws
Transfer Lubricant Pump Screws
Transfer Mount Adjusting Screws
Transfer Mounts to Hull Screws
Transfer Rear Output Shaft Capscrews
Transfer Rear Output Shaft Yoke Nut
Transfer to Transfer Case Mount Screws
Transmission Converter to Engine Flexplate Bolts
Transmission to Engine Flywheel Housing Bolts
Transmission Governor Cover
Transmission Modulator Retainer
Transmission Oil Filter Screw
Transmission Oil Pan Screws
Transmission Range Selector Lever Nut
Transmission Valve Body Screws
68
Lbs_ Ft_
150-190
130-170
60-66
32-38
22-26
60-70
15-17
25-30
30-32
90-105
50
400-450
30-32
115-125
34-40
30-35
50-60
25-30
83-100
31-33
31-33
60-70
325-420
100-120
105-135
90-115
18-20
100-120
32-37
32-37
200-240
20-30
35-50
60-75
30-35
35
60-75
20-30
30-40
25-30
35-50
700-900
200-220
34-40
35-45
15-20
15-20
10-15
10-13
15-20
8-12
N_m
203-257
176-230
69-91
44-53
30-36
69-93
20-23
34-41
41-43
122-142
68
452-610
41-43
156-169
46-54
41-47
68-81
34-41
113-136
42-45
42-45
81-95
449-581
136-163
145-187
124-159
24-26
136-163
44-51
44-51
277-332
26-41
47-68
69-102
41-47
47
69-102
26-41
41-54
34-41
47-68
948-1220
271-298
46-54
47-61
20-26
20-26
13-20
13-18
20-27
11-16
VEHICLE
TABLE 5-2. STANDARD TORQUE SPECIFICATIONS
a. SDfew Head Markings
SAE Grade 2 SAE Grade 5 SAE Grade 8
b. Standard Torque Specifications for Screws
Screw SAE Grade 2 SAE Grade 5 SAE Grade 8
Size Assembly Torque Assembly Torque Assembly Torque
Dry Lub. Dry Lub. Dry Lub.
R=.200 R=.150 R=.200 R=.150 R=.200 R=.150
4-40 5 In. Lbs. 4 In. Lbs. 8 In. Lbs. 6 In. Lbs. 12 In. Lbs. 9 In. Lbs.
4-48
6" 5" 9" 7" 13" 10"
6-32 10" 8" 16" 12" 23" 17"
6-40 12" 9" 18" 13" 25" 19"
832 19" 14" 30" 22" 41" 31"
8-36 20" 15" 31" 23" 43" 32"
1024 27"
21" 43" 32" 60" 45"
10-32 31 " 23" 49" 36" 68" 51"
1/4-20 66" 49" 8 Ft. Lbs. 75" 12 F t. Lbs. 9 Ft. Lbs.
1/4-28 76" 56" 10" 86" 14" 10"
5116-18 11 F t. Llls. 8 Ft. Lbs. 17" 13 Ft. Lbs. 25" 18"
5/1624 1 2" 9" 19" 14" 25" 20"
3/8-16
20" 15" 30" 23" 45" 35"
3/8-24 23" 17" 35" 25" 50" 35"
7116-14 30" 24" 50" 35" 70" 55"
7/16-20 35" 25" 55" 40" 80" 60"
1/2-13 50" 35" 75" 55" 110" 80"
1/2-20 55" 40" 90" 65" 120" 90"
9110 12
50" 110" 80" 150" 110"
9/1618
75" 55" 120" 90" 170" 130"
5/8-11 90" 70" 150" 110" 220" 170"
5/818 100" 80" 180" 130" 240" 180"
3/4-16 100" 120" 260" 200" 380" 280"
3/4-16 180" 140" 300" 220" 420" 320"
7/8-9 140" 110" 400" 300" 600" 460"
7/8-14 155" 120" 440" 320" 660" 500"
18 220" 160" 580" 440" 900" 680"
1-12 240" 170" 640" 480" 1000" 740"
11/8-7 300" 220" 800" 600" 1280" 960"
11/8-12 340" 260" 880" 660" 1440" 1080"
11/47 420" 320" 1120" 840" 1820" 1360"
11/412 460" 360" 1240" 920" 2000" 1 500"
1-3/8-6 560" 420" 1460" 1100" 2380" 1780"
13/8- 12 640" 460" 1680" 1260" 2720" 2040"
11/26
740" 560" 1940" 1460" 3160" 2360"
11/2 12 840" 620" 2200" 1640" 3560"
2800"
69
VEHICLE
1\1 OTES
70
VEHICLE
CHAPTER 6
limited Vehicle Maintenance
This chapter contains limited maintenance instructions to correct some of the discrepancies
that will be found during troubleshooting the vehicle and those generated through quarterly, semi-
annual and/or annual preventive maintenance checks/services. Items omitted or additional informa-
tion required for an item in this chapter will be found in the chapters assigned to each unit, assem
bly or system.
Section I - HULL ITEMS
6-1. ENGINE EXHAUST SYSTEM (Figure 6-1)
The engine exhaust system consists of two mufflers, two exhaust pipes and two exhaust pipe
extensions. To gain access to exhaust components, remove exhaust grille, open engine hatches, side
access door and remove engine compartment side panels.
A. Mufflers.
1. Removal. Remove eight nuts, lock washers, four U bolts and clamps securing each
muffler to the hull, retainer and exhaust pipes. Remove mufflers.
2. Inspection. Inspect mufflers for holes, rusted metal or broken seams.
3. Installation. Install in reverse order of removal.
B. Exhaust Pipes.
1. Removal.
a. Remove mufflers.
b. Remove two screws, washers and nuts securing each exhaust pipe to exhaust mani-
fold.
c. Remove exhaust pipes and gaskets. Discard gaskets.
2. Inspection and repair. Inspect exhaust pipes for holes, rusted metal, or warped flanges.
Replace if cracks are evident or mating surface is warped. Burrs or ridges may be removed with fine
mill file or stone.
3. Installation.
a. Install new gaskets.
b. Secure exhaust pipes to the exhaust manifolds with two screws, lock washers and
nuts. Torque screws to 18-20 ft. Ibs.
71
MUFFLER (2)
RETAINER
BRACKET
VEHICLE
o
,
Figure 6-1 Exhaust System
6-2_ HULL DRAIN PLUGS (Figure 6-2)
EXTENSION
PIPE (2)
~
A_ There are ten hull drain plugs used to drain water, fuel and oil from the hull and com-
ponents within the hull. Care must be taken to prevent. the plugs from seizing to the threaded
collars due to the lack of proper maintenance.
8_ At least twice a year during semi-annual inspection remove each plug, clean the threads in
the collar and on the plug with a wire brush. Lubricate each plug with GAA Grease and reinstall.
C. The foregoing should be accomplished more often depending on the use of the vehicle.
6-3. HYDRAULIC RESERVOIR (Figure 6-3)
A. This reservoir services two independent hydraulic systems, power steering system and
winch system.
B. As indicated on the lubrication chart a trouble free system should have the reservoir oil
level checked and maintained on a monthly basis. With problems, it will be necessary to check more
often until the problems have been eliminated. Remove the dipstick and add oil OE 10 to the re-
quired level indicated on the dipstick. Check strainer each time for contamination.
C. When replacing complete filter unit, the out port of filter unit must lead directly to
reservoir.
72
VEHICLE
HULL FRONT
DRAIN P l ~ G
r = ~
FUEL TANK ~
DRAIN PLUG
Figure 6-2 Hull Drain Plugs
RESERVOIR SCREW (2)
LOCKWASHER (2)
IN
PORT
OUT
PORT
FILTER
STRAINER
Figure 6-3 Hydraulic Reservoir and Oil Filter
73
/
I.
VEHICLE
Section II - ENGINE INJECTORS AND VALVES
6-4. INJECTOR, VALVE AND CROSSHEAD ADJUSTMENT
NOTE: I njectors and valves must be in correct adjustment at all times for engine to operate
properly. This controls engine breathing and fuel delivery to cylinder. Final adjustment must
be made when engine is at operating temperature. I njectors must always be adjusted before
valves. Final operating adjustments must be made using correct values as stated.
A. Temperature Settings. The fOllowing temperature conditions provide the necessary
stabilization of engine components to assure accurate settings.
B. Definition of "Cold Set". Engine must have reached a stabilized temperature (oil tem-
perature to be within 10 degrees F of ambient air temperature).
C. Definition of "Hot Set".
1. Set injectors and valves immediately after the engine has reached normal stabilized
operating oil temperature.
2. If oil temperature gauge is unavailable, set injectors and valves immediately after en-
gine has operated at rated speed and load or at high idle for a period of 20 minutes.
D. Valve Set Mark Alignment.
1. Turn crankshaft in direction of rotation until No.1 "VS" mark appears on the vibra-
tion damper or crankshaft pulley. See Figure 6-4 for location of valve set marks. In this position,
both intake and exhaust valves must be closed for cylinder No.1; if not, advance crankshaft one
revolution. See Figure 6-5 for firing order.
2. To turn crankshaft, insert a 3/4-inch square drive flex bar or equivalent in crankshaft
pUlley.
50)0
8
FIRING ORDER: '548-6-37-2
Figure 6-4 Valve Set Marks Figure 6-5 Firing Order Diagram
74
VEHICLE
NOTE: Do not use fan to rotate engine.
3. Adjust injector plunger, then crossheads and valves of first cylinder as explained in
succeeding paragraphs. Turn crankshaft in direction of rotation to next "VS" mark corresponding
to firing order of engine and corresponding cylinder will be ready for adjustment.
4. Continue turning crankshaft in direction of rotation and making adjustments until all
injectors and valves have been correctly adjusted.
NOTE: Two complete. revolutions of crankshaft are needed to set all injector plungers and
valves. Injector and valves can be adjusted for only one cylinder at anyone "VS" setting.
E. Cross head Adjustment (Figure 66).
NOTE: Before setting or checking valve train clearance, be sure crossheads are properly
adjusted. Valves and injectors must be set in sequence according to firing order to ensure
that the rocker train is loaded by the adjusted injector which deflects the shaft slightly and
thus affects valve clearances. Therefore, it is essential that injectors on any cylinder must be
set prior to valve clearances on the same cylinder being set.
1. Loosen valve crosshead adjusting screw locknut and back off screw (4) one turn.
2. Use light finger pressure at rocker level contact surface (1) to hold crosshead in con-
tact with valve stem (2) '(without adjusting screw).
3. Turn down crosshead adjusting screw until it touches valve stem (3).
4. With new crossheads and guides, advance setscrew an additional one-third of one hex
(20 degrees) to straighten stem on its guide (5) and compensate for slack in treads. With worn cross-
heads and guides, it may be necessary to advance screw as much as 30 degrees to straighten stem on
its guide.
5. Using Torque Wrench Adapter, tighten locknuts to 22 to 26 ft. Ibs. (3 to 3.6 kg m).
If adapter is not available, hold screws with screwdriver and tighten locknuts to 25 to 30 ft. Ibs.
(3.5 to 4.1 kg m).
6. Check clearance (6) between crosshead and valve spring retainer with wire gauge.
There must be a minimum of 0.020 inch (0.51 mm) clearance at this point.
4
2
3
5
6
Figure 6-6 Valve Crosshead
75
VEHICLE
F. Injector Plunger Adjustment.
NOTE: Before adjusting injector, tighten injector holddown screw to 30 to 35 ft.lbs. (41 to
47 Nm). The injector plungers must be adjusted with an in. Ibs. torque wrench.
1. Turn adjusting screw down until plunger contacts cup and advance an additional 15
degrees to squeeze oil from cup.
2. Loosen adjusting screw one turn, using a torque wrench calibrated in in. Ibs. and a
screwdriver adapter, tighten the adjusting screw to 60 in. Ibs. (6.8 Nm).
NOTE: After all injectors and valves are adjusted and engine has been started and warmed
up to 140 degrees F (60 degrees C) oil temperature, reset injectors to 60 in. Ibs. (6.8 Nm).
This is only necessary if injectors, lever assemblies, or push rods have been changed.
3. Hold injector adjusting screw and tighten injector adjusting screw locknut to 40-45
ft. Ibs. (54-61 Nm). When a torque wrench adapter is used, nut torque is reduced to 30-35 ft.lbs.
(41-47 Nm) to compensate for additional torque arm length. Figure 6-7.
G. Valve Adjustment. The same crankshaft position used in adjusting injectors is used for
setting intake and exhaust valves.
1. Loosen locknut and back off adjusting screw. Insert feeler gauge between rocker
lever and top of crosshead. Turn screw down until lever just touches gauge and lock adjusting screw
in this position with locknut. Torque locknut to 30-35 ft. Ibs. (41-47 Nm) when adapter is used;
40-45 ft. Ibs. (54-61 Nm) without torque wrench adapter; note Step 2 under "Injector Plunger
Adjustment".
2. Always make final valve adjustment after injectors are adjusted and with the engine
at operating temperature.
3. After all injectors, valves and crossheads have been adjusted, secure valve covers to
heads with new gaskets.
Figure 6-7 Adjusting Injector Plungers Figure 6-8 Tightening Adjusting Screw Locknut
76
VEHICLE
Section III - ENGINE LUBRICATION SYSTEM
The engine is pressure lubricated by a gear type pump mounted in the engine oil pan. A
regulator in the pump controls oil pressure. A remote mounted full flow oil filter is accessible by
removing the lower engine compartment side wall. The system a l ~ o includes an oil pressure gage
mounted on the instrument panel and an oil cooler on the right side of the engine block.
65. REPLACEMENT OF OIL FILTER (Figure 69)
A. Remove cover with filter.
B. Remove cover gasket and filter cartridge from cover.
C. Discard filter cartridge and cover gasket.
D. Thoroughly clean cover.
E. Install new filter cartridge into cover.
F. Position new cover gasket and filter assembly to adapter and secure.
G. Idle engine for five minutes and check oil level. Replenish oil as required.
FILTER
COVER
GASKET
(
I
Figure 69 Engine Oil Filter
77
COVER
VEHICLE
Section IV - FUEL SYSTEM
The engine fuel system, Figure 6-10,consists of right and left fuel tanks with gages, fuel tank
selector valve, fuel filter assembly, engine-driven fuel pump, and a fuel injector at each cylinder.
Replacement of the fuel filter elements and periodic injector tappet adjustment, similar to valve
adjustment on a gasoline engine, are the only normal service requirements of the fuel system.
66. FUEL REQUIREMENTS
No.1 or No.2 commercial diesel fuel is recommended. It provides the most power per gal-
Ion and is therefore the most economical. Care should be taken to be sure fuel is completely free
of dirt, water, and contaminants that may plug filters, injectors or damage the fuel pump.
i
_-
lEFT 1:
LEFT TANK
FUEL SUPPl V
LINE
RIGHT TANK
FUEL SUPPLY
LINE I RIGHT
FUEL TANK LY_j FUEL SELECTOR
VALVE
FUEL FILTER
SEPARATOR

TANK
RETURN LINE
FUEL
RETURN
LINE
FUEL FilTER
COALESCER
RETURN
FUEL CHECK
VALVE
.. -
I
FUEL __ ---+----l
PUMP '--______ JJ
Figure 610 Fuel System
78
: FUEl TANK
RIGHT TANK
RETURN LINE
FUEL SUPPLY
LINE
VEHICLE
6-7. FUEL PUMP (Figure 6-11)
The fuel pump, mounted between the engine cylinder banks, is driven through the vacuum
pump by the engine gear train. The pump picks up fuel from the tanks and provides fuel under
pressure to the injectors. An internal governor controls idling and maximum RPM. The throttle
controls fuel pressure to the injectors and in conjunction with the governor, controls engine torque
through the entire operating range. Normally, the fuel pump requires no periodic servicing. Fuel
pump, electrical connections, throttle linkage and fuel lines and fittings should be checked periodi-
cally.
A. Check electrical connections at fuel pump automatic shut-down solenoid for tightness
and freedom from corrosion.
B. Check throttle linkage for damage or wear. Pressure on accelerator pedal should move
fuel pump throttle lever through full range from idle stop to full throttle position. Adjust only if
idle speed or maximum governed speed is not within specifications.
C. Check fuel lines and fittings to and from the pump for signs of leakage or deterioration.
Figure 6-11 Fuel Pump
79
VEHICLE
68. INJECTORS (Figure 612)
Injectors receive fuel under low pressure from the fuel pump and inject it as an extremely
fine spray under high pressure into the combustion chambers. Ignition takes place spontaneously.
Fuel is supplied to the injectors through internal drillings in the cylinder head. Injectors are actu
ated by overhead rocker arms in the same manner as the intake and exhaust valves. The preventive
maintenance schedule requires valve and injector adjustment at the same intervals. See Section II
of this chapter for adjustment procedure.
PLUNGER SEATED IN CUP
1. CUP BYPASS ENDS
METERING ENDS
2. CUP RETAINER
3, BARREL
4. PLUNGER
5. CHECK BALL
6. GASKET
7. CUP
8. SCREEN
9. FUEL IN
10. ORIFICE
11. ORIFICE GASKET
12. COUPLING
13. ADAPTER
14. SPRING
15. LINK
16. FUEL OUT
11. '0' RING
18. NUT
19. ROCKER LEVER
20. ADJUSTING SCREW
21. PUSH ROO
22. TAPPET
23. CAMSHAFT LOBE
METERING PREINJECTION INJECT!ON
Figure 612 Injector Timing Operation
80
PURGING
VEHICLE
6-9_ FUEL FILTERS (Figure 6-13)
The fuel system filter assembly is located on the front hull wall to the right of the driver's
seat_ The right-hand element removes water from the diesel fuel_ The left-hand element provides
micronic filtration of solid contaminants_ Drain plugs in the bottom of the filters permit periodic
drainage of accumulated water.
A_ Filter Element Replacement.
FILTER
COALESCER
1. Remove bottom drain plug and completely drain filter.
2. Unscrew filter head screw and remove filter body.
3. Discard used filter element and clean out filter body with a clean solvent.
4. Remove and discard used filter head gasket and clean gasket cavity.
5. I nstall new head gasket supplied with cartridge.
6. Install new cartridge in body and attach body to filter head. Tighten screw securely.
7. Replace drain plug in bottom of filter.
8. Start engine and check all connections for leaks.
/
/
GASKET
G)
I
(;d0 FILTER
SEPARATOR
I
f
(-;1)
--_, I \
, :
[
I. I,
I '
DRAIN .)
I I DRAIN COCK

, .
. ,
PLUG ________ ../

Figure 6-13 Fuel Filters - Exploded View
81
VEHICLE
6-10. FUEL SELECTOR VALVE (Figure 6-14)
NOTE: Fuel level in tanks must not be higher than fuel pickup tube bulkhead fitting when
removing tank selector valve.
CAUTION: Before disconnecting fuel lines, a suitable container should be placed under valve
to catch fuel spill.
A. Removal.
1. Place valve handle in 0 F F position, disconnect right and left fuel tank lines and fuel
outlet line from thc selector valve fittings. Tag lines to assist when installing selector valve.
2. Remove screw securing valve handle to valve and remove handle.
3. Remove two screws; nuts and lock washers securing valve to identification bracket
and remove valve.
B. Installation. Install fuel selector valve in reverse order of removal, making sure selector
handle is properly positioned before tightening screw securing valve handle.
SCREW (21
\ LOCK
WASHER (21
;tV,,-
MOUNTING
INSTRUCTION r- ". "- J
PLATE "'-.
WASHER \ c'" ---- /

;' SELECTOR
, f VALVE
HANDLE .:
PLUG

Figure 6-14 Fuel Selector Valve and Gage
82
VEHICLE
611. FUEL GAGE (Figure 614)
NOTE: Fuel level in tank must be lower than gage hole in fuel tank before removing gage.
A. Removal.
1. Remove four screws securing gage to fuel tank.
2. Pull gage unit from tank.
3. Remove and discard gasket.
4. Remove two dial screws and dial.
B. Installation. Install fuel gage in reverse order of removal. Inspect that float does not in
terfere with side of fuel tank.
C. Adjustment. Note reading of gage at various fuel levels. It may be necessary to bend float
rod up or down to obtain proper reading.
612. FUEL SHUTDOWN VALVE (Figure 615)
The fuel shutdown valve mounted on top of the engine fuel pump, controls flow of fuel
from the pump to the injectors. When the starter switch is in the ON position, the valve is held
open by a solenoid. When the starter switch is OF F, the valve closes. The valve is equipped with a
manual override control. The control knob must be in the full counterclockwise position for nor
mal operation. For emergency operation in case of electrical failure, the override control knob is
turned fully clockwise to permit fuel flow through the valve.
A. Removal.
1. Disconnect electrical leads to solenoid.
2. Disconnect fuel line to injectors.
3. Remove two attaching screws and lockwashers.
4. Remove valve.
B. Disassembly.
1. Remove coil housing from valve housing.
2. Remove fuel shield and discard "0" ring.
3. Remove spring washer and platetype valve.
4. Remove manual override knob and unscrew override shaft from coil end. Discard
shaft and "0" ring.
C. Cleaning and Inspection.
1. Clean all parts except the coil assembly in mineral spirits.
NOTE: Do not wet the coil with solvent; instead, wipe it clean with a lint free cloth.
83
VEHICLE
2. VisuallY check valve and valve seat for wear, bonding failure or corrosion. Replace if
necessary. Valve seat should have a minimum seat 0.015 inch (0.38 mm) wide.
3. Check coil assembly with an Ohm meter, replace if below 28 ohms.
CAUTION: Be sure starting switch is in off position when checking coil.
D. AssemblY.
1. I nstall a new "0" ring on new override shaft and coat with lubricant.
2. Screw shaft into housing unit until it reaches bottom of its bore. Use depth micro
meter set at 0.118 inch (2.997 mm) and check distance from face of valve housing to tip of shaft.
If necessary, screw shaft out until it is 0.118 inch (2.997 mm) below housing face. Do not move
shaft and press on knob until it contacts valve housing which will act as a stop.
3. Place valve into valve housing with rubber side toward housing.
4. Apply lubricant to housing "0" ring and seat in groove.
5. Drop spring washer on valve with concave side up and piloted around valve locator.
6. Place fuel shield on valve housing and tighten screws to 25 to 30 in. Ibs. (2.8 to 3.4
Nm) torque.
E. Installation.
1. I nstall valve in reverse order of removal.
2. Check that manual override control knob is in full counter-clockwise position.
3. Check for proper operation and absence of fuel leaks. Should leakage exist, check the
main body for nicks or depressions where body and plate come in contact. Check the rubber seal in
the plate for swelling or other defects.
Figure 6-15 Shut-Down Valve
84
VEHICLE
SECTION V -AIR INTAKE SYSTEM
The air intake system consists of an engine air intake manifold, air cleaner, ducting from the
air cleaner to the manifold and an air restriction gage.
613. AIR CLEANER (Figure 6-16)
A. Removal.
1. Loosen air cleaner to intake manifold hose clamp at air cleaner.
2. Disconnect hose from air cleaner.
3. Remove two thumb screws securing air cleaner in mounting bracket clamps.
4. Remove air cleaner assembly from vehicle.
5. Loosen thumb screw securing end cover to air cleaner housing and remove cover.
6. Remove end cover and baffle.
7. Lift out filter element assembly from air cleaner housing.
HOSE ELBOW
COVER GASKET
END COVER
THUMB SCREW
THUMBSCREW
ADAPTER
NUT
CLAMP
Figure 616 Air Cleaner
85
VEHICLE
B. Servicing. Element can be cleaned with compressed air or by washing. Element should be
replaced after six cleanings. Compressed air is recommended when element must be reused immedi
ately because a washed element must be dried before reuse. However, washing does a better job and
must be used when exhaust soot has lodged in the filter.
1. Use filtered compressed air (100 psi maximum) to clean element. Insert air hose in
side element and rotate element while moving air hose up and down. Keep hose nozzle at least one
inch away from pleated paper.
2. Washing. Soak element 15 minutes or more in detergent and water. A special deter
gent containing a special additive for removing soot and carbon is available. Rinse in clean water
until water is clear (maximum water pressure 40 psi). Air dry or use warm flowing air.
3. Wipe inside of filter housing and end cover with clean cloth.
c. Inspection.
1. Place bright light inside element and rotate element slowly. If any rupture, holes or
damaged gasket are discovered, replace element.
D. Installation.
1. Install filter element in housing. Replace baffle and end cover and secure with clamp
ring.
2. Place air cleaner in mounting clamps and secure with thumbscrews.
3. Attach hose from intake manifold to air cleaner and tighten clamp.
4. Inspect all clamps for tightness.
5. Reset air restriction indicator to green.
614. AIR RESTRICTION INDICATOR (Figure 6-16)
A. Removal.
1. Remove filter and indicator from air intake hose coupling.
2. Unscrew indicator from filter.
B. Inspection.
1. Inspect filter and indicator for foreign matter.
2. Indicator stem must move freely by sucking on it with filter attached.
3. Depress reset button to release the red signal from view.
C. Installation. Install indicator and filter in reverse order of removal.
86
VEHICLE
Section VI - COOLING SYSTEM
The cooling system, figure 6-17, consists of a radiator and shroud, belt-driven water pump,
thermostat, cooling fan and shroud, tandem heat exchanger, coolant filter, plus required coolant
tubes, flexible hoses, fittings and clamps.
6-15. SERVICE
NOTE: When the coolant system continually requires coolant be added to maintain proper
level or engine is operating above 350
0
F temperature, this is an indication there are internal
or external leaks.
A. Service of the cooling system consists of periodic checks of the radiator, radiator hose
connections and engine and water pump gaskets for evidence of leaks. Any leaks that can be rem-
edied by tightening hose connections or mounting screws should be done immediately. Leaks
which require gaskets or parts replacement should be made as soon as possible.
NOTE: A 50/50 solution of water commercial permanent type anti-freeze (Ethylene Glycol)
is to be used in the cooling system for proper engine cooling and to retard corrosion. This
mixture is intended for year round use in all climates and does not require seasonal replace-
ment. A 50/50 mixture is indicated on a hydrometer as AOoF. Adjust solution to AOoF if
hydrometer check indicates a weak solution.
B. Anti-freeze should be of approved type and must be re-established. Contaminated or
diluted solutions must be drained and cooling system flushed. To flush system, proceed as follows:
1. Start and run engine at fast idle speed until normal engine coolant temperature
(170
0
F-185
0
F) is achieved.
" - ~ I
Figure 6-17 Engine Cooling System
87
VEHICLE
2. Remove hull rear drain plug and route drain hose through hole.
3. Stop engine and drain cooling system by opening hose drain cock.
4. Flush radiator and engine with clean water.
5. Close engine drain cock and connect radiator hoses.
6. Fill cooling system to within 2 inches of top of filler neck with coolant.
C. Only clean, soft water should be used with the coolant mixture in the radiator. Hard
water will form a scale, not only in the radiator core, but in the engine block and heads as well.
This scale or lime deposit causes hot spots in the engine and will plug the small passages of the
radiator core.
D. Rust, scale and sediment deposits in the cooling system can usually be removed by reverse
flushing of the system and using cooling system cleaner. Where water contains a high percentage of
minerals, the cooling system should be cleaned at least twice yearly to prevent heavy scale deposits.
For pressure flushing refer to the cooling system chapter.
616. RADIATOR CAP
When engine is started the water pump thermostat is closed permitting water temperature and
pressure to buildup within the engine. When normal operating temperature is reached the thermo-
stat opens, circulating water through radiator. If over-heating develops pressure in excess of 15 psi,
the system will automatically vent through the radiator cap.
A. Inspection.
1. Inspect radiator cap gasket, if damaged replace cap.
2. Install cap on radiator or cap pressure tester. If cap will not hold 15 psi replace cap.
6-17. WATER FILTER (Figure 6-18)
The spin-on water filter by-passes a small amount of coolant through a filtering and treating
element that controls acidity, removes impurities and helps reduce rust and corrosion. Anti-freeze
containing anti-leak additives should not be used in conjunction with the water filter. Anti-leak
additives may be filtered out and clog the filter making it ineffective. The filter element must be
changed periodically as indicated in Chapter 4 Maintenance Services.
A. Removal.
1. Close water shut-off valves on filter inlet and return lines.
2. Unscrew element and discard.
B. Installation.
1. Install new element, hand tighten until seal touches filter head. Tighten an additional
one-half to threefourths turn.
2. Open shut-off valves.
CAUTION: Mechanical tightening will distort or crack filter head.
88
SPIN ON
FilTER
R
SHUT OFF
VALVE
VEHICLE
Figure 618 Corrosion Resistor
618. FAN (Figure 619)
A. Removal.
1. Remove exhaust grille.
2. Remove six screws and lock washers securing fan and spacer to fan hub.
3. Remove fan and spacer from engine.
B. Installation. Install fan in reverse order of removal.
619. SHROUD RING (Figure 619)
A. Removal.
1. Remove engine compartment side panels, open engine access hatches and engine
access door.
2. Remove fan.
3. Remove six screws and lock washers securing shroud ring. Remove shroud ring.
B. Installation. Install shroud ring in reverse order of removal.
NOTE: Before tightening shroud ring screws, adjust shroud ring so fan is centered in shroud
ring. Tighten shroud ring screws.
89
VEHICLE
Figure 6-19 Fan and Shroud Ring
6-20. FAN BELTS (Figure 6-20)
A. Removal.
1. Remove exhaust grille.
2. Remove fan and fan spacer.
3. Loosen two screws securing fan hub shaft to mounting bracket.
NOTE: Fan hub will fall out of line when this is done.
4. Loosen adjusting screw in top of mounting bracket.
5. Remove fan belts from coolant pump and crankshaft pUlley.
B. Installation.
1. Place belts over coolant pump, crankshaft and fan hub pulleys.
SCREW (5)
LOCK
WASHER {51
NOTE: Fan belts must be installed in matched sets to obtain correct belt adjustment.
2. Tighten screws until the fan hub is straight.
3. Adjust belt tension by turning adjusting screw.
90
VEHICLE
Figure 6-20 Fan Belts
NOTE: Belt tension should be 110 pounds for new belts, 80 pounds for used belts. (Table
6-4).
4. Tighten two fan hub screws to 110 to 115 ft. Ibs. (149 to 156 Nml.
5. Recheck belt tension. Use belt tension gage.
6. Back out adjusting screw one-half turn to prevent screw breakage.
NOTE: All new belts will loosen after running a short period of time and must be readjust-
ed to installation tension. After initial installation and retensioning, belts should then be set
at running tension (80 ft. Ibs.).
7. I nstall fan and fan spacer.
8. Adjust fan shroud ring.
9. Install exhaust grille.
TABLE 6-4 BELT TENSION REQUIREMENTS
Belt
Fan
Alternator
I nitial Tension (New)
1101bs.
901bs.
91
R etension (After Run-I n)
801bs.
601bs.
VEHICLE
Section VII - TRANSMISSION
Corrective maintenance on the transmission in this section is limited to checking oil pressure,
adjustment of control cables and replacement of the neutral starter switch. For more detailed
maintenance refer to Chapter 11.
6-21. SHI FT CONTROL CABLE ADJUSTMENT (Figure 6-21)
A. Adjustment.
1. Disconnect control cable from selector lever on transmission.
2. Place selector lever on transmission in neutral position (second detent from full
forward position towards engine).
3. Place operator's selector control in the neutral (N) position, 1/16 inch from the stop.
4. Adjust trunnion on control cable rod so it fits into hole on transmission selector lever.
5. Install new cotter pin to hold trunnion in transmission selector lever. Do not spread
cotter pin at this time.
6. Move selector lever through all positions. The lever should be 1/16 inch from the stop
in each position. (This allows for cable backlash to properly match detents in transmission).
7. Spread cotter pin. Tighten cable lock nut against trunnion.
8. Secure all access panels.
9. Road test vehicle to check operation of selector.
6-22. NEUTRAL STARTER SWITCH (Figure 6-21)
A. Removal.
1. Remove cover panel between transmission range selector and transfer controls.
2. Remove stop nut and washer securing switch actuator arm to switch shaft.
3. Disconnect electrical wires to switch.
4. Remove jam nut securing switch to mounting bracket.
5. Remove switch.
B. Installation.
1. I nstall switch in reverse order of removal.
92
VEHICLE
6-23. MECHANICAL ACTUATOR CABLE ADJUSTMENT (Figure 622)
A. Adjustment.
1. Remove bolt and nut securing actuator cable clevis to fuel control lever.
2. Loosen lock nut securing clevis to control cable.
3. Push cable core until it is bottomed in actuator assembly on transmission.
4. Move fuel control lever to wide open throttle (W.O.T.) position (towards rear of
engine).
5. Rotate the clevis so that cable core is bottomed in actuator when fuel control lever
is in W.O.T. position.
6. Install clevis bolt and nut.
7. Tighten cable lock nut against clevis.
8. Check linkage for proper return to idle position.
9. Total cable control travel should not be less than 1.187 inches (30.15 mm) or more
than 1.56 inches (39.6 mm).
~ - - ~
~ ~
~
J ; ~ ~
i;I
CONTROL CABLE t
TRANSMISSION
SELECTOR
LEVER
CABLE
TRUNNION
COTTER PIN
Figure 6-21 Shift Control
93
FUEL CONTROL
LEVER
LOCK
NUT
Figure 622 Mechanical Actuator Cable Adjustment
VEHICLE
624. OIL PRESSURE CHECKING PROCEDURE (Figure 623 and 624)
WARNING: Proper safety precautions must be exercised during tests. A" personnel must
stand clear of the vehicle. Take precautions against movement of the vehicle. Gauges (vacuum,
pressure, tachometer! should have extended lines to permit reading inside the vehicle.
A. All oil level and pressure checks must be made at normal operating temperature (160
220
0
F).
B. Check oil level.
C. Insta" oil pressure gage (0300 psi). Connect tachometer.
D. Check oil pressures in the following manner:
CAUTION: Total running time for either of these combinations must not exceed 2 minutes.
NEUTRAL - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Pull the actuator cable to idle position against internal stop.
3. Engine at 1000 RPM - Normal pressure 90110 psi.
NEUTRAL - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full throttle position against internal stop.
3. Engine at 1000 RPM - Normal pressure 130150 psi.
FORWARD - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full throttle position against internal stop.
3. Engine at 1000 RPM - Normal pressure 130150 psi.
REVERSE - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full-throttle position against internal stop_
3. Engine at 1000 RPM - Normal pressure 225250 psi.
NOTE: It is important that the mechanical linkage is properly adjusted at this time.
1. Fuel control lever in full throttle position.
2. Push mechanical actuator cable to full throttle position against internal mechanical
stop.
94
VEHICLE
3. Adjust clevis so that pin fits freely through the hole in the fuel control lever and con-
tacts the end of the slot in the clevis, thus holcing the actuator cable in the full throttle position
when the fuel control is at full throttle.
4. Total cable travel should be 1.187 inches to 1.56 inches.
)
Figure 6-23 Transmission Check Points - Left Side
REVERSE
SIGNAL
PRESSURE
I
FROM
COOLER
BREATHER
Figure 6-24 Transmission Check Points - Right Side
95
VEHICLE
6-25_ FOUR WHEEL DRIVE SHIFT LINKAGE ADJUSTMENT (Figure 6-25)
A_ Remove transfer cover panel and rear tunnel cover exposing control cable ends and
control rods_
B_ Disassemble cotter pin and clevis pin securing control cable clevis to shift lever.
C. Push shift rod on transfer all the way in to engage detent (4-wheel drive position).
D. Move driver's 4-wheel drive shift control lever to IN position.
E. Adjust control cable clevis so clevis pin aligns with lever.
F. Install clevis pin and cotter pin. DO NOT spread cotter pin.
G. Test operation of shift control. Detents of driver's control lever must match those in
transfer case. Spread cotter pin.
NOTE: If sufficient adjustment cannot be made at transfer end of control cable, adjust con-
trol rod or driver's end of control cable.

CLEVIS PIN
COTTER PIN_
JAM
NUT
FOUR WHEEL
DRIVE CONTROL
CABLE
o
CLEVIS PIN
COTTER PIN
11---1---+-- CLEVIS
JAM NUT
RANGE
CONTROL
CABLE
Figure 6-25 Shift Linkage Adjustments
96
VEHICLE
6-26. RANGE SHIFT LINKAGE ADJUSTMENT (Figure 6-25)
A. Remove transfer cover panel and rear tunnel cover exposing control cable ends and
control rods.
B. Disassemble cotter pin and clevis pin securing control cable clevis to shift lever.
C. Push shift rod on transfer all the way in to engage detent (HI position).
D. Move driver's shiH control lever to HI position.
E. Adjust control cable clevis for "free pin" with lever.
F. Install clevis pin and cotter pin. DO NOT spread cotter pin.
G. Test operation of shift control. HI and LOW (neutral) the transfer unit must be in neutral
with no power output to propeller shafts. Spread cotter pin.
NOTE: If sufficient adjustment cannot be made a"t transfer end of control cable, adjust con-
trol rod or driver's end of control cable.
97
VEHICLE
Section VIII - TIRES AND WHEELS
This section contains instruction for removing, dismounting, mounting and installing tires and
wheels (Figure 6-26).
627. TIRES AND WHEELS
NOTE: Lug nuts on vehicle left side have left hand threads, lug nuts on vehicle right side
have right hand threads. When exchanging a wheel and tire the arrow on the sidewall must be
pointing in the forward direction of rotation.
A. Removal.
1. Break loose ten lug nuts.
2. Lift or jack vehicle so that tire just clears ground.
3. Remove ten lug nuts, tire and wheel.
B. Dismounting Tire.
1. Deflate tire completely by removing valve core.
2. Place wheel and tire on locating base, lock ring facing up.
3. Place shaft through wheel and lock shaft into locating base.
4. Coat tire bead and lock ring with rubber lubricant or soap.
5. Place bead breaking shoes on crosshead and position crosshead on tire with pump and
split nut.
6. Pump down until bead breaking shoes contact the tire bead just outside the lock ring.
7. Apply a little pressure to tire by pumping tire press downward. Use hammer to drive
bead breaking shoes between tire bead and lock ring. Again apply pressure to tire and force tire
down far enough so as to remove lock ring. Remove lock ring while tire is depressed.
8. Release tire press pressure. Remove bead breaking shoes. Remove shaft and crosshead
assembly from wheel locating base.
9. Turn tire and wheel assembly over and place on wheel locating base.
10. Place crosshead assembly through wheel and lock shaft into wheel locating base.
11. Coat tire around bead with rubber lubricant or soap.
12. Pump tire press downward until bead breaking shoes contact tire bead just outside
rim.
13. Apply a little pressure to tire press by pumping downward.
14. Use hammer to drive bead breaking shoes between tire bead and rim. Apply more
pressure to remove tire from wheel.
98
CAP-
VEHICLE
A/LUG
SCREW ~ ~
I ~ ~ ~
SPLIT
RING
RIM
Figure 626 Tire and Wheel - Exploded View
99
FORWARD
ARROW
..----TIRE
VEHICLE
15. Release tire press pressure. Remove bead breaking shoes. Remove shaft and cross-
head assembly from wheel locating base.
C. Repair.
NOTE: Be sure arrow on sidewall of tire points towards forward rotation of tire (Fig. 6-26).
1. Repair puncture with conventional repair equipment.
2. If valve is defective, replace valve.
D. Mounting Tire.
WARNING: Do not stand in front of wheel when tire is being inflated. If bead ring is not
seated properly in wheel groove, inflating tire can eject bead ring with considerable force.
NOTE: For easier assembly of tire on wheel clean all rust and dirt from wheel and tire beads.
Lubricate beads and wheel with tire lubricant or soap and water.
NOTE: Be sure arrow on sidewall of tire points towards forward rotation of tire (Fig. 6-26).
1. Place tire on wheel rim.
2. Place tire and wheel assembly on wheel locating base with lock ring side facing up.
3. Place lock ring on tire.
4. Place crosshead assembly through wheel and lock shaft in wheel locating base.
5. Apply pressure to depress the tire bead far enough to permit the installation of the
split ring.
6. After the split ring is properly installed, release pressure on pump.
7. To inflate tire, place bead breaking shoes about one inch over top of the tire sidewall.
8. After tire is inflated remove bead breaking shoes and crosshead assembly.
E. Installation.
1. Position wheel on hub lugs and secure with ten right or left hand lug nuts, depending
on which side of vehicle wheel is being installed.
2. Lower vehicle and alternately tighten and torque lug nuts to 350 to 400 ft. Ibs.
100
VEHICLE
Section IX - SERVICE BRAKES
Vehicle service brakes are four wheel, dual vacuum assisted and hydraulic actuated. The brake
system consists of: a master cylinder, two vacuum boosters, four wheel cylinders connected to
brake shoe assemblies and necessary tubing, hoses and fittings. The master cylinder relays hydraulic
pressure to the two vacuum-powered brake boosters. One booster increases hydraulic pressure to
the two front wheel cylinders, the other to the two rear wheel cylinders. The vacuum to operate
both power boosters are supplied by the engine driven vacuum pump. Maintenance in this section
contains minor brake shoe adjustment, adding fluid to master cylinder and adjustment of brake
pedal free travel.
6-28. MINOR ADJUSTMENT (Figure 6-27)
A. Place transfer shift lever in neutral.
B. Jack or lift vehicle up to allow both wheels to rotate freely.
NOTE: On axle that wheel is being adjusted both wheels must be free to rotate. With locking
differentials both wheels turn together unless differential is unlocked. Unlock differential by
rotating wheel being adjusted forward and opposite wheel rearward until a clicking sound is
noticeable. This indicates differential is unlocked and wheel that is being adjusted is free to
rotate.
C. Turn front shoe adjusting cam clockwise on left side of vehicle and counter clockwise on
right side of vehicle. This will bring lining of shoes into contact with drum. As cam is being adjust-
ed, rotate the wheel by hand until a slight drag is felt within the wheel. Stop adjusting cam at this
point and back off on cam slightly to allow wheel to rotate freely.
D. Repeat above procedures at each wheel.
629. PEDAL ADJUSTMENT
A. Brake pedal free travel should not be less than 1/8 inch nor more than 1/4 inch.
B. Adjust free travel to these limits by adjusting master cylinder push rod.
C. Loosen jam nut and turn push rod to obtain proper travel and tighten jam nut.
Figure 6-27 Brake Shoe Minor Adjustment
101
VEHICLE
Section X - PARKING BRAKE
The parking brake consists of a brake drum and a set of brake shoes mounted to rear of trans-
mission, a control cable and an operating lever. Maintenance in this section is limited to adjustment
of lever.
6-30. LEVER ADJUSTMENT
A. Place lever in OFF or released position.
B. Turn knob on end of lever handle clockwise to increase brake holding effort.
C. When knob adjustment runs out, the parking brake cable end at transmission needs
adjustment.
Section XI - STEERING SYSTEM
Limited maintenance of the steering system in this section is restricted to alignment of front
wheels.
6-31. FRONT WHEEL ALIGNMENT (Figure 6-28)
Front wheel misalignment is a major cause of premature and uneven tire wear. The factors
involved in front wheel alignment are caster, camber, turning angle, and toe-in.
A. Caster. Front axle caster is the inclination of the center line through upper and lower
steering knuckle trunnions toward rear of vehicle. Caster is established by design and is not adjust-
able.
B. Camber. Front wheel camber is the inclination of the vertical center line through the
wheel and tire away from vertical center line of vehicle. There is no adjustment for camber, however;
loose wheel bearings, loose steering knuckle bearings, or bent axle housing will affect camber.
C. Turning angle. Front wheel turning angle is the minimum angle through which the wheels
may be turned from straight ahead position. This angle is limited by nonadjustable turning stops.
D. Toe-in. Front wheel toe-in is the distance by which the wheels are closer together at the
front than at the rear when wheels are in the straight ahead position.
1. I nflate tires to correct pressure and place vehicle on a smooth, level surface with
wheel in the straight ahead position. Place toe-in gage between wheels ahead of the axle with gage
ends bearing against tire side wall and with both chains touching the ground. Set gage so pointer
registers zero. Remove gage and place at some relative position at the rear of axle with both chains
just touching the ground. The pointer will indicate amount of toe-in or toe-out. Correct toe-in is
1/8 + 1/16 inch measured at a distance of 13 inches from center of axle.
2. Loosen tie rod clamp screw and nut at both ends of tire rod.
3. Shorten or lengthen tie rod by turning tie rod with pipe wrench.
NOTE: When shortening or lengthening tie rod, the distance of change indicated on gage is
one-half the distance of tire movement.
102
VEHICLE
A
{ 13 INCHES
B MINUS A 0= TOEIN
13 INCHES

- L
r r
1---.
1eit
J

I
I

13 INCHES
'- '-I-'
B
Figure 628 Front Wheel Alignment
4. Tie rod clamp screws must be located vertically and to the rear of the rod to avoid
interference with shock absorbers during vehicle turns.
5. When adjustment is correct, torque clamp screws and nuts to 6080 ft. Ibs.
103
VEHICLE
Section XII -- ELECTRICAL
6-32. STARTING SYSTEM (Figure 6-29)
The starting system consists of two batteries, a starter switch, starter motor, starter solenoid
and connecting electrical cables and wires.
NOTE: Refer to electrical chapter 15 for complete detailed instructions for specific com-
ponents.
6-33. BATTERIES
A_ Service.
1. Overall Battery Check. Vehicle batteries should be tested prior to performing any
electrical checks in the vehicle. This vehicle has two 12-volt batteries connected in series, furnish-
ing 24 volts to the electrical system which uses a negative (-) and a positive (+) power feed to the
electrical components. Turn on the ignition switch and observe the battery indicator. Start the
engine, accelerate to 1200 rpm, and again observe the battery indicator.
IGNITION
STARTER
SWITCH
NEUTRAL SAFETY
SWITCH
P40 P42
STARTER
MOTOR
4
BUSS BAR
STARTER
SOLENOID.
'" -'

I;:
'"
u
'" oc
'"
>
co co:) co 01
UU(I) U U
00000
rt-}-t-I-
61
b
SLIP
RING
REF
+
12VOLT
BATIERY
ToeB
TO CONTROL
PANEL
P14
B+
ALTERNATOR
TO FUEL
VALVE
GRND

.-'-'----'-'--, DISCONNECT
+ SWITCH
71+ 12 VOLT
BATTERY
ENGINE GROUND
MOIOR
24 VOLT SUPPLY
Figure 6- 29 Starting System
104
VEHICLE
2. Adding Water. The water in the electrolyte solution evaporates because of high
temperature of excessive charging rates. Inspect battery and add distilled water or rain water at
intervals required by service and climatic conditions. Keep batteries filled with water to split ring
level.
634. HEAD LAMP (Figure 6-30)
A. Lamp Replacement.
1. Loosen four headlight door mounting screws and remove door from body.
2. Carefully remove head lamp and shock cushion and disconnect head lamp at connec-
tor. Remove headlamp from shock cushion.
3. Insert new head lamp into shock cushion. Connect head lamp at connector and posi-
tion to headlight body.
4. Position headlight door and tighten four mounting screws.
5. Turn headlights on and check operation in low and high beam position.
6-35. TAILLAMP (Figure 6-31)
A. Lamp replacement.
1. Loosen six taillight door mounting screws and remove door and seal.
2. Push in on lamp, turn lamp counterclockwise and pull lamp from socket.
HEADlAMP
LAMP
BLACKOUT
DRIVE ~ ~ ~ ~ ; ; ; ; ; ; ; : : = : : : : : : : : : - ......
b
LAMP
BLACKOUT
MARKER
HEADLIGHT
BODY ASSEMBl V
Figure 6-30 Headlamp - Partial Exploded View
105
VEHICLE
lAMP
TAILLIGHT
"""\ ....
..
C? LAMP
BLACKOUT
DRIVE
DOOR
ASSEMBl Y
LAMP
BLACKOUT
MARKER
Figure 631 Taillamp - Partial Exploded View
3. Position and push new lamp in socket. Turn clockwise until lamp is seated.
4. Position door and seal to taillight body and tighten six mounting screws.
5. Turn taillight on and check operation lamps.
636. DIRECTIONAL SIGNAL LAMP (Figure 632)
A. Lamp Replacement.
1. Remove two screws retaining light lens. Remove lens and gasket.
2. Push in on lamp, turn lamp counterclockwise and pull lamp from socket.
3. Position and push new lamp in socket. Turn clockwise until lamp is seated.
4. Position gasket and lens to body and secure with two screws.
5. Turn directional signal on and check operation of lamp.
106
LENS
. " ' ~ ' - - - - WASHER (2)
Figure 6-32
VEHICLE
GASKET
LIGHT
BODY
I S- nal Lamp - Directiona Ig Partial Exploded View
107
VEHICLE
NOTES
108
GENERAL
VEHICLE
CHAPTER 7
Hull Items
This Chapter contains removal and installation instructions for the following hull items:
interior panels and covers, interior pads, view blocks, driver's seat, observer's seat, side and rear
seat, driver's and observer's hatches, side doors, rear door, troop hatch, winch hatch, engine hatches,
engine door, gun port covers, ring mount, exhaust grille, fuel filler and cover, towing pintle and
shackle, rear view mirror, hydraulic reservoir, door and hatch latch handles, hold open latches,
weatherstrip seals, door and hatch crash pads and fixed fire extinguisher. For location of door and
hatches refer to figure 7-1.
OBSERVER'S
HATCH GUN
RIGHT FUEL
TANK FILLER COVER
WINCH HATCH
LEFT
FUEL TANK
FILLER COVER
DRIVER'S
HATCH
RIGHT SIDE DOOR
TROOP ACCESS HATCH
LEFT SIDE
DOOR
RADIATOR
HATCH
ENGINE
DOOR
REAR
DOOR
ENGINE
HATCH
RADIATOR
FILLER COVER
Figure 7-1 Location of Doors and Hatches
109
VEHICLE
Section I - INTERIOR PANELS & COVERS (Figure 7-2)
7-1_ TOOL BOX COVER
A. Removal. Turn latch to the vertical position, lift cover up and pull rearward to remove.
B. Installation. Position forward edge of cover into position, lower cover and turn latch to
the horizontal position to secure.
7-2. TUNNEL COVERS
A. Removal. All tunnel covers are removed in a similar manner either by unlatching latches
or by turning fasteners one quarter turn and sliding or lifting covers from hull.
B. Installation. Install in reverse order of removal.
7-3. ENGINE COMPARTMENT WALL & COVERS
A. Removal. All engine compartment walls and covers are removed by turnIng screws until
free from cage nuts and lifting or sliding walls and covers from hull.
B. Installation. Reverse removal procedure.
7-4. BATTERY HEAT SHIELD
A. Removal. Remove nuts securing heat shield to its supports. Remove shield.
B. Installation. Reverse removal procedure.
SIDE UPPER
FRONT
SIDE LOWER
REAR

NUT /'
CAGE NUT
INSPECTION
COVER
TUNNEL
FASTENER CENTER
STUD' ".,..- ...... .&9 __ _
TUNNEL
FRONT I _
FRONT
VENT WALL
RECEPTACLE
TRANSFER
COVER
TUNNEl
REAR

_ SPRING TOOLBOX
U
Figure 7-2 Interior Panels and Covers
110
VEHICLE
Section II - INTERIOR PADS (Figure 7-3)
7-5_ REMOVAL
Using a suitable scraping tool, remove insulating and crash pad from vehicle door, hatch and
other hull locations_ Clean mating surfaces of old adhesive, grease or oil.
7-6_ INSTALLATION
Apply sufficient methylethlketon (MEK solvent) to the precoated surface of the new crash
pads and place coated side down on mating surface of vehicle_ Press pads down firmly to assure
proper bonding_
INTERIOR
SEAT WALL
CREW RH
INTERIOR
OBSERVERS
LH CREW
DRIVER
INTERIOR
INTERIOR
Figure 7-3 Hull Insulating Pads
111
REAR
DOOR
INTERIOR
LH DOOR
VEHICLE
Section III - VIEW BLOCKS & CRASH PADS (Figure 74)
77. REMOVAL
A. Remove four wing screws and spacers securing view block crash pad and spall shield. When
removing the driver's double view block crash pad a center screw and flat washer must also be reo
moved. Remove crash pad and spall shield.
B. Remove two screws and clamps securing view block to hull opening. Remove view block
by placing a wooden block against inside of view block and lightly tapping until view block is free
of opening.
78. INSTALLATION
A. Clean the view block hull opening of all caulking compound, rust or foreign matter.
B. Apply a bead of caulking compound around top and sides of view block and across
bottom face of hull opening approximately 1/2 inch from outside edge.
C. Start view block in hull opening, then ram block into position to spread caulking com
pound evenly. Seat view block by tapping lightly with rubber mallet.
D. Secure view block with two clamps and screws.
E. Add caulking around outside edges of block to fill any openings between view block and
hull. Remove excess caulking.
F. Position spall shield and crash pad to back side of view block and secure with two spacers
and wing screws with driver's double view block crash pad a center screw and washer must also be
replaced.
SCREW FLATWASHER
__ -DRIVER'S
WING CRASH
14) PER CRASH PAD
PAD

PAD
SCREW 12)
VIEW
BLOCK
Figure 74 Removing or Installing View Blocks and Crash Pads
112
VEHICLE
Section IV DRIVERS SEAT
WARNING: The driver's seat is spring loaded and care must be taken to prevent personal
injury when working on seat assembly.
7-9. REMOVAL
Remove four nuts and lock washers securing driver's seat to deck studs and lift seat from
vehicle.
7-10. DISASSEMBLY
A. Remove four screws and lock washers securing seat back cushion to frame and remove
cushion.
B. Remove six screws and lock washers securing seat bottom cushion to seat base and frame.
Remove cushion.
7-11. ASSEMBLY
Assemble seat cushions in reverse order of disassembly.
7-12. INSTALLATION
Position driver's seat on deck studs. Secure with four lock washers and nuts.
Figure 7-5
SEAT
BASE
NUT 14)
FLAT WASHER 14)
Removing or Installing Driver's Seat
113
VEHICLE
Section V - OBSERVER'S SEAT
7-13. REMOVAL (Figure 76)
A. Remove two screws and lock washers securing seat back to bulkhead and remove seat
back as an assembly.
B. Remove three screws and lock washers securing seat bottom to bulkhead and remove seat
bottom as an assembly.
7-14. INSTALLATION
A. Position seat bottom assembly against bulkhead and secure with three lock washers and
screws.
B. Position seat back assembly against bulkhead and secure with two lock washers and
screws.
f

n II1I
SEAT BOTTOM =
ASSEMBl Y

SEAT BACK
ASSEMBLY '\
Figure 7-6 Removing or Installing Observer's Seat
114
VEHICLE
Section VI - SIDE AND REAR SEATS
All side and rear seats are removed and installed in the same manner as the observer's seat
bottom assembly.
Section VII - DRIVER'S & OBSERVER'S HATCHES HINGE TYPE
NOTE: Both driver's and observer's hatches are removed and installed in this same manner.
715. REMOVAL (Figure 77)
A. Insert a 1/2 inch pipe 12 inches long over tang of spring (4) at actuator (11). Pull pipe down
and hold spring free from cam.
B. Remove nut (13), screw (12) and cam (15) from actuator.
C. Slowly allow spring and pipe to unwind and remove pipe.
D. Remove cotter pin (7) from either end of hatch rod (8) and remove rod from hinge butts,
actuators, spacers and spring.
E. Remove hatch.
716. INSTALLATION
A. Position hatch (2) and actuators (3 and 11) on vehicle. I nstall two spacers (5 & 6) be-
tween hinge leafs and hinge butts. Install two spacers between actuators and hinge butts.
B. Thread rod (8) through hinge. butts, spacers and hinge leaf. Install spacer (9) into spring
(4) and position between actuators.
C. Finish threading shaft through spacer, spring, hinge butt, hinge leaf and spacers. Install
cotter pins (7) into shaft.
D. Hold hatch in the vertical position and adjust set screw (10) in actuator (11) against hinge
leaf to remove all play from hatch.
E. Insert pipe over spring tang and pull spring past hole in actuator (11). Install cam (15)
and screw (12). Secure cam in the lowest position with nut (13).
F. Test operation of hatch and adjust position of cam for desired hatch operation.
115
Figure 7-7
VEHICLE
es - Exploded View Driver's and Observer's Hatch
116
i I
i
VEHICLE
Section VIII - DRIVER'S & OBSERVER'S HATCH PIVOT TYPE
7-17. REMOVAL (Figure 7-8)
A. Loosen nut (1) and remove set screw (2) and nut.
B. Remove set screw (5) and drive pin (4) from hatch and hatch shaft (3). Lift hatch from
vehicle.
C. Remove spring (12) and drive pin (19) from bushing (6), link (10) and hinge shaft (3).
Remove shaft.
D. Remove screw (11), nut (18) and clevis (15) with link. Remove two screws (9) securing
spring retainer (8). Bushing (6) can now be removed from top of hull.
E. Drive pin (14) from clevis and link and unscrew ball (16) and handle (17). Remove
hatch from hull.
7-18. INSTALLATION
A. Install all parts in reverse order of removal.
B. Prior to tightening set screw (5), set screw (2) must be adjusted.
C. Position latch handle in the locked position, adjust set screw (2) so as to compress hatch
seal, and still allow operation of latch without difficulty.
D. With latch handle in the locked position tighten nut (1) and set screw (5).
E. Test operation of hatch.
117
VEHICLE
__ -2
----
----
---
Figure 7-8 Driver's and Observer's Hatch Pivot Mechanism - Exploded View
118
VEHICLE
Section IX - SIDE DOORS
7-19. REMOVAL (Figure 7-9)
A. Close door upper half and secure with door latch. Remove cotter pins, hinge pin, spring,
spring spacer and spacers.
B. Open latch and remove door upper half.
C. Close door bottom half and secure with door latches. Remove cotter pins from hinge rod.
CAUTION: Door spring is preloaded 1/2 turn.
D. Drive hinge rod from hinge butts and remove door spring and spacers.
E. Open latches and remove door lower half.
7-20. INSTALLATION
A. Position door on hull in closed position and lock door latches to retain door in position.
B. Insert tang of spring into position in door. Install two spacers and drive hinge rod through
right hand hinge butt, hinge leaf, spacers and into spring approximately 4 inches.
C. Lift free end of spring away from hull. Install a pipe 12 inches long over spring tang and
wind spring 1/2 turn. Allow spring to straighten out.
D. Install two spacers and drive hinge rod completely through spring, butts, leaf and spacers.
Remove pipe from spring and install new cotter pins in hinge rod.
E. I nstall upper door half by reversing removal procedures.
NOTE: When installing the two spacers at each hinge mount, install the thicker spacers
under the hinge leaves.
119
SPRING
SPACER
LOWER
DOOR
VEHICLE
COTTER
PIN 12)
SPACER 14)
Figure 7-9 Side Door - Exploded View
120
WEATHERSTRIP
COTTER PIN 12)
VEHICLE
Section X - REAR DOOR
721. REMOVAL (Figure 710)
WARNING: Place upper door in open position to relieve tension on door springs before
removing door or attaching hardware.
A. Remove two screws (25) and nuts (17) from door upper half (24) and swing links (26)
upward.
B. Close door and secure with door latches. Remove cotter pin (16), hinge pin (15) and
spacers (8 and 9) from both hinge butts. Remove door.
C. Remove cotter pin (12), spring eye retaining pin (10) and two flat washers (11) securing
one end of springs (5 and 7) to hull.
D. Remove cotter pins (13) from spring hinge rod and remove rod, adjusting links (26) and
two springs (5 & 7).
E. Close door lower half (23) and secure with door latches.
F. Remove cotter pins (18) from hinge rod (19) and drive rod from hinge butts. Remove
spacers (20 and 21), spring (22) and door.
722. INSTALLATION
A. Install rear door upper in reverse order of removal.
B. Position door on hull in the closed position and lock door latches to retain door in
position.
C. Insert tang of door spring into position in door. Install two spacers and drive hinge rod
through right hand hinge butt, hinge leaf and into spring approximately 4 inches.
D. Lift free end of spring away from hull. Install a pipe 12 inches long over spring tang and
wind spring 112 turn. Allow spring to straighten out.
E. Install two spacers and drive hinge rod completely through spring, hinge butts, hinge leaf
and spacers. Remove pipe from spring tang and install new cotter pins in hinge rod.
723. ADJUSTMENT
A. With upper half of rear door in open position, remove the two door mounted adjusting
link screws, nuts and lock washers. Loosen link locking nuts and screw links in for greater tension,
or out for less tension on door springs. Tighten locking nuts and secure adjusting links with screws,
lock washers and nuts.
NOTE: The tension on both springs should be equal.
121
Figure 710
VEHICLE
Exploded View
Rear Door-
122
,
, ;
,
(
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;
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I :
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I
VEHICLE
Section XI - TROOP FOLDING HATCH
7-24. REMOVAL (Figure 7-11)
A. Position hatch (3) in the vertical position to relieve tension on spring (12).
B. Drive pin (14) from hinge mount. Pull hinge shaft (15) from hatch (3) and hinge mounts.
C. Remove spring (12) and hatch stop (13). Remove hatch.
D. Drive pin (16) from hatch and hatch latch handle (17). Remove handle, plunger pin (19)
and spring (18).
E. Remove two cotter pins (21) securing pins (4). Remove pins.
F. After removing pins (4), remove latch handle (1) and spring (2). Separate two halves of
folding hatch (3).
- ~ - - --::::::----:
Figure 7-11 Troop Hatch - Exploded View
123
VEHICLE
G. Remove nuts (11), washers (10) and retainers (9) which attach crash pad (8). Remove
crash pad.
725. INSTALLATION
A. Install hatch and latch handle in reverse order of removal.
B. If set screws (5) were removed, adjust for distance of travel so latch (1) secures folding
hatch in open position.
Section XII WI NCH HATCH
7-26. REMOVAL (Figure 7-12)
A. Remove cotter pins, hinge pins and four spacers from each hinge mount.
B. Remove hatch.
7-27. INSTALLATION
Install winch hatch in reverse order of removal.
WINCH HATCH
SPACER 14)
Figure 7-12 Winch Hatch - Exploded View
124
. ,
!
,
VEHICLE
Section XIII - ENGINE HATCHES
7-28_ REMOVAL (Figure 7-13)
A_ Remove cotter pins from four hinge pins. Remove eight spacers and remove both hatches.
B. Remove four screws, lock washers and air intake protector from radiator hatch.
7-29. INSTALLATION
Install engine hatches in reverse order of removal.
RADIATOR
FILLER wvcn,
SCREW
ENGINE
HATCH
~ ~ __ SCREW (4)
/ O - - : : l : : : : : : : : ~ , LOCKWASHER 14)
'"
-----------
INTAKE
PROTECTOR
INTAKE
SCREEN
RADIATOR
~ ....... __ SPACER (4)
HINGE
PIN 12)
COTTER
I 12)
Figure 7-13 Engine Hatches - Exploded View
125
VEHICLE
Section XIV - ENGINE DOOR
7-30. REMOVAL (Figure 7-14)
A. Support door and remove two cotter pins, two hinge pins and four spacers from each
hinge mount.
B. Remove door.
7-31. INSTALLATION
Install engine door in reverse of removal.
WEATHERSTRIP
:
STEP
G \
13) HINGE PIN 12) COTTER PIN 12)
SCREW 13)
Figure 7-14 Engine Door - Exploded View
126
ENGINE
DOOR
SPACER 14)
VEHICLE
Section XV - GUN PORT COVERS
7-32. REMOVAL (Figure 7-15)
Remove two self-locking nuts and gun port locking knobs. Remove gun port inner and
outer covers.
7-33. INSPECTION
A. Inspect gun port covers for warpage, rust and stud thread damage.
B. Check locking knobs for thread damage. Rethread damaged threads using tracer die or
tap. If rethreading does not correct damage replace gun port outer cover or locking knob.
7-34. INSTALLATION
A. Place outer cover into position from outside of hull.
B. Position inner cover on studs protruding through hull.
C. Install locking knobs and new self locking nuts to studs. Tighten nuts flush with end of
studs.
2
' ~
Figure 7-15 Gun Port Covers - Exploded View
127
VEHICLE
Section XVI - RING MOUNT
7-35. REMOVAL (Figure 7-16)
A. Remove six screws (27), lock washers (22) and nuts (21), ring mount will have to be
rotated 360 degrees to allow access to nuts and lock washers.
B. Attach a suitable lifting sling to ring mount and lift from vehicle_
7-36. DISASSEMBLY
A. Position hatch (6) in the vertical position to relieve tension on spring (15).
B. Drive pin (17) from hinge mount. Remove hinge shaft (16) from hatch and hinge mounts.
C. Remove spring, (15) hatches, (6 and 31) and. two flanged bushings (9).
D. Drive pin (19) from hatch (6) and hatch latch handle (10). Remove handle (10), plunger
pin (8) and spring (7).
E. Remove two cotter pins (4) hinge pins (3), four spacers (5) and separate hatches (6 and
31).
F. Remove cotter pin (32), hinge pin (2), spring (1) and hatch latch (33).
G. Drive pin (14) from ring mount plunger. Remove plunger handle pin (12) plunger pin
(13) and spring (11).
H. Turn ring mount base (30) upside down. Remove twelve screws (25), lock washers (24)
and lift ring bearing (23) from base.
NOTE: Ring identification plate may have to be removed before proceeding with next step.
I. Remove plug from ring bearing and stand bearing in a vertical position with hole down.
Rotate bearing assembly until all bearing balls are removed and inner and outer bearing races can be
separated.
NOTE: Inspect balls for roundness and races for extensive wear signs. Replace assembly if
found defective.
J. Remove eight screws (28) flat washers (29) and crash pad (20).
7-37_ ASSEMBLY
Assemble ring mount in reverse order of disassembly.
NOTE: Clean bearing balls and races. Coat with a light film of grease before assembly.
7-38. INSTALLATION
Install ring mount in reverse order of removal.
NOTE: Lubricate ring mount by attaching grease gun to lubrication fitting, rotate ring
mount 360 degrees while lubricating to insure that all bearing balls are greased.
128
311---,-"
30-__ 1
VEHICLE
/"--_16
:.'l'<">----11

\-. __ 20
_---21
28:----.11 .........
---22
J---23

26
__ 0 _
- i
a------
21
Figure 7-16 Ring Mount - Exploded View
129
VEHICLE
Section XVII - EXHAUST GRILLE
7-39. REMOVAL (Figure 7-17)
A. Loosen five nuts while lifting up on toe clamp to hold J Bolt from turning and remove
exhaust shroud.
B. Lower nut and J Bolt. Turn J Bolt to clear hook from under hull retainer.
C. Lift exhaust grill from vehicle.
7-40. INSTALLATION
Install exhaust grill in reverse order of removal.
EXHAUST
SHROUD
'"

: J
1/
J BOLT 16)
.
/
o
Figure 7-17 Exhaust Grill - Exploded View
130
o
VEHICLE
Section XVIII - FUEL FILLER AND COVER
741. REMOVAL (Figure 718)
A. Pull detent pin or fuel cover lock, remove screw, nut, spacer and fuel cover.
B. Turn filler cap and pull sleeve from vehicle.
C. Remove six screws, filler guide and discard gasket.
742. INSTALLATION
Place a new gasket on hull and install fuel filler and cover in reverse order of removal.
r:::=::J -----SCREW
FUEL FILLER COVER, V
DETENT I I I
NUT
FILLER CAP
SLEEVE
GUIDE
GASKET
Figure 718. Fuel Filler and Cover - Exploded View
131
VEHICLE
Section XIX - TOWING PINTLE AND SHACKLE
7-43. REMOVAL
A. Remove four screws and nuts securing towing pintle to hull.
B. Remove cotter pin, shackle pin and shackle. Discard cotter pin.
7-44. INSTALLATION
Install towing pintle and shackle in reverse order or removal, using new cotter pin.
Section XX - REAR VIEW MIRROR
7-45. REMOVAL (Figure 7-19)
A. Remove screw, crown nut, washers and mirror ann from bracket.
B. Remove screw, two lock washers and mirror head from arm.
C. Spread bracket, remove screw and lock washer, flat washer and nut from hull.
746. INSTALLATION
I nstall rear view mirror in reverse order of removal.
SCREW
FLAT
CROWN
NUT
MIRROR
ARM
SCREW
. " ' ~ ! ~ r " " ' " ' "
L-.._/ - FLATWASHER (2)
LOCKWASHER ~ / C __ _
~
~ SCREW
BRACKET
NUT
Figure 7-19 Rear View Mirror - Exploded View
132
MIRROR
HEAD
VEHICLE
Section XXI - HYDRAULIC RESERVOIR
7-47. REMOVAL
A. Drain cooling system and remove radiator and shroud assembly.
B. Remove upper battery and battery heat shield.
C. Drain reservoir into five gallon can by removing drain hose cap and opening drain valve.
D. Remove four screws and lock washers securing flange elbow to dual pump inlet port.
E. Remove elbow and hose from dual pump inlet port. Discard Oring.
F. Disconnect pump bypass hose and return hose at tee near filter inlet.
G. Remove two screws and washers securing reservoir to hull.
H. Remove reservoir with filter assembly and hoses attached from vehicle.
I. Remove filter assembly and hoses from reservoir as required.
7-48. INSTALLATION
A. Install reservoir in reverse order of removal using new Oring at dual pump inlet port.
Section XXII - DOOR AND HATCH LATCH HANDLES
749. REMOVAL
NOTE: The removal procedures for all door and hatch latch handles are identical.
A. Remove nut securing handle to hull, hatch or door stud.
B. Remove spring washers, flat washers, ring retainers, spring and handle.
NOTE: Replace spring and spring washers if inspection reveals improper spring tension.
750. INSTALLATION
I nstall door and hatch latch handles in reverse order of removal.
751. ADJUSTMENT
A. To adjust latch handle tension remove nut, spring washers and handle. Remove or add flat
washers as required. Latch when locked must hold door or hatch tightly against weatherstrip seal.
B. To obtain proper tension on the handle, tighten or loosen nut securing handle and spring
washer. Handle must rotate freely yet remain fixed in any position.
133
VEHICLE
Section XXIII - HOLD OPEN LATCHES
752. REMOVAL
A. Remove T or ball handle and nut from release rod and remove release rod from outside
vehicles.
B. Remove cotter pin from latch pivot pin and remove pivot pin, latch and spring.
753. INSTALLATION
Install hold open latches in reverse order of removal.
Section XXIV - DOOR AND HATCH WEATHERSTRIP SEALS
754. REMOVAL
A. Adhesive Type.
1. Using a suitable scraping tool, remove seal from hatch opening. Remove seal strip
from overlapping edge of hatch.
B. Push On Type Weatherstrip Seal.
1. Pry seal away from door or hatch opening.
755. INSTALLATION (Figure 720)
A. Adhesive Type.
1. Clean hull, door or hatch seal area of all old adhesive, oil or grease.
2. Cut new weatherstrip seal approximately 6 inches longer than old seal or distance
around hull opening.
3. Apply adhesive to seal and matching areas of hull, door or hatch.
4. When adhesive becomes tacky start one end of seal at top or back of hull opening.
NOTE: Do not pull or stretch seal during installation.
5. When mating ends come together, cut seal to fit as close as possible to opposite end
and fit into place.
6. Fill opening around ends of seals with adhesive and close doors or hatches for approx
imately 10 hours so that seals are held in place while adhesive dries.
134
VEHICLE
\
WEATHERSTRIP
SEAL
Figure 7-20 Installing Weatherstrip Seals - Adhesive Type
B. Push On Type Weatherstrip Seal.
1. Starting at top center od door or hatch opening, push weatherstrip into position
around edge of opening.
2. Cut weatherstrip for snug fit at joint.
3. Apply adhesive where ends of weatherstrip meet. Allow adhesive to dry before clos-
ing door or hatch.
Section XXV - DOOR AND HATCH CRASH PADS
7-56. REMOVAL
Remove nuts, lock washers and clips securing crash pad to hatch or door frame. Remove
crash pad.
7-57. INSTALLATION
I nstall door or hatch crash pads in reverse order of removal.
NOTE: Tap crash pad with a rubber mallet to insure proper seating as nuts are being tight-
ened.
135
!
VEHICLE
Section XXVI -- FIXED FIRE EXTINGUISHER
7-58. SERVICE AFTER USE (Figure 7-21 and 7-22)
1. Pull ring on safety/relief valve to relieve actuator system pressure.
2. Disconnect actuation system hose at cartridge receiver/actuator assembly.
3. Open bursting disc union assembly.
4. Remove extinguisher from bracket.
5. Replace ruptured bursting disc with new disc.
NOTE: The bursting disc is made from a material which is designed to rupture within a cer-
tain pressure range. This is the most important part of the entire system. The position of the
rupture disc in the union of the dry chemical chamber outlet is important. The flat side of
the disc should always face the extinguisher. A wrench should be used to tighten the pipe
union but excessive over-tightening should be avoided. Over-tightening is likely to put stress
on the rupture disc and weaken it.
6. Fill extinguisher to rated capacity with dry chemical.
7. Clean fill opening threads and gasket seating surface.
8. Secure fill cap, hand tighten.
9. Remove cartridge guard assembly.
10. Remove empty cartridge.
11. Make certain receiver/actuator puncture pin is fully retracted.
NOTE: Weigh new cartridge. Weight must be within 1/4 oz. of weight stamped on cartridge.
12. Screw tully charged cartridge into receiver/actuator assembly, hand tighten.
13. Replace cartridge guard.
14. Secure extinguisher in bracket.
15. Assemble bursting disc union, wrench tighten.
16. Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.
17. Replace cartridge in remote actuator. Pull out button, insert ring pin and remove
empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actu-
ator button stem with lead and wire seal.
18. Check hose, fittings, and nozzles for mechanical damage; replace all hose that has
been exposed to fire areas.
19. Install new blow-off caps.
20. Record date of recharge.
136
/ ~ /
" ~ ,
J
Figure 7-21
VEHICLE
CAP
GASKET
~
t<
ACTUATOR
CARTRIDGE
~
\
Fixed Fire E - xtmguisher S ystem
137
\
\
\
GUARD
~
I ,
CARTRIDGE 1i' \
S A F ! v ~
VALVE
CYLINDER
HOSE

,
,
/
}
/
VEHICLE

e Extinguisher Piping
2 Fixed Ir Figure 7-2
138
UNION
\
\
\
I
VEHICLE
Section XXVII - HULL REPAIR
7-59_ GENERAL
The methods and materials described in this section are intended to supplement normal
fabrication techniques and procedures.
In order to maintain the high lever of ballistic protection offered by high hardness armor, it
must be welded somewhat differently than normal armor plate.
This means preserving the original hardness of the plate as much as possible during any repair
operation. To accomplish this, the heat input during cutting and welding operations must be held to
a minimum. The higher the heat input per inch of weld, the wider the heat affected zo.ne. In normal
welding operations the hardness reduction will extend 3/8 to 5/8 inch from the toe of the weld.
Any oxyacetylene cut will give approximately the same hardness reduction from the edge of the cut.
This should not be interpreted to mean that the ballistic qualities are lost in this area but only that
they are reduced to the extent that the base material has been softened.
7-60. METHOD OF REPAIR
The initial decision to be made when a repair is required is, should a patch be installed or the
damaged area be repaired with weld only?
The controlling factor in making this decision should be to keep the welding to a minimum
and thereby reduce the heat affected zone which reduces the ballistic quality of the plate in that
area.
7-61. PREPARATION AND REPAIR
NOTE: Due to unique characteristics, the high hardness armor used in the construction of
the vehicle must be fabricated and welded with a greater emphasis placed on edge preparation
than is normally done with armor plate. It is important that the suggestions made here be
followed as closely as possible and the welder be trained and qualified with the welding pro-
cesses to be used.
NOTE: Whenever vehicle repairs are performed that require welding in the area of the ve-
hicle fuel tanks, the tanks should be drained and thoroughly flushed with water before
welding.
A. Use a short arc length with low strength Ferritic Electrodes only.
B. The high side of current range for welding electrodes is preferred.
C. Use stringer bead technique. Do not use a weave bead technique.
D. Avoid preheat. Preheat at low temperature below 300 degrees F only when necessary to
avoid cracking problems under severe restraint conditions.
E. Complete weld repairs at low interpass temperatures, preferably below 100 degrees F,
never above 300 degrees F.
F. Preparation of cracks to provide a weld joint for repair is best accomplished by grinding.
Arc goughing is acceptable if large quantities of material must be removed.
G. After gouging, remove oxidized surfaces and all burn notches by grinding.
H. Welding in the flat or horizontal position is preferred. If welding in the vertical position
is required, welding should be accomplished in the upward direction.
I. Finished welds should not exhibit undercutting.
139
VEHICLE
J. Critical repair areas may required radius grinding at weld toes to reduce the notch effect
and improve repaired area.
K. High hardness steels are quenched and tempered. Heating at elevated temperature, straight
ening etc. will impair mechanical strength and ballistic properties and should be avoided.
Prior to effecting the repair of any crack or penetration, the extent of the crack or damage
shall be determined by visual and dye penetrant inspection.
Since cracks in high hardness armor tend to propagate once they have started, it is important
that repairs be initiated promptly using the following general procedure.
762. REPAIR ACCESSIBLE FROM BOTH SIDES OF PLATE
A. Grind out material at each end of the crack to stop further propagation. This "stopper"
should break through the plate in a small area at each end of the crack (figure 7-23 and 7-24).
B. Grind out a U shaped groove along line of crack to within 1/32 inch of the opposite side
of the plate (figure 7-25). Inspect for complete removal of crack using dye penetrant. Sand, grit or
shot blasted surfaces are not acceptable.
C. Deposit a tack weld at each end of the prepared groove (figure 7-26). Repair the area
between the tacks with weld, using the back step method and working toward the center of the
repair. This method keeps the internal stresses and plate temperature at a minimum (figure 7-27).
D. Using the same back step method, the "stopper grooves" should be welded last (figure
7 -28).
E. The reverse side should then be ground out along the original crack line, down to sound
metal, using dye penetrant to insure complete removal of the crack.
F. The ground groove should then be welded to insure a completely sound weld with a
crown or reinforcement to up to 3/32 inch above the plate surface (applicable to both sides).
G. The entire repair area should be re-inspected visually and with dye penetrant to insure
that cracking has not reoccurred.
7-63. REPAIR ACCESSIBLE FROM ONLY ONE SIDE OF PLATE
Repair of plate accessible from only one side is done in the same manner as when both sides
are accessible except that every effort should be made to get comp lete penetration of the plate from
the one side when welding. This may be accomplished by grinding through the plate to leave ap-
proximately 1/32 inch root gap along the line of the original crack.
7-64. PATCHES AND BACK-UP PLATES
When damaged areas are larger than four or five inches square. the area should beTepaired by
inserting a patch panel to replace the original damaged area. The edges of the adjacent plate and the
repair patch should be chamfered and have all evidence of burn notches ground off. The patch
should be cut and ground to allow a 1/8-3/16 inch root gap at each edge for a sound weld.
If damage is in an area where the insertion of a patch is not practical, a repaired area may be
protected with a back-up plate. The back-up plate should be fitted tight to the original hull plate
and held in place with plug welds of at least 3/4 inch diameter. The plug welds should be positioned
so they tie in to the repair welds in the original plate as much as possible. This method has two
advantages - it increases the strength of the repair and at the same time limits the heat affected
zone. Back-up plates should never be welded solid around the periphery of the plate. This induces
unwanted stress build-up in the plates which may cause cracking.
140
Figure 7-23 Cracked Plate
Figure 7-24 Stoppers Ground to Prevent Crack
From Propagating
Figure 7-25 Crack Ground Out to a "U"
Shaped Groove
VEHICLE
141
Figure 7-26 Initial Tack Welds
Figure 7-27 Welds Using the Back
Step Method
Figure 7-28 Welding of Stopper Grooves
Figure 7-29 Completed Repair
VEHICLE
Section XXVIII - FUEL TANK RESEALING
Whenever vehicle repairs are performed that require welding within approximately two inches
of the vehicle fuel tanks, the inside of the fuel tank must be recoated with a metal sealer to prevent
corrosion.
7-65. PROCEDURE
A. Open fuel tank cap cover.
B. Remove six screws and lift out the complete extension guide and filler neck assembly
including the fuel filler cap, filter screen, and inner sleeve extension.
C. Remove and discard the filler neck gasket. Thoroughly clean the gasket sealing surface.
D_ Unscrew inner fuel line compression fitting and remove inner fuel line. Plug the inner fuel
line bu I khead hole from inside the tank.
E. Remove the fuel gage assembly. Plug the bulkhead hole from inside the fuel tank.
F. Remove fuel return line and fuel tank vent fitting. Plug holes from inside tank.
G. Remove the fuel tank drain plug located on the vehicle underside.
H. If possible, use a wire brush to remove any scale or corrosion that may be present on the
fuel tank interior. Use compressed air to blowout dust, scale and dirt particles from the tank.
I. Replace fuel tank drain plug removed.
J. Fill the fuel tank with fuel resistant coating compound.
K. Remove the fuel tank drain plug and allow the coating compound to drain into a suitable
container (at least 40-gallon capacity).
L. Allow the coating to set for at least two hours. Then remove the plugs from the bulkhead
holes.
M. Wrap the threads of fittings with pipe thread sealant. Install fuel lines, fuel gage and vent
fitting.
N. Apply gasket compound to the filler neck gasket and insta!l the gasket.
O. Install the extension guide and filler neck assembly including the filter screen and inner
sleeve extension. Install six screws in the extension guide.
142
VEHICLE
CHAPTER 8
Power Plant and Engine
Section I - POWER PLANT
The power plant consists of engine, transmission and park ing brake assemblies, for removal
and installation purposes only. For maintenance on other than the engine refer to chapters pertain
ing to specific components.
NOTE: Throughout this chapter, the fan end of the power plant is referred to as the front
and the flywheel end as the rear. The terms right and left refer to the viewer's right and left
as viewed from the flywheel end of the engine and power plant.
81. PRELIMINARY INSTRUCTIONS
Removal of power plant is best accomplished by two or more men. Place vehicle under suit-
able lifting equipment.
NOTE: Arrange to have tools, lifting sling, engine stand and supports available for use when
needed.
CAUTION: Block wheels to prevent vehicle from moving when power plant is disconnected
from drive lines.
8-2. DISCONNECT PROCEDURES (Figure 8-1)
A. Place master switch in OFF position.
B. Remove all engine compartment panels, transmission and transfer tunnel covers. Open
engine hatches and access door.
C. Remove air outlet grille and mounting screws from muffler support bracket.
D. Disconnect exhaust pipes at engine exhaust manifolds.
E. Disconnect and remove air cleaner hoses and air cleaner.
F. Disconnect fuel supply and return lines at engine. Plug lines and ports to prevent con-
tamination.
G. Remove batteries, engine fan and spacer.
H. Drain and remove radiator shroud and hoses.
I. Remove screw and washer securing engine to hull ground strap.
/
J. Disconnect throttle cable from engine fuel pump.
143
VEHICLE
Starter Solenoid Cables View A Fuel Return Line View B
Hydraulic Pump Lines ViewC
Oil Filter Lines ViewD
Transmission Oil Cooler Lines View E Speedometer Cable View F
Figure 8-1 Power Plant Disconnect Points (1 of 2)
144
VEHICLe
T ransmi ssion Selector Cable ViewG
- - ~ \
! ~ ~ ~
Q--g
~ I
Q
n
Transfer Coupling
Q
n
View I
, '
,
Parking Brake Cable
\ ~
\ \t9
Rear Engine Mount
~ ~ - - - : 0)'\
----'-,- --
Oil Pressure Lead F rant Engine Mount
Figure 81 Power Plant Disconnect Points (2 of 2)
145
View H
ViewJ
VEHICLE
K. Loosen alternator tensioning device and swing alternator as close as possible to engine.
L. Disconnect wiring harness leads connected to: oil pressure unit (engine), coolant temper-
ature unit, fuel shut-off valve, alternator, starter solenoid and quick start system (if vehicle is so
equipped).
M. Disconnect vacuum hoses at vacuum pump. Plug lines and ports to prevent contami-
nation.
N. Disconnect hydraulic pressure hoses at dual hydraulic pump. Plug lines and openings to
prevent contamination.
O. Disconnect engine oil lines at remote mounted oil filter.
P. Disconnect transmission oil cooler lines at transmission. Plug lines and openings to pre-
vent contami nation.
Q. Disconnect speedometer drive cable at rear of transmission.
R. Disconnect transmission selector cable at transmission lever.
S. Disconnect transmission selector cable anchor bracket on transmission housing.
T. Disconnect parking brake cable from brake actuator lever by removing cotter pin and
clevis pin. Remove nut from screw securing parking brake cable clamp to bracket mounted on trans-
mission.
U. Remove eight bolts and nuts securing transmission to transfer flexible coupling sleeves.
V. Remove power plant to hull mounting hardware at three mounting points: horizontal
bolt, nut and lockwasher at front of engine and vertical bolt, nut and lockwasher at each side of
flywheel housing.
8-3. REMOVAL (Figure 8-2)
A. Install lifting sling to engine lifting brackets and attach lifting hoist to sling.
NOTE: When removing the power plant, the transmission end must be depressed and held
at an angle until the power plant is clear of the vehicle. Before starting to lift the power
plant, make sure that all connections are disconnected and that nothing will interfere or get
caught as the unit is being removed.
B. Hoist the power plant clear of vehicle and rest it on a suitable engine stand or blocking.
8-4. INSTALLATION
NOTE: When installing power plant assembly, the transmission end must be tipped down
approximately 20 degrees to go through the engine opening in hull, but must be leveled be-
fore being set down on the power plant mounts or the bilge pump, lines and brake lines may
be damaged.
A. Place rubber rear engine mounts with spacers in position on hull mounting brackets.
B. As the power plant is lowered into position, align rear engine mounts and insert bolts.
146
VEHICLE
Figure 82 Power Plant Removal
C. Install new gasket between transmission to transfer coupling sleeves.
D. Lower engine into position so that front engine mounting bolt can be inserted.
E. Loosely assemble nuts and washers on mounting bolts.
F. Align bolt holes of coupling sleeves and install eight bolts and nuts. Torque to 30 Ibs. ft.
(41 Nm).
NOTE: Use adjusting screws on transfer mounting bracket to align coupling sleeves.
G. Tighten rear engine mounting nuts so that approximately .06 inch (1.5 mm) clearance
exists between rubber mount and bottom washer. Tighten nuts or add spacers under rubber mounts
as required.
H. Tighten front mounting bolt and nut.
I. Assemble remaining components in reverse order of disassembly. All connections, parts
and accessories that were removed from the power plant during removal must be reinstalled after
the power plant is in the vehicle. If any components or accessories of the power plant were replac
ed, check all connections and related parts to assure that installations were accomplished correctly.
CAUTION: Because of the vacuum created within the engine compartment by the pusher
fan, serious overheating will occur if the engine compartment panels or tunnel covers are left
off. Therefore, these covers and panels must all be in place and secured at all times during
engine or vehicle operation.
147
VEHICLE
Section II - ENGINE
This section provides step-by-step procedures for complete disassembly, repair and assembly
of the engine, less all externally mounted accessories. If repairs require only partial disassembly,
perform only those steps necessary to make the repair. After the engine has been repaired, it is
essential to operate and test it through a run-in period. The run-in must be made to correct any
minor deficiencies and to perform checks and adjustments prior to installing the engine.
NOTE: For removal of power plant assembly from vehicle, refer to Section I of this Chapter.
For separation of the transmission assembly from engine, refer to Chapter 11, Power Train.
8-5. PREPARATION OF ENGINE
A. Draining.
1. Remove drain plug from crankcase oil pan and drail oil from engine.
2. Replace oil drain plug.
3. Drain fuel and water.
B. Inspection and Cleaning.
1. Remove hour meter, alternator, starter motor before cleaning.
2. Inspect engine and components during cleailing to locate possible leaks leading to
malfunctions of internal parts.
3. Clean all dirt and grease from surface of engine before any disassembly is attempted.
8-6. ENGINE DISASSEMBLY (Figure 8-3)
A. Prior to mounting engine on engine stand, remove the following:
1. Oil pressure and Temperature Transmitters.
2. Water Filter.
3. Mechanical Controls, Water, Air, Fuel Connections, Filters, Brackets and Lines.
4. Front Engine Support.
5. Oil Cooler and Connections_
6. Water Header Cover Plates.
7. Fan and Fan Hub, Belts and Brackets.
8. Exhaust Manifolds.
8-7. MOUNT ENGINE ON ENGINE STAND
A. Replace water header cover plate with mounting adapter plate. Secure engine stand adap-
ter to engine rebuild stand. Using engine lifting fixture, position engine to stand, secure with cap-
screws and lockwashers.
148
12
"T1
cC
"
~
~
3
CD
/ ~
CO / 5
.I:> W
to
m
"
'" 5
CD
30
29
31
1. HOSE/WATER PUMP
2. THERMOSTAT HOUSING
3. THERMOSTAT HOUSING SUPPORT
4. WATER PUMP
5. EXHAUST MANIFOLD
6. HEADER COVER
7. OIL COOLER
8. PISTON AND CONNECTING ROD
9. CYLINDER LINER
10. TAPPET/INJECTOR/PUSH ROD
13
23
11. CYLINDER HEAD
12. ROCKER ARMS AND SHAFT
13. PUSH ROO COVER
14. INTAKE MANIFOLD
, 5. CAMSHAFT
16. CAMSHAFT THRUST PLATE
17. CAMSHAFT GEAR
18. FLYWHEEL
19. FLYWHEEL HOUSING
20. CYLINDER HEAD COVER
~ .
~
21. GEAR HOUSING COVER
22. GEAR HOUSING
23, ENGINE BLOCK
24. CRANKSHAFT
25. OIL PUMP
26. OIL PAN
27. VIBRATION DAMPER
28. MAIN BEARING CAP
29. FRONT CeVER
30. COVER WITH SUPPORT
26
31, CROSSOVER FAN BRACKET
25
<
m
::c
C?
r
m
VEHICLE
B. With engine mounted securely to roll-over stand, remove the following:
1. Thermostat Housing and Support.
2. Front Water Connections.
3. Front Lifting Bracket.
4. Front Water Crossover.
5. Vibration Damper.
a. Remove capscrews securing damper and pulley to crankshaft. Figure 8-4.
b. Using suitable puller, remove damper.
CAUTION: Pounding or prying must not be resorted to in removing the damper.
6. Front Cylinder Block Water Header Cover Plate.
7. Water Pump.
8. Fuel Drain Line.
9. Air Intake Connections and Intake Manifold Assemblies.
10. Water Connections and Rear Engine Lifting Eye.
11. Fuel Pump.
a. Remove fuel supply and drain lines from fuel pump and cylinder head.
b. Remove fuel pump from vacuum pump.
c. Cover fuel pump connections to prevent entrance of dirt.
12. Vacuum pump.
13. Fuel Pump Drive.
14. Cylinder Head Covers.
15. Push Rod Cavity Covers.
16. Rocker Levers.
17. Push Rods.
18. Crossheads.
19. Injectors.
a. Remove injector hold-down yoke, using injector removal tool to remove injectors.
NOTE: Be sure plier section of tool is in last adjusting notch (fully open).
150
VEHICLE
Figure 84 Removing Vibration Damper Figure 85 Pulling Tappets
CAUTION: Do not use screwdriver or other hard object in adapter locating holes during
injector removal.
20. Oil Pan.
88. CYLINDER HEADS
A. Insert two guide studs in block, use lifting fixture to remove heads. Place on suitable
work table or holding fixture.
85.
B. Tappets.
1. Remove tappet guide plates.
2. Pull tappet assemblies from block with a wire hook or small slide hammer. Figure
NOTE: A small slide hammer can be made from 1/8 inch drill rod with a hook to fit in
tappet hole and 1 inch diameter steel for the slide hammer.
3. Remove spring from each tappet. Turn engine over on stand.
89. FLYWHEEL
A. Removal.
1. Remove flex plate, backup ring, and flex plate adapter.
2. Remove two flywheel capscrews on opposite sides of flywheel. Insert two threaded
studs, six inches long, in two holes to provide support for flywheel during removal.
151
Figure 86 Removing Camshaft Thrust
Plate Capscrews
VEHICLE
Figure 87 Removing Connecting Rod
NOTE: Insert a wooden block between crankshaft and cylinder block to prevent crankshaft
from turning while removing capscrews.
3. In two holes provided, insert two puller screws into flywheel. Turn in screws alter
nately to pull flywheel from crankshaft.
4. Straighten lockplates and remove capscrews securing camshaft thrust plate to block.
Figure 86.
5. Rotate camshaft gear and lift lightly while removing camshaft from block. Do not
remove gear from camshaft.
6. Oil Pump.
7. Gear Housing Cover and Spacer Plate.
8. Front Cover.
810. CONNECTING ROD AND PISTON ASSEMBLIES
A. Removal
1. Turn block as shown in Figure 87 and clean all carbon from upper inside wall of each
cylinder liner with fine emery cloth. Clean area thoroughly with compressed air.
2. Use care not to damage cylinder liners as connecting rods are withdrawn. Check each
rod and cap as removed to be sure it is stamped or labeled. Reassemble each connecting rod cap to
mating rod. Remove piston rings. Tape mating bearing shells together and label by cylinder.
3. Remove piston pin snap rings from pistons, heat aluminum pistons in hot water to
expand pin bores. Push pin from piston with thumb pressure.
152
VEHICLE
Figure 8-8 Pulling Liner with Liner Puller Figure 8-9 Liner Puller Plate Installed
CAUTION: Driving pins from piston will distort bore and necessitate scrapping of piston,
if not heated for expansion of pin bore.
8-11. CRANKSHAFT AND MAIN BEARINGS (Figure 8-3)
A. Removal.
1. Use main bearing cap puller to loosen each main bearing. Remove caps.
2. Remove each lower main bearing shell. Remove thrust half rings from each side of
rear main bearing cap and roll upper half thrust rings from block.
3. Using hooks protected by rubber hose (or a rope at two crank throws) and using
suitable hoist, lift crankshaft from cylinder block.
NOTE: Rotate crankshaft, if necessary, to facilitate removal.
4. Remove upper main bearing shells from cylinder block and tape bearing shells to-
gether in sets and mark with number corresponding to main bearing cap number as removed.
8-12. CYLINDER LINERS (4)
A. Use liner puller and liner puller bridge or equivalent to pull liners. Discard "0" rings and
crevice seals. (Figure 8-8).
CAUTION: To prevent liner breakage during removal from cylinder block, do not pull
liner with liner puller plate on or near extended part of liner_ Position plate 90
0
away from
this area. Figure 8-9.
153
VEHICLE
8-13_ CLEANING
A. Steam Cleaning.
1. Steam clean all disassembled units and parts except those that might be damaged by
steam or moisture with a steam jet and dry with compressed air. All units such as oil coolers, oil
pan, heat exchanger, etc., should be cleaned as quickly as possible to prevent hardening and drying
of accumulated foreign substances.
B. Glass Bead Cleaning.
Glass bead cleaning has been proven most effective for pistons, valves, cylinder heads, etc.
The nature and degree of treatment is controlled by the size of glass beads used, operating pres-
su re and exposu re time.
1. Bead size - for pistons and other similar parts, use U.S. sieve size No. 70. For general
purpose cleaning, use No. 60.
2. Operating pressure - 90 psi (5.4 kg/sq cm) for pistons, etc. for general cleaning
pressure from 90 to 125 psi (5.4 to 8.8 kg/sq cm) may be used.
3. Do not expose the part being cleaned to the bead blast any longer than absolutely
necessary. This is particularly true when cleaning soft material such as aluminum.
4. The only additonal cleaning required is to wash with water or blowoff with com-
pressed air. Be sure all foreign material has been removed from parts before reassembling.
C. Solvent/Acid Cleaning.
Several solvent and acid type cleaners are effective cleaning solutions, always follow manu-
facturers recommendations as to concentration and use.
CAUTION: Solvent cleaners may damage bearing shells and aluminum parts.
Remove all gasket material and deposits of sludge, carbon, etc. with a wire brush or scraper,
from units such as cylinder heads, oil pan, rocker lever housing and cover, etc. before submerging
them in wash tank.
CAUTION: Do not damage gasket surfaces.
1. Solvent solution should be heated to approximately 180 to 200 degrees F (82 to 93
degrees C) and kept in constant agitation. With sufficient heat, the agitation can be accomplished
by built-in baffle plates.
2. After unit disassembly, put all small parts in wire mesh baskets, steam clean, then
immerse in cleaning tank for as long as necessary. Larger parts can be lowered directly by chain
hoist into tank.
3. Cylinder block must have all pipe plugs removed from oil and water passages, etc.
Run rods with brushes or swabs through all oil passages, clean air vent hole (No.1 cylinder) that
opens into front water crossover. Figure 8-10. Scrape liner counterbore lightly to remove scale,
sand lower liner bore or use emery cloth to remove any nicks or burrs that might damage packing
rings as liner is installed.
154
VEHICLE
4. To remove heavy deposits of lime, use circulated acid type cleaner.
WARNING: The use of acid may be extremely dangerous to workmen and injurious to
machinery. Always provide a tank of strong soda water as a neutralizing agent.
5. Rinse all parts in hot water and dry with compressed air, blow cleaning fluid or
water from capscrew holes to prevent damage when capscrews are tightened.
6. Replace pipe plugs removed for cleaning, torque to specifications.
NOTE: If rebuild machining is required, replace pipe plugs and reclean affected area after
machining is completed.
7. If parts are not to be reused immediately after cleaning, dip them in a suitable rust
proofing compound.
NOTE: Rust proofing compound must be removed before installing parts in engine.
8-14. CYLINDER BLOCK
A. Inspection (Table 8-1).
Before any parts are discarded or used again, a careful inspection must be performed. The
inspection should include wearing surfaces and general over-all conditions.
NOTE: Inspection of cylinder block must be performed on a flat surface to prevent distor-
tion, do not leave on engine stand.
1. Using Dye Penetrants to Locate Flaws.
Use dye penetrant method for locating cracks, porosity, leaks, etc. Clean suspected
;'1Bctive area with kerosene or other grease-removing cleaner.
---_.
Figure 8-10 Block Air Vent Hole
155
VEHICLE
Apply dye penetrant allowing time for it to dissolve or enter into the defect (usually
about fifteen minutes), do not "force" dry. Remove all excess penetrant and apply developer so
defect will stand out. Cracks usually show up as a solid or dotted line; however, caution must be
observed as this can be a nondamaging forging lap. Porosity usually shows up as dots in local areas.
The wider the area spreads, the larger the defect.
2. Corrosion.
Corrosion most frequently occurs on portions of block nearest cylinder liners and is
evidenced by pitting. Discard block if area cannot be cleaned, or if area is distorted and cannot be
repaired by sleeving as outliend under "Parts Replacement and Repair".
B. Cylinder Liner Counterbore.
1. Check upper liner counterbore diameter at four equidistant points. See Table 81,
(Ref. No.1) for dimension. Counterbore at anyone cylinder can only vary 0.001 inch (0.03 mm) in
depth (Ref. No.2).
CAUTION: Thoroughly clean counterbore before measuring.
2. Check counterbore depth so installed liner will be assembled to correct protrusion
and to determine if refinish of counterbore surface is necessary. Depth of counterbore on a new
block is listed in Table 81 (Ref. No.2). If worn to or beyond limit, the cylinder block must be
salvaged using counterbore tool or replaced. If worn less than worn limit, the surface can be reo
finished and shims installed under the cylinder liner to restore proper protrusion.
3. An installed cylinder liner must protrude 0.006 to 0.009 inch (0.15 to 0.23 mm)
above milled surface of cylinder block. Table 81 (Ref. No.3). To check protrusion without actu-
ally installing liner, perform the following steps:
a. Measure liner flange with micrometer. Do not include bead on top of liner flange
in taking measurement. It should be 0.306 inch (7.75 to 7.77 mm).
b. Measure counterbore depth with dial indicator depth gauge or gauge block.
c. Check depth at four or more locations. Ledge must not be cupped more than
0.0007 inch (0.018 mm) throughout counterbore circumference.
d. If dimensions do not meet standards as outlined above, counterbore ledge must
be reworked. Calculate depth of cut that will permit using a standard shim to provide the desired
liner protrusion. Normally, a 0.007 to 0.009 (0.18 to 0.23 mm) cut will be adequate to recon-
dition counterbore.
NOTE: If material to be removed will result in a counterbore depth exceeding Worn Limit,
Table 8-1 (Ref. No.2), it is recommended block not be reused.
e. Check for variations in protrusion under each cylinder head. Variation cannot
exceed 0.002 inch (0.05 mm) under head nor can it exceed 0.001 inch (0.003 mm) at anyone liner.
4. The most accurate method of checking protrusion is as follows:
a. I nstall liner in block with proper number of liner shims beneath the flange. Shims
are available from 0.007 to 0.021 inch (0.18 to 0.53 mm). Use cylinder liner hold-down tool. Tool
should be spaced so even load will be applied.
156
VEHICLE
Table 8-1. CYLINDER BLOCK INSPECTION SPECIFICATIONS - Inch (mm)
Ref.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Measurement
Cylinder Liner
Counterbore
Inside Diameter
Depth
Cylinder Liner
Protrusion
(Installed)
Camshaft Bushing
Inside Diameter
Camshaft Bushing Bore
Inside Diameter
Uner to Block Clearance
Lower Bore
Cylinder Block
Lower Liner Bore
Inside Diameter
Main Bearing Bore
Inside Diameter
Main Bearing Cap
Interference Fit to Block
Tappet Bore in Block
Injector
Valve
Cylinder Block Height
From Main Bearing
Centerline
From Installed Checking Ring
Cylinder Liner
Inside Diameter
60 Deg. to 70 Deg. F
(16Deg.t021 DegC)
Worn
Limit
5.401
(137.19)
0.332
(8.43)
2.002
(50.85)
2.1885
(55.588)
3.7535
(95.339)
1.4025
(35.624)
1.1025
(27.978)
10.127
(257.23)
8.251
(209.58)
4.630
(117 .60)
New
Minimum
5.399
(134.41)
0.297
(7.54)
0.006
(0.15)
1.999
(50.78)
2.1865
(55.537)
0.002
(0.05)
5.094
(129.39)
3.752
(95.30)
0.001
(0.03)
1.400
(35.56)
1.100
(27.94)
10.147
(257.73)
8.271
(210.08)
4.6245
(117.46)
157
New
Maximum
5.401
(137.19)
0.299
(7.60)
0.009
(0.23)
2.001
(50.83)
2.1875
(55.563)
0.006
(0.15)
5.096
(129.44)
3.7530
(95.326)
0.003
(0.08)
1.401
(35.59)
1.101
(27.97)
10.153
(257.89)
8.277
(210.24)
4.626
(117.30)
VEHICLE
Table 8-1. CYLINDER BLOCK INSPECTION SPECIFICATIONS - Inch (mm)- (Continued)
Ref. Worn New New
No. Measurement limit Minimum Maximum
Crankshaft
13. Connecting Rod Journal
Outside Diameter 2.498 2.499 2.500
I
(63.45) (63.47) (63.50)
~
r-
14. Main Bearing Journal
Outside Diameter 3.498 3.499 3.500
(88.85) (88.88) (88.90)
--r
15. Thrust Bearing Surface 1.414 1.410 1.412
r-
To Rear Counterweight (35.92) (35.81) (35.87)

Main and Rod Journals .002
Out-of-round T.I.R.** (0.05)
*'T.I.R. - Total Indicated Runout
Main Bearings
16. Shell Thickness 0.12350 0.12450 0.12525
(3.1115) (3.1623) (3.1814)
(0.18) (0.038) (0.127)
W
Rod Bearings
16. Shell Thickness 0.09305 0.09435 0.09470
I
Crankshaft Thrust Rings
17. 173640553670 Std. * 0.149 0.151
(3.79) (3.84)
~
17. 173640553671 0.010 * 0.159 0.161
(0.25) Oversize (4.04) (4.09)
17. 173642553672 0.020

0.169 0.171
(0.51) Oversize (4.29) (4.34)
*Use Crankshaft End Clearance
Crankshaft End Clearance 0.020 0.004 0.014
(0.51) (0.10) (0.36)
Connecting Rod
10
18. Crankpin Bore Inside Diameter 2.6910 2.6925
=
(68.351 ) (68.390)
((If--
Out-olround 0.002
(0.05)
19. Center to Center 6.014 6.019 6.021
--
Length (152.76) (152.88) (152.90)
18
.." A
~
158
VEHICLE
Table 81. CYLINDER BLOCK INSPECTION SPECIFICATIONS - Inch (mm) - (Continued)
Ref.
Worn New New
No. Measurement
Limit Minimum Maximum
Piston Pin Bushing
20. Inside Diameter 1.3775 1.3760 1.3765
(34.989) (34.950) (34.963)
Connecting Rod
Alignment 0.008
Without Bushing (0.20)
Alignment 0.004
With Bushing (0.10)
Twist 0.020
Without Bushing (0.51)
Twist 0.010
With Bushing (0.25)
Connecting Rod Bolt
21. Minimum Outside 0.403
Diameter (10.24)
22. Pilot Outside 0.4387 0.4390 0.4395
Diameter (11.143) (11.151) (11.163)
11
Rod Bolt Hole
Pilot Inside Diameter 0.4394 0.4388 0.4393
(11.161) (11.146) (11.158) III
,
n
Rod Bolt Pad
1 1
Corner Radius 0.240 0.260
(6.10) (6.60)
Seat Radius by 45 Deg. Chamfer 0.040 0.050
(1.02) (1.27)
Side Clearance
Rod to Rod to 0.024 0.0076 0,018
Crankshaft (0.61) (0.193) (0,46)
Rod to Piston Boss 0.155 0.185
(3.94) (4.70)
Piston
23. Skirt Diameter at 4.6110 4.6150
4.6160
70 Deg. (117.119) (117.221)
(117.246)
I ( ~ \ l
Piston Pin Bore @----,J. ~ / l
24. Inside Diameter at 1.3749 1.3735 1.3739
70 Deg. F (34.922) (34.877) (34.897)
(21 Deg. C)
159
VEHICLE
Table 81. CYLINDER BLOCK INSPECTION SPECIFICATIONS - Inch (mm) - (Continued)
Ref.
Worn New New
No. Measurement Limit Minimum Maximum
Piston Pin
25. Outside Diameter 1.3733 1.3738 1.3740
(34.882) 134.895) 134.900)
Piston Ring
25719
!
Gap in Ring Travel

0.015 0.030
Area of Liner 10.38) 10.76)
205717
0
J
Gap in Ring Travel

0.013 0.023
Area of Liner (0.33) 10.58)
205718
\
Gap in Ring Travel * 0.025 0.035
Area of Liner 10.64) 10.89)
* Add 00.3 inch (0.08 mml ring gap to new
maximum for 0.001 inch 10.03 mm) wear
in cylinder liner wall.
Piston to Liner 0.016 0.0085 0.011
Clearance 70 Deg. F 10.411 10.216) 10.28)
121 Deg. C)
Camshaft Journal
26. Outside Diameter 1.994 1.996 1.997
1
150.65) 150.70) (50.72)
r U IllJJI r
Thrust Plate
Thickness 0.120 0.124 0.126
13.05) 13.15) 13.20)
160
VEHICLE
Table 81. CYLINDER BLOCK INSPECTION SPECIFICATIONS - Inch (mm) - (Continued)
Torque Specifications ft. lb. (Nm)
1/8
1/4
3/8
1/2
3/4
1-1/4
11/2
PIPE PLUG SIZE
MAIN BEARING CAPSCREWS
Step 1 Tighten to
Step 2 Advance to
Step 3 Tighten to
Step 4 Loosen
Step 5 Repeat Steps 1, 2 and 3 above
CONNECTING ROD NUTS
Step 1 Tighten to
Step 2 Advance to
Step 3 Loosen
Step 4 Tighten to
Step 5 Advance to
MINIMUM
15
30
35
45
60
75
90
(20)
(41 )
(47)
(61 )
(81 )
(102)
(122)
MINIMUM
55 (75)
115 (156)
165 (224)
All
MINIMUM
25 (34)
50 (68)
All
25 (34)
60 Deg.
MAXIMUM
20
35
45
55
70
85
100
(27)
(47)
(61 )
(75)
(95)
( 115)
(136)
MAXIMUM
65 (88)
125 (170)
175 (237)
All
MAXIMUM
30 (41)
55 (75)
All
25 (34)
60 Deg.
Cylinder Block and Head Gasket Dimensions - Inch (mm)
Distance from Crankshaft Centerline
to Cylinder Head Surface
10.147 to 10.153 (257.73 to 257.89)
10.142 to 10.153 (257.61 to 257.89)
10.137 to 10.143 (257.48 to 257.63)
10.127 to 10.133 (257.23 to 257.38)
Amount
of Cut
New Block
0.005 (0.13)
0.010 (0.25)
0.020 '0.51)
161
Thickness of Head
Gasket to be Used
Standard 0.050 (1.27)
Standard 0.050 (1.27)
0.010 (0.25) Oversize 0.060 (1.52)
0.020 (0.51) Oversize 0.070 (1.78)
VEHICLE
b. Use gauge block and check liner protrusion above the cylinder block at four equi"-
distant points outside the bead. Add or remove shims from beneath the liner flange as needed to
reach 0.006 to 0.009 inch (0.15 to 0.23 mm) protrusion.
c. With liner installed, check for out-of-round.
8-15. CAMSHAFT BUSHINGS
A. Inspection.
Use inside micrometers or dial bore gauge to measure camshaft bushing inside diameter.
Mark bushings for replacement if worn larger than 'Worn Limit", Table 8-1 (Ref. No.4) or are
chipped, scored or scratched. If bushings have turned in block bore, check block bore size; see
Table 8-1. Make certain oil passages between bushings and block oil holes are properly aligned.
If bushing replacement is necessary, see paragraph 8-20. '
8-16. CYLINDER LINER LOWER BORE
A. Installation.
1. Install a new cylinder liner in the block without packing rings or crevice seal.
2. Desirable clearance between liner and block should be as listed in Table 8-1 (Ref.
No.5), but liner contact with block is permissable as long as it does not cause liner out-of-round.
3. If clearances do not fall within limits, recheck after counterboring. Limits do not
apply with cylinder head installed and tightened to operating torque. If clearance is not correct,
check lower block packing ring bore inside diameter. Table 8-1 (Ref. No.6).
4. Lower liner bore concentricity should be checked with concentricity gauge. If a
piston seizure has occurred or after counterboring the cylinder block, check the counterbore to
lower cylinder liner bore concentricity.
8-17. MAIN BEARING CAPS
A. Inspection.
1. Caps must fit in block with no perceptible clearance or "shake". Milled faces of cap
must always rest on mating portion of block to prevent distortion during tightening. Caps must
have an interference fit to block of 0.001 to 0.003 inch (0.03 to 0.08 mm).
Replacement caps are available as service parts.
B. Assembly.
1. Assemble main bearing caps to block in operating position. Tighten capscrews to
operating tension.
C. Main Bearing Bore Inspection.
1. Gauge main bearing bores horizontally, vertically and diagonally with dial bore gauge
or inside micrometer properly adjusted to standards. See Table 8-1 (Ref. No.7) for dimensions.
2. Boring tool may also be used to check main bearing bore alignment. If it is definitely
determined that a main bearing cap has been distorted, mark block for boring.
162
"'
VEHICLE
818. WATER PASSAGES
A. Inspection.
1. Check all water passages to make sure they are open. Check for eroded water holes
which may prevent proper circulation.
2. Water holes not eroded more than 1/16 inch (1.59 mm) from edge of hold can be
sleeved.
3. Check for erosion with 1/32 to 3/32 inch (0.79 to 2.38 mm) from liner counterbore.
If not too deep, block may be resurfaced. Block must clean up before removing a maximum of
0.010 inch (0.25 mm) material.
819. TAPPET BORES
A. Inspection.
1. Measure tappet bores with telescope gauge, inside micrometers or a dial gauge. If
worn beyond limit in Table 81 (8) and (9) or outofround more than 0.0015 inch (0.038 mm),
replace block.
NOTE: After a thorough inspection of cylinder block, bushings and main bearing caps,
the decision must be made whether to install a new or reconditioned block assembly, replace
bushings or caps and how much can be done to rebuild or recondition the reusable parts.
820. CAMSHAF.T BUSHING
A. Removal and Replacement.
Bushings may be removed and installed with Camshaft Bushing Driver Kit. Locate bush-
ings on drive mandrel, align oil holes in bushings and block.
CAUTION: When installing new cam bushings in the block, care must be exercised to pre
vent the blocking of the oil drain hole at the front of number one cam bushing. If the drain
hole is blocked, full engine oil pressure on the nose of the cam can cause the camshaft to
severely wear the thrust plate.
821. MAIN BEARING CAP
A. Removal.
1. Replacement main bearing caps have 0.020 inch (0.51 mm) material in bore. Other
dimensions are the same as finished main bearing caps. New rear replacement cap does not have
capto-block dowel holes and must be machined.
2. If the cap is a rear cap:
a. Remove locating dowel from block. Locate and machine cap so thrust faces of cap
and block are flush. Use Prussian Blue on block surface to locate dowel holes in cap. Install cap
screws and torque to 55 ft. Ibs. (75 Nm).
b. Remove cap, drill dowel holes. Reinstall cap and ream dowel holes to the smallest
permissable oversize. Install dowel in block.
163
VEHICLE
3. If thrust bearing locating dowel must be replaced, install new dowel. Dowel must
have 0.090 to 0.105 inch (2.29 to 2.67 mm) protrustion from machined area of bearing cap mating
surface.
4. Install all caps on block and machine bore if necessary. Refer to Paragraph 8-17.
8-22. TOP SURFACE REFINISHING
A. Procedure.
Measure distance from head surface to main bearing bore centerline. Distance must not
vary more than 0.002 inch (0.05 mm) in each 20 inch (508.0 mm) length of engine. Head surface
flatness must not vary over 0.0005 inch (0.013 mm) for each 8.0 inch (203.2 mm) surface on
each bank. Waviness must not exceed 0.0004 inch (0.10 mm) in depth per inch (25.4 mm) of area.
NOTE: If necessary, a cylinder block may be salvaged by removing a maximum of 0.020
inch (0.51 mm) of material from the top surface. Thicker head gaskets and grommets are
required when block has been resurfaced. See Table 8-1.
8-23. MACHINING LOWER BORE ENTRY CHAMFER
A. Procedure.
If the lower bore of the lower bore entry chamfer is beyond the tolerances, pitted, or
erroded, one of the following operations may be performed to salvage the cylinder block.
If the erosion has occurred only on the entry chamfer and not in the packing ring sealing
area, the chamfer may be "built-up" by the use of a plastic steel compound such as Type "A"
Plastic Steel. The manufacturer's directions should be followed for this salvage procedure. Check
the chamfer depth after this operation and resurface the chamfer if beyond acceptable tolerances.
8-24. CYLINDER LINERS
A. Inspection.
1. Check for cracks in cylinder liners just under top flange, at bottom of liner, or above
top seal ring groove as follo.ws:
a. Magnetic Method.
b. Dye Penetrants.
2. Discard any liner with excessive corrosion or erosion and pits 1/16 inch (1.59 mm)
deep or more, or if dents, ptting or fretting on underside of liner flange cannot be removed by
lapping.
3. Check liner inside diameter with dial bore indicator. Replace if worn more than Worn
Limit, Table 8-1 (Ref. No. 12).
4. If cylinder liners are to be reused, deglaze cylinder liner walls.
164
VEHICLE
B. Cleaning.
1. Liners must be cleaned thoroughly with solvent, steam cleaner or hot soap and water.
It is recommended that cleaning operation be ended by scrubbing bore with a bristle brush to re-
move as much debris as possible. Blow liners dry with compressed air. Coat bore of liners gener-
ously with clean lubricating oil. If possible, let liners stand 5 or 10 minutes. Use white paper towels
to wipe lubricating oil from liner bores. Note gray and even black residue that appears with oil on
white towels. Repeat application of lubricating oil and wipe off with white paper towels.
2. All new cylinder liners should be cleaned of any residue collected during storage or
shipments by steam cleaning or hot soap and water. Oil lightly with clean engine oil before install-
ing in engine block.
8-25. CRANKSHAFT
A. Disassembly and Inspection.
1. If crankshaft gear condition is satisfactory, do not remove.
2. If crankshaft gear is chipped, cracked or broken, remove with bridge puller jaws.
If these tools are not available, strike chisel between teeth above the keyway several times. This
should loosen gear enough for removal by hand. Remove gear key.
3. Inspect crankshaft visually for scratches, nicks, cracks and obvious wear pattern and
measure crankshaft journals with micrometers. See Table 8-1 (Ref. Nos. 13 and 14).
4. Check crankshaft for out-of-round condition. Crankshafts should be reground if
main bearing or crankpin journals are worn out-of-round more than 0.002 inch (0.05 mm).
C. Clean Drillings in Crankshaft.
1. Remove all pipe plugs, clean all drilled oil passages in crankshaft with a rod and rag
as if cleaning a rifle barrel.
2. Lubricate threads with clean engine lubricating oil, install and tighten plugs to 60 to
95 in. Ibs. (6.8 to 10.9 Nm) torque. Stake pipe plugs by making a 1/64 inch (0.04 mm) indenta-
tion at outside diameter of threads with center punch.
D. Inspect Crankshaft Journals and Thrust Flange.
1. Carefully examine crankshaft journals and thrust flange at rear, Table 8-1 (Ref. No.
15), main bearing. If surfaces are scored or scratched, crankshaft should be reground and under-
size rod and main bearings or oversize thrust rings installed.
2. Reground crankshafts or those used with undersize rod and main bearings and/or
oversized thrust rings should be marked so correct bearing shells and thrust rings can be installed
in proper position. Figures 8-11, 8-12.
The marking for rod and main bearings are stamped on front counterweight. Marking
for thrust ring size and ring location must both be included in stamping on rear counterweight as
shown in Figure 8-12.
For example: Front - 0.010 inch (0.25 mm), and rear - 0.020 inch (0.51 mm).
165
1. fRONT COUNTERWEIGHT
2. STEEL STAMP IN 1/8" HIGH CHARACTERS THE CODE TO
IDENTIfY THE SIZE OF BOTH ROD AND MAIN JOURNALS.
10M" INDICATES SIZE OF MAIN JOURNAL
"R" INDICATES SIZE OF ROD JOURNALS
Figure 8-11 Identification of Rod and
Main Journal Size
E. Assembly.
VEHICLE
3
2
1. REAR FLANGE
2. REAR COUNTERWEIGHT
3. STEEL STAMP IN 1/8" HIGH CHARACTERS THE SIZE Of
BOTH FRONT AND REAR THRUST SURFACES ON LEfT SIDE
EDGE OF REAR COUNTERWEIGHT
"F" SIZE OF FRONT THRUST SURFACE
"R" SIZE OF REAR THRUST SURFACE
Figure 8-12 Oversize Thrust Bearing Mark
on Crankshaft
1. Install crankshaft gear, if removed.
a. Install key in shaft.
b. Heat gear to 400
0
F (204 C) by placing the gear in a temperature controlled oven
for a period of one hour at 400
0
F (204
0
C). Under no circumstances, should a torch be used as a
heating agent.
c. Lubricate flange with high pressure grease and drive gear onto shaft with piece of
tubing.
8-26. BEARINGS, MAIN AND ROD
A. Inspection.
1. Gauge bearings with ball point micrometer, dial indicator thickness gauge, or com-
parator. Discard bearings that are worn more than 0.001 inch (0.03 mm) or if chipped, flaked or
scored_ See Table 8-1 (Ref. No. 16) for thickness of standard bearings.
2. Total worn maximum oil clearance should not vary more than 0.002 inch (0.05 mm)
between adjacent main bearings.
NOTE: Under NO circumstances, should an attempt be made to scrape bearings, nor should
they be lapped or filed to increase oil clearances. A properly fitted bearing will appear dull
gray after a reasonable period of service, indicating it is running on an oil film_ Bright spots
indicate metal-to-metal contact and black spots indicate excessive clearance.
166
VEHICLE
8-27. CRANKSHAFT THRUST RINGS
A. Inspection.
1. The best measurement of wear on crankshaft thrust rings is the crankshaft end
clearance check. See "engine assembly", Paragraph 8-51 and Table 8-1.
2. Oversize thrust rings are available. Be sure to use the same size (thickness) half-ring
on both upper and lower portions (Table 8-1, Ref. No. 17). Stamp crankshaft rear counterweight
indicating size used.
NOTE: Allowable amount of wear on thrust ring depends upon wear of crankshaft sur-
faces. Installed in a cylinder block, crankshaft and clearance should not exceed 0.020 inch
(0.51 mm) at rebuild.
8-28. VIBRATION DAMPER
A. Inspection.
1. Inspect rubber element damper for cracks and elastic member for deterioration that
will impair its effectiveness.
2. Check for alignment of index marks on damper hub and inertia member. If out of
alignment more than 1/16 inch (1.59 mml. discard damper (Figure 8-13).
3. Check damper for eccentricity and wobble after installation. See "Engine Assembly".
4. Dampers are not subject to field repair. Therefore, if inspection shows them to be
defective, install new damper.
1. ALIGNMENT MARKS
Figure 8-13 Vibration Damper Alignment Marks
167
VEHICLE
829. CONNECTING RODS
A. Inspection.
1. Magnaglo all connecting rods, caps and bolts. Discard if cracks are detected.
NOTE: Be sure rod and cap are kept mated at all times.
a. Check rods for cracks with 1400 ampere current AC equipment or 1200 ampere
current DC or rectified AC equipment longitudinally between plates.
b. Check rods for cracks with 2400 to 2800 ampereturns with AC equipment or
2100 to 2300 ampereturns with DC or rectified equipment in a coil. Pay particular attention to
shaded critical areas shown in Figure 814.
NOTE: Ampereturns is defined as the amperage flowing through the coil, multiplied by the
number of turns in the coil. Most coils contain four turns, and therefore, only 700 amperes
need to be applied with AC equipment, or 575 amperes with DC equipment.
c. Apply one and onehalf percent wet solution while current is on. Make visual
inspection after each application of current.
2. Assemble cap to rod and alternately tighten nuts to operating tension as described
in Table 81.
3. Use rod checking fixture and locating mandrel to check bend and twist of connecting
rod according to dimensions of Table 81.
4. Check crankpin bore with a dial bore gauge. The bore must be within limits shown in
Table 81 (Ref. No. 18) to provide correct bearing crush. Outofround limits should not exceed
0.002 inch (0.05 mm).
5. Check piston pin bushing inside diameter with a dial bore gauge. If bore diameter
exceeds limits shown in Table 81 (Ref. No. 20), remove bushings and replace and resize as follows:
3
6
6
t}
1. PIN BUSHING BORE
2. PIN BORE
3. ROD LENGTH
4. CRANKPIN BORE
5, OEFLECT IN ROO
6. 80L T PAD RADIUS
Figure 814 Connecting Rod Specifications
168
VEHICLE
B. Replace Piston Pin Bushings.
1. Press out old piston bushings using connecting rod bushing driver.
2. Check to see if the rod is chamfered, if not, perform procedure listed below using
bushing driver to prevent damage to the piston pin bushing.
a. Install correct size bushing to bushing driver and secure with flat headed screw.
b. Set the guide screw holder in position, there are three notches, so guide screw will
follow on face of bore.
c. Adjust tool fit until point just clears guide screw and tighten in position with two
setscrews.
cut.
d. Install unit into connecting rod bore.
e. Adjust the guide screw (up or down) until tool bit just engages bore.
NOTE: A slight pressure is required against guide screw. To obtain this pressure, tighten set
screw in end of holder against guide screw.
f. Insert drive ratchet and turn tool one complete turn to clean up edge of bore.
g. Loosen guide screw and again turn tool one or more complete turns to give a clean
NOTE: Repeat until a uniform chamfer of 0.040 to 0.060 inch (1.02 to 1.52 mm) depth is
reached.
h. Remove tool from bore, turn over rod and chamfer other side using same pro-
cedure.
i. Use emery cloth to remove any sharp edges which may have been left on chamfer.
j. Thoroughly clean rod.
k. Ensure bushing is adequately lubricated with clean lubricating oil prior to installa-
tion.
3. Place connecting rod on block in horizontal position.
4. Assemble bushing driver with all components into connecting rod piston pin bore.
5. Ensure oil hole in bushing is aligned correctly.
6. Using a suitable arbor, press bushing into bore until sleeve contacts side of rod pin
boss.
7. Fill lubricating holes with soap to keep out shavings.
8. Mount connecting rod in Boring Machine. Bore bushing to 1.3760 to 1.3765 inch
(34.950 to 34.963 mm) inside diameter. Check size with connecting rod bushing gauge.
169
VEHICLE
NOTE: Lower mandrel should have only the two horizontal blades in place to properly
locate side position of piston pin end of rod during boring operation.
9. Remove sharp edges around oil grooves with a scraper.
10. Remove shavings and soap with compressed air.
11. Check all dimensions on rebushed rods on proper checking fixture.
8-30. PISTON RINGS
A. Installation.
1. Insert each ring in mating cylinder liner; position with head of piston so it is seated
squarely in ring travel area of liner.
2. Measure ring gap with a feeler gauge. Gap should be within limits given in Table 8-1.
3. Never file or stone chrome-plated rings.
8-31. PISTONS
A. Inspection.
1. Check top ring groove with ring groove gauge. Shoulders of gauge must not touch
ring groove lands if piston is to be reused. If shoulders touch, discard piston.
2. If ring groove gauge is not available, check wear with a segment of a new ring and a
feeler gauge.
a. Hold ring in groove, flush with the piston and insert 0.006 inch (0.15 mm) feeler
gauge.
b. If gauge enters groove without forcing or disengaging ring, wear is excessive and
piston should not be used.
3. Measure piston skirt diameter with micrometer at right angles to piston pin bore.
Pistons should never be reused if worn more than 0.004 inch (0.10 mm) on this diameter. Gauging
should be done at temperatures between 70
0
and 90
0
F (21
0
and 32
0
C).
NOTE: After measuring piston outside diameter, piston-to-liner clearance may be computed.
See Table 8-1 for clearance specifications.
4. Piston pin bore check at 70
0
F (21
0
C) should fall within limits shown in Table 8-1
(Ref. No. 24); add 0.005 inch (0.013 mm) per 10
0
F (-120 C) up to 90
0
F (32
0
C).
5. Check piston pin outside diameter with micrometer. Pins should not be reused if
out-of-round more than 0.001 inch (0.03 mm) or worn smaller than indicated in Table 8-1 (Ref.
No. 25). Reboring of piston pin bores and use of oversize pins is not practical because the mis-
alignment that results from such practice will cause seizure of piston or failure of connecting rod
bearings.
B. Piston-To-Connecting Rod Assembly.
1. Pistons are machined to a very close weight tolerance; therefore, as long as the same
part number piston is used throughout the engine, weight does not affect engine operation.
170
VEHICLE
2. Be sure rod and cap are stamped with cylinder number from which removed before
disassembly to prevent mixing parts.
3. Install one piston pin snap ring in groove of piston pin bore.
4. Heat aluminum pistons in boiling water in an oven at or below 210
0
F (98.9
0
C)
and install pin through piston and connecting rod pin bores before piston cools; at 70
0
F (21
0
C)
the pin fit is 0.0001 to 0.0003 inch (0.003 to 0.008 mm) which prevents pin assembly unless
piston is heated. Secure pin with second snap ring in groove at opposite end of pin bore.
CAUTION: Never drive piston pin in pistons. Driving may cause distortion of piston, causing
piston deizure in cylinder liner.
832. CAMSHAFT
A. Installation.
1. Check camshaft bushing journals with micrometers. Replace camshaft if journals are
worn beyond limits given in Table 81 (Ref. No. 26).
2. Using camshaft thrust bearing for template, cut a spacer from 0.003 inch (0.008 mm)
shim stock, leaving extension arms on each side for ease of removal. Cut the spacer in two.
3. Coat camshaft thrust bearing with Lubriplate Type 130AA or equivalent. Place
thrust bearing on camshaft.
4. Coat camshaft gear hub area with Lubriplate Type 130AA or equivalent.
5. Place two piece, 0.003 inch (0.08 mm) spacer in top of thrust bearing on gear side.
6. Heat gear to 400
0
F (204
0
C) in preheated oven.
7. Install key.
8. Place gear on camshaft hub and press until contact is made with the 0.003 inch
(0.08 mm) spacers. Be sure spacers can be withdrawn.
9. Use a 400
0
F (204
0
C) Tempstick crayon to determine heat applied.
10. Remove spacers and allow gear to cool.
CAUTION: Under no circumstances should camshaft end play be adjusted by striking a cold
gear in an attempt to move the gear on the shaft hub. If adjustment is required, the gear must
be reheated to 400
0
F (204
0
C). Always check timing when a new camshaft or gear is install
ed in an engine.
833. CYLINDER HEAD
834. DISASSEMBLY AND TESTING
A. Using suitable valve spring compressor, compress valve springs, remove half collets, reo
tainers, springs, valve spring guides and valves. If used, remove intake valve oil seals and discard.
B. Place valves on a numbered valve board for inspection.
171
VEHICLE
6
4
3
" LIFTING EYE
2. CLAMPING DEVICE
3, LOWER PLATE
4. CYLINDER HEAD
5, UPPER PLATE
6. HOLD DOWN SCREW
7. QUADRANT
Figure 815 Injector Sleeve Holding Tool Figure 816 Cylinder Head Installed
in Hydrostatic Tester
1. Pressure Testing.
a. Install injector sleeve holding tool (Figure 815) or a scrap injector assembly in
each injector sleeve. Tighten tool or injector holddown capscrews to fo to 12 ft.lbs. (14 to 16 Nm)
torque to seal lower end of injector sleeve and place cylinder head in hydrostatic tester. (Figure 8
16).
2. Air Test.
a. Use hoist or suitable lifting device to position head and tester over water tank,
connect air line with quick coupler, apply 30 to 40 psi (207 to 276 kPa) air pressure. Submerge
head in water deep enough to cover entire head. Check carefully around valve seats and injector
sleeve for cracks. Discard head if cracked, replace leaking sleeves.
3. Water Test.
a. Test cylinder head for leaks at 35 to 85 psi (241 to 586 kPa) water pressure with
water at 180
0
to 200
0
F (82
0
to 93
0
C) if possible. Check carefully around valve seats and injector
sleeve for cracks even though such cracks may not show water leakage. Discard head if cracked,
replace leaking sleeves.
b. Open water outlet of test fixture; check for free water circulation through cylin
der head. If restriction is evident, remove all pipe plugs and fuse plug; clean water jackets of salt,
lime or sludge.
(1) If alkaline cleaners are used in recommended concentration, immersion times
are followed and temperatures regulated according to instructions supplied with each product, no
damage will result to injector sleeve "0" rings.
(2) To remove heavy deposits of lime, use circulated acidtype cleaner.
C. Clean fuel passage with cleaning brush. Flush passages with solvent to remove
deposits.
172
VEHICLE
Table 8-2. CYLINDER HEAD SPECIFICATIONS - Inch (mm)
r
!'lei. Worn New New
No. Measurement Limit Minimum Maximum
,
1 . Valve Stem
Outside Diameter 0.3775 0.3785 0.3795
(9.589) (9.614) (9.638) I
Valve Head
~
iTn
f
I
2. Face Angle 30
0
30
0
~
~
B
Valve Guide
~
I
3. Inside Diameter 0.3827 0.3800 0.3817
t'0
)\ (9.721 ) (9.652) (9.695)
,
~
!
4. Assembled Height 0.775 0.800
i
I
(19.69) (20.32)
~
I
Valve Seat Insert
,
5. Outside Diameter 1.690 1.691
I
I
(42.93) (42.95)
I
-b \
Cylinder Head
~ 17'" ~
I
~ 1 1 ~ 0 ~ - 0
I
6. Counterbore Diameter 1.687 1.688
(42.85) (42.88)
I
------(6)-
!
Valve Seat Insert
I
7. Thickness 0.176 0.181
(4.47) (4.60)
, 8. Relaced Seat Width 0.063 0.125
i (1.59) (3.18)
I
Valve Spring
I
9. Assembled Height 1.686
,
(42.82)
!
Crosshead Guide
i
10. Outside Diameter 0.374 0.375 0.3755
(9.50) (9.53) (9.538)
-r-
I
11. Assembled Height 2.040 2.060
---
Hv
(51.82) (52.32)
-
Crosshead
I l J.,. 1'\
I
12. Stem Inside Diameter 0.380 0.376 0.378
~ ~
(9.65) (9.55) (9.60)
i
~ ~
13.
Cylinder Head Height 3.580 3.590 3.610
I (90.93)
I
(91.19) (91.70)
,
14. Injector Tip Protrusion 0.102 0.122
(2.59) (3.10)
i
174
VEHICLE
4. Magnetic Crack Detection.
a. As a precautionary measure, check cylinder head for cracks using magnetic crack
detector in valve and injector port areas. Discard head if cracked.
835. INSPECTION
A. Valve Seats.
1. Check for loose valve seat inserts by lightly tapping cylinder head near insert, if valve
seat is loose enough to bounce, mark for replacement. A slight looseness found only by tapping
when head is cold and covered with a film of oil is not objectionable.
2. If seat area width (Figure 8-17, Ref. No.2) exceeds 0.125 inch (3.18 mm) at any
point and cannot be narrowed sufficiently (Ref. No.2) during regrind, mark for replacement.
B. Injector Sleeves.
Note results of pressure test. Leaks indicate need for replacement of injector sleeves.
Visually check sleeves, which pass pressure test, for scratches on cup seat area. If seat area is scratch-
ed, mark for replacement.
C. Injector Tip Protrusion.
I njector sleeves that have passed the above tests must further be checked for injector
tip protrusion (seat depth) and seating pattern.
1. Lightly coat injector cup with Prussian Blue, install injector assembly into sleeve,
torque to 10 to 12 ft. Ibs. (14 to 16 Nm). Remove and check seat pattern. Bluing band must be
0.060 inch (1.52 mm) minimum in width and located approximately 9/32 inch (7.14 mm) from
bottom of head surface. If indicated seat width does not meet these specifications, mark sleeve
for replacement.
2. Install injector assembly, torque to 10 to 12 ft. Ibs (14 to 16 Nm). Measure tip
protrusion with injector tip protrusion checking tool (F igure 8-18). Tip protrusion must be 0.012
to 0.122 inch (2.59 to 3.10 mm), Table 8-2.
1. MINIMUM SEAT WIDTH 0.063 INCH (1.59 mm)
2. MAXIMUM SEAT WIDTH 0.125 INCH (3.18 mm)
Figure 8-17 Valve Seat Insert _. Cross Section Figure 8-18 Measure Injector Tip Protrusion
173
VEHICLE
Table 8-2. CYLINDER HEAD SPECIFICATIONS - Inch (mm) - Continued
VALVE SPRING DATA
Pounds Required to Compress
Approximate No. Wire Working Worn New New
Free Length Coils Diameter Height Limit Minimum Maximum
1.953 6.5 0.192 1.329 190 203 221
(49.61 ) (4.88) (33.76) (86.18) (92.08) (100.25)
Cylinder Head Plug Torque - (ft. lb. Nm)
PLUG SIZE MINIMUM MAXIMUM
1/8 inch 5 (7) 10
(14)
Fuse Plug 5 (1) 10 ( 14)
3/8 inch 35 (47) 45
(61)
1/2 inch 60 (81) 70
(95)
3/4 inch
65 (88) 75 (102)
1 inch 135 (183) 145 (197)
D. Valve Crosshead Guides and Crossheads.
1. Check guide outside diameter with micrometers. See Table 8-3 for worn replacement
limits.
2. Check guide for straightness. It should be at right angles with milled surface of head.
Mark guides for replacement if not straight or worn beyond replacement limit.
3. Check crossheads for cracks with Magnaglo process.
4. Check stem inside diameter (Figure 8-19, Ref. No.3) using a small bore gauge set at
0.3802 inch (9.657 mm). Use as a "No Go" gauge to check for wear beyond worn replacement
limit.
Table 83. ROCKER LEVER SPECIFICATIONS -Inch (mm)
WORN NEW NEW
MEASUREMENT LIMIT MINIMUM MAXIMUM
Bushing
Inside Diameter 1.129 1.1245 1.128
(28.68) (28.562) (28.65)
Shafts
Outside Diameter 1.122 1.123 1.124
(28.50) (28.52) (28.55)
175
VEHICLE
1. ROCKER LEVER CONTACT AREA
2. VALVE STEM CONTACT AREA
3. CROSSHEAD BORE
2
4. ADJUSTING SCREW THREADS
Figure 8-19 Crosshead Wear Points
5. Check for out-of-round holes, gauge at several points 90
0
apart. Do not use plug
gauge for this operation.
6. Visually check for excessive wear on rocker lever (1) and valve stem contact surface
(2). Check adjusting screw and crosshead threads (4) for wear or distortion. Mark for replacement
if excessive wear is found.
E. Valve Guides.
1. Check guide inside diameter using a small bore gauge set at 0.3829 inch (9.725 mm).
Use bore gauge as a "No Go" gauge, Table 8-2, (Ref. No.3).
2. Check for out-of-round holes; gauge at several points crosswise and endwise of head.
Do not use a plug gauge for this operation. Visually check valve guides for chips, cracks or burrs.
Mark for replacement any guides showing excessive wear or damage.
F. Valves.
1. Visual.
Clean valves with a buffer and polish with crocus cloth. Inspect, then discard, if:
a. Heads are cupped, cracked, pitted or worn too thin to regrind within limits. Check
valve head rim thickness, (A, Figure 8-20), it should be a minimum of 0.114 inch (2.90 mm).
b. Stems are worn beyond worn replacement limit as listed in Table 8-2 (Ref. No.1).
c. Collets recesses are worn so new collets will not fit securely in recesses.
176
VEHICLE
2. Magnetic Method.
a. Surface to be inspected must be cleaned to remove all foreign material which could
give false indications or react in any way with penetrant or developer. Vapor degreasing is recom-
mended.
b. Welded valves which have two types of metal, may be Magnaglo inspected. How-
ever, due to change of metal at weld, there will be a magnetic leakage at this point. This will be
indicated by a broad fuzzy pattern of magnetic particles. For this reason, such valves should be
magnetized in coil in low amperage, at 100 to 200 amps, and then inspected residually with Magna-
glo. A crack at, or near, the weld would show as a sharp, bright fluorescent line.
c. Valves with only one type of metal can be inspected in normal way. Magnetize
and inspect in two directions. Coil magnetization, use 100 to 300 amps. Inspect with residual
Magnaglo. Defects found after this magnetization will be in a transverse direction. Follow by head-
shot magnetization, at 500 to 700 amps, use residual Magnaglo. Defects by this magnetizing method
will be radial.
d. Magnetic indications should be as follows: Reference Figure 8-21.
(1) No magnetic indication over 1/2 inch (12.70 mm) in length or more than 5
indications spaced closer than 1/8 inch (3.18 mm) can be accepted in area (1).
(2) No visible or magnetic indication acceptable in area (2).
(3) No visible or circumferential magnetic indications are acceptable in areas
(3) and (4).
(4) No visible or magnetic indication is acceptable in area (5).
NOTE: "Visible" means indication can be seen by use of a 3 power magnifying glass after
removing magnetic particle suspension.
e. Demagnetize all acceptable parts.
Figure 8-20 Minimum Valve Head Rim Thickness
177
4
1
5,
~ t r - - - - - - ' d 9 III CD
Figure 821 Magnetic Indication Areas
of Magnaglo
VEHICLE
8-36. REBUILDING
A. Sleeve Eroded Water Holes.
Cylinder head surface around water holes must be free of any erosion, pits, scratches or
blemishes which are more than 0.003 inch (0.08 mm) deep in the area 1/16 to 5/32 inch (1.59 to
3.97 mm) from edge of water hole. Use water hole counterboring tool to enlarge hole for sleeve.
1. Coat sleeve, Figure 8-22 (Ref. No.1) with sealant, align sleeve in top of water passage
hole, drive into position using bushing driver (Ref. No.2) and hammer.
2. Use a flat mill file to file sleeve flush with top of cylinder head. Do not damage head
surface. Remove burrs from inside diameter of sleeve, clean all cuttings and filings from water
passages.
3. If proper sleeve is not available, heavy wall copper tubing may be used. Tubing must
provide 0.002 to 0.005 inch (0.05 to 0.13 mm) press fit. Overall length should be approximately
1/2 inch (12.70 mm); inside diameter must be 7/16 inch (11.11 mm) to allow proper water flow.
B. Resurface Cylinder Head_
If cylinder head has been scratched, etched or is uneven at point of contact in gasket
sealing area, head may be milled or surface ground.
1. Use valve seat extractor, remove all valve seat inserts. Remove swirl plates.
2. After resurfacing check head height, use micrometer or vernier depth gauge. Do not
remove more than indicated as worn limit. See Table 8-2.
3. Rework valve seat insert counterbore, remove amount of stock equal to that removed
during resurfacing.
C. Replace Valve Guides.
1. Drive out guides marked for replacement from underside of cylinder head. Install
new valve guide with mandrel. Install intake valve guides with oil mist hole facing exhaust mani-
fold side of head.
CAUTION: Failure to position oil mist hole correctly or failure to insure that oil mist hole
is fully open could result in high oil consumption or excessive valve guide wear.
2. If proper valve guide mandrel is not available, press guide into head. See Table 8-2
(Ref. No.4).
3. Normally valve guide inside diameter does not require reaming. I nsert valve stem
into guide and check for freedom of movement.
4. If reaming is necessary: Ream valve guide from bottom side of cylinder head using
reamer. Use lubricating oil or soluable oil and water solution for proper finish. Do not ream valve
guide beyond worn limit as listed in Table 8-2 (Ref. No.3).
D. Replace Crosshead Guides_
1. Remove crosshead guides marked for replacement using dowel puller.
178
VEHICLE
2
C5
- ,
~ ~ - - - - - - - - - - - -
I \
~
1 I \
I \
\ ,--
1. SLEEVE
2. BUSHING DRIVER
Figure 8-22 Drive Bushing Into Hole Figure 823 Counterboring for Valve Seat
2. Press new guides into cylinder head. If mandrel is not available, press new guides
into head to obtain protrusion as listed in Table 82 (Ref. No. 11).
3. Oversize crosshead guides may be installed as follows:
a. Drill guide bore in head to original depth with a 25/64 inch (9.92 mm) drill.
b. Lubricate and ream bore with 13/32 inch (10.32 mm) reamer.
c. Install oversize guide, as per Step 2 above.
E. Replace Valve Seat Insert.
1. If cylinder head has not been resurfaced, use valve seat extractor to remove valve
seat inserts that are marked for replacement. Remove swirl plates.
2. Enlarge counterbore to next oversize. Inserts are available in standard oversizes as
listed in Table 8-2.
3. Use valve seat insert tool driver, Figure 8-23 to hold and drive valve seat insert cutter
and valve guide arbor set when cutting valve seat insert counterbore.
4. Cut counterbore 0.006 to 0.010 inch (0.15 to 0.25 mm) deeper than insert thick-
ness to permit staking or peening of head to hold insert. Allow cutter to dwell upon reaching
proper depth to insure a flat seating surface.
5. Install swirl plate in intake valve seat counterbore with locking tang in positioning
groove.
6. Install valve seat insert and stake insert in head using tool driver over shaft of insert
staking tool. A 1/4 inch (6.35 mm) diameter round end punch may be used if staking tool is not
available.
CAUTION: Overswaging around insert may crack cylinder head.
179
VEHICLE
F. Grind Valve Seats.
"I. Use valve seat grinder and correct arbor from valve guide arbor set.
2. Check valve seat width, it should be 0.063 to 0.125 inch (1.59 to 3.18 mm). see 1
or 2, Figure 8-17.
3. If seating area (1) is wider than 0.125 inch (3.18 mm) maximum, stock can be re-
moved from points "AU and "B" with specially dressed stones. Narrowing should not extend
beyond chamfer on valve seat insert. Chamfer provides metal for staking or peening.
4. Check valve seat concentricity with valve seat indicator. Total run-out should not
exceed 0.002 inch (0.05 mm).
G. Replace I njector Sleeves.
Remove injector sleeves marked for replacement with injector sleeve puller and impact
wrench socket or equivalent.
H. Restore Injector Recess Surface.
1. If head was resurfaced, restore shallow recess area around injector port. Restore by
grinding with a 3 inch (76.2 mm) stone dressed to 2
0
+ 15 min. angle. Area should be 2.860 inches
(72.64 mm).
a. Using a scrap injector and cup, drill through bore and cup. Install injector in head;
secure with hold-down clamp and capscrew.
b. Ream injector bore to 3/8 inch (9.53 mm). Use valve guide arbor set with proper
grinding unit such as valve seat insert grinder and proceed as follows:
(1) I nsert proper arbor into reamed injector bore.
(2) Select 3 inch (76.2 mm) stone dressed to 2
0
+ 15 min. angle. Grind injector
recess until 2.860 inch (72.64 mm) diameter is obtained.
NOTE: A few light touches of the stone when finished dimension is obtained will produce
a proper finish.
I. Sleeve Installation.
1. Coat new "0" rings with clean vegetable oil. Install "0" rings into groove of cylin-
der head injector sleeve bore.
NOTE: Do not lubricate "0" rings more than 24 hours before assembly.
2. Using injector sleeve installation mandrel, push new injector sleeve into bore of cylin-
der head until it bottoms. Do not strike mandrel with hammer during this step. Remove mandrel.
3. Install injector sleeve holding tool. Tighten nut to 35 to 40 ft. Ibs. (47 to 54 Nm)
torque.
180
VEHICLE
4. Insert mandrel into sleeve bore, strike mandrel two moderate blows with hammer to
insure that injector sleeve is properly seated. Retighten injector sleeve holding tool to 35 to 40 ft.
Ibs. (47 to 54 Nm) torque.
5. Roll top 1/2 inch 02.70 mm) area of sleeve with expanding roller, Figure 824. Use
in. lb. (Nm) torque wrench to turn. Turn mandrel until a 25 to 35 inch (3 to 4 Nm) maximum
torque reading is obtained on torque wrench.
CAUTION: Overrolling of injector sleeve will cause deformation of sleeve into "0" ring
groove.
6. Cut injector seat to provide proper seat and injector tip protrusion. Use injector
sleeve cutter in a drill press with pilot, using a solid stream of good cutting oil to allow cutter to
cut freely without grabbing, etc. To determine amount of cut, insert injector and torque to speci-
fications, then measure tip protrusion. Depth of cut must provide 0.102 to 0.122 inch (2.59 to
3.10 mm) protrusion of injector cup tip beyond milled face of cylinder head when injector is in-
stalled at proper torque. Table 8-2.
7. Sleeve must "blue in" with Prussian Blue 360
0
around injector seat when injector
is installed in cylinder head. Bluing band must be 0.060 inch (1.52 mm) minimum width.
8. Water test cylinder head.
J. Grind Valves.
1. Check valve grinder setting by using a new valve and an indicator gauge.
a. Check valve in valve grinder on guide area of stem. Relieved portions on both ends
of guide area are not necessarily concentric to guide area of stem.
b. Indicate on ground face of valve.
c. Turn valve and mark high spot on head of valve.
d. Rechuck valve 180
0
from first position.
e. Repeat (b) and (c). If high spots are same for both (a) and (d) position, valve is
warped. If high spots occur in different positions, chuck is out of alignment. Runout should not
exceed 0.001 inch (0.03 mm).
2. Wet grind valves to an exact 30
0
angle from horizontal. Check rim thickness as shown
in Figure 8-20. If rim is less than 0.114 inch (2.90 mm), valve is not suitable for reuse.
3. Pencil mark valve face as shown in Figure 8-25 position in valve guide against a newly
ground valve seat, rotate valve 10
0
. A good seat will be indicated if all pencil marks are broken. If
pencil marks are not broken, tools need dressing or machine has not been properly adjusted. Final
check should be made with a vacuum tester.
4. Valve seats properly ground with precision equipment should not require lapping to
effect an air-tight seal; however, a small amount of lapping is ppermissible if necessary in order to
pass Valve Seating (vacuum) Test.
181
VEHICLE
o
Figure 824 Expanding Roller in Upper Injector
Sleeve Bore
K. Valve Springs.
Figure 825 Pencil Marks on Valves
Weak valve springs may cause valve flutter resulting in excessive wear on both valve and
seat. Valve flutter interferes with valve timing and may cause valve to strike top of piston.
Test valve spring on spring tester that is capable of accurate measurement of valve springs
length, apply required load for length as listed in Table 82. If valve springs compress to dimensions
shown, at less than load indicated under "wornlimit", discard valve spring.
837. ASSEMBLY
A. Install pipe plugs and fuse plug using sealant or sealing tape. Torque plugs to values listed
in Table 82.
B. Install cup plugs using correct plug driver.
1. Replacing cup plugs with cup plugs.
a. Remove leaking plug. Clean bore removing rust and scale.
b. Degrease new plug and coat with Lactite primer "N" or "T". Coat outside diameter
of plug with cup plug sealant. Drive in new plug until flush with cylinder head surface. Cup plug
must be below exhaust face surface.
c. If primer "T" was used, allow 5 minutes drying period. If grade "N" was used,
allow one hour.
2. Replacing cup plug with screw type plug.
a. Remove old cup plug.
b. Drill leaking plug hole using a 61/64 inch (24.21 mm) drill to a depth of 0.620 to
0.650 inch (15.75 to 16.5 mm).
182
VEHICLE
c. Tap hole using 3/4 inch N.P.T.F. Clean head of all drillings.
d. Install screw type plug using Lactite sealant or equivalent. Tighten to 75 to 80 ft.
Ibs. (102 to 108 Nm) torque.
NOTE: Cylinder heads contain breather or vent tubes that must be "open" on naturally
aspirated engines.
C. Lubricate valve stems with clean engine lubricating oil and insert valves in valve guides.
Install valve oil seals as outlined. Seals are used on intake valves only.
1. Place plastic sleeve and seal over valve stem.
2. Press seal into place over valve stem with driver until seateq on valve guide.
D. Install valve spring wear plates, install valve springs. Make sure valve springs will produce
the provided assembled height of 1.686 inch (42.82 mm) and load specifications, Table 8-2.
CAUTION: Valve heads must not extend past head surface. With new inserts and new valves,
protrusion should be 0.000 to 0.017 inch (0.0000 to 00.43 mm).
E. Use valve spring compressor to compress springs and insert new halfcollets to secure
valves and springs.
NOTE: New half-collets should always be used during cylinder head rebuild.
8-38. ROCKER LEVER AND SHAFT
A. Disassembly and Inspection.
1. Remove locating pin from mounting bracket.
2. Slide rocker lever shaft brackets and rocker levers from shaft. Tag rocker levers for
correct position as removed.
3. Remove cup plugs from each end of each shaft.
4. R e ~ o v e adjusting screw locknuts and adjusting screws from rocker levers.
5. Check rocker lever by magnetic inspection for surface imperfections and cracks. See
Figure 8-26 for most likely area of defects.
6. Gauge rocker lever bushings with telescope gauge and micrometer.
a. Set telescope gauge 0.0002 inch (0.005 mm) above worn limit of 1.129 inch
(28.68 mm) for use as "No Go" gauge.
b. Mark bushings worn beyond limits for replacement. See Table 8-3.
7. Check intake and exhaust rocker lever crosshead contact surface. If a wedge shape
pattern is evident, replace- rocker lever to avoid excessive wear. Also check crossheads for the same
sign of wear. If worn or damaged, replace with new rocker lever. Normally, most wear will be on
the crosshead.
183
VEHICLE
15"""""---
13
1. SHAFT
6. STAND, SHAFT fl. BUSHING
2. PLUG
3. NUT
7. INTAKE ARM
8. BUSHING
12. EXHAUST ARM
13. STAND, SHAFT
4. SCREW, ADJUST
5. PIN
9. INJECTOR ARM
10. SOCKET
14. LOCKWASHER
15. SCREW
Figure 8-27 Rocker Levers and Shaft
8. The ball end rocker lever adjusting screws must be true spheres. Test with 1/4 inch
(6.35 mm) radius gauge. If worn flat on bottom, replace.
9. Injector rocker lever sockets must be replaced if worn. Wear is easily detected by
"bluing in" with a new injector link. Bluing must show 80% circumferential contact.
10. Check thread condition on all screws and rocker levers. Check closely for thread
distortion at assembled position of locknut. Be sure screws will turn freely through rocker levers.
11. Check rocker lever shaft for scoring, galling, out-of-round and wear. If worn smaller
than Worn Limit, Table 8-3, install new shaft.
12. Examine rocker lever shaft brackets for cracks, breaks and stripped threads. Replace
as necessary. Visually check lever side surfaces which mate with adjacent levers. If galled, restore
surfaces to original smoothness.
184
VEHICLE
1. EXHAUST VALVE ROCKER
LEVER
2. INJECTOR ROCKER LEVER
3. INTAKE VALVE ROCKER
LEVER
4. ROCKER SHAFT SUPPORT
Figure 826 Magnetic Inspection
Crack Indication
Figure 828 Rocker Lever and Shaft Assembly
B. Repair.
1. Remove socket. If broken off, press out by drilling a small hole above socket. After
socket is removed, spot weld hole closed or install and stake socket head plug in hole. Press out
worn bushings with mandrel and block. Blowout passages with compressed air.
2. Install new steel bushings with mandrel, block and arbor press. Install flush with
surface.
C. Assembly.
1. Dip rocker lever shaft "cup" plugs in lubricating oil to prevent galling.
2. Drive "cup" plug in shaft using mandrel.
3. Install rocker lever adjusting screws and nuts to rocker levers.
4. Install sockets in injector rocker levers, if removed. Coat rocker lever shaft with clean
lubricating oil.
5. Position rocker lever shaft bracket with locating pin hole on rocker shaft. Align shaft
and bracket locating holes and secure with locating pin.
6. Slide valve rocker lever (1, Figure 828) (with oil hole in contact areaL injector lever
(2) and valve rocker lever (3) (without oil hole) onto rocker lever shaft. Slide rocker lever shaft
bracket (4) onto shaft, and repeat Step 6 until all levers are in place.
7. Slide last bracket into place. To facilitate handling, bind the rocker lever assembly
together with heavy rUbber bands or cord. Keep end of assembly away from locating pin UP to
prevent parts sliding off shaft.
CAUTION: Levers can easily be installed in the wrong position; care must be used to install
in correct position.
185
VEHICLE
839. ROCKER LEVER COVER
A. Inspection.
1. Clean with steam or hot water and detergent. Do not use chlorinated solvents, paint
stripper, petroleum based solvents, caustic or acid based chemicals as they will deteriorate the
rubber bonding.
2. Remove all gasket material from sealing edge of cover. Inspect for cracks, dents and
distorted sealing area; discard unserviceable parts. Inspect for cracks around capscrew holes.
840. CRANKCASE
A. Breather Servicing.
1. Disassemble breather.
2. Clean all metal and rubber parts in solvent. Use solvent that is not harmful to rubber.
Do not attempt to clean paper element. Dry thoroughly with moisture free compressed air.
3. Inspect rubber washers and gaskets; inspect body for cracks, dents or breaks. Discard
all unserviceable parts.
4. Using n.ew element, assemble breather.
841. TAPPETS
A. Disassembly and Inspection.
1. Remove spring clips from tappet bodies, if not previously removed; discard spring
clip. Place tappet body in suitable fixture (open end of fixture) with lockwire down.
2. Place fixture in a suitable arbor press. Using mandrel, press tappet pin from body.
(Figure 830). Discard pin and lockwire.
3. Press or knock out insert (1, Figure 829) with a small round punch from injector
tappet if worn excessively.
NOTE: Injector tappet body has a small hole in bottom of insert sealing area for access to
remove insert. .
4. Check for scored, flaked or chipped rollers (3, Figure 829), discard damaged parts.
NOTE: If any of the conditions above exist, camshaft should be checked very closely for
damage.
5. Measure tappet body outside diameter for wear; measure roller outside diameter and
inside diameter for wear. Discard "if worn beyond limits shown in Table 84.
6. Check tappet sockets by "bluing" corresponding new push rod on ball end and
rotating in tappet; a full seat should be indicated. For best results keep push rod with mating
tappet, especially if they are to be reused. Check body pin holes and insert hole for burrs before
assembly.
186
VEHICLE
0---------
'
L J
0
2
lJ
5 4
\ cbn
,..,
.do
I
0-
3
1. INSERT 4. ROLLER PIN
~
2. TAPPET BODY 5. lOCKWIRE
3. ROLLER
Figure 829 Injector Tappet Assembly --
Exploded View
Figure 830 Removing Tappet Roller Pin
B. Assembly.
1. If previously removed, press new insert (1, Figure 829) in tappet body (2). Make
sute insert is securely seated.
NOTE: Support tappet body in such a way as not to spring tappet forks.
CAUTION: Lubricating oil passage in pin and tappet must index for adequate lubrication.
2. Assemble spring and locating pin (injector tappet) in drilled end of fixture, with
small end of locating pin up.
3. Install tappet body in V block, with locating pin engaged in tapped pin bore.
NOTE: Lockwire side of tappet body to be in-the upward position.
4. Install new roller in tappet body and engage locating pin in roller bore. Install lock-
wire in new tappet roller pin.
5. Install roller pin to tappet body and align locating pin to index with slot in side of
tappet body. Insert 0.006 inch (0.15 mm) shim or feeler gauge between side of roller and tappet
fork.
6. Using a suitable mandrel and arbor press, press pin in tappet body through roller until
locating pin bottoms out in slot inside of body.
7. Remove mandrel and shim, rotate roller to make sure it rotates freely. If any restric
tion is felt, it is suggested pin be removed and a new pin installed. Restriction indicates a slight burr
picked up.
187
VEHICLE
Table 84. TAPPET AND PUSH ROD SPECIFICATIONS-Inch (mm)
.
,
:Ref. Worn New New
~
Measurement Limit Minimum Maximum
!
Injector Tappet
I
1 . Body Outside Diameter 1.3965 1.3980 1.399
I
(35.471) (35.51) (35.54)
Rolle, Outside
Diameter 1.1670 1.169 1.171
(29.64) (29.69) (29.74)
Roller Inside Diameter 0.6300 0.628 0.629
(16.002) (15.95) (15.98)
I
Rolle, Pin Outside
I
Diameter 0.6235 0.6245 0.625
(15.837) (15.862) (15.88)
Roller Side Clearance 0.022 0.005 0.017
(0.56) (0.13) (0.43)
Roller Concentricity - - 0.0005
Assembled - - (0.013)
1
Roller Squareness -
- 0.001
Assembled - - (0.03)
~ l
Valve Tappet
1. Body Outside Diameter 1.0965 1.098 1.099
(27.851) (27.89) (27.92)
I
Roller Outside Diameter 0.9770 0.979 0.981
~
(24.816) (24.87 (24.92)
'-".
I
Roller Inside Diameter 0.5040 0.502 0.503
(12.802) (12.75) (12.78)
Rolle, Pin Outside
Diameter 0.4985 0.4995 0.500
(12.662) (12.688) (12.70)
Roller Side Clearance 0.019 0.004 0.014
(0.48) (0.10) (0.36)
Roller Concentricity - - 0.001
Assembled - - (0.03)
Roller Squareness - - 0.001
Assembled - - (0.03)
I
Push Rods
I
Ball End Radius 0.3110 0.3125
I
Socket End Radius 0.2500 0.2515
I
Length 9.722 9.762
I
188
VEHICLE
C. Inspection of Tappet Assembly.
Inspection of tappet assembly requires a surface plate, small V block with clamp to hold
tappet in position and an indicator calibrated in tenths of a thousandth inch or (mm) attached to
a surface gauge.
1. Using a small wire, check indexing of pins and body lubricating oil passage. Check
freeness of roller by rotating two or three turns. If a "drag" is felt, the plating on pin has probably
picked up during assembly, due to burrs or pin not being held square during assembly.
2. Standard small V block on surface plate. Stand tappet assembly on surface plate with
roller up. Secure tappet in V block with clamp.
NOTE: Tools and parts must be clean to obtain a true check.
3. Using an indicator calibrated in tenths of thousandth inch or (mm), check concen-
tricity by rotating roller. Move indicator stand slightly and recheck. See Table 8-4 for dimensions.
CAUTION: Injector and valve tappet dimensions are not the same. Use correct dimensions
when checking wear.
4. Using same indicator as in Step 3 above, check squareness of roller by sweeping the
other end. Rotate tappet roller 180
0
and check again at roller ends by sweeping across the diameter.
See Table 8-4 for dimensions. It is permissible and recommended to exert some downward pressure
against roller when gauging to assure firm contact against roller pin.
CAUTION: Any parts that do not pass the checks above must be disassembled. (Perform
inspection during disassembly to determine the rejection). Reassemble tappets following
"Assembly" and "Inspection of Tappet Assembly" as described above.
5. Install spring clip and spring guide.
8-42. PUSH RODS
Each cylinder has an exhaust, injector and intake push rod. Intake and exhaust push rods are
identical. There are two types of valve push rods, one has no identification marks and the other has
two ridges 180
0
apart on each side of the socket O.D. Both are completely interchangeable. There
are four type injector push rods; the first has two ridges and has two diamond shaped cast ridges
180
0
apart between the ridges; the second has no ridges but has two notches around 180
0
apart
in socket rim; the third is easily identified by the longer socket O.D. which is 3/8 inch (9.53 mm)
long versus 1/8 inch (3.18 mm) length of the other versions; the fourth has two ridges similar
to the first but instead of a diamond shaped cast, it has a barrel shaped marking. Do not mix differ-
ent type injector rods in engine.
1. Check injector and valve push rod ball end with radius gauge for wear. See Table 8-4
for dimensions.
2. Test sockets of push rods with ball end of a new rocker lever adjusting screw or with
1/2 inch check ball, which should "blue" 75% of seat area.
3. Check push rods to see if they are bent. Push rods that are bent have usually had the
adjusting screws over-torqued. With push rod supported at ends of pivot points having a common
axis and with a dial indicator placed midway between ends, run-out must not exceed 0.025 inch
(0.64 mm) total indicator reading when rod is revolved 360
0
.
189
VEHICLE
843. LUBRICATION SYSTEM
8-44. OIL PUMP
Care must be taken during disassembly to mark or identify parts, such as pressure regulator
plunger, idler shaft, drive shaft, capscrews as to length size, location, etc., as removed in aid in
reassembly. Clean disassembled pump in an approved cleaning solvent as described in Engine Dis
assembly.
The oil pump as shown in Figure 831, pressure oil outlet (1), regulator bypass (2) and
suction tube (3).
A. Disassembly.
1. Refer to Figure 832; remove cover (17) from pump body (1); remove idler gear (13)
from idler shaft (12).
2. Support pump body and press drive shaft (14) through drive gear (4) and pump body
(1). Remove driven gear (15) from shaft (14) if shaft or gear is worn or damaged.
3. Using a suitable press, remove idler (12) shaft from body if worn.
4. Remove pressure regulator assembly (9) from pump body.
5. Remove screw (19), lock plate (10)' regulator yoke (20), cap (21), spring (22) and
plunger (23).
B. Inspection.
1. Inspect pump drive gear (4); discard if teeth are chipped, cracked, scored or show
excessive wear.
2. Inspect all other gears; discard if they have chipped teeth, or are scored.
3. Measure bushing(s) (5) in idler gear (13). Mark for replacement if over Worn Limit,
Table 85.
4. Inspect drive shaft (14) and idler shaft (12). Mark for replacement if scored or worn
smaller than Worn Limit, Table 85, (2) and (3).
1. OUTLET
2. REGULATOR BYPASS
3. SUCTION TUBE
Figure 831 Oil Pump Assembled
190
VEHICLE
1. BODY 9. PICK UP TUBE 17. COVER
2. LOCK PLATE 10. LOCK PLATE 18. SCREW
3. SCREW 11. BYPASS TUBE 19. SCREW
4. DRIVE GEAR 12. IDLER SHAFT 20. REGULATOR YOKE
5. BUSHING 13. IDLER GEAR 21. CAP
6. SCREW 14. DRIVSHAFT 22. SPRING
7 LOCK PLATE 15. DRIVEN GEAR 23. PLUNGER
8. GASKET 16. GASKET 24. SCREW
Figure 8-32 Oil Pump - Exploded View
5. Measure bushings (5) in body (1) and cover (17). Mark for replacement if worn larger
than shown in Table 8-5 (11).
6. Check gear pockets. If finished surfaces are damaged or worn excessively, discard
body.
7. Check pressure regulator plunger (23) fit in pump body. Discard if loose or worn be-
yond limits shown in Table 8-5 (4-5-6). Measure plunger bore in pump body. See Table 8-5 (7) for
dimensions.
8. Measu re spring (22) for free length. Discard if spring does not meet specifications.
C. Repair.
1. If bushings (5) in body were marked for replacement, remove and press new bushings
flush to 0.030 inch (0.76 mm) below outside surface.
2. If bushing in cover (17) was marked for replacement, remove and press new bushing
in cover to 0.040 to 0.060 inch (1.02 to 1.52 mm) below inside face of cover.
NOTE: Bushing in body and cover must be bored to 0.6165 to 0.6175 inch (15.659 to
15.685 mm). Bushings in idler gear must be bored to 0.6195 to 0.6205 inch (15.735 to
15.761 mm).
191
VEHICLE
Table 85. OIL PUMP DIMENSIONS - Inch (mm)
Ref. Worn New New
No. Measurement Limit Minimum Maximum
Bushing, Idler Gear
Inside Diameter 0.6215 0.6195 0.6205
(15.786) (15.735) (15.761)
Bushing, Pump Drive Shaft
1. Inside Diameter 0.6185 0.6165 0.6175
(15.710) (15.659) (15.685)
Drive Shaft
2. Outside Diameter 0.6145 0.6150 0.6155
(15.608) (15.621) (15.634)
P
Idler Shaft

3. Outside Diameter 0.6175 0.6180 0.6185 .1--,
(15.685) (15.697) (15.710)
:1
,
Drive Gear


Inside Diameter 0.6140 0.6145
(15.596) (15.608)
'"
Driven Gear
Inside Diameter 0.7495 0.7505
(19.037) (19.063)
Driven Gear to Idler Gear
Backlash 0.0240 0.0160 0.200 .E
(0.610) (0.406) (0.508)
JI
Depth of Bushing in
. :> I
Pump Cover 0.0400 0.0600
I
(1.016) (1.524)
cb
Depth of Bushing in
Pump Body 0.0000 0.0300
(0.00001 (0.762)
Pressure Regulator Plunger
Spring End

4. Outside Diameter 0.868 0.869 0.870
(22.05) (22.07) (22.10)
5. Inside Diameter 0.740 0.760

(18.80) (19:30)
Pressure End
6. Outside Diameter 0.868 0.869 0.870
(22.05) (22.07) (22.10)
Plunger Bore in Pump
Body 0.878 0.874 0.877
(22.301 (22.20) (22.28)
ByPass Valve Spring Data
Free Length 3.370 3.590
(85.598) (91.19)
Pump Drive Shaft
End Clearance 0.003 0.008
(0.08) (0.20)
192
VEHICLE
3. If bushings in idler gear were marked for replacement, remove and press new bush-
ings ingear.
a. Press in new bushings in idler gear to 0.130 to 0.160 inch (3.30 to 4.06 mm) below
surface from each end of gear.
D. Assembly.
1. Press idler shaft (12, Figure 8-32) into pump body to 0.005 to 0.035 inch (0.13 to
0.89 mm) below cover mounting face (3, Figure 8-34).
2. Press drive shaft (14) in driven gear (15) to maintain 0.875 to 0.905 inch (22.23 to
22.29 mm) shaft protrusion from end of gear. See (1, Figure 8-33).
3. Install driven gear (15) and shaft (14) into pump body; support drive shaft and press
drive gear (4) (12, Figure 8-32) on drive shaft.
a. Press drive gear (4) on drive shaft (14) to 3.800 to 3.820 inch (96.52 to 97.03 mm)
with concave side away from gear body. See (2, Figure 8-33). Slide idler gear (13) over idler shaft
( 12).
4. Install cover (17) to body. Torque screws to 15 to 17 ft. Ibs. (20 to 23 Nm). 8end
locking tangs over screw heads and cover.
5. With a dial indicator, check for 0.003 to 0.008 inch (0.08 to 0.20 mm) end clear-
ance on pump drive shaft. Table 8-6).
6. Install regulator plunger (23), spring (22), cap (21), and yoke (20). Secure with
screw (19) and lockplate (10).
1. PROTRUSION: 0.876 TO 0.905 INCH (22.23 TO
22.99 mm)
2. CONCAVE SIDE OF GEAR AWAY FROM BODY
3. CLEARANCE: 0.005 TO 0,035 BELOW COVER
MOUNTING FACE
Figure 833 Oil Pump - Cross Section
193
i
iRef.
f ~ O '
I
1.
2.
3.
4.
VEHICLE
Table 8-6. WATER PUMP DIMENSIONS - Inch (0101)
New New
F=
Unit or Part Minimum Maximum
(i)--
~
Shaft Outside Diameter
Impelier End 0.6262 0.6267
I-
Shaft Outside Diameter
Small Bearing Area 0.6692 0.6696 '==
(16.998) (17.008)
-
0-----
~
Shaft Outside Diameter r------
Puliey End 0.7874 0.7878
(19.999) (20.010)
Shaft Outside Diameter
Bearing and Puliey End
When Used With Double
Row Bearing 0.9843 0.9847
(25.000) (25.001 )
Impeller Bore
(3)---+-
~
Inside Diameter 0.6240 0.6245
(15.B50) (15.862)
Impelier to Body
Clearance 0.010 0.020
t ~ ~ ~
(0.25) (0.51 )
Minimum Press Fit Between
Shaft and Puliey 0.001
(0.03)
Minimum Press Fit Between
Shaft and I mpelier 0.001
(0.03)
845. OIL PAN
A. Inspection.
1. Visually check oil pan for cracks, or, if a leak is suspected, check using dye penetrant.
a. Spray suspected area with dye penetrant. Allow penetrant to dry for fifteen min-
utes. Do not "force dry".
b. Spray area with dye developer and check for crack indications.
2. Check thread inserts on oil pans. If damaged, replace. Check all threaded holes for
damaged threads.
194
VEHICLE
B. Repair.
1. Repair damaged thread inserts.
a. Determine hole size; then use proper thread insert extraction tool to remove
damaged thread inserts. Condition hole and insert new thread insert.
b. Use starting and finishing tap for thread inserts for new or oversize holes in alumi-
num. When tapping aluminum, use fuel oil for lubricant to prevent tearing.
c. After inserting, bend starting end toward center then back toward side of hole to
break off installation tip.
2. Repair small cracks in pan by welding. Do not weld finished surfaces.
3. Install pipe plugs in oil pan securely. Do not overtighten.
8-46. OIL FILTERS
8-47. FULLFLOW PAPER ELEMENT FILTER
A. Disassembly.
1. Remove filter case and element from filter head, remove seal ring and discard.
CAUTION: Be sure to remove oil sealing rings from full flow filter head before installing
new filter element.
2. Lift element from case; inspect element pleats. If metal is found in elements, an in-
spection of connecting rod and main bearings should be made. Discard element.
3. The filter by-pass valve normally requires no servicing; however, check to make sure
the valve works freely. The valve is spring loaded and opens on a spring differential. If valve is
sticky, perform following inspection.
B. Inspection.
1. Remove by-pass snap ring (3), Figure 8-34 and pull spring retainer (4), spring (5), and
by-pass disc (6) from filter head (8).
2. Remove snap ring from screw securing support, seal washer and spring on screw in
case. Slide bolt from case; remove and discard copper washer and seal.
3. Inspect all parts'for wear or distortion; discard and replace all damaged parts.
C. Assembly.
1. Assemble as shown in Figure 8-35. Failure to reinstall the lubricating oil filter com-
ponents correctly will result in serious damage to the engine due to unfiltered oil reaching the
bearings.
2. Coat all plugs and fittings with sealing tape or lead sealer; install in filter head.
195
L/
I. fiLTER CASE
2. fiLTER ElEMENT
3_ SNAp RING
4. SPRING RETAINER
&. SPRING
6. DISC
1. SEAL
8. filTER HEAD
Figure 8-34 Filter By-Pass Valve Assemblv
VEHICLE
Figure 8-35 New Sealing Arrangement
3. If removed, install by-pass disc (6, Figure 8-34), spring (5) and spring retainer (4) in
filter head (8); secure with snap ring (3).
4. Position new seal ring (7) or gasket on filter head (8). Slide new element (2) with seals
in place over screw and into filter case (1).
5. For convenience, do not secure filter case to head until head is mounted to side of
block or lubricating oil cooler housing. Head must be mounted with an internal mounting screw.
8-48. OIL LINES
A. Specifications.
1_ Hose used for lubricating oil or fuel should consist of a seamless synthetic rubber or
Teflon inner tube reinforced with fabric braiding and covered with a synthetic rubber-impregnated
oil-resistant fabric braid or rubber coating_
2. Rubber-lined hose should be capable of handling fluids ranging in temperature from
-40
0
to 300
0
F (-40
0
to 149
0
C), and be suitable for use with lubricating oil and/or fuel oil. Since
engine lubricating oil temperature may exceed 250
0
F (121
0
C) at full load operation and high
ambients, hose meeting SAE specification 100 R 1 and 100 R 5 will not be adequate unless it is
also capable of handling fluids within the temperature range as stated above.
3. Teflon-lined hose has a maximum temperature rating of 450
0
F (232
0
C), and cor-
rosion resistant stainless steel wire braid over Teflon liner using permanent swagged-type fittings.
4. Consideration should also be given to clamping of hose. That is, enough flexibility
has to be provided to accommodate relative movement and at the same time, clamps should be
located as required to prevent chafing of the hose.
196
VEHICLE
B. Assembly.
Replace hose and worn or cracked connections with new parts. Average life of flexible
oil hose is 100,000 to 200,000 miles (160,900 to 321,000 km), or 3200 to 6400 hours depending
upon amount of bend and temperature to which hose is subjected. For shops equipped to make up
hose from bulk hose, follow steps below to insure proper fitting installation.
1. Cut hose to required length using a hacksaw. Cut should be square with 50.
2. Hose should not be crushed while sawing (crushed hose will permit nipple to pick up
hose inner tube and block passage.).
3. Place socket in jaws of a vise. Check all fittings to make sure of fit on mating part.
4. Hold hose so it enters socket straight to prevent cocking of hose in socket. Rotate
hose counterclockwise while pushing it into socket.
5. Turn hose into s o c k ~ t until it bottoms, check to be sure it has bottomed and does not
bell in from being pushed in too far.
6. Place socket and hose assembly in jaws of a vise. (Clamp on the socket.) Apply lubri-
cation on nipple and inside of hose for ease of assembly.
7. After assembly, always look carefully inside fittings and hose for possible hose
damage. A cut in inside diameter of hose lining can plug hose bore when flow of fluid is sent
through hose.
849. OIL COOLER
A. Disassembly.
1. Remove cooler head, gasket, "0" ring, and brass retainer, being careful not to scratch
or mar sealing surface on element.
2. Use mineral spirits or equivalent to clean out lubricating oil and contaminants trapped
in housing by forcing cleaner through the oil ports.
3. To remove element from housing, insert two 7/32 inch (5.56 mm) rods 8 inches
(503.2 mm) long into the outside row of tubes opposite each other, rods should not drag bottom
of housing.
4. Place a bar on top of housing and bundle face between rods, and rotate element in
housing to unseat lower "0" ring. Lift up gradually on rods to free "0" rings.
B. Inspection.
1. To prevent hardening and drying of foreign substances clean immediately, after re-
moving end cover plates, with approved cleaning solvent that will not harm non-ferrous metal,
blow through core with compressed air.
2. Inspect core for corrosion or cracks where tubes are welded to end plates. Inspect
connections and liner for cracks or damage.
CAUTION: Engine lubricating oil cooler tube bundles must not be reused after an engine
in which metal particles may have been circulated through the lubricating system.
197
VEHICLE
3. Inspect coller assemblies for leakage between oil and water passages.
a. Clamp cooler assembly in fixture and assemble air connection.
b. Place unit in water tank and supply 1 to 4 psi (7 to 28 kPa) air pressure to water
side. Inspect for air leaks, porosity in casting, etc.
c. Apply line air pressure to 60 psi (414 kPa) to oil side. Inspect for air leaks.
C. Repair.
Repair damaged tubes by inserting a small 0.0. tube inside damaged tube. Cut and flare
ends; then solder securely. Do not damage adjacent tubes with heat while soldering. If more than
5% of tubes are defective, discard cooler.
NOTE: Repair instructions pertain only to failed coolers not covered under warranty.
O. Assembly.
1. Lubricate rubber "0" ring and place in groove at bottom of housing. Make sure ring
is not tiwsted and is free of cuts or nicks.
2. Push element into housing, aligning index marks (2) on housing and element.
3. Using proper "0" ring mandrel, install "0" ring around top of element. Place retain
ring over rubber "0" ring.
4. Assemble new gasket and cooler/filter head; secure snugly with capscrews and lock-
washers. Place assembly on flat plate or flat work bench with inlet and outlet flat on top of plate;
making sure both ends are on same plane; torque capscrews to 28 to 31 ft. Ibs. (38 to 42 Nm).
850. WATER PUMP
A. Disassembly.
1. Pull impeller (4, Figure 8-36) from shaft (12) with puller.
CAUTION: Do not thread the puller screws in more than five (5) threads or carbon face seal
may be damaged.
2. Using puller, pull drive pulley (16) from shaft (12).
3. Using a pair of snap ring pliers, remove large snap ring (14) from pump housing. Press
on impeller end of shaft to remove assembly from pump body. If bearing (11) remains in pump
body, press out bearing.
4. Remove carbon face seal (3) from pump body.
5. Remove flinger (10).
6. Press shaft from large bearing (13), (press on inner race of bearing) and small bearing
(11) if bearing remained on shaft.
7. Clean all non-ferrous parts, except bearings, in Bendix carburetor cleaner or equiv-
alent.
198
VEHICLE
5
4
!. PIPE PLUG
6. GASKET
11. BEARING
!6. PUllEY
2. WATER PUMP 7. CONNECTOR
12. SHAFT 17. PIPE PLUG
3. SEAT, W!SEAl .. SCREW
13. BEARING
".
PIPE PLUG
4. IMPElLER
.. lOCKWASHER
".
SIIAfT RING ! . SCREW
5. GASKET !O. FLINGER !5. flAT WASHER
Figure 836 Water Pump - Exploded View
B. Inspection.
1. Inspect water pump bearings. Replace bearings if rebuild is performed at 100,000
miles or greater.
2. Inspect water pump impeller. Mark for replacement if cracked or corroded to extent
that it will interfere with circulation.
3. Measure impeller bore and shaft outside diameter. There must be a minimum of 0.001
inch (0.03 mm) pressfit between shaft and impeller; replace if necessary. See Table 86.
4. Inspect water pump mounting parts for cracks. Replace as necessary.
5. Examine carbon face seal carefully to make sure it is not cracked or chipped. Replace
if rebuild is being performed at 100,000 miles or greater.
6. It is recommended that ceramic seat be removed and discarded if damaged or worn
excessively. Replace with a new rubber boot/ceramic seat combination type seat.
C. Assembly.
1. Lubricate shaft outside diameter lightly, with clean lubrication oil. Pack both large
and small bearing with grease meeting specifications given in "Wear Limits", Chapter 17.
NOTE: If double sealed bearings are used, remove inner bearing seal. Do not use lead base
sealer.
199
VEHICLE
2. Press bearing (11, Figure 8-36) on shaft (12) with shielded side toward impeller end
of shaft) until inner race seats against shoulder on shaft.
CAUTION: When installing bearings, press on inner race when installing over a shaft and on
outer race when installing in a bore.
3. Apply thin coat of sealant to inside diameter of pump housing where small bearing
seats. Fill cavity of bore 60% to 70% full of grease meeting specifications given in "Wear Limits",
Chapter 17.
4. Press shaft and small bearing into housing until it bottoms.
5. Press large bearing (13) over shaft and into housing until it seats on shaft shoulder.
Install snap ring (14) in bore of body to secure bearings in place.
6. Turn pump over and slide or press flinger (10) down to seat on bearing shoulder of
shaft.
7. Press carbon face seal (3) into housing until it seats.
8. Support shaft on impeller end and press drive pu lIey over shaft until hub is tight
against bearing inner race. Lubricate the inside diameter of the rubber seat with a Hght coat of water
soluble lubricant. Do not allow any lubricant on seal face of ceramic ring. Install the seat assembly
(rubber and ceramic) over water pump shaft until polished side of ceramic ring bottoms against
the carbon face of the pump seal.
9. Support shaft on pulley end and press on impeller, maintain 0.010 to 0.102 inch
(0.25 to 0.51 mm) clearance between impeller vanes and pump body. Turn impeller to insure
shaft turns freely.
8-51. FAN HUB
A. Disassembly.
1. Remove fan blade (9, Figure 8-37) by removing screws (7) and lockwashers (8). Re-
move fan spacer (12) from fan hub (20); discard gasket (13). Drain oil from hUb.
2. Pull cotter pin (15) and remove slotted nut (14); lift out washer (16),
3. Using a suitable press, press shaft (23) from hub; lift out front tapered bearing (17).
NOTE: As shaft is removed from hub, grease seal (22) will be damaged and must be replaced.
4. Using a suitable puller, pull rear bearing (21) from shaft; discard grease seal (22).
5. Pull both outer races (17 and 21) from fan hub using a suitable puller.
6. Remove snap rings (18).
7. Remove pipe plug(s) (19),
200
I. SCREW
2.- PUlUYClAMP
3. lOCIiWAStlER
4. SCREW
5. SCREW
e. lOCKWASIiER
1. SCREW
8. lOCKIVASHER
VEHICLE
9. fAN
10. fANSHROVO
11. CAGE NUT
12. FAtHILOT
13. GASKET
14. NUT
15. COnERPIN
16. HATWA$HER
17. 8EARING.CUP&CONE
18. SNAP RING
19. PIPE PLUG
10. PUllEY
21. BEARING, cur& CONE
22. SEAL
23. SIIAFT
Figure 8-37 Fan Hub - Exploded View
B. Cleaning and Inspection.
1. Clean parts with an approved solvent and dry with compressed air. Remove all traces
of lubricant.
2. Inspect ball bearings, races and fan hub shaft. Mark for replacement if rough or worn.
3. To determine if shaft or bearing is worn beyond limits, the spindle bearing surfaces
and inside diameter of bearings must be measured, to assure that a satisfactory press fit tolerance
is present. A 0.000 to 0.001 inch (0.00 to 0.03 mm) press fit tolerance between spindle and bearing
race is required to prevent bearing race from turning on spindle and damaging fan hUb.
4. Inspect threads for stripped or crossed threads; discard all damaged parts.
5. Inspect fan hub, pulley and pilot for chips, cracks or wear; replace as necessary.
C. Assembly.
1. Install snap rings (18) in fan hub housing.
2. Press outer races of tapered bearings (17 and 21, Figure 8-37) into fan hub housing;
outer races must seat against snap rings. Prepack bearings with grease meeting specifications listed
in "Wear Limits", Chapter 17.
3. Install rear bearing inner race (21) with largest inside diameter into rear of fan hub;
press new oil seal (22) into housing, flush with bore.
201
VEHICLE
4. I nstall shaft (23) through grease seal and rear bearing inner race. Align shaft in bearing
before pressing. Press inner race of bearing firmly against shaft shoulder, using a short length of
pipe over shaft and inside of pulley. Failure to press inner race against shaft shoulder will cause
assembly to loosen after it is placed in service and will cause early failure of fan hub bearings re-
su Iting from excessive end play.
5. Fill center hub cavity 60 to 70% full of grease or oil.
6. Install front bearing (17), clamp washer (16) and retainng nut (14). Torque nut to 20
ft. Ibs. (27 Nm).
nut.
NOTE: Hub must e rotated while nut is being tightened. Failure to rotate hub will result
in excessive end play.
7. Loosen nut approximately 50 to 30
0
or one-half the distance between slots on the
8. Support fan hub assembly in a suitable arbor press so that the shaft is free to turn.
Support as near the hub of the pulley as possible to prevent distortion and damage to the pulley.
9. Apply sufficient pressure to the nut end of shaft to force the inner cone against the
nut which will give the bearing sufficient ciearnace. Use a pressing action not a striking force. The
force required to move the inner cone against the nut should never exceed that required to press
the cone on the shaft. Note pressure reading on pressure gauge (if used) of press while assembling
the cone on the shaft.
10. Check shaft end clearance. It must be 0.003 to 0.008 inch (0.08 to 0.20 mm) and hub
must rotate freely. Loosen or tighten nut as required and repeat steps above; lock retaining nut
with cotter pin.
11. Press retainer (if used) 0.020 inch (0.51 mm) below hub surface.
NOTE: Replace any grease fittings used to apply lubricant with pipe plugs to prevent ,loss
of lubricant during operation.
8-52. COOLING (RADIATOR) FAN
The cooling fan has a two-inch pilot and six 25/64 inch (9.92 mm) diameter mounting holes
on a 3-1/2 inch (88.90 mm) bolt circle.
A. Fan Installation.
NOTE: When installing fan to fan hub, 5/16 inch (7.94 mm) capscrews must have 5/32
inch (11.91 mm) thread engagement, 3/8 inch (9.53 mm) capscrews must have 9/16 inch
(14.29 mm) thread engagement. 112 inch (12.7 mm) capscrews must have 3/4 inch (19.05
mm) thread engagement.
8-53. THERMOSTAT AND HOUSING
Thermostats are not subject to repair, but should be checked to make sure they are opening
and closing at the proper temperature.
202
VEHICLE
A. Disassembly and Inspection.
1. Remove water outlet connection; thermostat cover and thermostat. Remove thermo
stat seal from thermostat housing. Discard seal.
2. Check thermostat to see if it opens and closes at the correct temperature.
a. Immerse thermostat and thermometer in water.
b. Heat water to thermostat operating temperature.
c. Compare thermostat operation against temperature indicated on thermostat.
d. Lowrange thermostats start opening at 160
0
F (71 0 C) and are fully open at
175
0
F (79
0
C).
e. Intermediate thermostats start opening at 175
0
F (79
0
C) and are fully open at
185
0
F (85
0
C).
f. Highrange thermostats start opening at 180
0
F (82
0
C) and are fully open at
195
0
F (9
0
C).
3. Discard thermostat if it does not operate in correct range.
B. Assembly.
1. I nstall new seal.
2. Insert new or tested thermostat in housing.
NOTE: It has been found that in application where a vent line is provided to purge the
cooling system of air, the additional bleed hole in the thermostat has a tendency to cause
the engine to run cold in low ambient temperatures. To prevent this problem in these appli-
cations, a thermostat without a bleed hole must be installed.
8-54; WATER FILTER
A water filter is effective only when properly maintained and when used with a cooling
system that was new or properly cleaned before the filter was installed.
A. Remove filter from filter head if not previously removed. Discard filter.
B. Clean filter head with an approved solvent and dry with compressed air.
C. Inspect filter head for cracks and mutilated threads. Replace as necessary.
D. Install new pre-charge filter on filter head. Refer to Coolant Specifications, Chapter 17,
for proper filter.
8-55. VACUUM PUMP
Refer to Chapter 13, Section V.
203
VEHICLE
856. ENGINE ASSEMBL Y ._. ALL UNITS
A. Mount block to engine stand, using adapter plate.
NOTE: If cylinder line-toblock clearance has not been checked according to instructions
in Paragraph 814, cylinder liners must be installed at this time and linertoblock clearance
should be checked. However, if linertoblock clearance has been checked, follow assembly
procedures beginning with installation of crankshaft.
857. CRANKSHAFT AND MAIN BEARINGS
A. Installation.
1. Recheck all oil passages of crankshaft to be sure they are open and clean.
2. Ur.e a clean, soft rag to wipe main bearing bores and main bearings.
NOTE: If oversize main bearings are required, refer to Paragraph 817.
3. Lay upper main bearings in block engaging tang in recess. All upper main bearings
are grooved and drilled for lubrication of crankshaft. All tangs must be in recesses before main
bearing caps are torqued.
4. Coat upper main bearings (crankshaft side) with clean engine lubricating oil.
NOTE: Check crankshaft main bearing journal diameter and record to identify mating
flywheel; see "Flywheel" later in this section.
5. Lift crankshaft into position, using hooks protected with rubber hose or a rope sling
around two crank throws.
6. Apply clean engine lubricating oil to thrust ring (crankshaft side) and roll upper
thrust halfring into position, grooved sides next to crankshaft flange. Use upper thrust half-rings
with dowel locating holes omitted in upper position only.
NOTE: Reground crankshafts or those using oversize thrust rings should have markings
stamped on the rear crankshaft counterweight. Both the thrust ring size and ring location
should be in the stamping; for example: front 0.010 inch (0.25 mm) and rear 0.020 inch
(0.51 mm). Make sure the same sizes are used in pairs, upper and lower.
7. Position lower main bearings into main bearing caps. Lower main bearings are plain
with no grooves and no drillings. Coat crankshaft surface of lower main bearings thoroughly with
clean engine lubricating oil.
8. Install lower thrust halfrings to rear cap. Upper thrust halfrings are not doweled
to block; lower thrust rings are located with a dowel to main bearing cap. Dowel protrusion should
be 0.090 to 0.105 inch (2.29 to 2.67 mm) from machined area of bearing cap mating surface.
9. Install main bearing caps so numbers stamped on cap correspond with numbers
stamped on block. Main bearing caps are not interchangeable.
10. Lubricate threads of capscrews, flatwashers, and shoulders of capscrew heads with
clean lubricating oil. Threads must be completely covered with an oil film and threads must not be
damaged. Start each capscrew and set caps in position by alternately tightening capscrews. Do not
dislodge lower bearing when installing cap. Bearing tang must stay in recess of cap.
204
I
!
VEHICLE
11, Lubricate threads and start main bearing cap side bolts. Side bolts will be torquued
as follows.
12. Tighten both capscrews on each cap alternately to 55 to 65 ft. Ibs. (75 to 88 Nm)
starting with center main bearing and tightening alternately towards opposite ends of block.
13. Tighten both capscrews alternately to 115 to 125 ft. Ibs. (156 to 170 Nm).
14. Tighten both capscrewsalternately to 165 to 175 ft.lbs (224 to 237 Nm).
15. Loosen all capscrews to relieve tension.
16. Repeat Steps 12, 13 and 14 above.
17. Attach dial indicator gauge securely to cylinder block with contact point of gauge
resting on crankshaft flange face. Using small bar or equivalent, pry crankshaft toward front of
engine. Remove pry bar and set gauge at "0".
18. Pry crankshaft toward rear of engine and again remove pry bar. Total gauge reading
should be 0.004 to 0.014 inch (0.10 to 0.36 mm) with a new (or rebuilt) crankshaft and thrust
rings.
19. Rotate crankshaft to see that it turns freely. If end clearance is less than 0.004 inch
(0.10 mm), loosen capscrews slightly and shift crankshaft toward front end of engine then toward
rear of engine. Retighten capscrews as described above. Recheck end clearance.
20. If end clearance is more than 0.022 inch (0.56 mm), new or oversize thrust rings
must be installed. When an engine is being rebuilt, always bring crankshaft end clearance to 0.004
to 0.014 inch (0.10 to 0.36 mm) by using standard new parts or by using oversize thrust rings and
reconditioned crankshaft.
21. Check clearance between main bearing cap at side and cylinder block area. There
should be 0.000 to 0.006 inch (0.00 to 0.15 mm) maximum clearance before side capscrews are
installed.
22. Tighten side capscrews.
a. Tighten all side capscrews to 35 to 40 ft.lbs. (47 to 54 Nm).
b. Torque side capscrews to 100 to 110 ft. Ibs. (136 to 149 Nm) using sequence
shown in Figure 838. Rotate crankshaft to see that it turns freely.
5 9 8
4
~
r,QJ
'"
~ ~
'=
~
-
-'-
:::.. .S'.
-"-
0-
~ ~
0- c:-
~ 19 -=
~ ' i ' .. '
-".-
2 6 10 7
3
Figure 838 Side Capscrew Torquing Sequence
205
VEHICLE
858. CYLINDER LINERS
A. Installation.
1. Before installing liners, check liner lower skirt end, extended portion, for nicks or
sharp edges protruding into bore that could calise scoring of pistons. Remove nicks or burrs. Check
and establish liner protrusion as described in Paragraph 814. If necessary, install shims around
liners to maintain liner protrusion of 0.006 to 0.009 inch (0.15 to 0.23 mm).
2. Coat packing rings and ring lands on liner with light coat of engine lubricating oil.
Install crevice seal ring on flat machined surface above packing rings with beveled side out and to
bottom of liner. Roll each liner packing ring into position. Care must be taken not to stretch "0"
rings out of shape. Check for twisted rings in grooves, using mold mark on ring as guide; straighten
as required.
3. Lubricate machined packing ring bore of block with light coat of clean lubricating
oil. Align arrows on top of liner with longitudinal center line of cYlinder liner bores to prevent
contact with crankshaft. Push liner into place by hand carefully to avoid dislodging crevice seal.
4. Drive liner into block counterbore with liner driver and soft hammer. Tap lightly as
liner is seated to prevent "bounce".
5. Install liner holddown clamps; torque capscrews to 25 ft. Ibs. (34 Nm). Liner hold
down clamps should extend all the way across the top of the liner. Check liner protrusion at four
equidistant points with gauge block to determine if protrusion is uniform. Measure outside bead.
Do not damage liner bead when using holddown clamps. See Table 87 for liner protrusion.
6. Remove liner holddown clamps.
7. Check cylinder liner bore for roundness at several points within range of piston travel.
If liner is more than 0.002 inch (0.05 mm) outofround in packing ring area or 0.003 inch (0.08
mm) in top one (1) inch (25.4000 mm) of liner, remove liner and check for possible twisted seal
rings, cocked crevice seal or liner to block contact which would cause distortion of liner bore.
859. CONNECTING RODS AND PISTONS
A. Installation.
1. Install piston rings with ring expander. Place rings on piston with wonj "TOP" to top;
stagger ring gaps so they are not in line with each other or with piston pin.
2. Overexpanding piston rings when installing causes distortion. Do not expand end gap
more than eight times the nominal radial wall thickness of the ring. When installing oil ring expan
der and oil ring, be sure expander ring ends to not overlap. Oil ring expander gap should be located
1 BOO from oil ring gap.
3. Remove connecting rod cap from bolts and make certain bolt heads are seated squar
ely on rod shoulder. Keep rod cap with mating connecting rod.
4. Turn engine to vertical position on engine stand and rotate crankshaft so crank throw
for cylinder being worked on is at bottomcenter position. Using clean cloth, wipe rod journals
clean.
206
VEHICLE
Table 8-7_ ASSEMBLY SPECIFICATIONS --Inch (mm)
Measurement Worn Limit
Main Bearing
Journal Clearance
Connecting Rod Bearing
Journal Clearance
Crankshaft
End Clearance
Cylinder Liner
Protrusion
Connecting Rod
Side Clearance
Gear Train Backlash
Crankshaft to Camshaft
Crankshaft to Lubricating Oil Pump
Air Compressor to Camshaft
Camshaft End Clearance
Injection Timing
Refer to Table 8-9
0.007
0.007
0.022
0.024
Injector, Crosshead and Valve Adjustments
(0.18)
(0.18)
(0.56)
(0.61)
Refer to Injector and Valve Adjustment, Paragraph 8-103
Dynamometer Testing
Refer to Test Procedure, Paragraph 8-106, and Table 8-13
Lubricating Oil Pressure
Refer to Table 8-14
Blow-By
Refer to Test Procedure, Paragraph 8-106 and Table 813
Back Pressure
Refer to In-Chassis Run-In, Paragraph 8-110
207
New Minimum
0.0015 (0.038)
0.0015 (0.038)
0.004 (0.10)
0.006 (0.15)
0.0076 (0.193)
0.003 (0.08)
0.006 (0.15)
0.003 (0.08)
0.002 (0.05)
New Maximum
0.005 (0.13)
0.0045 (0.114)
0.014 (0.36)
0.009 (0.23)
0,018 (0.46)
0.009 (0.23)
0.010 (0.25)
0.009 (0.23)
0.006 (0.15)
VEHICLE
5. Use clean engine lubricating oil to lubricate rings and piston". Compress rings with
ring compressor. Insert piston and rod assembly in cylinder liner with cylinder numbered side of
rod toward outside of block. Push piston and rod assembly through ring compressor until rings
seat in liner. Do not force piston into liner.
6. Moving to other side of block grasp piston and rod assembly by rod bolts and pull to
rod journal. Leave assembly a short distance from actual seating.
NOTE: Chamfered side of rods must face respective crankshaft cheeks and nonchamfered
sides face one another.
7. Coat rod bearings (crankshaft side) with clean engine lubricating oil. Roll rod bear-
ings into rod. Bearing locking tang must fit in milled recess.
8. Coat lower bearing with clean engine lubricating oil and seat in rod cap with locking
tang in place. Install rod cap over bolts so numbered side of cap is matched with numbered side of
rod.
9. Lubricate bolt threads and hardened washers with clean SAE 50 lUbricating oil.
Install nuts and hardened washers to bolts.
10. Follow Steps 1 through 9 above; install piston and rod assembly opposite the one
just installed. Secure rod to same crankshaft journal.
11. Tighten connecting rod nuts. Lubricate threads with clean SAE 50 lubricating oil.
a. Tighten bolt nuts to 20 to 25 ft. Ibs (27 to 34 Nm).
b. Tighten both nuts to 50 to 55 ft. Ibs. (68 to 75 Nm).
c. Loosen both nuts completely to remove all tension.
d. Tighten both nuts to 20 to 25 ft. Ibs (27 to 34 Nm).
e. Advance nuts 60
0
in 30
0
increments.
12. Check rod for freeness and side clearance, using hand pressure to move rod sideways.
Tap lightly with soft hammer only if necessary. If rod is not free, loosen cap and check for dirt,
burrs, etc. Push rod apart; check for 0.010 to 0.018 inch (0.25 to 0.46 mm) clearance between rods
with feeler gauge at three locations around crankshaft.
860. GEAR HOUSING SPACER PLATE
Secure gear housing spacer plate with new gasket to rear of cylinder block. Gasket and plate
must be flush with bottom of block. Gasket will require trimming. Precautions must be taken that
a good clean cut of the gasket is made.
8-61. CAMSHAFT
A. Installation.
1. Lubricate lobes and journals with clean engine lUbricating oil and install camshaft in
block. Rotate and lift slightly to assist in installation. Caution must be exercised not to damage cam
lobes or journals.
208
VEHICLE
2. Index "0" mark on camshaft gear with "0" mark on crankshaft gear to insure correct
timing. Figure 839.
3. Secure camshaft thrust plate to block with new lockplates and capscrews. Bend lock-
plates.
4. Attach dial indicator gauge with proper holder and check camshaft end clearance.
Figure 8-40. It must be 0.002 to 0.006 inch (0.05 to 0.15 mml. If end clearance is not within limits,
remove camshaft and change thrust plate as outlined in Paragraph 8-32.
NOTE: Block must be in upright, horizontal position when checking camshaft end clearance
and gear backlash.
5. Shift dial indicator gauge and check gear train backlash, Figure 8-41. It should be
0.003 to 0.009 inch (0.08 to 0.23 mm). If backlash is not within limits, it is recommended that a
complete gear train be installed.
o
o
o
Figure 8-39 Camshaft and Crankshaft
Timing Marks
Figure 8-40 Checking Camshaft end Clearance
Figure 8-41 Checking Camshaft Gear Backlash
209
VEHICLE
8-62. TAPPETS
A. Installation.
1. Insta" new spring clips on a" tappets except injector tappets used at No.2 and 6
cylinders for injector timing purposes.
2. Insta" valve and injector tappets in tappet bores of block.
3. Insta" tappet guide plates as follows by: Holding tappet plate across tappet and tap-
ping lightly with soft hammer to align tappets. Place feeler gauge or shim between tappet plate and
tappet to maintain 0.004 to 0.016 inch (0.10 to 0.40 mm) clearance. Secure tappet plate with
lockwashers and capscrews. Torque capscrews to 18 to 20 ft. Ibs. (24 to 27 Nm).
NOTE: Do not install tappet guide plates on cylinders used for injection timing until timing
operation is completed.
8-63. CYLINDER HEADS
place.
A. Installation.
1. Make sure breather vent type assemblies on naturally aspirated cylinder heads are in
NOTE: Resurfaced blocks require thicker head gaskets and grommets than new blocks and
are available in 0.010 inch (25 mm) and 0.020 inch (0.51 mm) oversize. Do not use oversize
grommets with standard gaskets.
2. Insta" head gasket over oil ring dowels so word "TOP" on gasket is visible. Install
new "0" ring over ring dowels. Insta" guide studs in block.
CAUTION: When assembling the cylinder head gasket to the engine, make sure the two (2)
end cap gaskets and the two (2) dowel "0" rings are properly located. Block and head sur-
faces must be clean and dry and oil or adhesive must never be used.
3. Using head lifting bracket, lift cylinder head with hoist and lower into place over
ring dowels.
4. Coat short cylinder head capscrews with rust preventive lubricant and install. Snug
tighten each head in sequence shown in Figure 8-43. Keep rust preventive oil from internal engine
parts to prevent corrosive damage.
NOTE: Rust preservative lubricants with 2 percent or higher sulfated ash content must
be used.
8-64. INJECTION TIMING
A. Remove spring clips from injector tappets on cylinder used for timing check. Install
injector push rod in No.2 cylinder on right bank and No.6 on left bank.
B. Insta" timing fixture in injector bore. Indicator extension must rest in socket of injector
push rod. Tighten tool in place in injector mounting capscrew hole.
210
VEHICLE
4
5 6
3
TC
BTC
ATC
2
+
[
0 11\:;
0
,,;,\;
01 (j)
~ , . ~ - - . ~ ~ - - - - ~ - - - - -
12 0 6
ENGINE ROTATION
Figure 842 Injection Timing Procedure Diagram Figure 843 Cylinder Head Tightening Sequence
C. Bar engine in direction of rotation to top center firing position. At point of maximum
piston rise, "zero" dial indicator above piston, indicating piston travel from TDe, (1, Figure B42).
Both dial indicators will move in a clockwise direction when on correct stroke for timing.
D. Bar engine in direction of rotation to 60
0
after top center (2). At this point, top of
moving plunger should be in line with 60
0
groove on fixed scale.
E. Set indicator above push rod to within 0.010 inch (0.25 mm) of its fully compressed
position. Zero dial indicator.
F. Bar engine in direction opposite rotation to approximately 60
0
before top center (3)
or until 60
0
mark on plunger in injector bore is in line with groove on retainer. This is same index
mark indicated in step D.
G. Bar engine in direction of rotation until dial indicator above piston shows piston has
traveled to location shown at first check point (4, Figure B42) under "Piston Travel" in Table 89,
read push rod travel on dial indicator above push rod and check reading against limits shown in
Table 89.
H. Check push rod travel against piston travel at each of two remaining positions shown in
Table 89. If push rod travel is greater than limits shown, timing is slow. If push rod travel is less
than limits shown, timing is fast. A new camshaft key must be installed to bring push rod travel
within limits. Select next advance or retard key from Table 88. Refer to Paragraph 832 for cam
shaft and camshaft gear disassembly and assembly.
NOTE: Maximum push rod travel variation between cylinders is not to exceed 0.003 inch
(0.08 mm) at any of the three different piston travel check points.
I. Recheck timing as outlined above.
NOTE: Each 0.006 inch (0.15 mm) offset of key is equal to approximately 0.0025 inch
(0.64 mm) push rod indicator travel at the 0.2032 piston travel check. See Table 89.
J. Remove timing tool and injector push rod. Remove injector tappets used to check injec
tion timing and install spring clips on tappets. Install tappets.
211
VEHICLE
Table 88. CAMSHAFT KEY DATA - Inch (mm)
Push Rod Relative
Amount of Indicator Timing Timing
Offset Travel Assembly Instructions Change Affect
0.000 (0.0000) 0.0000 (0.0000)
0.007 (0.1778) 0.0025 (0.0635) Arrow toward rear of engine Adv. 1/2
0
Arrow toward front of engine Ret. 1/2
0
0.013 (0.3302) 0.0046 (0.1168) . Arrow toward rear of engine Adv. 1
0
Arrow toward front of engine Ret. 1
0
0.019 (0.4826) 0.0068 (0.1727) . Arrow toward rear of engine Adv.
1%0
Arrow toward front of engine Ret.
1%0
0.025 (0.6350) 0.0089 (0.2260) Arrow toward rear of engine Adv. 2
0
Arrow toward front of engine Ret, 2
0
0.031 (0.7874) 0.0110 (0.2794) Arrow toward rear of engine Adv.
2%0
Arrow toward front of engine Ret.
2%0
0.037 (0.9398) 0.0132 (0.3352) Arrow toward rear of engine Adv. 3
0
Arrow toward front of engine Ret. 3
0
Table 89. INJECTION TIMING SPECIFICATIONS
Piston Travel
Push Rod Travel - Inch (mm)
Inches (mm)
Nominal Fast Slow
0.2032 0.056 0.054 0.058
(5.161) (1.42) (1.37) (1.47)
865. INJECTORS
A. Installation.
1. Lubricate "0" rings with clean lubricating oil.
2. Lower injector into head. Align injector so button screen is toward center of Vee.
3. To seat PT (type D) injectors in cylinder heads; make a "T" handle from 5/8 inch bar
stock or equivalent. Drill a 5/16 inch hole 1/2 inch deep from the bottom and braze in a PT (type
0) injector link.
4. Place "T" handle, with link brazed in place, on top of injector plunger and apply
force by giving a quick hard push on "T" handle with palm of hand. A "snap" should be heard and
felt as cup seats in head. Make sure injector is seated properly before installing holddown clamp.
5. Install injector links (if removed) with part number to top.
6. Install holddown clamps, lockwashers and capscrews; torque capscrews to 30 to 32
ft. Ibs. (41 to 43 Nm). When installing holddown clamps, make sure holddown yokes do not con
tact crosshead stems.
7. Test injector plunger for freedom of up and down movement after torquing hold
down clamps.
212
VEHICLE
8-66_ CROSSHEADS
A_ Adjustment_
1. Hold crosshead firmly down on mating valve stem. Run crosshead adjusting screw
down until it touches valve stem. Position crosshead retainer_ Lock locknut.
2. Torque adjusting screw locknut to 25 to 28 ft. Ibs. (34 to 38 Nm). When torque
wrench adapter is used, torque nuts to 22 to 24 ft. Ibs. (30 to 33 Nm).
8-67. PUSH RODS AND ROCKER LEVER ASSEMBLIES
A. Installation.
1. Position rocker lever assembly to cylinder head. Coat rocker lever assembly cap-
screws with rust preventive lubricant and install in head; Jnug tighten.
2. Install push rods in tappets. Injector push rod fits between exhaust and intake push
rods. Engage push rod adjusting screws in push rod sockets. When installing in engine, do not in-
stall valve push rods in injector tappets or mix different type rods in engine. See Paragraph 8-42
and Table 8-4 to identify push rods.
3. Check for clearance between all rocker levers and rocker lever brackets. All rocker
levers and brackets should be evenly spaced to allow proper performance of levers.
8-68. TORQUE CYLINDER HEAD CAPSCREWS
A. Installation.
1. Install all capscrews and torque to 80 to 90 ft. Ibs (108 to 122 Nm) per sequence
in Figure 8-43.
NOTE: Capscrews securing rocker lever assembly are part of cylinder head capscrews.
2. Torque all capscrews to a final torque of 110 to 115 ft. Ibs. (149 to 156 Nm) using
same sequence.
CAUTION: After final torque is applied to capscrews, check all washers to be certain that
none are cracked or broken. Retorque cylinder heads on rebuilt engines after first hOllr of
operation.
8-69. GEAR HOUSING
A. Installation.
1. Check gear housing bore to crankshaft alignment.
a. With new gasket in place, position housing to block over dowels. Secure snugly
with capscrews, lockwashers and flatwashers.
b. Place dial indicator on end of crankshaft and check housing seal bore run-out. It
must not exceed 0.005 inch (0.13 mm). Figure 8-44.
213
I
-.
VEHICLE
&f.
~ ~ @
I I ~ Q
I ~ 0
_F'L
Figure 844 Checking Gear Housing Bore Alignment
c. If runout exceeds limits, remove housing and pull both dowels from block. Align
housing bore; use reaming fixture to ream dowel holes for smallest permissible oversize dowel.
Install new pin dowels (use pin type dowels only for field replacement). Repeat Steps a. and b.
above.
2. Remove housing from block. Apply Loctite to outside diameter of seal.
3. Press new oil seal into crankshaft bore from outside of housing (using seal driver)
until inner edge of seal is in line with inner face of gear housing. Be sure seal does not run in same
track as original seal.
a. Support gear housing in seal area.
b. Position seal with open end to inside of housing; press into place.
CAUTION: Failure to provide adequate support or to press against flat plate may crack
housing.
4. Check alignment of index marks on camshaft and crankshaft gears. Position gear
housing with new gasket over dowels in block and torque capscrews to 34 to 37 ft. Ibs. (46 to
50 Nm).
870. FLYWHEEL HOUSING
A. Installation.
1. If removed, instali sponge rubber dust seal to flywheel housing.
2. Inspect dowels. If worn or sheared, remove dowels and install new dowels.
3. Install flywheel housing to cylinder block; use hardened washer, snug tighten cap'
screws.
214
VEHICLE
871. FLYWHEEL HOUSING BORE
A. Installation and Alignment.
1. Draw chalk marks at 12, 6, 9 and 3 o'clock. Attach dial gauge and attachment to
crankshaft flange. Figure 8-45.
2. Check readings at 9 and 3 o'clock. If runout exceeds 0.10 inch (0.25 mm) move
housing onehalf of distance to center horizontally.
3. Check readings at 12 and 6 o'clock. If run-out exceeds specifications, move housing
to center vertically.
4. After readings are within limits, torque capscrews alternately to 70 to 75 ft. Ibs.
(95 to 102 Nm). Make final check after tightening. See Figure 8-46 for torquing sequence.
872. FLYWHEEL HOUSING FACE
A. Installation and Alignment.
1. Move indicator to housing face as shown in Figure 8-47.
2. Using a pinch bar between a main bearing cap and crankshaft throw, take up crank
shaft end clearance. Zero indicator at 12 o'clock position. Take up crankshaft end clearance in
. same direction each time.
3. Turn crankshaft and check all reading points on housing face.
4. Total flywheel housing face runout must not exceed 0.008 inch (0.020 mm).
5. If dowels were removed, ream dowel holes to smallest permissible oversize using
reaming fixture; install new pin dowels. See Figure 848 for location of dowels.
6. If necessary to correct housing face runout after bore has been aligned, remove
housing and recheck mating surfaces. Then, reinstall housing, re-align, dowel and re-torque cap
screws.
Figure 845 Indicating Flywheel Housing Bore Figure 846 Flywheel Housing.
Tightening Sequence
215
VEHICLE



Figure 847 Indicating Flywheel Housing Face
873. OIL PUMP
A. Installation.
Figure 848 Location of Gear and Flywheel
Housing Dowels
1. Position oil pump to block engaging pump drive gear in crankshaft drive gear. Secure
pump to block. Secure suction tube assembly brackets to block.
2. Attach a dial indicator to block and place indicator pointer on gear teeth (Figure 8
49). Rotate gear by hand to advance position and "zero" indicator. Rotate gear to retard position
and note reading; permissible backlash in inverted position is 0.0055 to 0.0135 inch (0.140 to
0.343 mm) and in upright position is 0.0025 to 0.0105 inch (0.064 to 0.267 mm). If not within
limits, gear train must be replaced.
874. FRONT COVER
A. Installation.
1. Install front cover over dowels with new gasket to block; secure dial indicator gauge
to crankshaft flange with dial pointer inside front cover bore. (Figure 850). Rotate crankshaft
and check total indicator reading. Runout must not exceed 0.010 inch (0.25 mm) maximum.
2. Check for alignment at bottom of front cover and cylinder block with straight edge.
Bottom face of front cover must be flush with oil pan flange on block within + 0.006 inch (0.15
mm). If cover will not align at bore or at pan flange, remove dowels and align cover; ream for
smallest permissible oversize dowels.
3. Remove cover; install wear sleeve and new oil seal.
a. Coat bore of cover with clean lubricating oil.
b. Position oil deflector in cover bore.
c. Position seal with open lip to inside of cover.
d. Using seal driver, press new seal in cover.
e. Coat oil seal lips with clean lubricating oil. Install cover to block and secure.
216
VEHICLE
F igu re 849 Checking Lubricating Oil Pump
Drive Gear Backlash
Figure 850 Checking Front Cover
Bore Alignment
875. OIL PAN
A. Installation.
1. Install new gasket to pan.
2. Position oil pan to block, making sure rear edge of pan is aligned with rear edge of
block. Install several pantoblock capscrews; snug tighten to hold pan in place.
3. Install capscrews through oil pan into gear housing. Snug tighten only.
4. Tighten pantogear housing and pantoblock capscrews alternately and evenly to
"pull" pan to block and gear housing. Torque 5/16 inch (7.94 mm) capscrews to 15 to 17 ft.lbs.
(20 to 23 Nm) and 3/8 inch (9.53 mm) capscrews to 25 to 30 ft.lbs. (34 to 41 Nm).
876. CRANKSHAFT ADAPTER
A. Installation.
1. Check contact between crankshaft and adapter by bluing, 70% minimum contact.
2. Measure crankshaft and adapter bore to insure press fit, 0.001 inch (0.25 mm) mini
mum.
3. Position adapter over dowel and onto crankshaft. Dip entire capscrew in clean engine
lubricating oil; allow to drain.
4. Install capscrews through adapter into crankshaft; tighten alternately to 135 to 140
ft. Ibs. (183 to 190 Nm) torque.
NOTE: Use hardened washers on flywheel adapter capscrews if the capscrews do not have a
machined washer surface.
217
VEHICLE
8-77_ FLYWHEEL
A. Installation.
1. Rotate engine stand to bring engine to running position.
2. Install two guide studs in crankshaft flange and position flywheel over guide studs.
3. Install hardened washers on capscrews and dip in clean engine lubricating oil; allow
to drain.
4_ Install flywheel capscrews and tighten to 55 to 60 ft. Ibs. (75 to 81 Nm) torque.
Tighten to final torque of 140 to 145 ft. Ibs. (190 to 197 Nm). Use torquing sequence shown in
Figure 8-51. Do not exceed torque values.
B. Alignment.
1. Attach indicator and check bore. Total run-out must not exceed 0.005 inch (0.13
mm) (Figure 8-52).
2. Shift indicator to check clutch mounting face. Rotate crankshaft taking up crank-
shaft end clearance as chalk marks align with indicator. Run-out must not exceed 0.0005 inch
(0.013 mm) per inch (mm) of diameter (8, Figure 8-52). Crankshaft must be kept to either front
or rear limit of thrust clearance while checking face run-out. If run-out exceeds limits, remove
flywheel and clean flywheel and crankshaft mating surfaces. Reinstall flywheel; recheck bores and
face.
8-78. ADAPTER - FLEXIBLE PLATE
A. Installation.
1. Position flexible plate adapter to the flywheel. Secure with lockplates and capscrews.
Torque capscrews to 45 to 50 ft.lbs. (61 to 68 Nm).
2. Position flexible plate and back-up ring to plate adapter. Secure with lockplates and
capscrews; torque to 45 to 50 ft. Ibs. (61 to 68 Nm).
Figure 8-51 Flywheel Capscrew Torquing Sequence
218
A - BORE
B - CLUTCH MOUNTING FACE
Figure 8-52 Flywheel Bore and Clutch Plate
Check Points
VEHICLE
8-79_ VACUUM PUMP
A_ Installation_
1_ Engage vacuum pump drive gear and camshaft gear. Secure vacuum pump and snug
tighten capscrews.
2. Attach a dial indicator gauge to gear housing and check gear backlash. Advance gear
as far as possible; "zero" indicator and retard gear; note reading. It must be 0.003 to 0.009 inch
(0.08 to 0.23 mm). If readings are out of limits, gear or gear train must be replaced.
3. Remove capscrews installed in Step 1 above.
NOTE: Check to see if plug is in end of vacuum pump crankshaft.
4. Slide bearing support over pump drive shaft and secure to gear housing.
5. Connect vacuum pump discharge tube to left bank push rod cavity cover. Be sure
vacuum pump crankshaft is plugged.
8-80. FUEL PUMP
Refer to Chapter 9 for fuel pump removal and installation.
8-81. AIR INTAKE MANIFOLDS
A. Installation.
1. Secure manifold with new gasket to push rod cavity cover on each cylinder head.
Be sure to use correct screws on assembly. Screws that are too long with hit bottom and do not
hold the manifold tight.
2. Torque capscrews alternately from side to side and end to end, starting in middle,
to 30 to 32 ft. Ibs. (41 to 43 Nm). Torque in 10 ft. lb. (14 Nm increments).
8-82. WATER CROSSOVER PIPE, WATER CONNECTION AND REAR ENGINE LIFTING EYE
A. Installation.
1. Secure water connection with new gasket to left bank cylinder head; place new hose
and clamps on water crossover pipe, if used.
2. Connect coolant supply pipe to vacuum pipe. Secure water connection, rear engine
lifting eye and new gasket to right bank cylinder head; position hose and secure with hose clamps.
883. FUEL LINES
A. Installation.
1. Connect fuel supply lines from fuel pump shut-down valve to cylinder heads. Install
fuel drain crossover tube to connections at rear of each cylinder head_
2_ Install fuel pump coolant check valve, if used, and orifice drilled elbow. Connect
fuel pump coolant line.
219
VEHICLE
884. AIR MANIFOLD CROSSOVER
A. Installation.
1. Install crossover to intake manifold using new gaskets.
2. Connect vacuum pump inlet to crossover.
885. WATER PUMP
A. Installation.
1. Install water pump with new gasket to cylinder block. Rotate pulley to check for free
turning motion.
2. Secure water inlet connection using new gasket to water inlet on water pump.
885. WATER PUMP
A. Installation.
1. Install water pump with new gasket to cylinder block. Rotate pulley to check for free
turning motion.
2. Secure water inlet connection using new gasket to water inlet on water pump.
886. CYLINDER BLOCK WATER HEADER COVER PLATE
Install cover plate with new gasket to left front of cylinder block.
887. CAMSHAFT COVER PLATE
Secure cover plate or fan hub bracket with new gasket to block. Locate gasket so oil passages
are clear.
CAUTION: Special care should be exercised so that the gasket between the camshaft cover
plate and the block does not tear or become displaced during assembly. If the gasket becomes
damaged, full engine oil pressure from the crossover will push on the front of the camshaft,
causing the thrust plate to be severely worn.
888. FRONT ENGINE SUPPORT
Secure support to front cover. Torque 1/2 inch capscrew to 68 to 75 ft. Ibs. (92 to 102 Nm).
889. CRANKSHAFT PULLEY/VIBRATION DAMPER
A. Installation.
1. Clean crankshaft and vibration damper mating faces thoroughly with a wire brush or
abrasive cloth. Install pulleyvibration damper combination to crankshaft. Torque capscrews alter
nately in 30 to 35 ft. Ibs. (41 to 47 Nm) increments to a final torque of 90 to 105 ft.lbs. (122 to
142 Nm).
220
VEHICLE
A - ECCENTRICITY
B - WOBBLE
Figure 8-53 Vibration Damper and Drive Pulley Check Points
2. With a dial gauge mounted to front cover, check vibration damper eccentricity and
wobble at points A and B as shown in Figure 8-53. Wobble must not exceed 0.009 inch per inch
of radius (0.23 mm per 25 mm). Eccentricity must not exceed 0.003 inch per inch of diameter
(0.08 mm per 25 mm).
8-90. THERMOSTAT HOUSING AND FRONT WATER CROSSOVER
A. Installation.
1. Position front water crossover housing with new gasket to front of block; snug
tighten capscrews.
2. Lubricate "0" rings with clean lubricating oil and install on water transfer tubes.
Insert tubes into water crossover housing.
3. Install thermostat housing on water transfer tube; position thermostat housing with
new gasket to right bank cylinder head. Snug tighten capscrews.
4. Install water connection cover on water transfer tube. Secure water connection
cover with new gasket to left bank cylinder head.
5. Install new hose and clamps on water by-pass connection. Position by-pass hose on
water pump and thermostat housing; center hose between by-pass connection, water pump and
thermostat housing while rotating connection to obtain desired position.
6. Tighten hose clamps and all capscrews and install fuel lines between heads.
8-91. FRONT ENGINE LIFTING EYE AND/OR ALTERNATOR BRACKET!WATER COVER
PLATE
Secure alternator bracket for high mount alternator and front engine lifting eye with new
gasket to left bank cylinder head. Torque capscrews to 30 to 35 ft. Ibs. (41 to 47 Nm).
221
VEHICLE
8-92. FAN HUB AND BELTS
A. Installation.
1. Secure bracket to block, if not previously installed.
2. Position fan hub in bracket and install flatwashers and locknut; install adjusting
screw.
3. Install belts. Torque locknut to 50 ft. Ibs. (68 Nml.
4. Using adjusting screw, tighten belts until a reading of 90 to 110 Ibs. is indicated on
appropriate belt tension gauge.
5. If belt tension gauge is not available, tighten bolts so pressure of index finger will
depress belt to values listed in Table 810. Also see Figure 854,
6. Tighten locknut by template method.
a. Tighten nut snugly by hand.
b. Apply initial torque of 50 ft. Ibs. (68 Nm). Using fan hub wrench advance nut
60
0
(1 hex.). This provides a final torque of 400 to 450 ft. Ibs. (542 to 610 Nm).
1/2
11/16
3/4
7/8
1
Table 8-10. BELT TENSION
Belt Width
Inch (mm)
Deflection per Ft. of Span
Inch (mm)
(12.70)
(17.46)
(19.05)
(22.23)
(25.40)
I
\
13/32
13/32
7/16
1/2
9/16
~ - - ~ - - - - - 2 - - - - ~ - - ~
1. DEFLECTION
2. SPAN BETWEEN PULLEYS
Figure 8-54 Checking Belt Tension Manually
222
(10.32)
(10.32)
(11.11)
(12.70)
(14.29)
VEHICLE
8-93_ REMOVE ENGINE FROM ENGINE STAND
A_ Secure engine with lifting fixture and suitable hoist_
B_ Remove engine from stand_ Set engine on engine supports.
CAUTION: Binding of capscrews when lifting engine may crack block; care must be taken
when removing engine from stand.
8-94. ENGINE WATER HEADER COVER PLATE
A. Installation.
1. Secure water header plate with new gasket to each side of cylinder block. Plate with
pipe tap and elbow for mounting vacuum pump cooling line mounts on left bank.
2. Starting with two center capscrews and working in both directions, tighten capscrews
alternately to 30 to 35 ft.lbs. (41 to 47 Nm) torque.
3. Install vacuum pump water inlet and outlet lines. Before installation check condition
of rubber sealing washers. Lubricate rubber washer with petroleum jelly to insure a proper seal
when tightening.
8-95. OIL COOLER
Install cooler assembly to cylinder block using new gaskets. Torque capscrews alternately
from end to end to 30 to 35 ft.lbs. (41 to 47 Nm).
8-96. OIL FILTER AND BRACKET
Mount bracket. Secure filter assembly to bracket. Connect all lubricating oil supply and drain
lines to respective locations.
8-97. DIPSTICK TUBE AND DIPSTICK
Install fitting in oil pan. Slide tube in fitting and tighten nut to 30 to 35 ft. Ibs. (41 to 47
Nm) torque. Install dipstick. Secure tube and tube clip.
8-98. EXHAUST MANIFOLDS
A. Installation.
1. Position exhaust manifold with new gaskets to each cylinder head. Position gaskets
with word "OUT" next to exhaust manifolds.
2. Torque capscrews to 30 to 32 ft.lbs. (41 to 43 Nm) in 15 ft. lb. (20 Nm) increments.
Coat capscrew threads with anti-seize compound to prevent "thread damage".
8-99. FUEL 01 L F I L TER AND BRACKET
A. Secure bracket to engine or desired mounting location.
B. Secure filter assembly to bracket and connect fuel from fuel filter to fuel pump.
223
VEHICLE
8100. ALTERNATOR
A. Installation.
1. Install alternator mounting bracket, if not previously installed; secure with cap
screws and hardened flatwashers.
NOTE: Do not use plain soft steel flatwasher or lockwashers for mounting alternator. Use
hardened steel flatwashers. Never use lockwashers. Torque 3/8 i n ~ h (9.5 mm) capscrews to
29 to 31 ft. Ibs. (39 to 42 Nm) 7/16 inch (11.1 mm) capscrews to 63 to 65 ft. Ibs. (85 to
88 Nm) and 1/2 inch (12.7 mm) capscrews to 77 to 89 ft.lbs. (104 to 108 Nm).
2. Position alternator to mounting bracket. A special bushing is used in mounting
bracket. It must be installed so that bushing flange is inside and against alternator mounting foot
of bracket. Secure with capscrew, hardened flatwasher and nut.
3. Position drive belts over drive pulley and fan hub pulley.
4. Adjust turnbuckle to obtain proper belt tension of 80 to 100 Ibs. reading on belt
tension gauge. Secure adjusting straps.
8101. STARTER MOTOR
A. Installation.
1. Insert starter motor (with spacer, if used) into flywheel housing. Move starter motor
toward block to clear flywheel ring gear.
2. Secure starter motor to flywheel housing. Torque capscrews to 60 to 70 ft. Ibs. (81
to 95 Nm).
8102. WATER FILTER
A. Installation.
1. Secure bracket to engine.
2. Secure water filter head or body to mounting bracket.
3. Connect water inlet and outlet lines to water filter. The inlet line connects to pres
sure side of water pump. Outlet line connects to suction side of water pump. Close inlet and outlet
valves until unit is placed in operation, except to check for coolant flow through filter during engine
test.
8103. ADJUST CROSSHEADS, INJECTORS AND VALVES
I njector plungers, crossheads and valves should be adjusted before starting engine first time
at cold setting and during engine test after engine reaches operating temperature.
A. Valve Set Marks Location.
1. Insert a 3/4 inch square drive flex bar or equivalent for barring engine. A 3/4 inch
square drive may also be inserted in vibration damper or crankshaft pulley to rotate crankshaft.
Use barring mechanism as shown in Figure 855.
224
Figure 855 Barring Engine with
Barring Arrangement
VEHICLE
\
Figure 856 Valve Set Marks
2. Valve set marks are located on vibration damper at front of engine. Figure 856.
CAUTION: With valve set marks on vibration damper, make sure index marks or inertia
member and damper hub are aligned. If marks are not aligned, remove vibration damper
and install new damper.
Before setting or checking valve train clearance, be sure crossheads are properly adjusted.
Valves and inje"ctors must be set in sequence according to firing order to ensure that the
rocker train is loaded by the adjusted injector which deflects the shaft slightly and thus
affects valve clearances. Therefore, it is essential that hijectors on any cylinder must be set
prior to valve clearances on the same cylinder being set.
B. Adjust Valve Crossheads.
1. Loosen valve crosshead adjusting screw locknut and back off screw two to three
turns until screw is free from valve stem.
2. Use light finger pressure at rocker lever contact surface to hold crosshead in contact
with valve stem (without adjusting screw).
3. Turn adjusting screw down until it just contacts its mating valve stem. Hold adjust
ing screw in this position and tighten locknut to 25 to 28 ft. Ibs. (34 to 38 Nm) with a torque
wrench. When using torque wrench adapter, torque to 22 to 26 ft. lb. (30 to 35 Nm).
4. Check clearance between crosshead and valve spring retainer (1, Figure 858) with
a feeler gauge. There should be a minimum of 0.025 inch (0.64 mm) clearance. Valve collet to
crosshead (2) should be 0.050 inch (1.27 mm).
C. Adjust Injectors and Valves Using Torque Wrench Methof of Injector Adjustment.
1. Bar engine in direction of rotation until "VS" mark on pulley is aligned with pointer
on front cover of gear case cover. In this position, both intake and exhaust valves will be closed for
one of two cylinders indicated. Make adjustments on this cylinder. (Figure 858).
NOTE: Do not use fan to rotate engine.
225
VEHICLE
Figure 857 Adjusting Crossheads
1. CROSSHEAD TO VALVE SPRING RETAINER CLEARANCE
F igu re 858 Crosshead to Valve Spring
Retainer Clearance
2. Adjust injector plunger and valves of each cylinder. Turn crankshaft in direction of
rotation to next "VS" mark corresponding to engine firing order. See Figure 859. Firing order is
1,5,4,8,6,3,7,2.
NOTE: Two complete revolutions of crankshaft are required to adjust all injector plungers,
crossheads and valves, by the torque wrench method. Injectors, crossheads and valves can be
adjusted for only one cylinder at anyone "VS" mark.
D. Adjust Injector Plunger.
Injector plungers must be adjusted with an in. lb. (Nm) torque wrench and a screwdriver
adapter to a definite torque setting.
1. Turn adjusting screw down until plunger just contacts cup, then advance an addi
tional 15
0
to squeeze oil from cup.
2. Loosen adjusting screw one turn.
3. Torque adjusting screw to specifications shown for cold setting in Table 811. Tighten
locknut to 40 to 45 ft. Ibs. (54 to 61 Nm) or to 30 to 35 ft. Ibs. (41 to 47 Nm) torque when using
adapter. See Figure 860.
Figure 859 Firing Order Diagram
226
VEHICLE
Table 811. INJECTOR PLUNGER ADJUSTMENT - TORQUE
Oil Temperature Oil Temperatu re
70
0
F (21
0
C) 140
0
F (60
0
C)
60 in. Ibs. (6.8 Nm) 60 in. Ibs. (6.8 Nm)
..
E. Adjust Valve Clearance.
The same engine position used in setting injectors is used for setting intake and exhaust
valves.
1. Loosen locknut and back off adjusting screw. Insert proper feeler gauge, according
to Table 812, between rocker lever and top of crosshead; turn screw down until lever just touches
gauge. Figure 81. Lock adjusting screw nut in this position.
Figure 860 Torquing Injector Locknut Figure 861 Adjusting Valves
with Adapter
Table 812. VALVE ADJUSTMENT VALVES
Valve Clearance
Oil Temperature Intake Exhaust
70
0
F (21
0
C) .012 (.30) .022 (56)
140
0
F (60
0
C) .010 (.25) .020 (51)
2. Torque locknut to 40 to 45 ft. Ibs. (54 to 61 Nm) with torque wrench. Torque to
30 to 35 ft. Ibs. (41 to 47 Nm) when using adapter.
3. After all injectors, valves and crossheads have been adjusted, secure valve covers to
heads with new gaskets.
227
VEHICLE
8-104_ ELECTRIC CONNECTIONS
Secure electric connections to mounted equipment. Refer to Chapter 15_
8-105. ENGINE TESTING
Engine break-in and testing are accomplished simultaneously. Break-in on a new or rebuilt
engine is necessary. It provides an operating period during which moving parts acquire their final
finish and mating surfaces reach a full seat. Engine testing helps detect possible assembly errors
and need for adjustments as engine "breaks in". It establishes a period for final adjustments for best
engine performance.
A. Priming The Fuel System.
1. Fill fuel tanks and filter(s) with clean No.2 diesel fuel oil.
2. Fill pump through plug next to tachometer with clean fuel.
3. If injector and valve or other adjustment have been disturbed, be sure they have been
properly adjusted before starting engine.
B. Priming the Lubricating System.
1. Fill crankcase to "L" (low) mark on dipstick. See Lubricating Oil Specifications,
Chapter 17.
2. Remove pipe plug from boss in engine oil filter head.
CAUTION: Do not prime engine lubricating system from by-pass filter_
3. Connect a hand or motor driven priming pump line from source of clean lubricatinq
oil to plug boss in housing. Prime until a 30 psi (207 kPa) maximum pressure is obtained.
4. Crank engine at least 15 seconds (with fuel shut-off valve closed or disconnected to
prevent starting, while maintaining external oil pressure" at a minimum of 15 psi (103 kPa).
5_ Remove external oil supply line and replace plug.
WARNING: Clean area of any lubricating oil spilled while priming or filling crankcase.
6. Finish filling crankcase to "H" (high) mark on dipstick.
C. Lubricate Cranking Motor and Alternator_
Use 6 or 8 drops of clean lubricating oil to lubricate cranking motor and alternator or
alternator bearings (if required)_ Avoid excessive oiling which would cause damage to wire insula-
tion_
D. Starting Procedure_
Normal Without Cold-Starting Aid
1. Set throttle for idle speed. Electric fuel shut-down valves operate automatically.
228
VEHICLE
NOTE: The manual over-ride knob provided on forward end of electric shut-down valve,
allows valve to be opened in case of electric power failure or if power is not available during
testing. Open by turning fully clockwise.
2. Press starter button on turn switch key to "start" position.
CAUTION: Do not crank engine continuously for more than 30 seconds. If engine does
not fire, wait two to five minutes before repating to avoid starter motor damage.
8-106. TEST PROCEDURE
A. Horespower Ratings.
1. The maximum horsepower ratings at rpm shown in Table 8-13, "Test Chart" are
for engines operating at No.1 Curve or intermittent-duty applications at sea level, 60
0
F (16
0
C)
intake air temperature and 29.92 inch (760.0 mm Hg) barometric pressure.
2. Where it is necessary to derate because of high altitude operation, the derating may be
done by reducing maximum governed rpm or maximum fuel rate. Refer to fuel pump section.
3. Naturally aspirated engines must be derated 3% for each 1000 ft. (304.9 m) altitude
above 500 ft. and 1% for each 10
0
F (16
0
C) ambient temperature rise above 85
0
F (29
0
C).
4. New or newly rebuilt engines are not required to deliver more than 96% or maximum
,rsepower at power checks.
8-107. BREAK-IN RUN
A. Initial Starting.
Start engine and idle at approximately 800 rpm no load for five to ten minutes. Check
oil pressure and water circulation; look for leaks.
B. At Each Phase.
1. Apply speed shown in Table 8-13.
2. Check crankcase pressure (blow-by). If pressure continues to drop, reduce run-in time
by half; otherwise, run engine for time period shown on test chart.
a. At Phase 1.
(1) Run engine until normal operating temperature has been obtained.
(2) Add lubricating oil to bring level up to "H" mark on bayonet gauge, allow oil
temperature to stabilize.
b. At Phase 2.
(1) Set engine idle, governed speed and fuel rate. Refer to Fuel System Section.
Retorque cylinder heads to specifications and sequence given in Paragraph 868.
c. At Phase 3.
229
Max. Rated
HP@RPM
500 ft. Alt.
@85
0
F
210 @ 3300
NOTES:
Max.
Fuel
Rate
Lbs./Hr.
82
VEHICLE
Table 8-13. TEST CHART
Max. 1/4 Hr.
Crankcase 1st Phase
Pressure HP@RPM
4 90@2000
1/4 Hr.
4th Phase
HP@RPM
180@3300
1/4 Hr. 1/4 Hr.
2nd Phase 3rd Phase
HP@RPM HP @ RPM
135@2500 155 @ 3300
Power Check
(5 min. Max.)
96% Rated HP
205@3300
(1) Naturally aspirated engines must be derated 3% for each 1000 ft. (304.8 m) altitude
above 500 ft. and 1% for each 10
0
F (6
0
C) ambient temperature rise above 85
0
F
(29
0
C).
(2) Crankcase pressure is given in inches of water.
(1) If blow-by rises, reduce load to preceeding phase and run for 30 minutes; then
return to original phase specifications.
d. At Phase 4.
(1) Run at speed and horsepower indicated.
(2) Check for leaks and tighten all exposed capscrews.
(3) Recheck valves and injectors. Refer to proper tables.
NOTE: Re-adjustment after 1 hour operation is necessary to assure lowest smoke potential
and avoid excessive injector train loads.
8-108. POWER CHECK
A. Run engine at rated speed for 5 minutes. It should develop 96% of rated horsepower at
standard fuel rate. Check crankcase pressure (blow-by). If pressure exceeds value shown in Table
13, reduce engine speed and load to preceding phase; run engine 30 to 45 minutes.
B. Repeat procedure described above until engine develops 96% rated horsepower at stan-
dard fuel rate within permissible crankcase pressure limit.
C. After power check is completed, remove pipe plugs in cylinder heads and install vent
plugs.
8-109. CHECKS DURING RUN-IN TEST
During the period of engine run-in, the following checks should be made frequently
230
VEHICLE
A. Lubricating Oil Check.
1. Lubricating oil pressure should remain at or near a constant figure at constant engine
speed and load (See Table 814) after normal operating temperature has been reached. Abnormally
high pressures may indicate blocked lubricating oil lines from the pump or increased oil clearances
which may be due to bearing failure.
2. If oil temperature rises sharply above 225
0
F (107
0
C), shut down engine and correct
as necessary.
3. New lubricating oil filter elements will absorb oil. Therefore, engine must be shut
down after five or ten minutes of operation and additional oil added to bring oil level to "H"
mark on dipstick. Check oil level every phase during runin test.
Table 814. NORMAL LUBRICATING OIL PRESSURE
Idle (525620 rpm) Rated Speed
PSI (kg/sq em) PSI (kg/sq em)
10 (70) Minimum 40/75 (2.80/5.25)
NOTE: Individual engines may vary from above pressures.
B. Engine Coolant Check.
After engine is started, add coolant as necessary to completely fill cooling system and
replace entrapped air. Coolant should not exceed 200
0
F (93
0
C) or drop below 160
0
F (71
0
C)
during engine operation. Do not turn engine off immediately after a load run. Heat stored in the
iron masses will boil coolant in the jackets if air and coolant circulation is immediately stopped
while engine is hot. Allow engine to idle for a few minutes before shutting down.
C. Fuel Pressure Check.
For fuel pressure reading adjustment, refer to fuel pump section.
D. Final Runln.
1. Start engine. Idle at 800 to 1000 rpm, no load, for 5 to 10 minutes. Check oil pres
sure and water circulation. Correct any leaks.
2. Operate at 1/4 to 1/2 throttle for first 5 to 10 hours.
3. Operate at 1/2 to 2/3 throttle for next 45 to 50 hours.
4. After 50 hours of operation, do not operate engine at full load and speed in excess
of 5 minutes continuously at any time. After 5 minutes full power, drop back to 3/4 throttle.
5. During the first 100 hours service:
a. Do not idle engine for long periods.
b. Watch instruments closely. Decrease engine rpm if oil temperature reaches 2500 F
(121
0
C) or if coolant temperature exceeds 190
0
F (188
0
C).
231
VEHICLE
c. Operate with a power requirement low enough to allow acceleration to governed
speed under any condition.
8110. PAINT ENGINE
A. Prior to painting, clean surface for maximum paint adherence. Dry with compressed air.
1. Cover all openings, pulley grooves, instrument faces and belts. Cover all dataplates,
exposed threads, wire terminals, hose fittings and pipe openings with waterproof paper to tape.
B. Cover clutch contact surface on flywheel with anti-rust compound, if engine is not going
into immediate service.
C. Spray outside surfaces of castings and corrodible parts with a primer coat to serve as a
base for the second coat of engine enamel.
8-111. E N G " ~ E STORAGE
On any engine not in service, the unpainted machined surfaces are subject to rust and cor-
rosion. The rate of corrosion varies with climatic conditions. An engine stored in a climate with a
high amount of moisture in the air will corrode more rapidly than an engine stored in a dry climate.
A. Temporary Storage.
If an engine remains out of service for three or four weeks (maximum six months), special
precautions should be taken to prevent rust. The operations listed below are required to minimize
or prevent damage to temporarily stored engines.
1. Engine must be started and operated until thoroughly warm. Disconnect fuel lines to
engine fuel filter and injector drain line. Fill two containers, one with diesel fuel and a second with
preservative oil.
2. Start engine with fuel line to filter using diesel fuel. The injector drain line can flow
into the container with diefiel fuel. After engine is running smoothly, switch fuel line to container
with preservative oil. Operate five to ten minutes on preservative oil. Stop engine and reconnect
the fuel lines.
3. Drain oil pan, fuel filters and fuel tank and reinstall drain plugs. Oil pan may remain
empty until engine is ready for use. Tag engine with warning tag.
4. Turn fuel pump manual shut-off valve to "Off". Spray lubricating oil into intake
manifold and vacuum pump while cranking engine slowly.
5. Cover all openings with tape to prevent entrance of dirt and moisture.
6. Drain coolant from cooling system unless it is permanent type antifreeze with rust
inhibitor added.
7. Store engine in a dry and uniform temperature area.
8. Turn engine crankshaft two or three revolutions each three to four weeks.
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VEHICLE
B. Permanent Storage.
1. When engine is to be stored six months or more, the lubricating system, cooling
system, fuel system, crankcase and external parts must be protected against rust and corrosion.
2. Start engine and operate at fast idle until the engine is thoroughly warm. Stop engine
and drain old oil.
3. Fill crankcase to full. mark on dipstick with preservative oil, U.S. Military Specifica-
tion MIL-L-21260, Type P-l0, Grade 2 SAE 30.
4. Disconnect fuel lines to engine fuel filter and injector drain lines. F ill two containers,
one with diesel fuel and a second with preservative oil U.S. Military Specification MI L-L-644,
Type P9.
5. Start engine with fuel line to filter using diesel fuel. The injector drain line can flow
into the container with diesel fuel. After engine is running smoothly, switch fuel line to container
with preservative oil. Operate five to ten minutes on the preservative oil. Stop the engine and re-
connect the fuel lines.
6. Drain oil pans of pumps, coolers, filters and crankcase, etc. Replace all plugs after
draining.
7. Remove intake and exhaust manifolds. Spray all intake and exhaust ports, including
vacuum pump intake port, with preservative oil. Replace intake and exhaust manifolds.
8. Inspect cooling system. If coolant is contaminated, drain and flush. Fill with rust
preventive compound.
9. Brush or spray a film of rust preventive compound on all exposed, unpainted sur-
faces of engine. Use a rust preventive conforming to Type P-2, Grade 1 or 2, U.S. Military Speci-
fication MIL-C-16173C. Remove cylinder head covers and spray rocker levers, valve stems, springs,
gu ides, crossheads and push tubes. Replace covers.
10. Cover all engine openings with heavy paper and tape. Tag engine to indicate that it
has been treated with preservatives and crankshaft should not be turned over. Tag should show
coolant has been removed, date of treatment, and indicate that engine is not ready to run.
11. Store engine in an area where air is dry and temperature uniform.
NOTE: Engines in storage more than 24 months should be flushed out with a suitable
solvent or light, hot oil and then be reprocessed with rust preventive materials. Periodically
inspect engines for rust or corrosion. Take corrective action if necessary.
12. Although the preservative materials may be added to and used for the same purpose
repeatedly, they must be kept clean, the accumulated deposits should be removed after being
allowed to settle.
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VEHICLE
8-112_ PREPARING A STORED ENGINE FOR SERVICE
When an engine is removed from storage and put into service, the following operations
should be performed.
A. Clean Engine.
1. Clean accumulated dirt fro}ll exterior of engine. Remove covers, tape and wrappings.
2. Use suitable cleaner to remove rust preventive compound from unpainted surfaces.
3. Refill crankcase with clean lubricating oil. Flush and fill cooling system.
B. Inspection.
1. When an engine has been stored for six months or less, it is necessary to adjust injec-
tors, valves and belts. Tighten cylinder head capscrews and connections. Replace filters and check
air filter and screens.
2. When an engine has been stored for six months or more, the following procedure
should be followed:
a. Flush fuel system with clean fuel oil until all preservative oil is removed.
b. Remove plug from oil gallery and force hot, light mineral oil through the oil
passages to flush away all preservative oil. Turn over engine crankshaft three or four revolutions
during flushing operation.
c. Replace all filters and clean all screens before engine is started.
d. After inspecting engine and parts, make sure all preservative oil and gummed oil
has been flushed away. Start engine as described in Engine Testing, Paragraph 8-105.
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VEHICLE
CHAPTER 9
Fuel System
This Chapter covers maintenance and repair procedures for fuel system components.
NOTE: Refer to limited vehicle maintenance for maintenance procedures of the following
fuel tank selector valve, fuel pump, filters, lines and hoses and fuel shut-down valve.
Section I - FUEL PUMP
NOTE: The fuel pump should be removed and replaced only after it has been definitely
determined that the pump is faulty. Problems such as low power or hard starting are more
often due to dirty f\lel filters or improper throttle linkage adjustment than faulty fuel pump.
Check Troubleshooting Section for other causes of trouble before replacing the fuel pump. A
fuel pump requiring recalibration or other repairs must be replaced with a new or rebuilt
unit.
9-1. REMOVAL (Figure 9-1)
A. Drain cooling system and remove radiator.
B. Remove engine air intake hoses and air intake manifold.
C. Disconnect throttle linkage at throttle lever.
D. Remove electrical connections at shut-down valve.
E. Remove fuel supply and drain lines.
F. Remove bolts attaching fuel pump to drive coupling.
G. Remove fuel pump.
H. Plug all ports and disconnected fuel lines to prevent entrance of dirt.
9-2. INSTALLATION
A. Inspect new or rebuilt unit before installation. Be sure unit is clean and all screws are
tight.
B. I nstall fuel pump in reverse order of removal.
C. I nstall air intake system.
D. Install radiator and refill system with coolant.
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VEHICLE
Section" - FUEL PUMP DRIVE
9-3_ FUEL PUMP DRIVE
9-4_ OIL SEAL
Do not allow oil seals to turn while installing shafts against sealing lip_ To provide a positive
seal, the sealing lip must always compress with the pressure applied_
9-5_ BORES IN HOUSING
If bushings have turned in the retaining bore and have ruined the bore, scrap both bushing
and housing_ If both are satisfactory, clean bore before pressing bushing into place_
9-6_ DISASSEMBLY
A_ Using a suitable pu IIer, pu II drive gear from shaft_
B_ Press drive shaft and pulley from housing_
C_ Press drive shaft from pulley.
D. Remove oil seal from housing.
9-7. INSPECTION
A. Inspect housing for cracks or burrs; replace if damaged_
B. Inspect bushing(s) in housing. If damaged or worn larger than worn limit, Table 9-1, press
defective bushing from housing.
C. Inspect gear for worn or broken teeth. Discard and replace as necessary.
D. Inspect drive shaft for wear, chips or burrs. Discard shaft if worn smaller than worn limit,
Table 9-1 (1) at bearing location.
E. Measure shaft outside diameter at pulley location and pulley inside diameter to determine
amount of press fit between shaft and pulley. See Table 9-1 (2).
F. Measure shaft outside diameter at drive gear location and drive gear inside diameter to
determine amount of press fit between shaft and drive gear. See Table 9-1 (3) for dimensions.
Gear 1.0. should be 1.000 to 1.0005 inch (25.400 to 25.413 mm).
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VEHICLE
Table 9-1. FUEL PUMP DRIVE SPECIFICATIONS - Inch (mm)
REF. WORN NEW NEW
NO. MEASUREMENT LIMIT MINIMUM MAXIMUM
Bushing 1.8775
Inside Diameter (47.689)
1. Shaft Outside Diameter 1.8695 1.8705 1.8715
At Bearing Location (47.485) (47.511) (47.536)
2. Shaft Outside Diameter 0.8000 0.8005
At Pulley Location (20.320) (20.333)
Pulley 0.7985 0.7995
Inside Diameter (20.282) (20.307)
3. Shaft Outside Diameter 1.0020 1.0025
At Drive Gear Location (25.451 ) (25.464)
Drive Gear 1.0000 1.0005
Inside Diameter (25.400) (25.413)
9-8. ASSEMBLY
A. Press new bushings, if removed, into drive housing with a suitable mandrel. P r e ~ s inner
bushing into housing bore 2.6000 to 2.620 inch (66.04 to 66.55 mm) from face of housing. Press
outer bushing into housing bore to 0.640 to 0.660 inch (16.26 to 16.76 mm) from face of housing.
B. Install shaft in housing. Press drive gear on shaft with hub next to shoulder, leaving
0.001 to 0.007 inch (0.03 to 0.18 mm) end clearance.
C. Coat seal with clean lubricating oil. Place oil seal over shaft with open side toward hous-
ing and press into bore of housing.
D. Press pulley on shaft until it seats against shoulder.
9'9. DRIVE PULLEYS
A. Inspection and Repair.
1. Check for cracks and chips in hub, web and groove areas and for wear in grooves and
oil seal sleeve. If wear on sleeve is visible:
a. Remove worn oil sleeve by splitting with chisel. Do not damage pulley hub.
b. Press new sleeve onto pulley hub with mandrel until it is flush to 0.015 inch
(0.35 mm) below face of hub. Consult latest Parts Catalog 114102 for correct pulley/sleeve com-
bination.
237
ELECTRICAL
LEAD
7
!
VEHICLE
Figure 9-1 Fuel Pump
Section III - INJECTORS
NOTE: Cleaning and calibration of fuel injectors is described in paragraph 6-4. Replace
injectors-with new or authorized rebuilt units as required.
9-10. REMOVAL (Figure 9-2)
A. Remove cylinder head valve cover.
B. Disengage rocker lever from injector.
C. Remove injector hold-down plate.
D. Remove injector from cylinder head with special or improvised tool.
NOTE: Take care when prying up that injector does not pop out of head and drop to the
floor.
E. Use a wooden tool wrapped with cloth to wipe carbon from injector sleeves in cylinder
head. DO NOT use metal object to scrape sleeves.
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VEHICLE
9-11. INSTALLATION
A. Lubricate the 0 rings with 20 to 30 weight engine oil. DO NOT use Lubriplate_
B. Start injector into bore, guide by hand until aligned in bore and not binding.
C. Place improvised tool or clean blunt object on injector body and "seat" injector with
quick hard push. A snap should be heard and felt as cup seats in copper sleeve.
NOTE: DO NOT use wooden hammer handle or similar tool to seat injectors. Dirt or splin-
ters may drop into injector causing malfunction or injector failure.
CAUTION: If injector is not completely seated, 0 rings may be damaged when pulled down
by hold-down plate.
O. Install hold-down plate lockwashers and cap screws. Torque cap screws 30 to 35 ft. Ibs.
(41 to 47 Nm).
CAUTION: Be certain holddown plate does not contact cross head stems.
E. Test injector plunger for movement after torquing holddown capscrews. If plunger is not
free, retorque capscrews.
Section IV - AIR INTAKE SYSTEM
The air intake system consists of the air cleaner, air inlet hose, engine intake manifold and air
restriction gage. Refer to Chapter 6, Section V, for air cleaner services and maintenance instructions.
239
VEHICLE
240
VEHICLE
CHAPTER 10
Cooling System
This Chapter contains maintenance instructions for the following cooling system compo-
nents: engine coolant thermostat, coolant pump, tandem heat exchanger, radi"ator and surge tank.
WARNING: When removing filler cap from a hot radiator use caution as boil-over pressure
of coolant or steam may cause burns to personnel.
Section I - ENGINE COOLANT THERMOSTAT
10-1. REMOVAL (Figure 10-1)
A. Thermostat removal requires removal of thermostat housing.
1. Loosen clamp securing coolant outlet hose to thermostat housing outlet connection.
Remove hose from connection.
2. Loosen clamp securing by-pass hose to thermostat housing.
3. Disconnect coolant tube at elbow in thermostat housing.
4. Loosen clamp and remove hose at shut-off valve in thermostat housing.
5. Remove four capscrews and lockwashers securing thermostat housing to housing
support. Remove thermostat housing and gasket. Discard gasket.
6. Remove thermostat and seal from thermostat housing. Discard seal.
10-2. INSPECTION
A. Check thermostat to see if it opens and closes at correct temperature.
1. Immerse thermostat and suitable thermometer in water.
2. Heat water to thermostat operating temperature - n-85
0
C (170-185
0
F).
3. Thermostat should start opening at noc (170
0
F) and be fully open at 850C (185
0
F).
10-3. INSTALLATION
A. Replace thermostat if it does not operate in correct range. Use new seal and gasket.
1. Place seal and thermostat in housing.
2. Install thermostat housing in reverse order of removal. Use new gasket.
3. Close engine drain cock and fill radiator with coolant.
4. Start engine and check for coolant leaks.
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VEHICLE
II
BYPASS HOSE
CLAMP J
~
l ~
Figure 10-1 Removing or In,stalling Engine
Thermostat and Coolant Outlet Hose
Figure 102 Removing or Installing Radiator Hose
Section II - COOLANT HOSES AND TUBES
104. REMOVAL (Figure 102)
A. Remove engine compartment side panels and transmission cover.
B. Open engine hatches and engine side access door.
C. Open engine drain cock and drain engine coolant,
D. Loosen hose clamps securing cracked, broken or damaged hose or tube. Remove hose
or tube.
E. Remove clamps from damaged hose or tube.
105. INSTALLATION
A. I nstall new hose or tube in reverse order of removal.
B. Close engine drain cock and fill radiator with coolant.
C. Start engine and check for coolant leaks.
D. Close hatches, side door and install side panels and transmission cover.
242
VEHICLE
Section III - ENGINE COOLANT PUMP
10-6. REMOVAL (Figure 10-3)
A. Refer to limited vehicle maintenance chapter for removal of engine fan, spacer, shroud
and fan belts.
1. Open engine drain cock and drain coolant from engine block.
2. Loosen clamps and remove bypass hose from pump body.
3. Loosen clamps and remove inlet hose from pump housing coolant connection.
4. Remove four screws and lockwashers securing pump body to block.
5. Remove pump and gasket. Discard gasket.
10-7. DISASSEMBLY
A. Pull impeller from shaft with puller.
CAUTION: Do not thread the puller capscrews in more than five (5) threads or carbon face
seal may be damaged.
B. Using puller, pull drive pulley from shaft.
C. Using a pair of snap ring pliers, remove large snap ring from pump housing. Press on im
peller end of shaft to remove assembly from pump body. If bearing remains in pump body, press
out bearing.
D. Remove carbon face seal from pump body.
E. Remove flinger.
F. Press shaft from large bearing, (press on inner race of bearing) and small bearing if bear
ing remained on shaft.
G. Clean all non ferrous parts, except bearings, in Bendix carburetor cleaner or equivalent.
10-8. INSPECTION AND REPAIR
NOTE: When repairing coolant pump utilize coolant pump repair kit.
A. Inspect water pump bearings. Replace bearings if rebuild is being performed at 100,000
miles or later.
B. I nspect water pump impeller. Mark for replacement if cracked or corroded to extent that
it will interfere with circulation.
C. Measure impeller bore and shaft outside diameter. There must be a minimum of 0.001
inch (0.03 mm) pressfit between shaft and impeller; replace if necessary.
D. Inspect water pump mounting parts for cracks. Replace as necessary.
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VEHICLE
BYPASS HOSE --,U--5I
CLAMPS (2) c
INLET
HOSE
CONNECTION ----.,
Figure 10-3 Engine Coolant Pump
E_ Examine carbon face seal carefully to make sure it is not cracked or chipped. Replace if
rebuild is being performed at 100,000 miles or later.
F. It is recommended that ceramic seat be removed and discarded if damaged or worn ex-
cessively. Replace with a new rubber boot/ceramic seat combination type seat.
G. To remove wear sleeve, if used, from drive to pulley:
1. Grind a 15 degree angle on end of a 3/16 inch straight shank round punch.
2. Secure pulley in a vise. Do not tighten vise too tight; it could cause pulley to crack.
3. Using small chisel punch, drive sleeve from pulley hub by placing punch through
puller holes in pulley; discard sleeve.
10-9. ASSEMBLY
A. Lubricate shaft outside diameter lightly, with clean lubricating oil. Pack both large and
small bearing with grease meeting specifications.
NOTE: If double sealed bearings are used, remove inner bearing seal. Do not use lead base
sealer.
B. Press bearing on shaft (with shielded side toward impeller end of shaft) until inner race
seats against shoulder on shaft.
CAUTION: When installing bearings, press on inner race when installing over a shaft and on
outer race when installing in a bore_
C. Apply a thin coat of sealant to inside diameter of pump housing where small bearing
seats. Fill cavity of bore 60% to 70% full of grease meeting specifications.
D. Press shaft and small bearing into housing until it bottoms.
E. Press large bearing over shaft and into housing until it seats on shaft shoulder. Install snap
ring in bore of body to secure bearings in place.
244
I
I I
I
VEHICLE
Figure 10-4 Engine Coolant Pump - Exploded View
F. Turn pump over and slide or press finger down to seat on bearing shoulder of shaft.
G. Press carbon face seal into housing until it seats.
H. Support shaft on impeller end and press drive pulley over shaft until hub is tight against
bearing inner race. Lubricate the inside diameter of the rubber seat with a light coat of water sol-
uble lubricant. Do not allow any lubricant on seal face of ceramic ring. Install the seat assembly
(rubber and ceramic) over water pump shaft until polished side of ceramic ring bottoms against the
carbon face of the pump seal.
I. Support shaft on pulley end and press on impeller, maintain 0,010 to 0.020 inch (0.25 to
0.51 mm) clearance between impeller vanes and pump body. Turn impeller to insure shaft turns
freely.
10-10. INSTALLATION
A. Coat new gasket with suitable sealant, position pump body and gasket on engine block
and secure with four capscrews and lockwashers.
B. Connect by-pass and inlet hoses.
C. Install fan belts and adjust. Install fan spacer, fan and shroud. Refer to limited mainten-
ance chapter.
D. Close engine drain cock and refill cooling system.
E. Start engine and check for coolant leaks_
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VEHICLE
Section IV - TANDEM HEAT EXCHANGER
10-11. REMOVAL
A. Drain cooling system.
B. Drain transfer unit hydraulic system reservoir.
C. Disconnect two transmission oil cooling system hoses at transmission.
D. Disconnect two transfer unit oil cooling system hoses at tandem heat exchanger.
E. Disconnect clamps securing engine cooling system hose elbows to tandem heat exchanger.
Remove hose elbows.
F. Disconnect two clamps securing tandem heat exchanger to hUll.
G. Remove tandem heat exchanger.
10-12. INSTALLATION
A. I nstall tandem heat exchanger and connecting hoses in reverse order of removal.
B. Refill transfer unit hYdraulic system.
C. Refill engine cooling system.
D. Operate vehicle and check system for leaks.
Section V - RADIATOR
10-13. CLEANING
A. Pressure flushing radiator, engine block and tandem exchanger.
NOTE: Clean system using a recommended cooling system cleaner according to directions
on label.
1. Drain radiator and engine block, and remove radiator inlet and outlet hoses.
2. Disconnect and plug hose from coolant pump to radiator surge tank.
3. Remove thermostat and reinstall housing.
4. Connect a radiator flushing gun to outlet connection on engine thermostat housing,
using a length of rubber hose.
5. Install a drain hose on the water pump inlet.
6. Connect flushing gun to sources of water and air pressure.
246
VEHICLE
NOTE: Do not exceed 15 psi air pressure.
7. Leave water valve open.
8. Open and close air valve to agitate and force away any foreign material. Continue
operation until water runs clear.
9. For final block flushing, fill block with water by restricting drain hose and then
remove engine drain cock and drain plug. Use air pressure not exceeding 15 psi until water from
block drain runs clear.
10. To pressure-flush radiator and surge tank, disconnect two flushing hoses from engine
and attach them to radiator. Attach flushing gun hose to lower radiator tank and drain hose to top
tank.
11. Fill radiator with water, leave water valve open, and open and close air valve. Con-
tinue operation of air valve until water runs clear.
12. For final radiator flushing, attach flushing gun to top hose and repeat flushing oper-
ation.
13. To pressure flush tandem heat exchanger, attach flushing gun to heat exchanger out-
let hose and drain hose to heat exchanger inlet. Perform flushing operation until water runs clear.
14. Test thermostat. Install thermostat in engine using new gasket.
15. Install new pre-charge water filter element.
16. Install radiator hoses and tighten hose clamps. Fill cooling system to 1% inches below
filler neck, using 50/50 water and anti-freeze (ethylene glycol) solution.
17. Run engine until the temperature gage indicates normal operating temperature and
continue an additional five minutes to release any air trapped in system. Check coolant level and,
if necessary, add additional coolant. Check all connections for leaks.
10-14. REMOVAL (Figure 105)
A. Remove transmission cover and engine close out panel.
B. Open engine hatch over radiator.
WARN I NG: When removing filler cap from a hot radiator use caution as boil-over pressure of
coolant or steam may cause burns to personnel.
C. Remove radiator cap.
D. Disconnect hoses from radiator.
E. Disconnect de-aeration line from surge tank.
F. Remove nuts and washers securing radiator and shroud to the radiator mounts.
G. Remove radiator and shroud from vehicle.
247
SCREWS THAT
SECURE SHROUD
( 'I
;-u
VEHICLE
Figure 105 Removing or Installing Radiator
H. Remove screws and washers securing radiator shroud to radiator. Remove shroud.
1015. REPAIR
Small holes, cracks and open seams may be soldered in accordance with general metal shop
practices. Broken, cracked, or damaged radiators must be replaced.
1016. INSTALLATION
A. The radiator and shroud are assembled and installed in reverse order of removal.
B. After installation, fill radiator with a 50/50 coolant solution and operate engine for a
short period, Check level of coolant in radiator. Replenish as necessary to bring coolant to proper
level.
C. I nstall new precharge water filter element,
D. Check radiator and hose connections for leaks.
E. Allow engine to warm up and check coolant using a hydrometer. A reading of 40
0
F
indicates a 50/50 water and antifreeze solution. Adjust solution to 40
0
F if hydrometer check
indicates a weak solution,
248
VEHICLE
CHAPTER 11
Power Train
This Chapter contains maintenance instructions for the following power train components:
transmission, flexible gear coupling, propeller shafts and universal joints.
Section 1 - TRANSMISSION
The vehiclp. uses an automatic transmission with four forward gear ranges and one reverse.
This section describes transmission overhaul and repair of internal components. See limited vehicle
maintenance chapter for adjustment of transmission controls and pressure test procedure.
11-1. REMOVAL (Figure 111)
NOTE: Removal of the transmission from the engine can only be accomplished after power
plant has been removed from veh icle.
CAUTION: Engine must be securely supported at both ends so it will not tip or slide when
weight of transmission is removed.
A. Support the transmission securely on a jack, hoist or other removal equipment.
B. Remove twelve screws and lockwashers securing transmission housing to engine flywheel
housing.
C. Remove access plate on engine flywheel housing.
D. Through access hole, remove six drive cover bolts securing converter drive cover to engine
flex plate.
CAUTION: Do not pull the transmission away from the torque converter. The torque con
verter drive cover must be entirely free of any restraint by the flex plate or crankshaft pilot
when the transmission separates from the engine.
E. Move the transmission and torque converter rearward until completely clear of the engine.
F. Keep the rear of the transmission low to prevent the converter slipping forward.
G. Install a retaining strap across the converter.
249
VEHICLE
Figure 111 Transmission Removal
112. INSTALLATION
A. Checking Torque Converter Location (Figure 112).
When the transmission is installed, the torque converter is axially positioned by the flex plate.
When properly positioned, the torque converter assembly is free of all restraints against fore and aft
movement except that of the flex plate.
1. To determine that there will be ample clearance for positioning the torque converter,
measure as indicated in Figure 11-2.
2. The dimension should not exceed 1.594 inches (40.48 mm). A greater dimension
indicates that the torque converter assembly is not properly installed into the transmission.
B. Checking Flex Plate Drive Assembly (Figure 113).
1. Inspect the flex plate. Replace it if worn or damaged. Examine the flex plate for
cracks, distortion and elongated holes. Examine the starter ring gear for damaged teeth, cracks and
failed welds.
2. Check the engine crankshaft end play. It must be within specified limits.
3. Check the concentricity of the engine crankshaft hub with the inside diameter of the
engine flywheel housing at the transmission mounting surface. Runout should not exceed 0.020
inch (0.51 mm).
4. Refer to figure 11-3 for proper position of flex plate, installed.
250
1.594 IN. 140.48 MMI MAX
LI
CONVERTER
VEHICLE
TRANSMISSION
HOUSING
Figure 11-2 Torque Converter
Location Dimension
C. Handling Transmission.
FLYWHEEL
HOUSING
FLEX PLATE/RING GEAR
ASSEMBLY
1.7215 IN. (43.726 mml
1.6005 IN. (40.652 mm)
WEAR PLATE
FJ-j-----f- CRAN KSHAFT
~
j ~ iSHAFTHUB
lU ADAPTER
Figure 11-3 Flex Plate Location Dimension
1. Remove the torque converter retaining strap when the transmission is in position for
installation.
CAUTION: The transmission must be handled very carefully after the strap is removed to
avoid separating the torque converter from the transmission. Keep the rear of the transmis-
sion lower than the front at all times.
D. Coupling Transmission to Engine (Figure 11-4).
1. Align the flex plate and torque converter so that the drive bolts can be installed
(fig. 11-1). A pilot tool (fig. 11-4) can be used to maintain alignment.
2. Lubricate the center pilot boss with molybdenum disulphide grease.
3. Push the transmission toward the engine while guiding the pilot boss on the drive
cover into the flex plate center bore_
4_ Engage the pilot diameter of the transmission housing in the flywheel housing bore.
5'. Install the bolts that secure the transmission housing to the engine flywheel housing.
Tighten the bolts to 35-45 ft. Ibs. (47-61 Nm) torque.
6. Tighten the drive cover bolts to 34-40 ft. Ibs. (46-54 Nm) torque.
251
MAKE FROM 3/8 - 16 BOLT
TAPER
SCREWDRIVER SLOT
TO AID REMOVAL
VEHICLE
FLYWHEEL
HOUSING
Figure 11-4 Pilot Tool for Installation
Section II - GENERAL OVERHAUL INFORMATION
PILOT
PLATE
This section provides information required before proceeding with the overhaul of the trans-
mission_ Tools and equipment for overhaul are discussed. Replacement parts and service kit infor-
mation is provided. The importance of cleanliness and careful handling is stressed. Helpful in-
formation on cleaning and inspection is given. General information on the removal and installation
of the transmission is given. Torque specifications for bolts and nuts are tabulated. Information on
wear limits and spring specifications are referenced.
11-3. TOOLS AND EQUIPMENT
A. Improvised Tools and Equipment.
1. A work table similar to the one shown in Figure 11-5 may be improvised.
NOTE: The transmission holding fixture may be mounted on the work table.
B. Special Tools.
Special tools are shown in Figures 11-6, 11-7 and 11-8. These tools are identified in the
special tools Table 11-1.
252
46
24
VEHICLE
,_---78
~ OIL DRAIN
srEEL TOP
OIL
DRAIN
(BOTH SIDES)
NOTE, ALL DIMENSIONS SHOWN
ARE IN INCHES
TROUGH
2 X 6BOARD
FOR TOP FRAME
AND LEG BRACKETS
4 X 4LEGS
l6-GAUGE SHEET STEEL
1112 IN. DEEP
1112 IN. WIDE
Figure 115 Work Table
C. Mechanic's Tools, Shop Equipment.
available.
1. The following tools, in addition to the common tools ordinarily required, should be
Snapring pliers
Depth micrometer
Headless guide bolts, 5/16 x 4 (2)
Torque wrench
Dial indicator set (for checking end play)
Gear and bearing pullers
2. A press for disassembly and assembly of springloaded clutches and for installation
of pressfit parts is required.
3. A suitable hoist of at least 114ton capacity is required.
4. A hot plate or heating equipment (for heating bearings or other interference fit parts
to aid assembly) is required.
253
VEHICLE
5. The following should be available:
Clean shop cloths (do not use waste)
Boxes, receptacles for parts
Supply of wood blocks
Oil-soluble grease
Cleaning supplies (brushes, solvents, etc.)
Sealer - Perfeot Sealer No.4 or Permatex No.2, or equivalent (for plugs, seals)
11-4. REPLACEMENT PARTS
A. Ordering Information.
Refer to the current issue ot Parts Catalog No. 114102 for information.
B. Parts Normally Replaced.
The following parts are normally replaced at each transmission overhaul.
1. Gaskets
2. Washers or snaprings damaged by removal
3. Oil seals, piston seal rings
4. Center support bolt
254
VEHICLE
Table 111. SPECIAL TOOLS (TRANSMISSION)
Use Illustrated
Fig. Item Tool No. Description Figures
116 1 204093 Output shaft seal installer 11101
116 2 204273 Oil pump seal installer 1136
11-6 3 206813 Installer, stator bearing 1134
11-6 4 204274 Output shaft bushing installer,
(Used with 204263) 1161
116 5 204263 Driver handle, (Used with 204274, 1134,1135
206813,206820, and 206822) 1161
116 6 204272 Stator shaft front bushing installer, (also
front and rear sun gear shaft bushings) 1135,1163
116 7 203965 Shift valve adjusting ring tool Not illustrated
11-6 8 203976 Selector shaft seal installer 1172
116 9 204259 Forward and fourth-clutch spring compressor 1139,11-47
116 10 203977 Center support lifting bracket 1122
11-6 11 203964 Sun gear shaft retainer assembly 1186
116 12 206814 Screw, thumb (Use with 203964) 1186
116 13 204091 Thrust washer selection gage bar 1196
11-6 14 203962 Converter end play checking fixture 1129
116 15 204092 Spacer selection gage 1188
117 16 204227 Forward clutch clearance gage 1142
117 17 204095 Fourth-clutch clearance gage 1150
11 7 18 203969 Firstandreverse clutch clearance gage 1177
11-7 19 203968 Thirdclutch clearance gage 1194
117 20 204264 Converter leak test fixture 1130
117 21 204262 Transmission holding fixture base 1111
(203978) (Used with 203985)
11 7 22 203985 Transmission holding fixture 11 11
(Used with 204262)
255
VEHICLE
Table 111. SPECIAL TOOLS (TRANSMISSION) - Continued
Use Illustrated
Fig. Item Tool No. Description Figures
117 23 204094 Firstandreverse clutch spring compressor 1127
11 7 23A (Part of Firstanpreverse clutch spring compressor base 1190
(Used separately to position components
during thrust washer selection)
117 24 203966 Output shaft positioning sleeve 1164
117 25 204260 Front support slide hammer (2) 1117
117 26 (Part of Slide hammer adapter (2) 1117
204260)
117 27 203967 Center support compressor assembly 1184
117 28 (Part of Snapring gage 1185
203967)
118 29 204271 Forward clutch inner seal protector 11-40
118 30 204270 Firstandreverse clutch inner seal protector 1173
118 31 204269 Forwardandfourth clutch outer seal protector 1140
118 32 204268 Lockring installer 1156
118 33 206815 Indicator, dial (Use with 206818, 1129
206819,206816, and 206817)
118 34 206815 Rod 1/4"x 101/2" long (Used with 1129
206815,206817,206818, and 206819)
118 35 206817 Adapter, lug (Use with 206815, 1129
206816,206818, and 206819)
118 36 206818 Clamp, magnetic (Use with 206815, 1129
206816,206817, and 206819)
118 37 206819 Adapter, swivel (Use with 206815, 1129
206816,206817, and 206818)
118 38 204267 Rear bearing puller assembly (in vehicle) 11108
(Includes 203963 and 204266)
256
VEHICLE
Table 11-1. SPECIAL TOOLS (TRANSMISSION) - Continued
Use Illustrated
Fig. Item Tool No. Description Figures
11-8 39 204265 Rear bearing installer (with or without output 11-89
shaft installed)
11-8 40 206820 Installer, Support Bushing (Used with 204263) 11-54
11-8 41 206821 Tool, Regulator Valve 11-33
11-8 42 206822 Installer, pump bushing Not Illustrated
3
2

6
/
~
7
8
{
" ~
~
,
11
b
0
I
,.
15
9
10
13
Figure 116 Special Tools (1 through 15)
257
VEHICLE
Figure 11-7 Special Tools (16 through 28)
y ~
,
~
33
29 30
32
31
~ b
"
&r.
~
I 36
35
~
16
cQ
39 40
42
41
Figure 11-8 Special Tools (29 through 44)
258
VEHICLE
11-5. CAREFUL HANDLING
During all rebuild procedures, parts and subassemblies must be handled carefully to prevent
nicking, scratching and denting. Parts which fit together closely and have proper operating clearance
can bind if damaged. Parts which depend upon smooth surfaces for sealing may leak if scratched.
This is very important concer(ling parts of the control valve body assembly (valves, when dry, must
move freely by their own weight). Such parts should be carefully handled and protected during
removal, cleaning, inspection and installation as well as being kept clean while in containers await-
ing installation.
11-6. CLEANING, INSPECTION
A. Dirt Causes Malfunction.
All parts must be clean to permit effective inspection. At assembly, it is very important
that no dirt or foreign material be allowed to enter the transmission. Even minute particles can
cause the malfunction of close-fit parts, such as valves.
B. Cleaning Parts.
1. All the metallic parts of the transmission except bearings should be cleaned thor-
oughly with volatile mineral spirits or by the steam-cleaning method. Do not use caustic soda
solution for steam cleaning.
2. Parts shou Id be dried with compressed air. Steam-cleaned parts should be oiled
immediately after drying.
3. Clean oil passages by working a piece of soft wire back and forth through the pas-
sages and flushing with mineral spirits. Dry the passages with compressed air.
4. Examine parts, especially oil passages, after cleaning, to make certain they are entirely
clean. Reclean them if necessary.
C. Cleaning Bearings.
1. Bearings that have been in service should be thoroughly washed in volatile mineral
spirits.
2. If the bearings are particularly dirty or filled with hardened grease, soak them in the
spirits before trying to clean them.
3. Before inspection, oil the bearings with the same type of oil that will be used in the
transmission.
NOTE: Never dry bearings with compressed air. Do not spin bearings while they are not
lubricated.
D. Keeping Bearings Clean.
Since the presence of dirt or grit in ball bearings is usually responsible for bearing fail-
ures, it is important to keep bearings clean during removal and installation. Observance of the
following rules will do much to insure maximum bearing life.
259
VEHICLE
1. Do not remove the wrapper from new bearings until ready to install them.
2. Do not remove the grease in which new bearings are packed.
3. Do not lay bearings on a dirty bench; place them on clean, lint-free paper.
4. If assembly is not to be completed at once, wrap or cover the exposed bearings
with clean paper or lint-free cloth to keep out dust.
E. Inspecting Cast Parts, Machined Surfaces.
1. Inspect bores for wear, scratches, grooves and dirt. Remove scratches and burrs with
crocus cloth. Remove foreign matter. Replace parts that are deeply scratched or grooved.
2. Inspect all oil passages for obstructions. If an obstruction is found, remove it with
compressed air, or by working a soft wire back and forth through the passage and flushing it out
with cleaning solvent.
3. Inspect mounting faces for nicks, burrs, scratches, and foreign matter. Remove such
defects with crocus cloth or a soft stone. If scratches are deep, replace the defective part.
4. Inspect threaded openings for damaged threads. Chase damaged threads with the
correct size used tap (a new tap can cut oversize).
5. Replace housings or other cast parts that are cracked.
6. Inspect all machined surfaces for damage that could cause oil leakage or other mal-
function of the part. Rework or replace the defective parts.
F. Inspecting Bearings.
1. Inspect bearings for roughness of rotation. Replace a bearing if its rotation is still
rough after cleaning and oiling.
2. Inspect bearings for scored, pitted, scratched, cracked, or chipped races, and for
excessive wear of rollers or balls. If one of these defects is found, replace the bearing.
3. Inspect a defective bearing's housing and shaft for grooved, burred or galled con-
ditions that would indicate that the bearing has been turning in its bore or on its shaft. If the
damage cannot be repaired with crocus cloth, replace the defective part.
4. When installing a bearing on a shaft, heat the bearing to 200
0
F (93
0
C) in an oil
bath (approximately 30 minutes). Use the proper size installation sleeve and a press to seat the
bearing.
5. If a bearing must be removed or installed without a sleeve, press only on the race
which is adjacent to the mounting surface. If a press is not available, seat the bearing with a drift
and hammer, driving against the supported race.
G. Inspecting Bushings, Thrust Wasners.
1. Inspect bushings for scores, burrs, roundness, sharp edges and evidence of over-
heating. Remove scores with crocus cloth. Remove burrs and sharp edges with a scraper or knife
blade. If the bushing is out-of-round, deeply scored, or excessively worn, replace it, using the proper
size replacement.
260
VEHICLE
NOTE: Whenever it is necessary to cut out a defective bushing for removal, use care to not
damage the bore into which the bushing fits.
2. Inspect thrust washers for distortion, scores, burrs, and wear. Replace the thrust
washer if it is defective or worn.
H. Inspecting Oil Seals, Gaskets.
1. Inspect seal rings for cuts and hardness. Replace sealring if these defects are found.
2. When replacing lip-type oil seals, the lip side must be toward the oil to be sealed in
(toward the inside of the unit). Use a non-hardening sealing compound on the outside diameter
of the seal to help prevent oil leaks. Coat the inside lip of the seal with high-temperature grease to
protect the seal during shaft installation and to provide lubrication during initial operation.
3. Replace all composition gaskets.
4. Inspect hook-type seal rings for wear, broken hooks, and distortion.
5. Install a new hook-type sealring if the ring shows any wear on the outside diameter,
or if there is excessive side wear.
6. The sides of the seal ring must be smooth (0.005-inch maximum side wear). The
sides of the shaft groove (or the bore) in which the sealring fits should be smooth (50 microinches
equivalent) and square with the axis of rotation within 0.002 inch. If the sides of the grooves have
to be reworked, install a new seal ring.
I. Inspecting Gears.
1. Inspect gears for scuffed, nicked, burred or broken teeth. If the defect cannot be
removed with a soft stone, replace the gear.
2. Inspect gear teeth for wear that may have destroyed the original tooth shape. If this
condition is found, replace the gear.
3. Inspect the thrust face of gears for scores, scratches, and burrs. Remove such defects
with a soft stone. If scores, scratches, and burrs cannot be removed with a soft stone, replace the
gear.
J. Inspecting Splined Parts.
Inspect splined parts for stripped, twisted, chipped or burred splines. Remove burrs with
a soft stone. Replace the part if other defects are found. Spline wear is not considered detrimental
except where it affects tightness of fit of the splined parts.
K. Inspecting Threaded Parts.
Inspect parts for burred or damaged threads. Remove burrs with a soft stone or fine file.
Replace damaged parts.
L. Inspecting Snaprings.
Inspect all snaprings for nicks, distortion and excessive wear. Replace snapring if any of
these defects are found. The snapring must snap tight in its groove for proper functioning.
261
VEHICLE
M. Inspecting Springs.
Inspect springs for signs of overheating, permanent set or wear due to rubbing adjacent
parts. Replace the spring if anyone of these defects is found. Refer to the spring chart at the end
of Chapter 17.
N. Inspecting Clutch Plates.
1. Inspect friction-faced steel plates (internal-splined plates) for burrs, imbedded metal
particles, severely pitted faces, excessive wear, cone, cracks, distortion, and damaged spline teeth.
Remove burrs, using a s9ft honing stone; Replace plates which have other defects.
2. Inspect steel plates (external-tanged plates) for burrs, scoring, excessive wear, cone,
distortion, imbedded metal, galling, cracks, breaks and damaged tangs. Remove burrs and minor
surface irregularities, using a soft-honing stone. Replace plates which have other defects.
3. The amount of cone in clutch plates is determined by measuring the distance between
the inside diameter of the plate and a level surface (Figure 11-9). Discard plates having cone (refer
to wear limits, Chapter 7).
LEVEL ,URFACE CLUTCH PLATE
I
MEASURE HERE FOR CONE
Figure 11-9 Method of Measuring Clutch Plate Cone
O. Inspecting Sealing Surfaces.
1. In areas where the outside diameter of a hook-type or step-joint sealring makes con-
tact, inspect for stepwear, nicks, scratches and scoring. Remove only the raised metal portion of
these defects with crocus cloth or a soft stone. Polishing the area to remove the defect is not neces-
sary nor desirable. If the defects are too severe, replace the defective part.
2. At locations contacted by spring-loaded, lip-type oil seals, inspect for nicks, scratches,
roughness or other surface irregularities. Also inspect for imbedded particles, step-wear and dirt on
flanges or any other components exposed to external contamination. Remove the defects and re-
store the finish. If finish cannot be restored, replace the part.
262
VEHICLE
11-7. WEAR LIMITS
Refer to Chapter 17 for general and specific information covering parts, fits, clearances and
wear limits.
11-8. SPRING SPECIFICATIONS
Refer to the spring chart in Chapter 17 for spring identification and specifications.
11-9. TORQUE SPECIFICATIONS
The torque specifications in Table 11-2 apply to all assembly procedures.
Table 11-2. TORQUE SPECIFICATIONS
Figure Item Location
11-32 15 Oil pump assembly
11-32 19 Oil pump assembly
11-32 14 Oil pump assembly
11-32 9 Oil pump assembly
11-32 10 Front support assembly to case
11-68 7 PTa cover
11-68 12 Oil check plugs
* 11-68 23 Governor cover
1168 26 Mechanical actuator retainer
11-70 18 Valve body to case
11-70 16 Detent lever
11-70 14 Oil pan
* 11-70 12 Oil pan
11-70 2 Case to center support
1170 20 Selector shaft, inside
**11-70
**
Selector shaft, outside
'5 ft. lb. (0.7 kgsmeterl minimum after gasket sets
"Not illustrated (Refer to Paragraph 11-47 for procedure)
263
Size
5/16-18
5/16-18
5/16-18
5/16-18
5/16-18
3/8-16
1/8-27
5/16-18
5/16-18
1/4-20
1/4-20
5/16-18
5/16-18
3/816
3/824
3/824
ft. Ibs.
15 to 20
15 to 20
15 to 20
15 to 20
13 to 16
15 to 20
10 to 15
15 to 20
15 to 20
8 to 12
8 to 12
10 to 15
10 to 13
39 to 46
15 to 20
15 to 20
Torque
kgs.meter
2.0 to 2.8
2.0 to 2.8
2.0 to 2.8
2.0 to 2.8
1.8 to 2.2
2.0 to 2.8
1.4 to 2.0
2.0 to 2.8
2.0 to 2.8
1.1 to 1.7
1.1 to 1.7
1.4 to 2.0
1.4 to 1.8
5.4 to 6.7
2.0 to 2.8
2.0 to 2.8
VEHICLE
Section III - DISASSEMBLY OF TRANSMISSION INTO SUBASSEMBLIES
This section covers disassembly of the transmission into subassemblies. The subassemblies
are then rebuilt in SectionlV. The procedures are arranged in a logical sequence by which the trans-
mission is completely broken down into smaller units. Differences in assemblies, where procedures
are affected, are noted.
11-10. PREPARATION OF TRANSMISSION
A. Drain Oil.
Make sure oil has been drained as described in Paragraph 8-2.
B. Check Linkages and Lines.
Make sure that all linkages, controls; cooler and filter lines, temperature and pressure
connections, input and output couplings have been removed as described in Paragraph 8-2.
C. Remove transmission from engine as described in Paragraph 11-1.
D. Inspection and Cleaning.
1. Inspect transmission and components during cleaning to locate possible leaks leading
to malfunctions of internal parts.
2. Clean all dirt and grease from surface of transmission before any disassembly is
attempted.
11-11. REMOVAL OF EXTERIOR PARTS
A. Torque Converter.
1. The torque converter can be removed by pulling it forward to disengage it from the
stator and turbine shafts (Figure 11-10). Nothing fastens the converter to the transmission except
when a safety strap has been installed (Paragraph 11-1).
2. If desired, the torque converter may be left on the transmission, and removed later
(See B (3) below).
B. Mounting in Holding Fixture.
1. For overhaul, the transmission should be mounted in a holding fixture (22, Figure
11-7) as shown in Figure 11-11. The holding fixture is bolted to the PTa opening after removing
the cover (if used). Refer to Figure 11-8 for proper position of the fixture.
2. The holding fixture is first attached to the transmission. Then the transmission and
fixture are hoisted into position for attachment to the fixture base (21, Figure 11-7) on the work
table.
3. If not previously removed, the torque converter can be lifted from the transmission
(Figure 11-12). Refer to Paragraph 11-19 for inspection of the torque converter assembly.
264
VEHICLE
Figure 11-10 Removing Torque Converter Prior to Overhaul
Figure 11-11 Transmission in Holding Fixture
265
VEHICLE
Figure 11-12 Removing Torque Converter During Overhaul
266
VEHICLE
C. Mechanical Actuator.
The mechanical actuator must be removed from the transmission prior to removing the
transmission from the vehicle. See Paragraph 8-2 (W).
D. Governor.
1. Remove fOllr bolts that retain the governor cover (F igure 11-13). Remove the cover
and gasket.
2. Remove the governor, rotating it clockwise to disengage the drive gears. Refer to
Paragraph 11-20 for inspection of the governor.
E. Oil Pan.
1. Remove 21 screws that retain the oil pan (Figure 11-13).
2. Remove the oil pan (Figure 11-14). Remove the oil pan gasket.
F. Oil Filter.
1. Remove the screw that retains the oil filter (Figure 11-14). Remove the oil filter.
2. Remove the oil intake pipe and sealring (Figure 11-15).
11-12. REMOVAL OF CONTROL VALVE BODY
A. Selector Detent.
1. Remove the bolt that retains the roller and spring assembly (Figure 11-15).
2. Remove the roller and spring assembly.
B. Valve Body.
1. Remove the 2-3/4 inch bolt from the center of the valve body (Figure 11-15).
2. Remove seventeen 2-1/4 inch bolts that retain the valve body.
3. Remove the control valve body (Figure 11-15) by lifting upward on the body and
the three attached oil tubes.
CAUTION: Do not allow the selector valve to drop out of the valve body when the body is
removed. Either tape or wire it in place, or remove it from the front of the body.
4. Remove the three oil tubes. Remove the oil screen from the valve body, at the gov-
ernor feed tube bore (F igure 11-15). If the oil screen is located in the governor feed tube where the
tube enters the transmission housing, remove and discard it, regardless of its condition. This screen
is to be replaced by a wire screen and relocated in the governor feed tube bore.
5. Apply a small amount of oil soluble grease to the end of nonmagnetic rod (1/4 inch
diameter). Insert the rod (greased end first) into the valve body cavity and remove the ball (Figure
11-16).
6. Remove the center support anchor bolt and flat washer (Figure 11-16).
267
\
~
SCREW 1211
VEHICLE
Figure 11-13 Removing Governor Assembly
BOLT, 2-1/4 LONG (18)
FIRSTREVERSE
CLUTCH TUBE
Figure 11-14 Removing Oil Pan
VALVE BODY
INTAKE
PIPE
Figure 11-15 Removing Oillntal<e Pipe
268
VEHICLE
Figure 11-16 Removing Governor Check Valve Ball
11-13. REMOVAL OF OIL PUMP AND FORWARD CLUTCH
A. Oil Pump.
1. Remove two bolts and washers from directly opposite holes in the oil pump body
(Figure 11-17).
2. Remove nine bolts and washers from the front support. Discard washers.
3. Install slide hammers (25, Figure 11-17) into the holes from which the bolts were
removed in line 1.
4. Hammer upward with the slide hammers to loosen the oil pump assembly (Figure
11-17). When free, lift the oil pump assembly out of the transmission case.
5. Remove the slide hammers, and replace the two bolts and washers removed in line 1.
Do not tighten the bolts.
6. Remove two hook-type seal rings (18, Figure 1132) and thrust washer (17) from the
oil pump assembly.
7. Refer to Paragraph 11-22 for rebuild of the oil pump assembly.
B. Forward Clutch and Turbine Shaft.
1. Remove the front support gasket (Figure 11-18).
2. Grasp the turbine shaft (Figure 11-18) and lift out the forward clutch and turbine
shaft assembly.
3. Remove the nylon thrust washer from the rear of the clutch assembly.
4. Refer to Paragraph 11-23 for rebuild of the forward clutch and turbine shaft assem-
biy.
269
VEHICLE
<:,-,:
TURBINE
SHAFT
Figure 11-17 Removing Oil PUmp Assembly Figure 11-18 Removing Front Support Gasket
11-14. REMOVAL OF FOURTH AND THIRD CLUTCHES
A. Fourth Clutch.
1. Grasp the spring retainer on the fourth clutch (Figure 11-19) and lift out the fourth
clutch assembly.
2. Refer to Paragraph 11-24 for rebuild of the fourth clutch assembly.
3. Remove sun gear shaft (Figure 11-20).
B. Third Clutch.
1. Remove the snap ring that retains the third-clutch back plate (Figure 11-20).
2. Remove the back plate.
3. Remove the six third-clutch plates (Figure 11-21).
11-15. REMOVAL OF CENTER SUPPORT ASSEMBLY AND GEARS
A. Center Support Assembly.
1. Remove the snapring that retains the center support assembly (F igure 11-21). This is
a selective thickness snapring. Refer to paragraph 11-28, line A-2.
2. Install the center support lifting bracket (10, Figure 11-6) into the recess between
the hook-type sealrings on the center support hub.
270
VEHICLE
3. Lift carefully, straight upward, on the lifting bracket to remove the center support
assembly (Figure 1122).
'\


,",RETAINER ASSEMBLY

/' 7 (/
Figure 1119 Removing FourthClutch Assembly Figure 1120 Removing Sun Gear Shaft Assembly
INTERNALSPlINED
PLATE
Figure 1121 Removing ThirdClutch Plates Figure 1122 Removing Center Support Assembly
271
VEHICLE
CAUTION: The center support is fitted to the transmission case with very little clearance.
It may bind in the case if the case is cold. Heat the case slightly, if necessary. Do not use a
torch to heat the case. A sun lamp, or a current of warm air is sufficient. If the support
assembly starts upward and then binds, tap it downward and lift again.
4. Refer to Paragraph 11-25 for rebuild of the center support assembly.
5. Remove the thrust washer from the front planetary sun gear (Figure 11-23).
B. Gears.
NOTE: Before the planetary gears and shafts assembly can be removed, the rear output
flange must be removed.
1. Grasp the transmission main shaft, and lift the planetary gears and shafts assembly
out of the transmission case (F igure 11-24).
NOTE: It may be necessary to tap upward on the output shaft with a soft-faced mallet
while lifting on the gear pack.
2. Refer to Paragraph 11-26 for rebuild of the planetary gears and shafts assembly.
3. Governor drive (13) (Figure 11-68), speedometer drive gear (14) and spacer (15)
may come out with the gear pack, or may stay in the transmission. Remove these parts.
11-16. REMOVAL OF SECOND AND FIRST-AND-REVERSE CLUTCHES
A. Second Clutch.
1. Remove the snapring that retains the second clutch. (Figure 11-25).
2. Remove three external-tanged, and three internal-splined, second-clutch plates.
3. Remove the second-clutch back plate (Figure 11-26).
B. First-and-Reverse Clutch.
1. Remove snapring (1) (Figure 11-58) that retains the first-and-reverse clutch back plate
(2). Remove the back plate.
2. Remove one internal-splined plate (3) and one external-tanged plate (4).
3. Remove rear ring gear (5) and the remaining clutch plates.
4. On earlier models, the rear ring gear is part of the rear carrier assembly and is removed
with the planetary gears and shafts assembly. (Refer to Paragraph 11-26B).
5. Install the first-and-reverse clutch spring compressor (23, Figure 11-7). Tighten the
nut to compress the clutch springs sufficiently to clear the snapring (Figure 11-27).
6. Remove the snapring. Remove the compressor.
272
VEHICLE
7. Remove the spring retainer, and the 22 piston return springs.
8. Remove the firstandreverse clutch piston (Figure 11-27). Remove the two lip-type
seal rings from the piston.
1117. REMOVAL OF OUTPUT SHAFT SEAL AND BEARING
A. Output Shaft Seal.
1. Remove oil seal (19) (F igure 11-68), from the rear of the transmission case.
2. Clean the bore from which the oil seal was removed.
B. Bearing.
1. Remove the snapring that retains the output shaft bearing (F igure 11-28).
2. Remove the bearing from its bore. (Refer to Paragraph 11-39).
3. Remove the transmission case, with its remaining attached parts, from the trans-
mission holding fixture. Refer to Paragraph 11-27 for rebuild of the transmission case.
THRUST
WASHER
/ \
SUN GEAR
Figure 1123 Removing Front Sun Gear
Thrust Washer
273
Figure 11-24 Removing Planetary Gears
and Shafts Assembly
VEHICLE
Figure 11-25 Removing Second-Clutch Snapring
Figure 11-27 Removing First-and-Reverse Clutch
Spring Retainer Snapring
274
/
Figure 11-26 Removing Second-Clutch Back Plate
Figure 11-28 Removing Output Shaft Bearing
Snapring
VEHICLE
Section IV - INSPECTION AND REBUILD OF SUBASSEMBLIES
This section describes the inspection of, or the disassembly and assembly of various sub-
assemblies which were removed in Section III.
11-18. GENERAL INFORMATION FOR SUBASSEMBLY REBUILD
A. Tools, Parts, Methods. (Refer to Paragraphs 11-3, 11-4 and 11-5).
B. Cleaning, Inspection. Refer to Paragraph 11-6 for the cleaning and the inspection pro-
cedures.
C. Torque Specifications. The specific torque values for each threaded fastener is stated at
each assembly step. Torque values are also presented in Pargraph 11-10.
D. Wear Limits, Spring Data. Refer to Chap.ter 17 for wear limits and spring data.
E. External Plugs, Hydraulic Lines.Prior to installation, apply a small amount of non-
hardening sealant into the threads of each plug. Tighten the plugs sufficiently to prevent leakage.
F. Clutch Pack Procedure_ Soak the friction-faced clutch plates in transmission fluid for a
minimum of 2 minutes prior to assembly.
11-19. TORQUE CONVERTER INSPECTION
A. Closed Unit Assembly.
Because the torque converter assembly is closed and welded after assembly of the internal
parts, no repairs can be made. The assembly can be tested, however, to determine its condition in
two areas. End play of the internal elements can be measured, and the outer shell can be tested for
leaks.
B. End Play Measurement.
1. Clear the torque converter of oil. Examine the oil for evidence of foreign material
or metal particles, indicating transmission or converter internal damage.
2. Support the converter assembly on the converter cover (pump hub upward). Place the
converter end play gage, (Item 14, Table 11-1) into the converter pump hub (Figure 11-29).
3. Retain the body of the gage in the pump hub with one hand while rotating the
center screw, locking the gage to the turbine hub. Do not overtighten.
4. Assemble Items 33, 34, 35, 36, and 37 as shown in Figure 11-29. Install the above
items onto the converter pump hub as shown in Figure 11-29.
5. Adjust the lug attachment Item 35 so the dial will make firm contact with the top of
the center screw (Figure 11-29).
6. Set the dial to read zero and lift the center screw (Figure 11-29) as far as possible.
Record the dial indicator reading. If the converter and play exceeds 0.037 inch (0.940 mml. the
torque converter assembly should be replaced.
275
VEHICLE
. 33 IF IG. 118)
ITEM 34 (FIG. 11
ITEM 35 {FIG. 11
ITEM 37 (fiG. 1
14 (FIG. 116)
Figure 1129 Checking End Play of Torque
Converter Elements
C. Leak Test.
CENTER BODY
Figure 1130 Pressurizing Torque Converter
. for Leak Test
1. Clear the torque converter of oil. Examine the oil for foreign matter or metal, indio
eating internal damage.
2. Install the torque converter leak test fixture (Item 20, Table 111) onto the converter.
The center body must be installed first, with its nut loosened (toward top of body).
3. Next, place the converter, and the center body, in the fixture bracket. Tighten the
nut firmly to seal the center body in the torque converter hub.
4. Pressurize the converter to 75 psi (5 kg/sq. cm.) maximum. Submerge the pressur
ized assembly in water, and observe closely for bubbles that indicate leakage. If the assembly leaks,
it should be replaced.
WARNING: Be sure that all pressure is exhausted from the converter before loosening the
nut and removing the test fixture.
5. Release the air from the torque converter by pushing on the valve stem in the air
fitting on the center body.
1120. GOVERNOR INSPECTION
A. Inspect the governor to determine that its function has not been impaired. If dirt or other
foreign materials are present, clean the governor as explained in C below. If the governor function is
still impaired, disassemble the governor as explained in B below.
B. Remove pins "AU shown in Figure 1131 and carefully remove the governor weights and
springs. Slide the governor valve out of its housing and after cleaning the valve and housing, check
for wear. If wear is evident, replace the governor, otherwise assemble the governor by reversing the
disassembly procedure above. Be sure the governor valve is installed as shown in Figure 1131. New
pins must be used at reassembly. These pins, with instructions, are available in kit form. See Parts
Catalog 114102 for detail part number.
276
VEHICLE
GOVER.NOR FEED
(MUST OPEN 0.020 MIN)

EXHAUST
A
GOVERNOR
PRESSURE
PORT
A
Figure 11-31 Governor Assembly - Showing Port Openings
C. Hold the governor assembly, drive gear upward, as shown in Figure 11-31. Hold one
weight outward against its stop. Check the opening at the governor feed port. This is the distar.ce.
the governor valve land clears the bottom side of the port. Repeat this check while holding the
other weight outward against the stop. The minimum opening should be 0.020 inch (0.508 mm).
If the opening is less, replace the governor.
CONTROL VALVE BODY
The control valve body is not disassembled in the field due to its complexity. Remove control
valve body as described in Paragraph 11-12. Replace the assembly in reverse logical order of Para-
graph 11-12.
11-22. OIL PUMP DISASSEMBLY - REBUILD
A. Disassembly (Figure 11-32).
1. Remove sealring (27) from front support (13).
2. Remove six bolts (9) and washers (8) from the front of pump assembly (7). Discard
washers.
3. Remove three bolts (19) and two bolts (14), from front support and bearing assembly
(13).
4. Separate pump body and gear assembly (7) from front support and bearing assembly
(13). Remove pump driven gear and pump drive gear from pump assembly (7).
5. Remove sealring (5) from pump body (7).
6. Remove oil seal (4) and if parts replacement is necessary, bushing (6).
7. If necessary for parts replacement, collapse bushing (26) and remove it from stator
shaft. Do not damage the bore.
8. If necessary for parts replacement, remove roller bearing (15) from stator shaft.
CAUTION: Do not attempt to remove stator shaft from front support (13).
277
VEHICLE
9. Install main regulator valve remover (41) (Figure 11-8). Compress spring stop (22)
against main-pressure regulator valve spring (21) and remove retainer ring (23) as shown in Figure
11-33.
10. Remove spring stop (22) and spring (21) from the valve bore of front support (13).
11. Remove main-pressure regulator valve assembly (20) from the same bore. Orifice
plug (24) is used in earlier models only.
12. Turn the front support over, remove pin (25) from front support (13) and remove
valve plug (28) from the smaller end of the main-pressure regulator valve bore.
NOTE: Refer to Paragraph 11-18.
B. Assembly (Figure 11-32).
1. Install valve plug (28) into the main-pressure regulator bore of front support (13).
Install pin (11) in to the pump body side of front support (13).
2. Install main-pressure regulator valve assembly (20), stem-end first, into the opposite
end of the valve bore.
3. Install valve spring (21) and spring stop (22), smaller end first.
4. Install main regulator valve remover (41) (Figure 11-8). Compress spring stop (22)
against spring (21) and install retainer ring (23) into its groove in the valve bore as shown in Figure
11-33.
5. If roller bearing (15) was removed, press a new bearing into the end of stator shaft
until the outer edge of the bearing measures 0.595 to 0.615 inch (15.113 to 15.621 mm) from the
end of the shaft. Press on the lettered end of the bearing. An installer (3) is availab.e. Figure 11-34
illustrates installation of the roller bearing.
6. If bushing (26) (Figure 11-32) was removed, press a new bushing into the opposite
end of shaft until the outer end of the bushing is flush to 0.005 inch (0.127 mm) below the end of
the shaft. An installer (6) is available. (Figure 11-6). Figure 11-35 illustrates the installation of the
bushing.
7. If bushing (6) (Figure 11-32) was removed, install a new bushing. The split in the
bushing must be located within the 10 to 12 o'clock position in the pump body, when viewing the
front of the body (within a 60
0
area immediately left of a vertical line extending upward from the
pump body center). Use installer (Item 42, Figure 11-8) to press the bushing into the front of the
pump body. The front edge of the bushing should extend 0.010 to 0.020 inch (0.254 to 0.508 mm)
above the surface when installed.
8. Coat the oil seal bore in pump body (7) (Figure 11-32) with Perfect Sealer No.4 or
an equivalent sealer and install oil seal (4), with the lip facing inward. Figure 11-37 shows the in-
stallation of the oil seal, using the special installer (2) (Figure 11-6).
9. Install pump driven gear (Figure 11-32) into pump body (7).
10. Install pump drive gear into pump body (7), with the internal tangs of the gear point-
ing away from bushing (6). .
278
~ ,
I
l
Figure 11-32
VEHICLE
Torque & Oil Pump Converter
279
16
PUMP Y
ITEM 41 118)
Figure 11-33 Removing (or installing)
Main Regulator Valve
Figure 11-35 Installing Stator Shaft
Front Bushing
VEHICLE
6 (FIG. 11-6)
ITEM 5 (FIG. 11-6)
STATOR SHAFT
PUMP BODY
Figure 11-34 Installing Stator Shaft Rear Bearing
ITEM 2 11-6)
Figure 11-36 Installing Oil Pump Seal
280
holes.
VEHICLE
NOTE: Pump body (7). driven gear and drive gear is a matched assembly. The parts must be
replaced as a matched set - never individually.
11. Grease and install sealring (5) onto pump body (7).
12. Install front support assembly (13) onto pump body assembly (7), aligning the bolt
13. Install six 5/1618 x 1 inch bolts (9) and new rubber coated washers (8) into pump
side of the oil pump assembly. Tighten the bolts finger tight.
14. Install three 5/1618 x 13/4 inch, selflocking bolts (19) and two 5/1618 x 1 inch,
self-locking bolts (14) into the same side.
15. Tighten the bolts (9) to 13-16 ft. Ibs. (18-22 Nm) torque. Tighten the bolts (14) to
15-20 ft. Ibs. (20-28 Nm) torque.
16. Grease and install sealring (27) onto the outer diameter of front support (13).
11-23. FORWARD CLUTCH AND TURBINE SHAFT - REBUILD
A. Disassembly (Figure 11-38).
1. Locate the snapring gap by looking between the tips of the PTa gear internal splines
and the roots of the housing splines. Light can be seen in the gap area.
2. At the opening (omitted housing spline) closest to the snapring gap, insert a small
screwdriver and push the snapring toward the housing until a 5/64 x 0.020 (1.984 x 0.508 mm)
steel strip (5 to 7 inches long) (13 cm x 18 cm) can be inserted in the root of the housing spline
nearest the snapring gap. (Figure 11-37).
FORWARD
CLUTCH HOUSING
SHIM 2
SNAP RING
PTOGEAR
Figure 11-37 Removing PTO Gear from Forward Clutch Housing
281
Figure 1138
VEHICLE
h & Turbine Shaft Forward Clute
282
VEHICLE
3. Repeat procedure (2) above, at the opposite side of the snapring gap.
4. Using the screwdriver in the openings (omitted splines) as required, to depress the
snapring, place steel strips in housing spline roots as necessary to hold the snapring inward. Work
from the strips first installed to a point opposite the gap.
5. Use as many strips as required (8 should be sufficient) and place them at positions
that will hold the snap ring entirely clear of the PTO gear splines.
6. When the snapring clears the PTO gear splines, light can be seen through all spaces
(except those holding steel strips) between PTO gear spline tips and housing spline roots. Remove
the gear.
7. Remove hook-type sealrihg (1) from turbine shaft. Turn the assembly over.
8. Using a screwdriver, remove snapring (15) from forward clutch housing (4). Remove a
fourth-clutch driving hub (16) from the housing.
9. Remove forward clutch hub (13) from the housing.
10. Remove the thrust bearing race (12), thrust needle bearing (11) and the thrust bearing
race (10) from the hub of forward clutch housing (4).
11. Remove the five external-tanged clutch plates (18) and five internal-splined clutch
plates (17) from the clutch housing (4).
12. Place the clutch assembly in a press with spring retainer up (Figure 11-39).
ITEM 9 {FIG. 1161
Figure 11-39 Removing (or installing) Forward Clutch
Spring Retainer Snapring
283
VEHICLE
13. Place compressor tool (9) (Figure 116) with an opening for snapring pliers upon
spring retainer and compress the retainer until snapring (9) is freed. Using snapring pliers, remove
snapring (9). Release the press and remove the assembly.
14. Remove spring retainer (8) and sixteen clutch springs (19).
15. Remove forward clutch piston (20) and sealrings from clutch housing (4). If neces
sary, turn the clutch housing over and "bump" the piston from the housing.
16. Remove piston outer sealring (21) and piston inner sealring (6) from piston (20).
Inspect ball (7) to make sure it moves freely in housing (4). If the piston is replaced, be sure the
new piston has the same letter identification stamped on the piston (A, B or C) that appeared on
the replaced piston.
17. Remove clutch housing sealring (5) from housing (4).
NOTE: Refer to Paragraph 11-18.
B. Checking Clutch Pack Clearance (Figure 1138).
NOTE: Steps 1 through 10 below, explain a method for establishing the clutch plate clear
ance with the plates installed in the transmission. Steps 11 through 16 below, explain an
alternate method, before the clutch is installed.
1. To insure proper running clearance, the clearance should be checked as outlined
below before assembling the clutch.
2. Place forward clutch housing and turbine shaft assembly (4) on the work table, with
the shaft down. Install clutch housing sealring (5). with the lip of the sealring facing downward.
Grease the seal and make sure it is centered in its groove.
3. Place forward clutch piston (20) on the work table, with the return spring side up,
and install outer seal ring (21). with the lip of the seal ring facing downward. Install inner seal ring
(6) with the lip of the sealring facing downward, into the inner diameter of piston (20). Grease both
seals and center each seal in its bore.
NOTE: If a new piston is used, refer to instructions in A (16) above.
4. Place seal ring protector tools (29 and 31, Figure 118) over the inner and outer seal
ring surfages of the piston housing (Figure 11-40). Lubricant applied to the outer surface of tool
(29) and the inner surface of tool (31) will help prevent the dislocation of the seals during tool
removal.
5. Install piston (20). with seal rings, into forward clutch housing (4) until the piston
bottoms against the housing. Remove tools (29) and (31) from housing.
6. Beginning with an external-tanged plate, alternately install five externaltanged (18)
and five internal-splined (17) clutch plates into forward clutch housing (4).
7. Install fourthclutch driving hub (16) into housing (4), engaging the tangs in the
slots. Install snapring (15) into housing (4).
284
VEHICLE
ITEM 29 (Fig. 11B)
HOUSING
!=igure 1140 Installing ForwardClutch Housing Piston, Using Sealring Protector Tool
8. While holdihg clutch driving hub (16) up firmly against snap ring (15), measure with
a feeler gage the clutch running clearance at the point indicated in Figure 1141. This clearance
should be 0.0765 to 0.1265 (1.9431 to 3.2131 mm). Figure 1142 shows how to make the check,
using a special gage (16) (Figure 117).
Figure 1141 Forward Clutch Clearance
Check Point
285
FORWARD ~ 1 I 1 ' T ~ H
AND TURBINE SHAFT ASSY
ITEM 18 (Fig_ 11-7)
FOURTH CLUTCH
DRIVING HUB
Figure 1142 Checking Forward Clutch
Clearance
VEHICLE
NOTE: The smaller end of the gage should pass between the hub and first plate. The larger
end shou Id not.
9. If the clutch running clearance is not within the specified limits, remove snapring
(15) (Figure 1138), driving hub (16), and clutch plates (17 and 18). Replace external-
tanged plates (19) and internal-splined plates (18), as required, to obtain the desired running clear-
ance. Refer to wear limits, Chapter 17, to determine the plates which should be replaced.
10. Repeat steps 6, 7 and 8 above. When the clutch running clearance is within the
specified limits of 0.0765 to 0.1265 (1.9431 to 3.2131 mm), remove snapring (15), clutch driving
hub (16), and clutch plates (17 and 18). Retain the clutch plates as a package until required.
NOTE: Steps 11 through 16, below, explain the alternate method for establishing clutch
plate clearance with the clutch plates in a press.
11. Beginning with an external-tanged plate, alternately place five external-tanged places
(18) and five internal-splined plates (17) onto a press bed.
12. Place the fourth-clutch driving hub (16) on top of the clutch plates. Center the hub
and plates in the press.
13. Do not exert force on the hub extension. Install a sleeve and plate over the hub
extension (Figure 11-43) and apply a compression load of 980 to 1020 pounds (445 to 464 kg.).
14. Measure the stack dimension. Refer to Figure 11-43 and select the proper piston,
A, B or C (marked on piston).
15. Remove the sleeve and plate from the fourth-clutch driving hub and place the clutch
plate and hub package on the work table until ready for installation.
PRESS 9801020 lBS.
445464 kg
PLATE
FOURTHCLUTCH
DRIVING HUB
t
INTERNAL-SPLINED
_--CLUTCH PLATE (5)
X
I ___ EXTERNAL-rANGED
...L CLUTCH PLATE (5)
DIMENSION X USE PISTON
0.9825-1.0065 C
24.9555-26.5651 mm
1.00651.0325 B
25.565126.2255 mm
1.032&-1.0585 A
26.2255-26.8859 mm
Figure 11-43 Determining Forward-Clutch Piston Thickness
286
VEHICLE
16. Install piston as outlined in Steps 2 through 5 above.
NOTE: Refer to Paragraph 11-18.
C. Assembly (Figure 11-38).
1. Install sixteen clutch springs (19) onto their spring guide bosses on the piston, and
install spring retainer (8) onto the springs, the spring recess side of the retainer facing the springs.
2. Place the clutch assembly in a press, with the spring retainer up. Using compressor
tool (9) (Figure 11-6), compress the clutch springs until the snapring groove in the clutch housing
is exposed.
3. Using snapring pliers, install snapring (9) into clutch housing (4). (See also, Figure
11-39). Release the press and remove the clutch assembly.
4. Install the flat bearing race onto the hub of the forward clutch housing (Figure 11-
44). Install the thrust needle bearing and the lipped bearing race so that it encloses the bearing.
Retain the bearing and races with oil-soluble grease.
5. Install the forward clutch hub into the clutch housing (Figure 11-45).
6. Beginning with an external-tanged clutch plate, install the clutch package removed
in B (10) or (15) above. Refer to Figure 11-45.
7. Install fourth-clutch driving hub (16) (Figure 11-38) into housing (4) and secure the
hub with snapring (15).
8. Retain the forward clutch housing and turbine assembly (4) (Figure 11-38) on the
work table, shaft side down.
BEARING RACE (LIPPED)
THRUST BEARING
Figure 11-44 Installing Forward-Clutch
Thrust Bearing
287
CLUTCH HOUSING
PLATE (5)
Figure 11-45 Installing Forward Clutch Plates
VEHICLE
9. Install snapring (2) into the snapring groove in forward clutch housing (4).
10. Place PTO gear (3) onto the forward clutch housing. Be sure the chamfer on the in-
side diameter of the PTO gear is facing downward (F igure 11-46).
11. Compress snapring (2) into the clutch housing and install the PTO gear. Be sure the
gear is positioned so that the snap ring expands into the gear.
12. Install hooktype sealring (1) onto turbine shaft of assembly (4).
11-24. FOURTH CLUTCH - REBUILD
A. Disassembly (Figure 1147).
1. Place fourth-clutch assembly on the work table, with snapring (1) upward. Remove
snap ring (1), back plate (2), five internal-splined clutch plates (3), and five external-tanged clutch
plates (4).
2 .. Place fourth-clutch housing assembly (6) in a press. Depress piston return spring
retainer (11) and remove snapring (12) and spring retainer (11). Figure 11-48 shows this procedure,
using the special compressor (9), Figure 11-6.
3. Remove the sixteen piston return springs (10) (Figure 11-47) and remove fourth-
clutch piston (9).
4. Remove seal ring (8) from outside diameter of piston (9). Remove seal ring (7) from
the inside diameter of the piston bore in fourthclutch housing (6). Check the sealring groove
thoroughly for burrs and rough spots in bottom and sides.
UP
) ~ ~ ~ ~ ~
DOWN
CHAMFER
Figure 11-46 PTO Gear Chamfer
288
VEHICLE
4
Figure 11-47 F ourth clutch
289
VEHICLE
NOTE: Refer to Paragraph 11-18.
B. Checking Clutch Pack Clearance (Figure 11-49).
NOTE: Steps 1 through 10 below, explain a method for establishing the clutch plate clear
ance with !he plates installed in the transmission. Items 11 through 16 below, explain an
alternate method, before the clutch is installed.
1. To insure proper running clearance, the clearance should be checked, as outlined
below, before assembling the clutch.
2. Place fourth-clutch housing assembly (6), open (front) side- upward, on the work
table. Install clutch housing sealring (7), lip downward, into the groove of the housing, inner hub.
Lubricate the sealring and center it in the groove.
3. Place fourth-clutch piston (9) on the work table, return spring side (front) upward.
Install piston outer sealring (8), lip downward, onto piston (9). Lubricate seal ring with an oil-
soluble grease. No seal ring is used in the inner sealring groove of this piston.
NOTE: If piston (9) must be replaced, be sure that the identification mark (A, B or C) on
the new piston is the same as that on the replaced piston.
4. Place seal ring protector tool (31) (Figure 11-8) over the outer sealring surface of
piston housing (6). Lubricant applied to the inner surface of tool (31) will help prevent the dis
location of the seal during tool removal.
5. Install piston (9), with seal ring (8) into clutch housing assembly (6). Be sure that
the piston bottoms in the housing. Remove seal ring protector tool (31) from the piston housing.
6. Beginning with an external-tanged clutch plate (4), alternately install five plates
(4) and five internal-splined clutch plates (3) onto piston (9).
7. Install clutch back plate (2), flat side first, onto the last clutch plate (3) installed.
Install snap ring (1) into housing (6).
8. Hold back plate (2) firmly upward against snapring (1). With a feeler gage, measure
the clearance between the back plate and the clutch plates at the point indicated in Figure 11-49.
This clearance should be 0.0625 to 0.1125 (1.5875 to 2.8575 mm). Figure 1150 shows this check,
using a special gage (17) (Figure 11-7). The smaller end of the gage should pass between the back
plate and the first-clutch plate; the larger end should not.
9. If the clutch running clearance is not within the specified limits, remove snap ring
(1), (Figure 11-47), back plate (2), and clutch plates (3 and 4). Replace clutch plates (3 and 4)
with new plates as required to establish the proper running clearance. Refer to wear limits, Chap-
ter 17, to determine the plates which should be replaced.
10. Repeat Steps 6, 7 and 8 above. When the running clearance is within 0.0625 to
0.1125 inch (1.5875 to 2.8575 mm), remove snapring (1), clutch backing plate (2), and clutch
plates (3 and 4). Retain the clutch plates as a package until required. Complete the assembly pro
cedures as outlined in C below.
NOTE: Steps 11 through 16, below, explain an alternate method for establishing clutch
plate clearances with the plates in a press.
290
VEHICLE
1/
,
ITEM 9 lG. 116)
RETAINER
Figure 11-48 Removing (or installing) Fourth-Clutch Spring Retainer Snapring
Figure 11-49 Fourth-Clutch Clearance Check Point
291
VEHICLE
ITEM 17 (Fig. 1l7)
BACK PLATE
Figure 11-50 Checking Fourth-Clutch Clearance
11. Beginning with an external-tanged plate (4), alternately install five plates (4) and
five internal-splined clutch plates (3) onto a press bed.
12_ Place fourth-clutch backing plate (2) on top of clutch plates (3 and 4), flat side down.
Center the plates on the bench.
13. Place a steel plate on top of the backing plate, as shown in Figure 11-51. Apply a
compression load of 980 to 1020 pounds (445 to 464 kg_).
14. Measure the stack dimension. Refer to Figure 11-51 and select the proper piston,
A, B or C (marked on piston).
PRESS 9801020 las.
445464 KG.
STEEL PLATE
25.31125.9207 mm
1.0205.1.0465 8
25.920726.5811 mm
1.0465.1.0725 A
26.5811-27.2415 mm
_--- FOURTH CLUTCH
'A- BACKING PLATE
1--___ EXTERNALTANGED
CLUTCH PLATE
1 ____ INTERNAL-SPlINEO
CLUTCH PLATE
BENCH
Figure 11-51 Determining Fourth-Clutch Piston Thickness
292
VEHICLE
15. Remove the steel plate from the fourthclutch backing plate (Figure 1151) and place
the clutch plate package on the work table until ready for installation.
16. Install piston as outlined in Steps 2 through 5 above. Complete the assembly pro
cedures as outlined in C below.
C. Assembly (Figure 1147).
1. Install sixteen return springs (10) onto their guide bosses on piston (9). Install spring
retainer (11), spring recess side first, onto the springs.
2. Place the clutch assembly in a press, spring retainer upward. Lay snapring (12) on its
approximate installed position, on spring retainer (11).
3. Using a compressor (9) (Figure 116) which provides access to the snap ring, depress
the spring retainer until it clears the snapring groove in the housing hub (Figure 1148). Install the
snapring, and release the pressure from the retainer. Remove the clutch assembly from the press.
1125. CENTER SUPPORT ASSEMBLY - REBUILD
A. Disassembly (Figure 1152).
1. Remove pistons (11 and 9) with attached parts, from center support assembly (6).
2. Remove eight retainer washers (10). Cut the retainer washers to prevent damaging
the piston projection (F igure 1153).
3. Remove spring retainers (11). Remove twentyfour piston springs (12) ..
4. Remove piston inner seal rings (8) from pistons (9).
5. Remove piston outer sealrings from pistons (9).
6. With the center support (6) and bushing (14) standing upright, remove the two hook
type sealrings (15).
NOTE: Refer to Paragraph 11-18 above.
7. If parts replacement is necessary, place support (6) and bushing (14) in a press, seal-
ring grooves side up. Press bushing (14) out of support, being careful not to damage bushing bore.
B. Assembly (Figure 11-52).
NOTE: Before assembling the center support assembly, piston (9) (Figure 11-52) must be
used to establish the proper clearance in the second clutch. Refer to Paragraph 11-30A.
1. Place center support (6) in a press, sealring grooves side up. Using bushing tool (42)
(Figure 11-8), install bushing (14) as shown in Figure 11-54. Be sure the oil hole in bushing (14) is
in proper alignment with the oil hole in support (6).
2. If a special bushing tool is not available, press bushing (14) flush to 0.010 inch (0.254
mm) below the surface adjacent to the bore. The bushing must withstand 500 pounds of end load
specified in the direction of the arrow in Figure 11-55 after assembly. To insure proper alignment
of the oil hole in bushing (14) with the oil hole in support (6), identifying notch of bushing must
lie in the area inrlicated in Figure 11-55.
293
Figure 11-5
VEHICLE
3
d & Third Clute 2 Secon
294
h & Center Support
I
! !
I
VEHICLE
3. Place pistons (9) (Figure 1152) on the work table, with the four ejector pin bosses
upward. Install piston return springs (12) in the twelve holes in third-clutch piston (9). Install piston
return springs (12) in the twelve holes in second-clutch piston (9).
4. Place spring retainers (11) on pistons (9) so the four holes in retainers (11) are in line
with the four ejector pin bosses on pistons (9). A small amount of pressure will depress piston re-
turn springs (12). Start eight new selflocking retainer washers (10), using tool (32) (Figure 11-8)
shown in Figure 11-56 onto the eight ejector pin bosses. To assure that retainer washers (10) do not
obstruct piston travel, the following procedure is suggested. Assemble piston, springs, spring retainer
and self-locking retainer washers. Place this assembly in the piston bore in support assembly (6).
Pistons (9) should touch the bottoms of the piston bores before spring retainers (11) touch outside
diameter of support assembly (6). Apply pressure to self-locking retainer washers (10) until spring
retainers (11) are seated. Check alignment of tangs on spring retainers (11) to slots in support
assembly (14) before applying pressure to self-locking retainer washers (10).
5. Apply oil-soluble grease to the inner and outer diameter seal ring grooves on pistons
(9). Install sealrings (8) into inside diameter grooves of pistons (9). 8e sure the lips of the sealrings
face the same direction the flat side of the piston does. Special care is required during installation
of the sealrings onto the pistons to prevent distortion, cutting or stretching.
NOTE: Do not install the pistons and their components at this time. Set the pistons and the
center support aside until the second and third-clutch plate clearance check is made in
Paragraph 11-30.
6. Install two hook-type seal rings (15) onto the hub of center support (6).
11-26. PLANETARY GEARS AND SHAFTS - REBUILD
A. Disassembly (Figure 11-57).
1. Lay the planetary gears and shafts assembly on its side on the work table. If not
previously removed, remove sun gear shaft (1), thrust washer (2) and front planetary sun gear (3).
2. Remove front planetary carrier assembly (5) from ring gear (8).
3. Remove selective thrust washer (4) from front planetary carrier assembly (5), and
thrust washer (6) from center planetary carrier assembly (9).
4. Remove snapring (7) which retains front planetary ring gear (8) to planetary con-
necting drum (19). Remove ring gear (8) and center planetary carrier assembly (9) from drum (19).
5. Remove center planetary sun gear (10) and thrust washer (11).
6. Remove main shaft (14) and its attached parts. Remove snapring (12), center ring
gear (13), spiral snapring (16) and rear sun gear (19).
7. Remove snapring (22) that retains rear planetary carrier assembly (21) to planetary
connecting drum (19).
8. Remove output shaft (24) with attached parts.
9. Remove needle bearing assembly (17) and bearing race (18) located between the
output shaft and the rear sun gear.
295
~ ~ ; ~ ~ ~ : ~ ~ RETAINER WASHER
THIRD CLUTCH PISTON
Figure 11-53 Removing Self-Locking
Retainer Washers
PRESS FLUSH
TO 0.010 BELOW THIS SURFACE
0.254 mm
Figure 11-55 Center Support Assembly
VEHICLE
",.,""" ' ~ /
CENTER SUPPORT
Figure 11-54 Installing Center Support Bushing
296
ITEM 32
(FIG. "81
CENTER
SUPPORT
THIRD
CLUTCH PISTON
Figure 11-56 Installing Selflocking
Retainer Washer
VEHICLE
Figure 1157 Planetary Gears and Shafts Assembly
297
VEHICLE
Figure 11-158 First & Reverse Clutch
298
VEHICLE
10. Place the output shaft on a work bench in a vertical position (rear planet carrier up).
If necessary, force the planet carrier down until snapring (20) is clear of carrier. Remove snapring
and bearing (23).
11. Remove rear carrier assembly (21) from the output shaft.
12. If parts replacement are necessary, remove the roll pin, the bushing and the orifice
plug from output shaft (25) (Refer to Figure 1158) and the two bushings (1) from sun gear shaft
(2).
NOTE: Refer to Paragraph 1118.
B. Assembly (Figure 11-57).
NOTE: Items 1 through 5 below, explain the assembly rebuild of parts illustrated on Figure
11-60. Items 6 through 8 and 11 through 25 illustrate parts on Figure 11-57.
1. If orifice plug (25) (Figure 11-60) was removed from output shaft (25), install new
plug. Press plug clear of chamfer.
2. If bushing (23) was removed, install a new bushing into output shaft (25), following
the instruction given in Figure 11-59. Bushing installer (4) is available for this and can be used as
shown in Figure 11-61.
3. If bushings (1) were removed from sun gear shaft (2), install new bushings. Follow
the instructions in Figure 11-62. Figure 11-63 shows this procedure, using bushing installer (6)
(Figure 11-6).
4. If bushing in planetary carrier (7) (Figure 11-60) was damaged or distorted, replace
carrier assembly.
5. If spring pin (24) was removed from output shaft (25), install a new pin. The pin
must not extend beyond 0.160 inch (4.064 mm) from shaft surface.
0.6485
0.6475
mOl) DlAA
mrn)
(9.398 mm)
WHEN MOUNTED ON DIA A TOTAL RUNOUT
OF DIA B TO BE WITHIN 0.002 (0.0508 mm)
BUSHING MUST WITHSTAND APPROX.
350 LB LOAD IN DIRECTION SHOWN
Figure 11-59 Output Shaft Assembly
299
VEHICLE
Figure "60 G ear Unit & Output Shaft
300
VEHICLE
ITEM 5 (FIG. 11-6}
ITEM 4 (FIG. 116)
Figure 11-61 Installing Output Shaft Bushing
ITEM 6 (Fig.
Figure 11-63 Installing Sun Gear Shaft Bushing
301
DIAA
REF
I

1.0000
125.4381mm)
(25.400 mm)
DIAB
BOTH ENDS
:=::
\
1 PRESS
-I- flUSH TO
0.Q10 10.254 mm)
BELOW BOTH ENDS
DIA B MUST BE CONCENTRIC WITH DIA A
"wITHIN 0.002 TIR (0.0508 1I11ll)
EACH BUSHING MUST WITHSTAND THE
SPECIFIED LOAD IN THE INDICATED
DIRECTION
Figure 11-62 Sun Gear Shaft and Bushings
OUTPUT
SHAFT
k
BOLT. 1/220
Figure 11-64 Planetary Gears Assembled for
Measuring for Selective Thrust Washer
VEHICLE
6. Install the rear planetary sun gear (15) (Figure 11-57) onto main shaft (14), small
end first. Secure the sun gear to the main shaft with spiral snapring (16).
7. Install center ring gear (13), concave side forward, onto the rear sun gear and secure
with snapring (12).
8. Install the rear planetary carrier assembly (21) into planetary carrier connecting drum
(19) and secure the carrier with snapring (22). Note the broad groove in the drum outer diameter
is away from the carrier.
9. Install ball bearing assembly (23) over snapring groove end of output shaft (24).
Install output shaft (24) (snapring groove first) into rear planetary carrier assembly (21). Secure it
with snapring (20).
10. Install positioning tool (24) (Figure 11-7) over output shaft and retain with 1/2-20
bolt (Figure 1164). Tighten the bolt to 30 ft.lbs. (40 Nm) torque.
11. Lubricate race (18) and bearing assembly (17) with oil-soluble grease. Install race
and bearing onto output shaft adjacent to the rear sun gear.
12. Install main shaft (14) and attached parts into rear planet carrier (21). Index sun
gear (15) with pinions of rear planet carrier.
13. Install thrust washer (11) (Figure 11-57) against the front side of the rear sun gear.
14. Install center planetary carrier assembly (9), smaller diameter end first, into plan-
etary connecting drum (19). Index the carrier splines with the splines in the connecting drum.
15. Install center sun gear (10), large end first against thrust washer (11).
16. Install front planetary ring gear (8) (larger diameter first) into planetary connect-
ing drum (19) and secure with snapring (7).
17. Lubricate and install thrust washer (6) around the hub of front planet carrier (5).
18. Install front planetary carrier assembly (5) onto center sun gear (10).
19. Using a depth micrometer, determine the measurement of dimension A of Figure
11-65. Select the correct thrust washer according to the table shown in Figure 11-65.
20. Take the micrometer measurements, shown in Figures 1166 and 11-67. The differ-
ence between these measurements is dimension A in Figure 11-65. .
21. Remove positioning tool (24) (Figure 11-7) from output shaft previously installed
in Step 12, above.
22. Lubricate and install thrust washer (4) (selected in Step 20 above) onto center sun
gear (10).
23. Install front planetary sun gear (3), spline chamfer first, into front planetary carrier
assembly.
NOTE: Thrust washer (2) (Figure 11-57) and sun gear shaft assembly (1) will be installed
after the gear and shafts assembly is installed into the transmission.
302
VEHICLE
SELECTIVE WASHER
SEE TABLE
-"U--DIMA
MEASURED BY THRUSTING ----'
CENTER SUN GEAR AND FRONT
CARRIER TOWARD OUTPUT
SHAFT WITH BEARING THRUST
IN THIS DIRECTION
DIMENSION A SElECTIVE IDENTIFICATION
0.071 . 0.090
0.0900.109
0.1090.128
0.8034 mm-2.286 mm)
(2.286 mlU-2.7686 1111ll)
(2.768B mm-3.2512 nlm)
WASHER NO.
6 8 ~ . 7 1 1
6831772
6831773
1
2
3
Figure 1165 Selection of Thrust Washer for Planetary Gear Assembly
Figure 1166 Measuring Depth of Front
Planetary Carrier
303
DEPTH
I
I
Figure 1167 Measuring to Front of Center
Planetary Sun Gear
VEHICLE
11-27_ TRANSMISSION CASE -- REBUILD
A. Disassembly (Figure 11-68).
, I
I I
I
Figure 11-68 Transmission Case
304
VEHICLE
1. To remove the manual shift lever, use the following procedure. Remove the retainer
pin and locknut (Figure 1169).
2. Hold the selector lever in one hand and remove the selector shaft by carefully pulling
the selector shaft through the oil seal in the case. Remove the selector lever.
3. Remove seal (24) (Figure 1170) from the transmission case.
4. Do not remove snapring (16) (Figure 1168) unless replacement is necessary. Traces
of aluminum on the outer race of bearing (17) indicates rotation of the outer race within the trans
mission housing and possible damage to the snapring and to the bearing bore in the transmission
housing.
5. Do not remove breather (4) from transmission case (1) for cleaning. It is a press fit,
and should be cleaned while in the case.
6. Check governor support pin (28) for evidence of wear. If damaged, replace the pin.
Refer to Figure 1171. .
NOTE: The alignment of the governor pin with the governor bore in the transmission case
is critical. The governor must rotate freely, without interference with either the case bore
or the pin. Any interference will result in damage to the governor body, the bore in the case
and/or the governor driven gear.
7. Inspect two test plugs (12) (Figure 1168). Replace if damaged.
8. If it is necessary to replace a damaged name plate, remove one drive screw.
NOTE: All replacement parts ordered refer to the information on the nameplate. There
fore, it is imperative that the new nameplate be stamped with identical information.
NOTE: Refer to Paragraph 1118.
SELECTOR
VALVE PIN
- - - ~ - ~ - - ~
\
n
RETAINER
PIN
SELECTOR
LEVER
Figure 1169 Selector Shaft Components
305
VEHICLE
I an, Oil Filter & Control Valve Body Figure 11-70 0-1 P
306
VEHICLE
B. Assembly (Figure 1168).
1. If snapring (16) was removed, install new snap ring. Be sure to inspect the bore of
bearing (17) for damage.
2. Coat the inside diameter of oil seal (19) with oilsoluble grease, and coat the inside
diameter of the seal with a nonhardening sealant. Install the seal, lip first, into transmission case
(1) (Figure 1168). Figure 1172 shows "the installation of the oil seal, using a special installer (8)
(Figure 116).
3. Holding selector lever (23) (Figure 1170) so that the selector valve pin is facing
the inside of the case, slide selector shaft seal (24) through opening in case (1) (Figure 1168),
oil seal (24) (Figure 11-70), and slot in selector lever (23). Attach locknut (20) and retainer lever
(19). Tighten the locknut to 15 to 20 ft.lbs. (20 to 27 Nm) torque. Refer to Figure 1169.
4. Replace breather (4) (Figure 11-68) if there is any evidence of damage. It is pressed
into the case.
5. If governor drive pin (28) was removed at disassembly, install a new replacement.
Press the pin to dimensions shown on Figure 11-71. Refer to the note following A (6) above.
Section V - ASSEMBLY OF TRANSMISSION FROM SUBASSEMBLIES
This section covers assembly of the transmission from subassemblies. Paragraph 11-28 dis-
cusses components which are selective, to provide proper clearances. Paragraph 11-29, and those
following, outline the assembly procedures.
11-28. SELECTIVE COMPONENTS
A. Establish Clearances.
1. Several components are available in graduated lengths or thicknesses to provide the
proper running clearances. These components are selected by taking measurements at certain stages
in the assembly of the transmission.
2. Alternate methods for establishing clutch plate running clearances are introduced
below. Their application simplifies assembly rebuild where production methods are used.
3. The components which are selected during assembly of the transmission are tabulated
below:
307
VEHICLE
Item
*Part Number
Thrust washer 206596 thru
206601
Snapring 206259 thru
206262
Second and third 206256 and
clutch back plate 206267,206256
First and reverse 206297 thru
clutch back plate 206299
Spacer
206320 thru
206325
*Order from current Parts Catalog 114102
PRESS TO D.M.'NSII)N
SHOWN
Illustration
17 (Figure 11-32)
5 (Figure 11-52)
2,13 (Figure 11-52)
2 (Figure 11-58)
15 (Figure 11-68)
ITEM 8 (FIG. 116)
Figure 1171 Governor Support Pin Location Figure 1172 Installing Selector Shaft Oil Seal
308
VEHICLE
B. Clutch Plate Stack.
1. An initial clutch plate running clearance check may be in excess of the required dim-
ension. Do not install a thicker back plate if excess clearance can be eliminated by installing new
clutch plates.
2. Refer to wear limits, Chapter 17 for clutch running clearance.
11-29. OF FIRST-AND-REVERSE CLUTCH AND GEARING.
A. First-and-Reverse Clutch.
1. Place the transmission case assembly into the holding fixture (Figure 11-11), convert-
er housing upward.
2. Place the first-and-reverse inner seal protector tool (30) (Figure 11-8), over the hub in
the transmission housing (Figure 11-73).
3. Install the inner and outer lip-type sealrings into the grooves in the first-and-reverse
clutch piston. The lips of both sealrings must face toward the rear of the transmission. Lightly
lubricate the surface of the piston bore and protector tool (30) (Figure 11-8) with Dexron oil be-
fore installation.
4. Install the piston and sealrings into the transmission case rear bore, engaging the
piston tang into the slot in the case (Figure 11-73). 8e sure the lip of the sealring on the outside
diameter of the piston is not distorted. Remove the protector tool.
5. Install 22 springs into the recesses in the piston. Install the spring retainer onto the
springs (Figure 11-74).
6. Lay the spring retainer snapring on the spring retainer (Figure 11-74).
Figure 11-73 Installing First-and-Reverse
Clutch Piston
309
Figure 11-74 Installing First-and-Reverse Clutch
Spring Retainer Snapring
VEHICLE
7. Install spring compressor (23) (Figure 11-7) into the rear bearing bore of the trans-
mission case (Figure 11-74). Check springs for proper alignment.
8. Tighten the wing-nut on the spring compressor until the spring retainer clears the
snapring groove. Spread the snapring, and install it into its groove. Remove the spring compressor.
9. Place the first-and-reverse ring gear on a work table, extended teeth down. Beginning
with an internal-splined plate, alternately install six internal-splined and six external-tanged clutch
plates onto the rear ring gear (Figure 11-75).
10. Align the tangs of the external clutch plates on the ring gear and install the gear and
plates into the transmission as a package. Be sure the extended teeth on the ring gear remain at the
top of the gear after installation.
11. Install the two remaining clutch plates, steel plate first. Install the clutch back plate
(wide surface down) and secure with a snapring (Figure 11-76).
NOTE: Steps 12 through 14 below, explain a method for establishing the clutch plate
clearance with the plates installed in the transmission. Steps 15 through 19 below, explain
an alternate method before the clutch is installed.
12. Using clutch clearance gage (18) (Figure 11-7), check the clearance between the
snapring and the back plate (Figure 11-77). The smaller end of the gage should go into the clear-
ance while the larger end should not.
NOTE: The prescribed clearance range for first-and-reverse clutch is 0.0405 to 0.1005 inch
(1.0287 to 2.5527 mm).
INTERNALSPLINED
PLATE
RING
INTERNALSPLINED
PLATE
EXTERNAL-T ANGED
PLATE
Figure 11-75 Installing First-and-Reverse Clutch Plates Onto Rear Ring Gear
310
VEHICLE
13. If the clearance is excessive (larger end of gage will pass between the snapring and the
back plate), new plates may be installed to reduce the clearance. If the clearance is still excessive
after new internal-splined and external-tanged clutch plates are installed, a thicker back plate is
required.
14. If clearance is insufficient (small end of gage will not enter), a thinner back is re-
quired. Back plates are stamped with identifying numbers (1, 2 or 3). Thicknesses are as follows:
Identification 1
Identification 2
Identification 3
0.683 to 0.693 thk (17.3482 to 17.6022 mm)
0.647 to 0.657 thk (16.4338 to 16.6878 mm)
0.611 to 0.621 thk (15.5194 to 15.7734 mm)
NOTE: Steps 15 through 19 below, explain an alternate method to establish clutch plate
running clearance before the clutch is installed.
15. Place first and reverse clutch piston (B) (Figure 11-58) on a press bed, spring pocket
side up. Support the piston with a circular plate, placed between the press bed and the piston.
16. Beginning with external-tanged plate (4), alternately place seven external plates (4)
and seven internal-splined plates (3) on top of piston (8). Place a steel plate on top of the clutch
plates (Figure 11-78).
17. Center the plates on the bench. Apply a compression load of 980 to 1020 pounds
(445 to 464 kg.).
18. Measure the stack dimension. Refer to Figure 11-78 and select the compatible plate
1, 2 or 3 stamped on plate.
19. Remove the steel plate from the top of the clutch plates. Refer to Items 2 through
11 above for rebuild.
BACK PLATE
Figure 11-76 Installing FirstandReverse
Clutch Back Plate
311
Figure 1177 Checking FirstandReverse
Clutch Running Clearance
VEHICLE
___ "I<t'''' 9801020 LBS
1445-464 kg )

F'i'----INTERNAL-SPLINED
CLUTCH PLATE (7)
EXTERNALTANGEO
CLUTCH PLATE (7)

FIRST AND REVERSE


CLUTCH PISTON
PLATE
BENCH
DIMENSION X USE PLATE
2.2875 TO 2.3235 1
2.3235 TO 2.3595 2
2.3595 TO 2.3955 3
Figure 11-78 Determining First-and-Reverse Clutch Back Plate Thickness
B_ Planetary Gears and Shafts Assembly_
1. Grasp the planetary gears and shafts assembly by the main shaft and lower the unit
into the transmission (Figure 11-79). Mesh the internal teeth of the previously installed rear ring
gear (Paragraph 11-29 (A), (Steps 9 through 11), with the rear planetary carrier pinion teeth. Be
sure the unit bottoms.
2. Install sun gear shaft assembly (long splines first) and front sun gear thrust washer
(Figure 11-80).
REAR
PINION
MAIN SHAFT
Figure 11-79 Installing Planetary Gears and
Shafts Assembly
312
Figure 11-80 Installing Sun Gear Shaft Assembly
and Thrust Washer
VEHICLE
NOTE: Application of air pressure to the firstandreverse clutch, after installing the gear
pack, will lift the ring gear (and gear pack) slightly if all splined plates are not engaged.
1130. INSTALLATION OF SECOND CLUTCH AND CENTER SUPPORT
A. Second Clutch (Figure 1152).
1. &stablish the proper clutch running clearance, as outlined in 2 through 6 below. If
new internal and external clutch plates are used, see Items 7 through 9, below.
2. Support the secondclutch piston, convex (front) side downward on a flat surface of
a press bed. Stack three externaltanged clutch plates, and three internalsplined clutch plates,
alternately, onto the apply face of piston (Figure 1181).
3. Place a flat plate or disc upon the stacked plates. With a press, apply 980 to 1020
pounds (445 to 464 kg.) force against the plate or disc.
4. While the force is applied, measure the combined thickness of the piston and six
clutch plates designated X on Figure 11 81.
5. Note the identification number (1 or 2) stamped on back plate (13) (Figure 1152).
If the identification number is 2, the dimension obtained in 4 above should be within 1.5165 to
1.5425 inches (38.5191 to 39.1795 mm). If not, replace worn plates 4 and/or 3 with new plates
as required to obtain the specified measurement. Refer to wear limits, Chapter 17, for clutch plate
dimensions.
6. If the identification number on back plate (13) is 1, the dimension obtained in 4
above, should be within 1.4995 to 1.5165 inches (38.0875 to 38.5191 mm). If not, replace worn
plates 4 and/or 3 with new plates as required to obtain the specified measurement. Refer to wear
limits, Chapter 17, for clutch plate dimensions.
NOTE: If new internal and external clutch plates are used, follow Items 7 through 9 below.
7. Repeat Items 2, 3 and 4 above.
8. If the X measurement is within 1.5165 to 1.5425 inches (38.5191 to 39.1795 mm).
use back plate (13) (Figure 1152) with the stamped identification number 2.
9. If the X measurement is within 1.4905 to 1.5165 inches (37.8587 to 38.5191 mm),
use back plate (13) with the stamped identification number 1.
10. Carefully place piston (9) (Figure 1152) in piston bore of support assembly (6).
Sealring (7 and 8) must have their lips facing into the piston bore in support assembly (6). A tang
on each spring retainer must engage a slot in the center support.
11. Install the second-clutch back plate (Figure 1182). Note the location of the single
tang in the single slot in the transmission case.
12. Beginning with an internalsplined plate, alternately install three internalsplined,
and three externaltanged clutch plates (Figure 1182). The single tangs of the clutch plates must
align with the single tank of the back plate.
313
INTEANAl-SPlINED
(3)
PISTON
PRESS 980-1020 LBS
{445-464
STEEL
Figure 11-81 Checking Second-Clutch Plate
Running Clearance
VEHICLE
INTERNAL SPLINED
(2)
EXTERNAL TANGED
(3)
I
PLATE
Figure 11-82 Installing SecondClutch Plates
13. Install the snapring (0.155/0.157 [3.937/3.9878 mmJ thick, marked green) that
retains the second-clutch plates (Figure 11-83). The snapring gap should be located toward the top
of the transmission case.
B. Center Support Assembly.
1. If the center support contains the third-clutch piston, remove it.
2. Install the remaining assembly (center support, second-clutch piston, etc.) into the
transmission case. Use the center support lifting bracket (10) (Figure 11-6) to lower the assembly
into the transmission case, as shown in Figure 11-22. Be sure the tapped hole in the support is
aligned with the bolt hole in the bottom of the case.
3_ Remove the lifting bracket. Temporarily install the original 3/8-16 x 1-inch anchor
bolt into the support. Tighten the bolt finger tight.
4. Install the center support compressor (27) (Figure 11-7), as shown in Figure 11-84.
Use two of the 5/16-18 x 1-3/4-inch oil pump assembly retaining bolts to nitain the compressor.
5. Tighten the compressor bolt to 5 ft. Ibs. (6.9 Nm).
6. Using the snapring gage (28) (Figure 11-7), measure the snapring groove clearance
(Figure 11-85). The gage has four lugs of different thicknesses. The thickest lug which will enter
the groove indicates the thickness of the snapring required.
314
VEHICLE
Figure 11-83 Second-Clutch Snapring Installed
ITEM 28 (Fig. 11-7)
Figure 11-84 Compressing Center Support for
Snapring Measurement
ITEM 27 (Fig. 117)
GENTER
SUPPORT
Figure 11-85 Measuring for Selection of Center Support Snapring
315
VEHICLE
7. Select a snapring, as shown below:
Gage Lug Snapring Color Snapring Thickness
Blue Blue 0.148 to 0.150 (3.7592 to 3.81 mm)
Yellow Yellow 0.152 to 0.154 (3.8608 to 3.9116 mm)
Green Green 0.155 to 0.157 (3.937 to 3.9878 mm)
Red Red 0.158 to 0.160 (4.0132 to 4.064 mm)
8. Remove the center support compressor.
9. Attach the center support lifting bracket. Remove the anchor bolt from the bottom
of the transmission case. Remove the center support. Place the center support on a work table and
clean the piston bore of all foreign matter.
10. Remove the sealrings from the third-clutch piston and inspect them for damage.
Using Dexron oil, lightly lubricate the piston bore in the center support and the lips of the seal-
rings. Install the piston and its attached parts, engaging the small lug on the third-clutch spring re-
tainer with the slot in the center support. Be sure the lips of the sealrings face the bottom of the
piston cavity in the center support.
NOTE: Both the second and third clutch pistons must bottom in their respective bores.
Failure to conform will affect transmission performance.
11. Attach the center support lifting bracket to the center support and carefully lower
the support into the transmission case, as shown in Figure 11-22. Prior to installation, align the
threaded hole in the support with the hole in the bottom of the transmission case. Install the plain
washer and a new 3/8-16 x 1-inch anchor bolt into the support. Tighten the bolt, finger tight.
12. Install the snapring selected in 7 above. Be sure the snapring gap is located toward
the top of the transmission case.
NOTE: It may be necessary to use the center support compressor to install the snapring.
11-31. INSTALLATION OF REAR BEARING SPACER AND FOURTH CLUTCH
A. Selecting, Installing Rear Bearing Spacer.
1. Install the sun gear shaft retainer (Figure 11-6) (11) onto the transmission main shaft.
Be sure retainer sleeve is seated on sun gear shaft while tightening thumb screw (Figure 11-86).
2. Position the transmission, rear end upward. Install the governor drive gear, engaging
its slot with the pin in the output shaft (Figure 11-87).
3. Install the speedometer drive gear onto the output shaft.
4. Using a soft drift, tap against the speedometer drive gear to seat all the installed
components.
316
VEHICLE
-----------
------------------,-,'-
OUTPUT SHAFT
Figure 11-86 Installing Sun Gear Shaft Retainer
Figure 11-87 Installing Governor Drive Gear
5. Loosen the thumbscrew on the spacer selection gage (15) (Figure 11-6) and position
the gage against the output shaft (F igure 11-88). Push the straight member of the gage against the
rear of the speedometer drive gear. Push the lipped member against the rear bearing front snapring.
When the gage is in firm contact with these parts, and the concave side of the straight member is
firmly against the output shaft, tighten the thumbscrew.
6. Remove the gage, and using a depth micrometer, measure the distance from the end
of the straight member to the lip of the curved member. Use this dimension to select the proper
rear spacer, as listed in the following chart. Install the spacer.
MICROMETER DIMENSION
From To Use Spacer* Marked
.9833 (24.97582 mm) .9873 (25.07742 mm) 206320 1 Groove
.9968 (25.31872 mm) 1.0008 (25.42032 mm) 206321 2 Grooves
1.0103 (25.66162 mm) 1.0143 (25.76322 mm) 206322 3 Grooves
1.0238 (26.00452 mm) 1.0278 (26.10612 mm) 206323 4 Grooves
1.0373 (26.34742 mm) 1.0413 (26.44902 mm) 206324 5 Grooves
1.0508 (26.69032 mm) 1.0548 (26.79192 mm) 206325 6 Grooves
*Order from Parts Catalog 114102
7. Using bearing installer (39) (Figure 11-8), install the rear bearing as shown in Figure
11-89. Install the beveled snapring, flat side down.
317
Figure 11-88 Measuring for Selection of
Rear Bearing Spacer
VEHICLE
ITEM 3'(FIG. 118)

Figure 11-89 Installing Rear Output Shaft Bearing
8. Check the end play of the transmission output shaft as follows.
9. Place the first-and-reverse clutch spring compressor base (23A) (Figure 11-7), flange
side down on the output shaft (Figure 11-90). Secure the base to the output shaft with a 1/2-20
bolt. Tighten the bolt to 15 ft. Ibs. (20 Nm) torque.
10. Lift the output shaft with a screwdriver (Figure 11-90) and measure the distance
from the top of the flange to the rear of the transmission. Release the output shaft and repeat the
measurement. A minimum of 0.015 inch (0.381 mm) and a maximum of 0.042 inch (1.067 mm)
is acceptable.
NOTE: A dial indicator, shown in Figure 11-90, or a depth micrometer may be used to
establish minimum and maximum measurement.
11. Remove the spring compressor i:>ase, turn it over, and reinstall it. Tighten the center
bolt to 15 ft. Ibs. (20 Nm) torque. Align the spring compressor base with the two parking brake
mounting holes in the transmission case (Figure 11-91). Install two 1/2-13 bolts through the base
and into the case. Tighten these bolts evenly to 5 to 8 ft. Ibs. (7 to 11 Nm) torque. This positions
the gear pack and all components for an accurate selective thrust washer measurement in Para-
graph 11-33.
B_ Fourth Clutch.
1. Reposition the transmission, front upward. Carefully remove the sun gear shaft re-
tainer (Figure 11-86) without moving the sun gear shaft.
318
VEHICLE
ITEM 23A (FIG. 11-7)
DEPTH GAUGE
PARKING BRAKE : : : : ~ ~ J ; : ~ ~ ~ - 9
MOUNTING HOLES"'::: I
J
OUTPUT SHAFT
Figure 1190 Checking End Play of Output Shaft
Figure 1191 Positioning Components for Front
Thrust Washer Measurements
CAUTION: DO NOT REMOVE the sun gear shaft assembly before checking the required
clearance shown on Figure 1192. If the clearance is less than 1/8 inch, proceed with Item 2,
otherwise omit Item 2 and proceed with Item 3.
2. If the sun gear shaft assembly is properly seated, there should be approximately 1/8
inch {3.175 mm} clearance from the end of the sun gear shaft assembly to the shoulder on the main
shaft shown in Figure 1192. If the shaft is not properly seated, a slow rotation with a slight up and
down motion may seat it. If not, remove the shaft {noting its relative position to the main shaft}
and center the front sun gear thrust washer so the sun gear shaft will pass.
NOTE: The sun gear shaft assembly must be properly seated to establish an accurate clear
ance between the forward clutch housing and the front support and bearing assembly. Refer
ence Paragraph 1133.
3. Check to make sure that the two hooktype sealrings are in place on the hub of the
center support.
4. Install the fourthclutch assembly {as rebuilt in Paragraph 1124} onto the splines of
the sun gear shaft.
1132. INSTALLATION OF THIRD AND FORWARD CLUTCHES
A. Third Clutch.
NOTE: Establishing clutch clearances by a method other than explained below, is not neces-
sary. The clearance for this clutch is so tolerant it will accept all internal and external plates
within their required wear limit. (Reference Chapter 17).
319
SUN GEAR SHAFT
FRONT
SUN GEAR
~ ~
;"'7
r
~
k2,
~
--=
VEHICLE
~
MAIN SHAFT
r=
;=
APPROX.
1/8 IN.
3.175mm
~ CENTE R SUPPORT
~ G E A R
ASHER
r9t
Fr.ONT SUN
THRUST W
zr
~
I-V:
ii
~
Figure 11-92 Sun Gear Shaft Clearance
1. Beginning with an external-tanged clutch plate, alternately install three external-
tanged, and three internal-splined plates. The single tangs on the plates must engage the single slot
in the transmission case (Figure 11-93).
2. Install the third-clutch back plate, aligning its tangs with those of the three clutch
plates (Figure 11-94). This plate is identified by the mark 2. DO NOT USE A PLATE MARKED 1.
3. Install the snapring that retains the back plate. The snapring is identified by a green
mark and is 0.155 to 0.157 inch (3.957 to 3.9878 mm) thick. Position the snapring gap toward the
top of the transmission case. (Figure 11-94).
4. Using the third-clutch clearance gage (19) (Figure 11-7). check the clutch running
clearance. The thin end of the gage should pass between the snapring and the back plate; the thick
end should not. The prescribed clearance is 0.029 to 0.119 inch (0.7366 to 3.0226 mm).
5. If clearance is excessive (larger end of gage enters plates). new clutch plates should
replace worn plates. Refer to wear I imits in Chapter 17 for clutch plate dimensions.
B. Forward Clutch and Turbine Shaft Assembly.
1. Install the thrust washer onto the hub of the forward clutch assembly, retaining it
with oil-soluble grease (Figure 11-95).
2. Install the forward clutch and turbine shaft assembly. The hub splines engage the
transmission main shaft. The splines on the fourth-clutch drive hub engage the internal-splined
plates of the fourth clutch.
3. Rotate the forward clutch assembly one or two revolutions, while pushing it down-
ward.
320
INTERNAlSPLINED
PLATE (3)
VEHICLE

CENTER
ASSV
Figure 11-93 Installing Third-Clutch Plates
SNAP RING
Figure 11-94 Checking Third-Clutch Running Clearance
321
FORWARD
CLUTCH ASSY
FOURTH CLUTCH
DRIVE HUB
VEHICLE
PTO DRIVE
GEAR
Figure 11-95 Installing Thrust Wa'sher at Rear of Forward Clutch Hub
11-33. INSTALLATION OF OIL PUMP ASSEMBLY
A. Selection of Front Thrust Washer.
1. Lay the thrust washer selection gage bar (13) Figure 11-6) into the transmission
case, as shown in Figure 11-96. Place the depth micrometer so that its stem passes through the
center hole in the gage bar.
2. Align the gage bar so that the micrometer stem is above the thrust washer surface
of the forward clutch housing (Figure 11-96).
3. Measure the distance from the top of the gage bar to the thrust surface of the clutch
housing (F igure 11-96). Subtract 1.00 inch (25.4 mm) or the thickness of the gage bar and record
the difference.
DIMENSION
Thrust Washer
From To Part Number Marked
.056 (1.4224 mm) .060 (1.524 mm) 206596 0
.072 (1.8288 mm) .076 (1.9304 mm) 206597 1
.089 (2.2606 mm) .093 (2.3622 mm) 206598 2
.105 (2.667 mm) .109 (2.7686 mm) 206599 3
.121 (3.0734 mm) .125 (3.175 mm) 206600 4
.138 (3.5052 mm) .141 (3.5814 mm) 206601 5
322
VEHICLE
4. Use the dimension recorded in 3 above, to select the proper thrust washer as listed in
the preceding table.
B. Oil Pump Assembly.
1. Using oilsoluble grease, install the thrust washer selected in A, 4 above, onto the oil
pump assembly (Figure 11-97). The tab on the washer must engage the cast recess in the front
support.
2. Install the two hook-type seal rings onto the hub of the front support (Figure 11-97).
3. Lubricate the sealrings and thrust washer with oil-soluble grease .
1/213 SOL T 121
ITEM 23A (Fig. 117)
. ~
FORV,ARD ~
CLUTCH A S S Y ~
j
J
Figure 11-96 Measuring for Selection of Front Thrust Washer
323
VEHICLE
Figure 1197 Installing HookType Sealrings onto Oil Pump Assembly
4. Install the front support gasket, aligning the bolt holes in the gasket with those in the
transmission case (Figure 1198).
5. Install two 5/1618 headless guide bolts into two opposite holes in the gasket and
transmission case.
6. Grasp the oil pump assembly by the stator shaft and lower it into the transmission
housing (F igure 1199). Be sure the support bottoms.
7. Install nine 5/1618 x 1314 inch, selflocking bolts, with nine new rubber coated
washers, into the front support and transmission case. Tighten the bolts to 13 to 16 ft. Ibs. (18 to
22 Nm) torque.
8. To check the turbine shaft end play, mount a vernier dial caliper on the turbine shaft.
Raise the shaft, extending the depth gage to bear upon the stator shaft and record the dial reading
(Figure 11100).
9. Release the shaft and record the dial reading. If the dial reading does not fall within
the desired end play range of 0.0053 (min.) to 0.0337 (max.) (0.1346 to 0.8559 mm), the thick
ness of the selective thrust washer referenced to in Paragraph 1133 must be recalculated.
10. Remove the compressor base (installed in Paragraph 1131A (9 and 11, above), from
the transmission case and output shaft.
324
I
- I
VEHICLE

,----
7 1 SHAFT
?' FORWARD f' ""
/ CLUTCH __
Figure 11-98 Installing Front Support Gasket
GUIDE PINS
G
Figure 11-99 Installing Oil Pump Assembly
325
VEHICLE
STATOR SHAFT
Figure 11-100 Measuring Turbine Shaft End Play
11-34_ INSTALLATION OF OUTPUT SHAFT OIL SEAL
A_ Coat the oil seal lip with high-temperature grease (MI L-G-3545A).
B. Coat the outside circumference of the oil seal with non-hardening sealer. Start the oil
seal, lip first, squarely into the rear bore of the transmission case.
C_ Using the output shaft seal installer (1) (Figure 11-6), drive the oil seal into the case until
the installer seats against the case (F igure 11-101).
NOTE: The rear of the oil seal should be 0.51 to 0.55 inch (12_95 to 13.97 mm) forward of
the brake mounting surface of the transmission case.
D_ Install the output flange components. Tighten the retaining bolt to 83 to 100 ft. Ibs.
(115 to 138 Nm) torque. Stake the tab washer into the flange washer. Bend the tab washer against
a flat of the bolt head.
11-35_ INSTALLATION OF VALVE BODY, OIL FILTER AND OIL PAN
NOTE: The control valve body assembly will perform properly only if it is functionally
compatible with the main housing channeling. Refer to Parts Catalog 114102 for part num-
bers and serial number application.
A. Control Valve Body.
1_ Tighten the center support anchor bolt to 39 to 46 ft. Ibs. (54 to 64 Nm) torque
(Figure 11-102).
326
VEHICLE
ITEM 1 (FIG. 116)
Figure 11101 Installing Output Shaft Oil Seal Figure 11102 Installing Governor Check
Valve Ball
2. Install the governor check valve ball into the channel in the transmission case (Figure
11102).
NOTE: It is necessary to install the control valve assembly from a prone position (under the
vehicle). grease the governor check valve ball with an oilsoluble grease and locate it on the
separator plate of the assembled control valve.
3. Position the control valve body on the transmission case, in its approximate installed
position (Figure 11103).
CAUTION: Do not allow the selector valve to fall out during handling of the assembly.
4. Install governor oil screen (5) (Figure 1170) closed end first, into the valve body,
at the governor feed tube opening (Figure 11103).
NOTE: Inspect both ends of the governor feed tube. Some models contained a plastic oil
screen located where the governor feed tube unites with the housing. This screen must be
replaced with a wire screen and relocated in the governor feed tube bore (Figure 11103).
5. Install the governor pressure tube.
NOTE: If the governor feed and pressure tubes are installed, rear end first, they will not
align properly when the control valve is installed. They may appear to align until installation
of the valve body is attempted.
6. Install firstreverse clutch tube.
7. Lift the valve body, and swing the three tubes into proper position to enter their
holes in the transmission case.
327
VEHICLE
BOLT, 21/4 LONG (181
FIRSTREVERSE
CLUTCH TUBE
VALVE BODY
e GOVERNOR PRESSURE -
TUBE y" ;=::
Figure 11-103 Installing Oil Intake Pipe
8_ Lower the valve body onto the case, while engaging the rear ends of the tubes in the
case, and the selector valve on the selector lever (F igure 11-103).
9_ Install the detent spring, with its roller over the selector lever, and its rear tab in the
hole immediately behind the bolt hole (Figure 11-103)_
10_ Install a 1/4-20 x 1-3/4 inch bolt into the detent spring and valve body. Install a
1/4-20 x 2-3/4 inch bolt (later models have 2-1/4 inch bolt) near the center of the valve body.
Install seventeen 1/4-20 x 2-1/4 inch bolts into the remaining bo.lt holes.
11. Shake the valve body slightly, and the ends of the bolts will start into the tapped
holes in the transmission case.
12. Tighten the nineteen bolts evenly to 8 to 12 ft. Ibs. (11 to 17 Nm) torque.
NOTE: The detent spring must be held in alignment over the selector lever while the 1-3/4
inch bolt is tightened.
B. Oil Filter.
1. Install seal ring onto the straighter end of the intake pipe (Figure 11-103). Lubricate
the sealring with oil-soluble grease.
2_ Install the intake pipe and sealring (Figure 11-103).
328
VEHICLE
3. Install the oil filter onto the intake pipe, making sure the grommet fits the intake pipe
snugly (Figure 11104).
4. Retain the oil filter with one 5/1618 x 5/8 inch, washerhead screw. Tighten the
screw to 10 to 15 ft. Ibs. (14 to 20 Nm) torque.
NOTE: Twist the intake pipe until it enters the grommet squarely, if it appears to be mis
aligned.
C. Oil Pan.
1. Position the oil pan gasket on the transmission case, aligning its bolt holes with those
in the case (Figure 11105).
2. Install the oil pan, deeper end forward (Figure 11105).
SCREW, 5/8 LONG
Oil FILTER
\
Figure 11104 Installing Oil Filter
329
o
=::::::::::::::
VEHICLE
Figure 11-105 Installing Transmission Oil Pan
NOTE: If installation of the oil pan and gasket from a prone position is necessary, place the
gasket on the oil pan aligning all bolts holes (Do not use grease to retain the gasket to the
oil pan.) Insert two bolts (opposite each other) through the oil pan and gasket. Align the oil
pan holes to those in the transmission case. Insert the bolts into the case and tighten two or
three threads. Install the remaining bolts taking care not to damage the gasket.
3. Retain the oil pan with twenty-one 5/16-18 x 5/8 inch, washer-head screws (Figure
11-106). Tighten the screws evenly to 10 to 13 ft.lbs. (13.8 to 17.9 Nm) torque.
11-36. INSTALLATION OF GOVERNOR, MECHANICAL ACTUATOR AND TORQUE CON-
VERTER.
A. Governor.
1. Install the governor cover gasket onto the transmission case, using oil-soluble grease
to retain it (Figure 11-106).
2. Install the governor assembly by pushing it inward with a slight rotation counter-
clockwise (F igure 11-106).
3. Install the governor cover, and retain it with four 5/16-18 x 9/16 inch bolts. Tighten
the bolts to 15 to 20 ft. Ibs. (20 to 27 Nm) torque.
330
VEHICLE
SCREW (21)
Figure 11-106 Installing Governor Assembly
B. Mechanical Actuator.
1. Install the valve actuating rod (29), larger diameter end first (Figure 11-68).
2. Install the sealring (30) onto the mechanical actuator (24). Lubricate the sealring
with oil-soluble grease. Install the mechanical actuator into transmission case ensuring that the
seal ring seats properly.
3. Install the retainer (27) bent tabs toward transmission, and secure it with a 5/16-
18 x 3/4 inch bolt. Tighten the bolt to 15 to 20 ft.lbs. (20 to 27 Nm) torque.
C. Torque Converter Assembly.
1. Install the torque converter assembly, engaging the turbine shaft with the converter
turbine, the stator shaft with the stator, and the hub with the oil pump drive gear (Figure 11-107).
2. Secure the torque converter assembly against faHing during handling of the transmis-
sion by attaching a strap between one of the drive lugs and the transmission case.
3. Remove the transmission drive, or plug, as required.
4. Remove the transmission from the holding fixture.
5. Install gasket (5) (Figure 11-68). cover (6), and six 3/8-16 x 1 inch bolts (7). Tighten
the bolts to 15 to 20 ft. Ibs. (20 to 28 Nm) torque.
VEHICLE
Figure 11107 Installing Torque Converter Assembly
332
VEHICLE
118)
Figure 11-108 Removing Output Shaft Rear Bearing
11-37. INSTALLATION OF EXTERNAL SELECTOR LEVER
Before installing the external selector lever, refer to Paragraph 11-47 for procedure_
11-38. REMOVAL OF BEARING (Transmission in Vehicle)
Disconnect the vehicle drive shaft and drive flange from the transmission. Remove the snap-
ring that retains the output shaft bearing. (Refer to Figure 11-28)_ Place the feet of tool (38)
(Figure 11-8) between the balls of the rear bearing, retaining them by the inner and outer race of
the bearing. Insert legs (38) (Figure 11-8) through the slots in puller body. Install two nuts, one on
each leg_ Rotate the center screw in the puller body until the base of the screw makes contact with
the output shaft. Tighten the two nuts maintaining a perpendicular relationship between the two
legs and the puller body and a parallel relationship between the puller body and the rear of the
transmission case. Tighten the center screw and carefully remove the bearing (F igure 11-108)_
Section VI - PREVENTIVE MAINTENANCE
This section outlines the routine and periodical procedures required to maintain the trans-
mission in good operating condition. Included are instructions for inspection, for the care of the oil
system and breather, for checking temperatures and pressures, for care of external cooler and
piping, and explanations of operating characteristics and troubleshooting. Tabulated troubleshoot-
ing information is included at the back of this section.
11-39. INSPECTION AND CARE
The transmission should be kept clean to make inspection easy_ Check for loose bolts, loose
or leaking oil lines, condition of control linkage and hose to vacuum modulator, and for oil leakage.
Check the transmission oil level at the intervals specified in Figure 4-1, and refer to Paragraph 11-40
below_
333
VEHICLE
11-40. CHECKING OIL LEVEL
A. Importance of Proper Level.
Maintaining the proper oil level is very important. The transmission oil is used to transmit
power and to cool and lubricate transmission parts. If the oil level is too low, the result can be poor
performance (converter and clutches will not receive adequate oil supply). If the oil level is too high
(above Full mark on dipstick, with engine idling, normal operating temperature - 160
0
to 220
0
F,
sump) (70
0
to 104
0
C), overheating results from the oil being churned and aerated. Drain any ex-
cess oil to restore the proper level.
B. Foaming and Aerating.
1. Transmission performance will be affected when the oil foams or aerates. The pri-
mary causes of aeration are: low oil in the sump; too much oil in the sump; or a defective or missing
seal ring on the intake pipe.
2. A low oil level (denoted on the dipstick) will not completely envelope the oil filter.
Therefore, oil and air is drawn by the input pump and is directed to the clutches and converter,
causing converter cavitational noises and irregular shifting. The aeration also changes the viscosity
and color to a thin, milky liquid.
3. At normal oil level (Full mark on the dipstick) the oil is slightly below the planetary
gear units. If additional oil is added bringing the oil level above the Full mark, the planetary units
will run in the oil, foaming and aerating the oil. Overheating and irregular shift patterns can occur
when the oil is aerated.
4. A defective seal ring (7), Figure 11-70 on the filter intake pipe will also cause the
input pump to draw air and oil from the sump, causing the same problems as in 2 above.
C. Protect Fill Pipe.
When adding oil or checking oil level, dirt or foreign material must not be allowed to
enter the fill pipe. Before removing the dipstick, clean around the end of fill pipe.
D. Oil Check Procedure.
The transmission oil level may be checked by the following procedure:
1. Operate the transmission until normal operating sump temperature (160
0
to 220
0
F)
(71.0 to 103.0
0
C) is reached.
CAUTION: The oil level rises 0.5 to 0.6 inch (12.7 to 15.24 mm) as sump temperature
increases from 75
0
- 80
0
F (24.0
0
- 26.0
0
C). Do not fill above the Add mark before the
transmission has reached operating temperature. One quart of oil raises the oil level approxi-
mately 0.5 inch (12.7 mm).
2. Shift the transmission through all drive ranges to fill clutch cavities and oil passages.
3. Shift the transmission to neutral and operate the engine at idle speed.
4. Apply the parking brake, with vehicle parked level.
::!::!4
VEHICLE
5. Check oil level on the dipstick. It should register at the Full mark, under the condi
tions stated above.
E. Safe Level.
The safe operating level is from the Add mark to the Full mark on the dipstick. The Add
level is 0.50 inch (12.7 mm) below the Full level. The difference between the two marks corres-
ponds to one quart of oil (1 liter) of oil.
11-41. KEEPOILCLEAN
Oil must be handled in clean containers, fillers, etc. to prevent foreign material entering the
transmission.
CAUTION: Containers or fillers that have been used for ethylene glycol antifreeze must not
be used for oil that is to be used in the transmission. Clean around oil filler tube before
removing transmission. Grease used internally must be non-fibrous, low temperature and oil
soluble. Check current issue of Parts Catalog 114102 for proper replacement oil filter. Keep
filters in cartons until ready for installation.
11-42. OIL SPECIFICATIONS
11-43. OIL, GOVERNOR OIL SCREEN AND OIL FILTER CHANGE INTERVALS
The oil and oil filter should be changed every 25,000 miles or 12 months, whichever occurs
first. Also replace or clean the governor oil screen (5) (Figure 11-70).
11-44. 01 L, GOVERNOR OIL SCREEN AND OIL FILTER CHANGE PROCEDURES
CAUTION: Shift the transmission to neutral before changing oil.
NOTE: It is imperative that the governor oil filter screen be replaced or cleaned at each oil
change.
A. The transmission should be at operating temperature (160
0
F minimum) (71
0
C) when
oil is drained. This will insure quicker and better drainage.
B. Remove the drain plug (12) and washer (11) from the oil pan and allow the oil to drain.
NOTE: All of the oil in the transmission and external system cannot drain - some will re-
main in the system. Approximately 11 quarts (10.0 liters) are required to refill the trans-
mission.
C. After draining is completed, install drain plug (12) and washer (11). Refer to Paragraph
11-45 following.
D. If the transmission internal oil filter is to be changed at this time, disconnect the oil fill
tube and remove 21 washer-head screws (14) (Figure 11-70) that retain oil pan (13) to the trans-
mission case. Discard pan gasket (10) and clean pan (13) with mineral spirits or thinner.
E. Remove one screw (14) that retains the filter, and pull out filter (9) and oil intake pipe
(16). Remove seal ring (7) and discard.
335
VEHICLE
F. Clean or replace the governor oil screen. The screen is located in the governor feed tube
bore. Replacement of the screen can only be accomplished by removing the governor feed tube.
This tube and the two remaining tubes are held in place by the control valve body. Refer to Para
graph 11 12 for valve body removal procedures and Paragraph 11
G. Install a new seal ring (7) onto the top end of the oil intake pipe, and lubricate the
ring with the same type oil as used to refill the transmission.
H. Insert the intake pipe and seal ring into the hole in the bottom of the transmission.
stall a new oil filter assembly (includes grommet) onto the intake pipe.
I. Install the 18 x 5/8 washerhead screw (14), and tighten it to 10 to 13 ft. Ibs.
(13.8 to 17.9 Nm) torque.
J. Place the oil pan gasket onto the oil pan. Do not use any substance as a gasket retainer.
CAUTION: Do not use gaskettype sealing compounds inside the transmission or where they
might get washed into the transmission. Also, only greases may be
lIsed (except oil pan gasket) for temporarily retaining parts during assembly.
vegetable base cooking compounds or fibrous greases must not be used inside the
mission.
K. Install the oil pan, deeper end forward. Guide the pan and gasket carefully into place.
Guard against dirt or foreign material entering the pan. Retain the pan to the housing with four
washerhead screws. Install each screw, by hand, one at a time, into each corner of the
pan.
L. Install the remaining 17 screws by hand, carefully threading each through
the gasket and into the transmission. Bottom off of the screws before tightening any of them.
M. Tighten all 21 screws evenly, while checking gasket fit. to 10 to 13 ft.lbs. (13.8 to 17.9
Nm) torque.
N. Install the filler tube at the side of the pan.
O. Remove the dipstick and pour approximately 10 quarts (9.464 liters) of transmission
fluid into the transmission through the filler tube. Then refer to Paragraph above, to finish
filling the transmission.
OIL CONTAMINATION
A. Water Leakage.
1. Before changing the oil, increase the temperature of the oil to normal running level.
Inspect the breather for oil spewing. Drain the oil from the oil pan. If the oil is gray or cloudy,
the presence of water is indicated. Excessive quantities of water in the oil will cause rust and pitted
transmission parts, reducing the life of the transmission.
2. Remove the oil pan and clean thoroughly. Inspect the engine radiator for evidence
of oil (this may also indicate engine oil leakage). During disassembly (Section III) and rebuild
(Section IV). inspect all gaskets and seals for blistering and wrinkling, indicating presence of water.
336
VEHICLE
B. Metal Particles.
Metal particles in the oil (except for the minute particles normally trapped in the oil
filter) indicate damage has occurred in the transmission. When these particles are found in the
sump, the transmission must be disassembled and closely inspected to find the source. Metal con-
tamination will require complete disassembly of the transmission and cleaning of all internal and
external circuits, cooler filter, and all other areas where the particles could lodge.
C. Coolant Leakage.
If engine coolant containing ethylene glycol leaks into the transmission oil system, im-
mediate action must be taken to prevent malfunction and possible serious damage. The transmis-
sion must be completely disassembled, inspected and cleaned. All traces of the coolant, and varnish
deposits resulting from coolant contaminations, must be removed. Replace all gaskets and seals.
D. Auxiliary Filter.
1. After a transmission failure that introduces debris into the transmission oil system,
complete removal of debris cannot be assured. Repeated cleaning and flushing will probably not
remove all debris from the oil cooler or other hidden areas of the cooler circuit.
2. To prevent a repeat failure, caused by eventual movement of trapped debris, installa-
tion of an auxiliary filter between the oil cooler and transmission is recommended. This recommen-
dation applies whether the transmission is overhauled, or replaced by a new or rebuilt unit.
3. Approved filters with 40 micron particle filtering capacities such as t h ~ AC Filter PF
132, AC PM 16-1 for the Fram HP-l mounted to the Fram HPK-2 filter base, can be used satis-
factorily. Maximum pressure drop in the filter must not exceed 3 psi (0.216 kg. sq. cm.) at 4.5
9pm (17 hr/min), at 180
0
F (81
0
C).
4. Install the filter into the line from the cooler to the transmission. Use No.8 hose
(13/32 I.D. min.) with a length great enough to allow power pack movement. Proper hose size will
permit a minimum flow rate of 4.5 gpm (14.06 kg/cm
2
), and a minimum inside diameter, at fit-
tings, of .391 inch (9.931 mm). All hoses must meet SAE 100 R5 specifications, with an operating
range between -40
0
F to +300
0
F (50 C to 147
0
C).
5. The total cooler circuit (to and from cooler) pressure drop should not exceed 25 psi
(1.7575 kg/cm
2
at 17 Ipm). Verify relief valve operating pressure. It should be 6 to 15 psi (.4218
to 1.0545 kgs/cm
2
).
6. Filter elements should be replaced after the first 5,000 miles and at 'normal oil change
intervals thereafter.
11-46. BREATHER
The transmission breather is pressed into the top of the transmission. This serves to prevent
pressure within the transmission and relieve surges. The breather must be kept clean and the passage
open.
11-47. LINKAGE
A. Importance of Proper Adjustment.
337
VEHICLE
Proper adjustment of the manual selector valve linkage is important as the shift tower
detents must correspond exactly to those in the transmission. Periodic inspections should be made
for bent or worn parts, loose threaded connections, loose bolts and an accumulation of grease and
dirt. All moving joints must be kept clean and well lubricated.
B. Linkage Adjustment.
1. The manual selector lever should move easily and give a crisp feel in each position.
The linkage should be adjusted so that the stops in the shift tower match the detents in the trans
mission.
2. When the linkage is correctly adjusted, the pin which engages the shift lever linkage
at the transmission can be moved freely in each range.
CAUTION: Proper installation of the external selector lever is imperative to the function
of the transmission. Excessive torque applied to the external selector lever retaining nut
may damage the internal selector lever.
3. Rotate the selector shaft to position 123-4. Place the external selector lever onto
the tapered area of the selector shaft. Be sure the flats on the shaft are adjacent to the flats on the
lever. Install the lever retaining nut. Hold the lever against rotation and tighten the nut to 15 to
20 ft. Ibs. (20.7 to 27.6 Nm) torque. Do not exceed maximum torque requirement of 20 ft. Ibs.
(27.6 Nm).
C. Mechanical Actuator Adjustment.
1. It is imperative that the mechanical linkage be properly adjusted for efficient per
formance.
2. Place the fuel control lever on the engine at full throttle position.
3. Place the mechanical actuator cable at full throttle position against the mechanical
stop.
4. Adjust the clevis at the fuel control lever so the pin fits freely through the hole in
the clevis, making sure the lever is secure.
5. Total cable control travel should not be less than 1.187 inches (30.15 mm) or more
than 1.56 inches (39.6 mm).
6. Refer to oil checking chart, Table 115.
1148. SHIFT SPEED ADJUSTMENTS
NOTE: Transmission shift points cannot be satisfactorily adjusted if the transmission has the
wrong governor installed. Check the twodigit code on the head of the governor with the code
shown in the current Parts Catalog 114102 for the governor listed for your transmission
assembly part number. If the letter "M" follows the twodigit code, the governor is a service
replacement assembly. If the "M" is not included, the governor was installed at original
factory build.
338
VEHICLE
A. Calibrated on Test Stand or In Vehicle.
1. Proper timing of shift speed points is necessary for maximum transmission perform-
ance. Shifts may be adjusted on the test stand when the transmission is rebuilt or overhauled, or
during road testing of the vehicle.
2. Test stand equipment differs among rebuild or overhaul facilities. Some shops may
have equipment to drive and load the transmission with instrumentation for observing performance.
Other shops may have test stands on which the valve body and governor can be calibrated before
installation into the transmission. If test stand equipment is not available, satisfactory calibrations
of shift points may be made after road testing of the vehicle.
B. Location of Adjusting Components.
1. Shift speeds are changed by changing the positions of adjusting rings that determine
the retaining force of certain valve springs in the valve body.
2. A special tool, Item 7, -- see special tools table in Section 11-- is used to depress and
rotate the adjusting rings to the proper positions. Clockwise rotation increases spring force and will
raise the shift point. Counterclockwise rotation will reduce spring force, and lower the shift point.
NOTE: Each notch of adjustment will alter the shift point approximately 50 rpm.
C. Checks Before Adjusting Shift Points.
1. When calibration is to be made during a road test, or on a t ~ s t stand that simulates
road operation, certain preparations must be made.
2. Warm up the transmission or test stand setup to normal operating temperature
(160
0
to 220
0
F [70
0
to 103
0
Cj for road test).
3. Check the engine governor setting, and adjust if required, to conform to the trans-
mission's engine speed requirements.
4. Check the engine for satisfactory performance before checking shift points.
5. Check the linkage that controls the mechanical modulator valve actuator in the trans-
mission for proper level, routing and operation.
6. Check the shift selector linkage for proper range selections.
7. Provide accurate instrumentation required for observing speeds, temperatures, pres-
sures, vacuum, etc.
D. Calibration by Road Test Method.
1. Note the governed speed of the engine (C, 3, above). This is the base speed from
which checks and adjustments are made.
339
VEHICLE
2. Automatic upshifts should occur as follows:
1-2 - within 400 rpm below engine governed speed.'
2-3 - within 300 rpm below engine governed speed.'
3-4 - within 200 rpm below engine governed speed!
'Vehicle loaded.
NOTE: Before road test, determine the vehicle tachometer error with a test tachometer.
Make corrections for error, as required in subsequent tests.
3. Drive the vehicle and check the engine speed (at full throttle). at which each upshift
occurs. Each upshift should occur at the speed specified above.
4. If an upshift speed does not reach that specified, the shift point may be raised by
adjusting (increasing) the spring force on the 1-2-3-4 or 3-4 shift signal valve. If the upshift speed
exceeds the specified rpm, or if upshift does not occur at all, the spring force must be reduced.
Adjust the force on only the springs for valves that do not upshift at the proper speed.
NOTE: If more than one shift signal valve spring requires adjustment, it may be necessary
to adjust the modulator valve one position in the same direction as for the signal valves. If
all upshift points are either too high or too low, by approximately the same amount, only
the modulator valve should be adjusted.
5. Refer to Sections III, IV and V for procedures covering removal and replacement of
affected components.
E. Alternate Method Using Speedometer Readings.
1. When a tachometer is not available for checking shift points, the vehicle speedometer
can be used. Proceed as outlined in 2 through 4 below.
2. Check the top speed of the vehicle in each selector hold position (first, second, third
gears). Record the top speed for each.
3. For checking the shift points, place the selector at DRIVE (D) so that all automatic
shifts can occur. Drive the vehicle at full throttle from a standing start until the 3-4 upshift occurs,
recording the mph at which each upshift occurs.
4. Compare the upshift speeds recorded in 2 above. The 2-3 upshift should occur at ap-
proximately two mph below the top speed of second gear. The 3-4 upshift should occur at approxi-
mately two mph below the top speed for third gear. The 1-2 upshift is not to be adjusted relative
to hold speed. The 2-1 downshift at closed throttle should occur at 3 to 5 mph (5 to 8 km ph).
F. Calibration by Test Stand Method.
1. Table 113 provides detailed information required for adjusting shift points on trans
missions matched to engines having a governed speed of 3300 rpm.
2. The actual adjustment procedures are as outlined in D above. However, the base for
checks and adjustments is output shaft speed instead of engine governed speed. Individual output
shaft speed ranges are given for each shift.
340
Engine Governed Speed
Range
Drive
DR3
DR2
VEHICLE
Table 11-3. SH I FT POINT CHECK
OUTPUT RPM AT START OF SHIFT
Throttle Shift
Full
Closed
Full
1-2
2-3
3-4
4-3*
3-2'
2-1
4-3
3-2
3300 RPM
RPM
770-830
1220-1355
2020-2160
530-750
590-810
20-450
2290-2770
1380-1740
DR1 I
I ______________ ________________ ________________ _d
2-1 930-1100
*4-2 Downshift is acceptable
11-49. EXTERNAL LINES AND OIL COOLER
A. External Lines.
1. Inspect for loose or'leaking connections, worn or damaged hoses, tubing and loose
fastenings.
2. Examine the radiator coolant for traces of transmission oil. This condition indicates
a faulty heat exchanger.
B. Oil Cooler_
Transmission operation at abnormally high temperatures can cause clogging of the oil
cooler as well as transmission failure. It is suggested the oil cooler system be thoroughly cleaned
after each major or minor rebuild. Failure to do so may cause poor performance, overheating and
transmission damage.
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VEHICLE
11-50. TRANSMISSION STALL TEST
A. Purpose.
A stall test should be conducted when the power train (engine and transmission) is not
performing satisfactorily. The purpose of the test is to determine if the transmission is the mal-
functioning component.
CAUTION: When conducting a converter stall test, the vehicle must be positively prevented
from moving. Both the parking and service brakes must be applied and, if necessary, the ve-
hicle should be blocked to prevent movement forward or in reverse. Do not maintain the
stalled condition longer than 30 seconds due to rapid heating of the transmission oil. With
the transmission in neutral, run the engine at 1200 to 1500 rpm for two minutes to cool the
oil between the tests. Do not allow the converter-out temperature to exceed 300
0
F (147
0
C).
Keep close check to prevent the engine cooling system from overheating.
B. Procedure.
1. A torque converter stall test is performed by locking the transmission output, putting
the transmission in gear, accelerating the engine to full throttle, and noting the maximum rpm the
engine will attain. The speed attained is then compared to the speed specified by the vehicle manu-
facturer as normal for those conditions. An engine speed above or below the specified range may
indicate a malfunction in the engine or transmission.
NOTE: Engine power will decrease with an increase in elevation (altitude) becoming more
pronounced at greater elevation. This will result in a lower engine speed under converter-
stall conditions.
2. After making allowances for elevation, a low engine speed may indicate the engine
is not delivering full power. Refer to engine service Chapter 8, for engine repair information.
3. If low engine speed persists after engine is tuned, refer to the troubleshooting pro-
cedures and chart in Paragraph 11-54.
4. If high engine speed is noted, refer to the troubleshooting chart in Paragraph 11-54.
11-51. PRESERVATION AND STORAGE
A. Preservative Selection.
When transmissions are to be stored or remain inactive for extended periods of time,
specific preservative methods are recommended to prevent rust and corrosion damage. The length
of storage will usually determine the preservative method to be used. Various methods are described
below.
B. Storage, New Units.
New units contain preservative oil when shipped from Cadillac Gage Company, and can
be safely stored for 6 weeks without further treatment.
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VEHICLE
C. Storage, Month to Six Weeks.
1. The following procedures will prepare a transmission for a month to six weeks stor-
age, depending on the environment.
2. Drain the oil as described in Paragraph 2, 11 -44 B. Remove the transmission oil filter
element(sl.
3. Install the drain plugs and new filter element.
4. Fill the unit to operating level with any commercial preservative which meets U.S.
Military Specifications MI L-L-21260, Grade 1, to latest specifications.
5. Operate the unit for at least 5 minutes at a minimum of 1000 rpm. Shift the trans-
mission slowly through all selector positions to thoroughly distribute the oil, then stall the con-
verter to raise the oil temperature to 225
0
F (106
0
C).
CAUTION: Do not allow temperature to exceed 225
0
F (106
0
C). If the unit does not have
a temperature gauge, do not stall for more than 30 seconds.
6. As soon as the unit is cool enough to touch, seal all openings and breather with
moisture-proof tape.
7. Coat all exposed, unpainted surfaces with a good grade of preservative grease, such
as Petrolatum (MI L-C-11796), Class 2.
8. Repeat the above procedures (5) through (7) at monthly' intervals for indefinite
storage.
D. Storage, 1 Year - Without Oil.
1. Drain oil as described in Paragraph 11 -44 B.
2. Seal all openings and breather with moisture-proof tape.
3. Coat all exposed, unpainted surfaces with a good grade of preservative grease.
4. Atomize or spray 2 ounces (60 ml) of Motorstor* or equivalent, into the transmis-
sion through the oil pan drain plug.
5. If additional storage time is required, 3 and 4 above should be repeated at yearly
intervals.
E. Storage, 1 Year - With Oil.
1. Drain the oil as described in Paragraph 11 -44 B. Remove the transmission oil filter
element.
2. Install the drain plug and new filter element.
3. Fill the transmission to operating level with a mixture of Dexron transmission fluid,
and a 3 percent (30 parts Dexron oil to 1 part Motorstor) preservative or equivalent.
343
VEHICLE
4. Operate the unit for approximately 4 minutes at a minimum of 1000 rpm. Shift the
transmission slowly through all selector positions to thoroughly distribute the oil, then stall the
converter to raise the oil temperature to 225
0
F (106
0
C).
CAUTION: Do not allow temperature to exceed 225
0
F (106
0
C). If the unit does not have
a temperature gauge, do not stall for more than 30 seconds.
*Motorstor is a preservative additive manufactured by the Daubert Chemical Company, Chicago,
Illinois. Motorstor (under the designation of "Nucle Oil") is covered by U.S. Military Specifications
MIL-L-46002 (ORO) and MIL-I-23310 (WEP).
5. As soon as the unit is cool enough to touch, seal all openings and breathers with
moisture-proof tape.
6. Coat all exposed, unpainted surfaces with a good grade of preservative grease.
7. If additional storage time is required, 3 through 6 above should be repeated at yearly
intervals, except it is not necessary to drain the transmission each year - just add the Motorstor,
or equivalent.
F. Restoring Units to Service.
1. If Motorstor, or equivalent, was used in preparing the transmission for storage, use
the following procedures to restore the unit to service.
2. Remove the tape from openings and breather.
3. Wash off all the external grease with solvent.
4. Add Dexron automatic transmission fluid to proper level.
NOTE: It is not necessary to drain oil and Motorstor mixture from the transmission.
5. If Motorstor, or equivalent, was used in preparing the transmission for storage, use
the following procedures to restore the unit to service.
6. Remove the tape from openings and breathers.
7. Wash off all the external grease with solvent.
8. Drain oil as described in Paragraph 11-44 B.
9. Install a new oil filter element(s).
10. Refill transmission with Dexron automatic transmission fluid to proper level.
344
I
I
I
I
I
I
I
I
VEHICLE
11-52_ TROUBLESHOOTING - BEFORE REMOVAL FOR OPERATION
A. Visual Inspection.
Do not operate the vehicle prior to completing the procedures described in this para-
graph. Inspect for oil leakage. Visually inspect all splitlines, connections, valve bodies, oil level
indicator tube, and plugs for leaks. Oil leakage at splitlines may be caused by loose mounting
bolts or defective gaskets. Tighten all bolts and plugs where leakage is found. If mounting bolts
are tight and oil continues to leak, install a new gasket. Oil from the indicator tube may be caused
from foaming and aerating. (Refer to Paragraph 11-40 B).
11-53. TROUBLESHOOTING - BEFORE REMOVAL AND DURING OPERATION
A. Determine Trouble Cause.
If the inspection in Paragraph 11-52 above, does not reveal the cause of the failure, and
the vehicle is operable, further troubleshooting is necessary. Do not remove the transmission from
the vehicle until the causes of trouble listed in the troubleshooting chart, Paragraph 11-54 below,
are checked.
B. Proper Engine Tuning.
In order to make a thorough test of the transmission while it is mounted in the vehicle,
be sure that the engine is properly tuned, and the oil level in the transmission is correct. Refer to
Paragraph 11-40 for checking oil level.
11-54. TROUBLESHOOTING - TRANSMISSION REMOVED FROM VEHICLE
When the malfunction of a transmission is not ascertained by tests or inspections before
removal from the vehicle, the transmission may be mounted on a test stand and checked (if a test
stand is available). Particular attention should be given to proper oil level and to correct linkage
adjustment in every transmission test.
11-55. TROUBLESHOOTING CHART
The troubleshooting information, below, outlines the possible causes of transmission troubles
and their remedies. Capital letters indicate the symptom; numerals following the symptom indi-
cate several possible causes; corresponding numerals in the right column indicate remedies for the
causes.
NOTE: The various oil pressure check points are shown in the top and bottom views of
Figure 11-109. The various oil pressures are listed in Table 11-5.
11-56. OIL PRESSURE CHECKING PROCEDURES
Refer to end of this section, Table 11-5.
345
VEHICLE
MAIN
PRESSURE
REVERSE SIGNAL
PRESSURE
Figure 11109 Transmission Check Points
346
VEHICLE
Table 11-4. TROUBLESHOOTING CHART
CAUSE: REMEDY:
A. AUTOMATIC SHIFT AT TOO HIGH SPEED
1. Governor valve malfunctioning.
2. Mechanical actuator cable kinked,
broken or not properly adjusted.
3. Mechanical actuator malfunctioning.
1. Clean or replace governor and governor
screen.
2. Replace or repair cable.
3. Replace actuator.
B. AUTOMATIC SHIFTS AT TOO LOW SPEED AT FULL THROTTLE
1. Governor valve stuck.
2. Governor spring weak.
3. Mechanical actuator cable kinked,
broken or not properly adjusted.
4. Mechanical actuator malfunctioning.
C. LOW MAIN PRESSURE IN ALL RANGES
1. Low oil level.
2. Oil filter element clogged.
3. Sealring on oil pickup tube leaking
or missing.
4. Mainpressure regulator valve spring weak.
5. Control valve body leakage.
6. Valves sticking.
7. Oil pump, worn or damaged.
1. Clean or replace governor.
2. Replace governor.
3. Replace or repair cable.
4. Replace actuator.
1. Add oil to proper Level (Para. 11-44).
2. Replace filter (Para. 11-44).
3. Install new seal ring (Para. 11-44).
4. Check spring and replace if necessary.
5. Replace valve body assembly.
6. Replace valve body assembly.
7. Replace oil pump.
D. LOW MAIN PRESSURE IN FIRST GEAR, NORMAL PRESSURE IN OTHER FORWARD
RANGES
1. First gear circuit of control valve body,
leakage.
2. Excessive leakage at first-and-reverse
piston seals.
1. Replace control valve body, (Para. 1121).
2. Overhaul transmission; replace seals (Sec
tion III thru V).
E. BUZZING NOISE OCCURRING INTERMITTENTLY
1. Low oil level.
2. Air leak at oil intake pipe.
3. Clogged filter.
4. Aerated oil.
1. Add oil to proper level (Para. 11-40).
2. Replace intake pipe seal and filter, (Para.
11-44).
3. Improper oil level (Para. 11-40).
4a. Improper oil level (Para. 11-40).
b. Improper or contaminated oil.
F. EXCESSIVE CREEP IN FIRST-AND-REVERSE GEARS
1. Engine idle speed too high. 1. Adjust to correct idle speed.
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VEHICLE
CAUSE:
Table 114. TROUBLESHOOTING (Continued)
REMEDY:
G. LOW LUBRICATION PRESSURE
1. Oil level low.
2. Excessive internal oil leakage.
3. Cooler lines restricted or leaking.
1. Add oil to proper level (Para. 11-40).
2. Check other pressures (refer to C and E
above); check valve body mounting bolts.
3. Check for kinks, leakage; replace lines if
necessary.
H. 01 L LEAKING INTO CONVERTER HOUSING
1. Engine crankshaft rear oil seal, leakage
2. Charging oil pump, liptype seal at
torque converter, leaking.
3. Seal ring around 00 of oil pump, leaking.
4. Cracked weld in converter assembly,
leaking.
1. Replace rear oil seal.
2. Replace pump seal (Para. 1122).
3. Replace 00 seal (Para. 1122).
4. Replace converter assembly (Para. 1119).
I. TRANSMISSION HEATING UP IN ALL RANGES
1. Oil level low.
*2. Oil level high.
3. Engine cooling system restricted.
*4 Oil cooler lines restricted.
*5. Broken parts in converter.
1. Add oil to proper level (Para. 11-40).
2. Drain oil to proper level (Para. 11-40).
3. Refer to Chapter 10.
4. Clean or replace lines.
5. Replace converter assembly (Para. 1119).
J. NO RESPONSE TO MOVEMENT OF SHIFT LEVER
1. Range selector linkage unhooked.
2. Range selector linkage defective or broken.
3. Main pressure low.
4. Range selector not engaged at control
valve.
*Can also result in excessive fuel consumption.
1. Hook up linkage.
2. Repair or replace linkage.
3. Refer to C above.
4. Install or replace parts involved (inside oil
pan) (Para. 1135).
K. HIGH STALL SPEED (Refer to Paragraph 1148)
1. Oil level low.
*2. Clutch pressure low
*3. Forward clutch slipping (forward).
*4. Firstandreverse clutch slipping.
1. Add oil to proper level (Para. 1140).
2. Refer to 0 above.
3. Rebuild forward clutch (Para. 11-23).
4. Rebuild firstand-reverse clutch (Para. 11-29)
L. LOW STALL SPEED (Refer to Paragraph 11-48)
1. Engine not performing efficiently (may
be due to high altitude)
2. Broken converter parts.
1. Refer to Chapter 8.
2. Replace converter assembly (Para. 11-19).
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VEHICLE
Table 114. TROUBLESHOOTING (Continued)
CAUSE:
M. ROUGH SHIFTING
1. Manual selector linkage out of adjustment.
2. Control valves, sticking.
3. Governor valve malfunctioning.
4. Mechanical actuator cable kinked,
broken or not properly adjusted.
5. Mechanical actuator malfunctioning.
6. Engine idle speed too fast.
REMEDY:
1. Adjust linkage (para. 1147).
2. Replace or rebuild control valve (Para.
1121).
3. Clean or replace governor and governor
screen.
4. Replace or repair cable.
5. Replace actuator.
6. Adjust engine idle speed screw.
N. ENGINE OVERSPEEDS ON FULL THROTTLE UPSHIFT
1. Piston seals leaking or clutch plates
slipping in range involved.
2. Forward clutch piston seals or clutch
plates slipping (all upshifts).
3. Broken seal rings on front support hub.
4. sticking governor valve.
1. Overhaul transmission (Section III thru V).
2. Overhaul forward clutch and piston assem
bly (Para. 1123).
3. Replace rings (Para. 1133 B),
4. Clean or replace governor.
O. EXCESSIVE SLIPPAGE AND CLUTCH CHATTER IN ONE RANGE (not in all ranges)
1. Clutch slippage in that range clutch.
2. Excessive oil leakage in range
piston seals.
3. Oil leakage in valve components for
that particular range
1. Overhaul clutch.
2. Overhaul clutch and piston assembly.
3. Overhaul control valve body assembly
(Para. 1121),
"Clutch slippage may be recognized by alternate racing and loading of the engine which is, at
times, accompanied by a violent chatter.
P. DIRTY OIL
1. Failure to change oil at proper interval.
2. Heat excessive.
3. Clutch failure.
4. Damaged oil filter.
Q. OIL LEAK AT OUTPUT SHAFT
1. Faulty or missing seal at output flange.
R. SLIPPAGE IN ALL FORWARD GEARS
1. Oil level low.
2. Clutch pressure low.
3. Forward clutch slipping,
1. Change oil, install new filter (Para. 1144).
2. Refer to I above.
3. Overhaul transmission.
4. Replace filter (Para. 1144),
1. I nstall new liptype seal in rear of transmis
sion housing (Para. 1134),
1. Add oil to proper level (Para. 1140).
2. Refer to C above.
3. Rebuild forward clutch (Para, 1123),
349
VEHICLE
Table 114. TROUBLESHOOTING (Continued)
CAUSE: REMEDY:
S. SLIPPAGE IN FOURTH AND REVERSE GEAR ONLY
1. Fourth clutch slipping. . 1. Rebuild clutch and replace piston seals
(Para. 11-24).
2. Broken sealrings on support assembly hub. 2. Replace sealrings (Para. 11-24).
T. SLIPPAGE IN REVERSE AND FIRST GEAR: PROPER FUNCTION IN OTHER FORWARD
GEARS
1. Firstandreverse clutch slipping.
U. VEHICLE MOVES FORWARD IN NEUTRAL
1. Range selector linkage out of adjustment.
2. Forward clutch failed and dragging.
1. Overhaul clutch and replace piston seals
(Para. 11 29).
1. Adjust linkage properly.
2. Rebuild forward clutch (Para. 1123).
V. VEHICLE MOVES BACKWARD IN NEUTRAL
1. Range selector linkage out of adjustment. 1. Adjust linkage properly.
2. Fourth clutch failed and dragging. 2. Rebuild clutch assembly (para. 11-24).
W. THROWS OIL OUT OF TRANSMISSION FILLER TUBE
1. Dipstick loose.
2. Oil level too high.
3. Oil level too low.
4. Breather stopped up.
5. Water in oil.
X. VEHICLE WILL NOT PUSH START
1. Normal operation (no rear pushstart
pump).
1. Tighten cap; replace if necessary.
2. Drain oil to proper level (Para. 11-40)
oil may also come out breather.
3. Fill oil to proper level.
4. Clean or replace breather.
5. Drain oil (Para. 1145 A).
350
VEHICLE
Table 11-5. OIL PRESSURE CHECKING PROCEDURES
WARNING: Proper safety precautions must be exercised during tests. All personnel must stand
clear of the vehicle. Take precautions against movement of the vehicle. Gauges (vacuum, pressure,
tachometer) should have extended lines to permit reading inside the vehicle.
All oil level and pressure checks must be made at normal operating temperature (1600-2200F)
(70-103C).
Check oil level, refer to Paragraph 11-40.
Install oil pressure gauge (0.300 psi) (0.0219 kg/cm
2
).
CHECK OIL PRESSURES IN THE FOLLOWING MANNER:
.' '
NEUTRAL - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push or pull the actuator cable to idle position against
internal stop.
3 .. Engine at 1000 RPM.
NEUTRAL - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full throttle position against
internal stop.
3. Engine at 1000 RPM.
I
!
FORWARD - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full throttle position against
internal stop.
3. Engine at 1000 RPM.
~ '7 ,"; -, .,'
REVE RSE - Brakes Applied
1. Mechanical actuator disconnected from fuel control.
2. Push the actuator cable to full throttle position against
internal stop.
3. Engine at 1000 RPM.
Normal PSI
90-110
6.327-7.733 kg/cm
2
130-150
9.139-10.545 kg/cm
2
130-150
9.139-10.545 kg/cm
2
225-250
15.8175-17.575 kg/cm
2
IMPORTANT THAT THE MECHANICAL LINKAGE IS PROPERLY ADJUSTED AT THIS TIME.
1. Fuel control lever in full throttle position.
2. Push mechanical actuator cable to full throttle position against internal mechanical stop.
3. Adjust clevis so that pin fits freely through the hole in the fuel control lever and contacts
the end olthe slot in the clevis, thus holding the actuator cable in the full throttle posi-
tion when the fuel control is at full throttle.
4. Total cable travel should be 1.187 to 1.56 inches (30.1498 to 39.624 mm).
351
VEHICLE
Section VII - SPECIFICATIONS, DATA CHART
Model ................................................................... AT 540
Rating:
Input torque ............................................ 325 ft. Ibs. (max) (450 Nm)
Input speed ...................................................... 4000 rpm (max)
Input horsepower (net installed) .......................................... 200 (max)
Metric horsepower (net installed) ...................................... 202.8 (max)
Vehicle application, gross vehicle weight (max) .................. 36,000 lb. (16,363 kilograms)
Mounting:
Engine .......................................... SAE 3 automotive housing, two side
Vehicle ................................................ Mounting pads (in addition,
transmission may be overhung)
Drive .................................................................. F lexplate
Rotation (viewed from input):
Input. ................................................................... right
Output (in forward ranges) ................................................... right
Output location .................................................... In line with input
Dry weight (basic configuration) ............... " ................. 275 lb. (125 kilograms)
Parking brake provision ....................... Mounting provided at rear of transmission case
Output flange .............................................. Supplied by Cadillac Gage
Oil capacity (less external system) .................. 325 U.S. gal. (14.79 liters) for initial fill as
Temperatures:
received from factory; 3.75 U.S. gal.
(17 .06 liters) for initial fill when dry;
2.75 U.S. gal. (12.51 liters) for refill
Sump ........... '" ...................... , ............... '" .250
o
F (120
0
C) max
To Cooler - Converter-out .......... _ .... __ .. __ ..... _ ............ 300
o
F (14 7
0
C) max
Normal Operation .......... _ ............................. , 160
0
-220
o
F (700-103
0
C)
Minimum ......................................................... 100
0
F (37
0
C)
Clutches .................................... ; ............ Oil wet, hydraulic-actuated,
spring-released, self compensating for wear
Gearing ....................................... Planetary, straight-cut spur, coolant mesh
Power takeoff (converter driven):
Mounting (one opening) ....... _ ..... _ ....................... SAE regular duty, 6-bolt
Drive gear ...................................... 6/8 pitch, 55 teeth, 20
0
pressure angle
Location ............ _ .................................. Right side, viewed from rear
Oil filter ......................................................... Integral (in sump)
352
VEHICLE
SPECIFICATIONS, DATA CHART (Continued)
Su mp .................................................................... 1 ntegral
Input pressure oil pump .......................................... Positive displacement
Oil type .................................................................. Dexron
Oil pressure ..................................................... Refer to Table 115
Converter
Number of stages .............................................................. 1
Number of elements ........................................................... 3
Stall-torque mu Itiplication .................................................. 2.0: 1
Drive range and sequences ................................ Reverse, N, 1-23-4, 1-2-3, 1-2, 1
Drive range and shift control (external) ....................................... Mechanical
Shifting mechanism (internal control) ......................................... Hydraulic
Shift modulation ........................................................ Mechanical
Neutral start and reverse signal switches .............................. Suppl ied by customer
Speedometer drive:
Type ............ " ......... 13/16-20 UNEF threaded for SAE regular duty - thread type
Drive gear data (cross axis) ........................ 5 teeth, 29 normal pitch, 85
0
, 20',30",
left helix angle, 20
0
normal pressure angle
TRANSMISSION RATIOS (mechanical*)
Range Clutch(es) Engaged Ratio
Neutral F irst-and-reverse 0
First Forward and first-and-reverse 3.45: 1
Second Forward and second 2.25:1
Third Forward and third 1.41:1
Fourth Forward and fourth 1.00:1
Reverse Fourth and first-and-reverse 5.02:1
'Overall torque multiplication ratio of transmission (output stalled) is the product of the converter
torque multiplication ratio (2.01:1) and the mechanical (gear) ratio.
353
VEHICLE
SCREW, 5/8 LONG
OIL FILTER
Figure 11-110_ Oil Filter Replacement
11-57_ TRANSMISSION OIL FILTER REPLACEMENT (Figure 11-110)
A. Removal.
1. Mount transmission in suitable holding fixture in inverted position.
NOTE: Transmission must be completely drained of hydraulic fluid.
2. Remove 21 screws retaining oil pan to transmission housing.
3. Remove oil pan and gasket. Discard gasket.
4. Remove filter retaining screw.
5. Remove filter and filter intake pipe. Discard filter and intake pipe seal ring.
B. Installation.
NOTE: Use filter and gasket kit for replacement.
1. Clean oil pan. Remove all traces of old gasket from sealing surface.
2. Lubricate new seal ring with oil soluble grease and install on straighter end of intake
pipe.
3. Position intake pipe in transmission.
354
VEHICLE
4. Install new oil filter on intake pipe. Make sure filter grommet fits intake pipe snugly:
5. Install filter retaining screw. Torque to 10 to 15 ft.lbs. (14 to 20 Nm).
NOTE: Twist intake pipe if it appears to be misaligned. Pipe must enter filter squarely.
6. Install oil pan with new gasket. Do not use grease to retain gasket.
NOTE: Deep end of pan must be towards front of transmission.
7. Install oil pan retaining screws taking care not to damage gasket. Tighten evenly, then
torque screws to 10 to 13 ft.lbs. (14 to 18 Nm).
8. Install drain plug. Torque to 15 to 20 ft.lbs. (20 to 27 Nm).
11-58. GOVERNOR FI L TER SCREEN REPLACEMENT
A. Removal.
1. Remove oil filter assembly.
2. Remove bolt retaining manual selector detent spring and roller assembly.
3. Remove spring and roller assembly.
4. Remove long bolt from center of valve body.
5. Remove 17 shorter bolts retaining valve body in position.
6. Remove valve body by lifting upwards on the valve body and three attached oil tubes.
CAUTION: DO NOT allow manual selector valve to drop out of front of valve body.
CAUTION: Governor check valve ball which will drop out of channel in transmission case if
transmission is rotated in holding fixture. Remove ball if transmission is to be rotated.
7. Remove three tubes from rear of valve body.
8. Remove filter screen from governor feed tube bore.
B. Installation.
1. Install governor filter screen, closed end first, into governor feed tube bore.
2. Install governor feed tube.
3. Install governor pressure tube.
NOTE: Governor tubes must be installed in valve body before installing valve body in trans-
mission. If the governor and pressure tubes are installed rear end first, they will not align
properly when the control valve is installed. They may appear to align until installation of
the body is attempted.
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4. Lift the valve body, and swing the three tubes into proper position to enter their
holes in the transmission case.
5. Lower the valve body onto the case, while engaging the rear ends of the tubes in the
case and the selector valve on the selector lever.
6. Install the detent spring, with its roller over the selector lever, and its rear tab in the
hole immediately behind the bolt hole.
7. I nstall a 1/4-20 x 1-3/4-inch bolt into the detent spring and valve body. I nstall long
bolt near the center of the valve body. Install 17 shorter bolts into the remaining bolt holes.
8. Shake the valve body slightly, and the ends of the bolts will start into the tapped
holes in the transmission case.
9. Torque tighten the 19 bolts evenly to 8 to 12 ft.lbs. (11 to 16 Nm).
NOTE: The detent spring must be held in alignment over the selector lever while the 1-3/4-
inch bolt is tightened.
10. Install oil filter.
11. Install oil pan.
11-59. PARKING BRAKE
A. Removal.
1. Obtain a length of pipe 2 to 3 feet long that will slip onto parking brake actuator
lever and apply parking brake. With parking brake locked, remove bolt and washer securing brake
drum flange to transmission output shaft. Release brake.
2. With suitable puller, pull brake drum and flange from output shaft.
3. Remove four bolts securing brake assembly to transmission housing. Remove brake.
4. Remove parking brake bellcrank and cable brackets as required.
B. Installation.
1. Check rear oil seal for failure or damage. Replace if required.
2. Install parking brake on transmission housing flange. Torque four mounting bolts to
31-33 ft. Ibs. (42-45 Nm) torque.
3. Install brake drum and flange on output shaft. Install mounting bolt and tab washer.
Tighten bolt to 83-100 ft. Ibs. (113-136 Nm) torque. Bend washer tab against flat of bolt head,
stake washer into recess in flange retainer.
4. Install parking brake cable brackets and bell crank if removed.
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Section VIII - FLEXIBLE GEAR COUPLING
The flexible gear coupling couples the transmission to the transfer unit and permits flexing
or slight misalignment between these two units.
NOTE: If removal of the flexible gear coupling is required when the power train is installed
in the vehicle, it is necessary to partially disconnect and shift position of transfer unit.
11-60. REMOVAL
A. Remove eight bolts and nuts joining coupling sleeves.
B. Remove transfer upper mounting screw and nut. Lift input side of transfer to allow re-
moval of coupling hubs.
C. Remove gasket between coupling sleeves.
D. Using suitable puller, remove gear coupling hub{s) from transmission output adapter
and/or transfer input shaft.
E. Remove key from keyway.
F. Separate coupling sleeve from hub.
G. Remove 0 ring from sleeve groove. Discard 0 ring.
11-61. INSTALLATION
NOTE: Suitable protective gloves are required when handling heated parts.
A. Heat gear coupling hub in oil bath or oven to approximately 200
0
F (93
0
C).
B. Install new 0 ring in sleeve.
C. I nstall sleeve over hub.
D. Place key in keyway.
E. Place hub and sleeve assembly in position on transmission output adapter and/or transfer
input shaft.
NOTE: If hub cannot be pressed into position by hand, install bolt with suitable washer or
plate in tapped hole in adapter and/or input shaft. Draw coupling hub into position by
tightening bolt.
F. Lower transfer into position and install mounting screw and nut. Torque to 200-220 ft.
Ibs. (271-298 Nml.
NOTE: A new gasket must be installed between coupling sleeves when transfer unit is
coupled to transmission.
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Section IX - TRANSFER
The transfer is a two-speed gearbox connected between transmission and axle drive trains. Its
purpose is to transfer power from power plant to rear and front axles. Four wheel drive and HI
LOW range are manually controlled from the driver's position. For adjustment of transfer controls,
see Limited Maintenance, Chapter 6.
11-62. SEAL REPLACEMENT (Figure 11111)
A. Input Drive Shaft.
1. Disconnect flexible gear coupling sleeves.
2. Remove the upper mounting pivot screw (8), nut (7), spacers (1), and raise transfer
case enough to allow removal of gear coupling hub from input shaft.
3. Using a suitable puller, remove gear coupling hub (26) from input shaft Figure 11-
113.
4. Pry old seal out of bearing cap.
5. Clean seal area, and apply sealing compound to outside of a new seal and tap it into
place. Install new seal with lip facing out.
6. Install gear coupling hub and sleeve assembly on input shaft. Use tapped hole in end
of input shaft to pull hub into position.
7. Lower the transfer case into position.
8. Connect halves of flexible gear coupling using new gasket.
9. Install transfer case upper mounting pivot screw and nut.
10. Check lubricant level. Replenish as necessary.
B. Front Output Shaft.
1. Remove intermediate propeller shaft (1) Figure 11-113.
2. Remove yoke by pulling straight out and then pry out old seal.
3. Clean seal area, and apply sealing compound to outside of new seal and tap it into
place. Install new seal with lip facing out.
4. Install yoke by pushing it on shaft until it seats firmly.
5. Connect intermediate propeller shaft to transfer case front axle drive yoke.
6. Check lubricant level. Replenish as necessary.
C. Rear Output Shaft.
1. Disconnect rear axle propeller shaft (20) from transfer rear output shaft yoke (Figure
11-113).
2. Remove cotter pin, nut, washer and yoke from output shaft of transfer and then
pry out old seal.
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Figure 11-111 Transfer Mounts
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3. Clean seal area, and apply sealing compound to outside of new seal and tap it into
place. Install new seal with lip facing out.
4. Install yoke, and washer. Torque nut to 700900 ft. Ibs. (9481220 Nml and install
cotter pin.
5. Check lubricant level. Replenish as necessary.
6. Connect rear axle propeller shaft to transfer rear axle drive yoke.
7. I nstall hose boot and adapter.
11-63. LUBRICANT RESERVOIR
A_ Removal.
1. Remove magnetic drain plug at drain port and drain reservoir.
2. Disconnect three hoses at reservoir ports.
3. Remove two screws and lockwashers securing reservoir to hull. Remove reservoir.
B. Installation.
1. I nstall in reverse order of removal.
11-64. LUBRICANT PUMP
A. Removal.
1. Disconnect inlet and outlet hoses from pump.
2. Remove four screws and washers securing pump to transfer case.
B. Installation.
1. Apply gasket material to pump mounting surface.
2. Attach pump to transfer case. Be sure oil pump drive tang engages slot in pump drive
plate.
3. Torque mounting screws 20-30 ft. Ibs. (26-41 Nml.
4. Attach pump inlet and outlet hoses.
11-65. TRANSFER REMOVAL
A. Drain lubricant from transfer and lubricant reservoir.
B. Disconnect hoses at transfer and lubricant pump.
C. Remove four nuts, lockwashers and screws securing the rear propeller shaft flange to the
rear axle companion.
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D. Remove the intermediate propeller shaft universal joint retaining nuts, lockwashers and
U bolts.
NOTE: If the universal joint bearing cap strap is broken, tape the universal joint cross-shaft
bearings to eliminate the possibility of losing the bearings.
E. Remove eight bolts and nuts joining flexible gear coupling sleeves.
F. Loosen both hull to transfer boot clamps.
G. Loosen ball joint locknut at transfer 4-wheel drive shift linkage and unscrew ball joint
pivot screw.
H. Loosen ball joint locknut at transfer range shift linkage and unscrew ball joint pivot screw.
I. Remove lower transfer mounting screw, spacer, washers and nut.
J. Remove upper transfer mounting screw, washers and nut.
1<. Position suitable hoisting equipment and attach to transfer lifting ring. Guide the rear
propeller shaft through the hole in the hull and remove the transfer from the vehicle.
11-66. DISASSEMBLY (Figure 11-112)
A. Remove drain plug located on lower front of transfer case and drain gear lubricant.
B. Remove eight screws and washers from transfer inspection cover and remove cover.
C. Remove rear output shaft nut and washer and remove yoke. Remove wear sleeve from
yoke.
D. Remove six screws and washers from declutch carrier housing and remove housing. Re-
move bearing cap.
E. Remove four screws and washers securing carrier cap to housing. Remove cap and shims.
F. Using a suitable puller remove yoke seal from carrier cap and discard seal.
G. Remove front bearing cup from clutch housing.
H. Pull front output shaft with front and rear bearings attached from front of clutch hous-
ing. Using suitable puller remove bearings from shaft.
I. Remove clutch shifter sleeve.
J. Remove rear bearing cup.
1<. Unscrew and remove inspection pipe plug from housing.
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Figure 11-112 Transfer - Exploded View
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L. Remove detent retaining plug, washer, spring and ball.
M. Place a screwdriver through the inspection pipe plug hole and remove the shift fork lock
ing set screw.
N. Slide the shifter rail from front of housing and remove the shift fork through the rear of
clutch housing.
O. Remove shifter rail seal. Discard seal.
P. Remove six screws and washers from helical gear front bearing cover and remove cover.
Remove bearing cup.
Q. Remove 12 screws (10 short and 2 long) and washers from transfer cover and remove
cover.
R. Remove hilo shift shaft screw and gasket. Remove spring, plunger, and ball from trans
fer. Remove shifter shaft plug.
S. Remove hilo shift shaft assembly, helical gear shaft and output shaft assemblies from
transfer.
1. Using suitable press, remove high speed gear and beari;lg cone from helical gear shaft.
Use puller to remove low speed gear cone.
2. Using press, remove front output gear and bearing cone from input shaft.
3. Remove clutch collar.
4. Remove rear output gear and bearing cone from output shaft using press.
5. Remove snap ring from high speed output gear.
6. Using puller, remove bearings from hi and lowspeed output gears.
7. Using wire cutter, remove lockwire from hilo shifter shaft fork. Tap out roll pin and
remove fork from shifter shaft.
T. Remove five screws and washers from oil pump adapter and remove pump/adapter assem-
bly and shims.
U. Remove four screws and washers from oil pump and remove pump from adapter.
V. Remove two allen head screws from idler gear shaft and remove oil pump drive plate.
W. Remove five screws and washers from idler bearing front cover and remove cover.
X. Remove two screws from idler shaft and remove idler shaft washer.
Y. Using suitable press, drive out idler shaft and front idler bearing from transfer and remove
idler gear. Remove rear idler bearing from transfer case.
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Z. Remove five screws and washers from transfer input shaft front cover and remove cover.
AA. Remove five screws and washers from input bearing cap and remove cap and shims.
Using puller, remove input shaft oil seal.
AB. Remove two screws from input shaft and remove washer.
AC. Using press, drive out input shaft and front input shaft bearing, and remove oil seal
wear sleeve.
AD. Remove input shaft gear. Using puller, remove input shaft bearing from transfer case.
AE. Remove oil dipstick.
AF. Remove six screws and washers from helical gear rear cover and disconnect oil dip
stick tube assembly from transfer. Remove cover, shims, bearing cup, and dipstick tube assembly.
AG. Loosen locknut and remove lifting eye from transfer.
1167. INSPECTION AND REPAIR
A. Clean all parts with cleaning solvent and wipe or air dry with compressed air.
CAUTION: Do not allow bearings to spin when drying with compressed air.
B. Inspect housing and retainer caps for cracks, breaks, chips, distortion and stripped threads.
C. Inspect bearings and cups for galling, chipped rollers, scoring, wear, breaks, cracks, miss-
ing rollers and irregular wear patterns.
D. Inspect all shafts for scoring, wear, worn keyways, cracked or damaged splines and strip-
ped threads.
E. Inspect all gears for chipped, cracked or broken teeth and worn keyways.
NOTE: If gear replacement is necessary all four gears must be replaced as a set.
F. Inspect shifter rail and fork for stripped threads, wear, distortion and worn detents.
G. Inspect all seals and mounting bushings and replace if necessary.
11-68. ASSEMBLY
NOTE: Apply gasket material before assembling cover and caps to transfer. Apply lubri-
plate to all seal wear surfaces and lubricate all bearings prior to assembly.
A. Press front input bearing onto input shaft. I nstall washer and torque screws to 60-75 ft.
Ibs. (69-102 Nm).
B. Insert input gear in transfer through inspection cover opening. Position gear in place and
press input shaft assembly through gear until gear bottoms against bearing.
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C. Press rear input shaft bearing onto shaft. Use tapped hole on shaft end to draw oil seal
wear sleeve onto input shaft. Install input bearing front cover and secure with five screws and wash
er. Torque screws to 60-75 ft.lbs. (69-102 Nm).
D. Install oil seal in the input bearing cap.
E. Install shims and cap assembly and adjust input shaft end play to .010-.015 in. Secure
with five screws and washers and torque screws to 60-75 ft.lbs. (69-102 Nm).
F. Press front idler gear bearing onto idler shaft. Install washers and screws and torque to
60-75 ft. Ibs. (69-102 Nm).
G. Insert idler gear in transfer through inspection cover opening. Position gear and press the
idler shaft assembly through gear until gear bottoms against bearing.
H. Press rear idler gear bearing onto shaft. Install pump drive plate and secure with two allen
head screws. Torque screws to 60-75 ft. Ibs. (69-102 Nm).
I. Install idler gear front cover and secure with five screws and washers. Torque screws to
60-75 ft. Ibs. (69-102 Nm).
J. Install pump adapter and shims. Adjust idler shaft end play to .010-.015 in. by adding or
removing shims. Secure adapter with five screws and washers and torque screws to 60-75 ft. Ibs.
(69-102 Nm).
1<. Attach oil pump to pump adapter with four screws and washers. Torque screws to 20-30
ft. Ibs. (26-41 Nm).
CAUTION: Make sure oil pump drive tang engages slot in pump drive plate.
L. Using press, install hi speed helical gear and cones on helical gear shaft.
M. Using press, install low speed gear, bearing, and cone on output drive shaft.
N. Install clutch collar (with chamfer facing low speed gear) and press on hi speed gear and
bearing. Secure with snap ring, then press on bearing cone.
O. Assemble fork on shifter shaft and install roll pin. Secure with lockwire.
P. Install shift fork assembly, helical gear shaft and output drive shaft assemblies in transfer.
Q. Install shifter shaft plug and torque to 80 ft.lbs. (108 Nm).
R. Install transfer case cover on transfer. Secure with 12 screws (10 long and 2 short) and
washers and torque short screws 35-50 ft. Ibs. (47-68 Nml, long screws 60-75 ft.lbs. (69-102 Nm).
Check to see that the bushing is installed in the output shaft recess facing the declutch assembly.
S. Install helical gear front bearing cup and cover and secure with six washers and screws.
Torque screws to 60-75 ft. Ibs. (69-102 Nm).
T. Insert output shaft front bearing CLIp in the transfer cover_
U. Replace shifter rail seal with suitable seal replacer tool.
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V. Position shifter fork in housing and engage shifter rail at center of lock screw hole. In
stall lock screw through inspection hole and tighten.
W. Install and tighten inspection pipe plug.
X. Install detent ball, spring, washer and retaining plug. Tighten retaining plug.
Y. Install rear bearing cup in clutch housing with the large end of the taper facing toward the
front of the housing.
Z. Press on front output shaft bearings with the widest diameter of the bearing facing each
other.
AA. Position the clutch shifter sleeve in the clutch shifter fork with the groove end of the
sleeve facing toward the front of the housing.
AB. Insert the front output shaft in the housing, engaging the splines of the clutch shifter
sleeve and seating the rear bearing in the rear bearing cup.
AC. Position front output shaft bearing cup in housing with the wide taper of the bearing
facing toward the rear of the housing.
AD. Replace seal in carrier cap, using a suitable tool.
AE. Positipn shims and carrier cap to housing. Retain in place with four screws and wasKo
ers. Adjust front output shaft end play to .002-.006 in. by adding or removing shims. Torque screws
20 to 30 ft. Ibs. (26-41 Nm).
AF. Attach deciutch assembly to transfer with six screws and washers. Torque screws 30-
35 ft. Ibs. (47-68 Nml.
AG. Install output shaft rear bearing cup. Press oil seal in rear output shaft cap and install
cap. Add or remove shims to obtain .001-.005 in. output shaft end play. Secure with seven screws
and washers and torque screws to 35-50 ft. Ibs. (47-68 Nm).
AH. Press wear sleeve on output yoke and coat with IUbriplate.
AI. Install yoke on output shaft being careful not to damage oil seal.
A J. Install yoke washer and nut on output shaft and torque nut to 700-900 ft. Ibs. (948-
1220 Nm).
AK. Install helical gear rear bearing cup, shims, and cover and adjust helical shaft end play
to .002-.006 in. by adding or removing shims. Secure with five screws and washers and torque
screws to 60-75 ft.lbs. (69-102 Nm).
AL. Install oil dipstick tube assembly and secure bracket to helical gear rear cap with
screw and washer. Torque screw to 60-75 ft.lbs. (69-102 Nm). Install dipstick.
AM. Install drain plug and torque to 35 ft. Ibs. (47 Nm).
AN. Install lifting eye.
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11-69_ INSTALLATION
A. Using suitable hoisting equipment, position transfer in vehicle.
B. Guide transfer into mounting brackets.
C. Position hull boot and clamps over transfer flange.
D. Insert lower mounting screw, spacer, washers and nut.
E. Insert upper mounting screw, washers and nut.
F. Align flexible gear coupling sleeves. Install new gasket between sleeves. Install eight
bolts and nuts joining sleeves. Torque bolts 25-30 ft.lbs. (34-41 Nm).
G. Connect intermediate drive shaft universal joint retaining lJ bolts, lock washers and nuts.
H. Position rear propeller shaft to rear axle companion flange. Install retaining screws, lock-
washers and nuts.
I. Torque upper and lower mounting screws 200-220 ft.lbs. (271-298 Nml.
J. Instal shift linkage ball joint pivot screws. Tighten locknuts.
K. Connect hydraulic lines to transfer case and pump.
L. Refill transfer with approved lubricant.
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Section X - PROPELLER SHAFTS
11-70_ REMOVAL (Figure 11-113)
A. Front Propeller Shaft.
1. Remove four nuts, lockwashers and bolts securing front propeller shaft yoke to front
axle companion flange.
2. Remove four nuts, lockwashers and two u-bolts securing front propeller shaft to inter-
mediate shaft yoke.
3. Remove front propeller shaft assembly.
B. Intermediate Propeller Shaft.
1. Remove four nuts, lockwashers and two u-bolts securing front propeller shaft to inter-
mediate propeller shaft yoke.
2. Remove six screws and lockwashers securing center bearing retainer plate to bulk-
head. Slide plate rearward on propeller shaft to clear bulkhead.
3. Remove four nuts, lockwashers and two u-bolts securing propeller shaft to transfer
yoke.
4. Remove shaft assembly.
5. Remove cotter pin and nut securing yoke to shaft. Remove yoke.
6. Remove center bearing seal and center bearing.
C. Rear Propeller Shaft.
1. Loosen two clamps securing hose boot to transfer and hull adapter.
2. Remove four screws and lockwashers securing boot adapter to hull. Remove adapter.
3. Disconnect four nuts and lockwashers and two u-bolts securing propeller shaft to
transfer output shaft yoke.
4. Disconnect four nuts, lockwashers and bolts securing propeller shaft to rear axle com-
panion flange.
5. Remove propeller shaft.
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\
111
Figure 1 1 - 1 1 ; - - ; : : : ~ : : : : ~ = - - - - -
Propeller Shafts - Exploded V' lew
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D. Universal Joints (Figure 11115).
NOTE: Universal joints that are connected by u-bolts have a tie strap holding bearing caps
together. If this strap is broken, caps must be installed in yoke with strap end portion in relief
which is cast in yoke. If this procedure is not carefully followed, cap may be cracked when u
bolts are tightened.
1. Remove propeller shaft.
2. Remove snap ring securing each bearing at end of journal. Remove lubricating fitting.
Tap (with a soft round drift) exposed face of one journal bearing until opposite bearing comes out
of yoke. Tap exposed end of journal until second bearing is driven from yoke. Remove journal by
moving it to one side as far as possible and tilting to clear side of yoke. Repeat procedure to remove
journal from other yoke. Remove four seals and seal retainers from journal.
1171. CLEANING
Clean all parts in mineral spirits paint thinner or dry-cleaning solvent. Make sure all parts are
thoroughly cleaned of grease, dirt and grit. Check to make sure lubrication and relief openings are
clean and open. Vhen necessary, soak parts in solvent and brush with stiff brush to remove caked
grease. Dry parts thoroughly with compressed air. Cover parts until ready for installation.
1172. INSPECTION AND REPAI R
Inspect yokes for cracks, wear, or bent condition. Inspect spider bearing journals for nicks,
burrs and scratches. Spider lubrication tunnels must be clean, free and open. Inspect bearing for
cracks, wear or broken needles. \II,'orn condition is usually indicated if needles drop out of bearing,
or if journal bearing surfaces show marks of needles. Replace u-joint if any of the above discrep-
ancies exist.
11-73. INSTALLATION
A. Universal Joints (Figure 11114).
NOTE: Universal joints must be replaced as a complete unit.
1. Install lubrication fitting in spider with fitting faCing toward shaft yoke. Position re-
tainer and seal on each journal prior to positioning it in yoke bore.
2. Position spider in yoke by inserting one journal trunnion into yoke and tilting journal
until opposite trunnion enters yoke.
3. Work GAA grease into journal bearings until bearing needles are lubricated and hold
fast to the sides of the cap. Do not pack.
4. Press bearing caps into yoke and over journal until snap ring grooves are exposed.
Install snap rings.
5. Lubricate universal joint after all four caps are installed with snap rings in place.
B. Propeller Shafts.
1. Repack' intermediate shaft center bearing cavities with GAA grease. I nstall bearing on
shaft and position seal over bearing.
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YOKE
Figure 11114. Universal JOint - . Exploded View
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NOTES
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CHAPTER 12
Suspension
This chapter contains removal, disassembly, cleaning, inspection and repair, assembly and
installation of suspension components. To prevent repetition of instructions and to facilitate repair
procedues in this chapter, the following steps will be taken to prepare vehicle.
1. Loosen wheel lug nuts.
2. Lift or jack vehicle up to where wheels are free of ground.
3. Remove wheels and lower vehicle onto a hull dolly or jack stands. The dolly or stands
must be located with respect to vehicle center of gravity and free of axle housing mounting channels.
They must be high enough to permit axle housing and differential carrier to clear hull when lowered
for removal.
WARNING: The axle housing with differential carrier mounted is top heavy and will flip as
it is being removed. To prevent injury to personnel and damage to equipment, it is recom
mended that a saddle type fixture to fit the contour of housing be fabricated. The design
must prevent housing from rotating by utilizing box design of axle housing. To assist the reo
moval and movement of axle housing once removed, it is recommended that fixture be adapt
able, to a portable, automatic, heavy duty, hydraulic jack. With this facility the axle housings
may be removed and positioned for installation with safety.
Section I - SHOCK ABSORBERS, SPRINGS AND JOUNCE BUMPERS
121. FRONT SHOCK ABSORBER (Figure 121)
A. Removal.
1. Remove lower nut (12), retaining washers (11) and bushings (10) securing shock abo
sorber (13) to axle mounted shock absorber bracket stud (14).
2. Remove upper nut (12), retaining washer (11) and bushings (10) securing shock abo
sorber to hu II bracket stud.
3. Remove front shock absorber.
B. Inspection.
The shock absorber must be replaced if it has been running cold or if there are signs of
oil leaks. Replace worn bushings, grommets and damaged mounting hardware.
C. Installation.
Install front shock absorbers in reverse order of removal.
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Figure 12-1 Front Suspension - Exploded View
12-2_ REAR SHOCK ABSORBER (Figure 12-2)
A_ Removal.
1. Remove upper nut (16), retaining washer (17) and bushings (18) securing shock ab-
sorber (19) to hull mounting bracket stud_
2_ Remove lower nut (16), retaining washer (17) and bushings (18) securing shock ab-
sorber to rear spring shock absorber bracket stud (14) and remove shock absorber.
B. Inspection - Refer to Front Shock Absorber.
C. Installation. Install rear shock absorber in reverse order of removal.
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6
. - Exploded View

Suspension
Figure 12-2
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12-3_ FRONT SPRINGS (Figure 12-1)
A. Removal.
1. Remove four nuts (15) from U bolts (18) securing clamp plate and shock absorber
bracket (14) to axle.
2. Remove shock absorber bracket, clamp plate, U bolts and jounce bumper (19) and
jounce bumper pad (17).
3. Raise and support front of vehicle hull to free load on spring.
4. Remove screw (1), nut (3) and washer (2) securing spring mounting pin to hull front
spring hanger.
5. Remove screw (1), nut (3) and washer (2) securing spring shackle to hull rear spring
hanger. Remove front and rear spring pins (6 and 9).
6. Lift spring (16) off spring to axle seat and remove spring.
7. Remove screw (8), nuts (3) and washer (2) securing spring shackle (4) to spring rear
eye. Remove shackle from spring by removing pin (9).
8. Remove bearing (5) from shackle if worn or damaged.
B. Inspection.
1. Excessively worn or damaged pins, pads, bushings, U bolts and mounting hardware
must be replaced.
2. Thoroughly inspect spring for broken leaf or worn hardware. Replace spring if leaf is
broken.
C. Installation.
1. I nstall front spring in reverse order of removal. Torque spring hanger pin pinch screws
to 32 to 37 ft. Ibs. and U bolt nuts to 200 to 240 ft. Ibs.
12-4. REAR SPRINGS (Figure 12-2)
A. Removal.
1. Remove front screw (1), lock washer (2) and nut (3) securing shackle pin (6) to hull
spring hanger.
2. Remove rear screw (1), lock washer (2) and nut (3) securing spring eye pin (8) to rear
hu II spring hanger.
3. Remove four nuts (11) from two U bolts (15).
4. Remove clamp plate (12), U bolts (15) shock absorber bracket (14) and jounce stop
pad (13).
5. Remove front pin (6) and rear pin (8) from spring and hull hangers. Remove spring.
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B. Inspection. Refer to front spring.
C. Installation. Install rear springs in reverse order of removal. Torque spring hanger pin
pinch screws to 32-37 ft. Ibs. and U bolt nuts to 200-240 ft. Ibs.
12-5. JOUNCE BUMPERS (Figures 12-1 and 12-2)
A. Removal.
1. Pull or pry jounce bumper (19) (Fig. 12-1) or (20) (Fig. 12-2) from mounting stud. A
lubricant may be used on stud to aid in removal of bumper.
B. Inspection.
1. Inspect bumper for chunking out of rubber, which is an indication of weak or bad
shock absorbers. Hard dryed mud or gravel built up on top of spring can cause damage to bumper.
Replace damaged bumper.
C. Installation.
1. Apply a small amount of hydraulic fluid around hole in end of jounce bumper.
2. Position jounce bumper with hole centered over bumper mounting stud.
3. Insert a lever between bottom of jounce bumper and top of spring. Pry bumper up-
ward until it seats around mounting stud.
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Section II - AXLE HUBS AND BEARINGS
126. REMOVE (Figure 123)
A. Drain axle lubricant.
B. Remove wheel.
C. Remove 10 screws (1) and washers (2) securing front axle shaft drive flange (3) and/or
rear axle shaft (4) to hub (15). Remove front drive flange and/or rear axle shaft.
D. Retract brake shoes, to provide drum shoe clearance.
E. Remove wheel bearing lock nut (5) with wheel bearing lock nut wrench.
F. Remove adjusting nut lock (6). Remove wheel bearing adjusting nut (7) with adjusting
nut.
G. Remove outer bearing cone (9) and hub and drum (14 or 15).
H. Using suitable puller remove inner oil seal (12 or 13) from hub and discard. Remove inner
bearing cone (11).
I. Using suitable tools, remove inner and outer bearing cups (10).
NOTE: Do not remove bearing cups unless replacement is necessary.
127. REPACKING FRONT AXLE BEARINGS
NOTE: Rear axle bearings are oil lubricated.
A. Immerse bearing cones in drycleaning solvent or volatile mineral spirits painHhinner.
B. Clean with brush to remove old lubricant and blow dry with compressed air. Do not spin
bearing. Inspect bearings and replace if questionable.
C. Wash hub thoroughly with drycleaning solvent or mineral spirits paint thinner to remove
old lubricant. Inspect bearing cups and replace if questionable.
D. Completely fill spaces around rollers and above and beneath cone with bearing lubricant.
E. Apply thin coating (approximately 1/16 inch thick) of bearing lubricant to inside surface
of hub, outside surface of spindle, and inner surface of drive flange.
CAUTION: Do not pack or fill hub with lubricant as this may result in leakage.
128. INSTALLATION
A. Press inner and outer bearing cups into hub.
B. Install inner bearing cone and oil seal into hub.
C. Position hub onto spindle.
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~
!O!
~
=<!
Figure 12-3 Removing or Installing Hubs and Bearings
379
VEHICLE
D. Install outer bearing cone, oil seal on rear hub and adjusting nut.
E. I nstall wheel.
F. Refill axle with lubricant to prescribed level.
G. Tighten adjusting nut to 50 ft. Ibs. while rotating wheel and hub in both directions until a
drag is felt, then back off nut 1/6 to 1/4 turn. Rotate in both directions to seat bearing.
H. Install adjusting nut lock so that pin on nut enters closest hole in lock.
I. I nstall lock nut and torque to 100-150 ft. Ibs.
J. Install front axle shaft drive flange or rear axles drive shaft to hub. Secure with ten screws
and lock washers.
K. Adjust service brakes.
L. Lower vehicle and torque wheel lug nuts to 350-400 ft. Ibs.
M. Raise wheel and check wheel bearing adjustment. G rasp tire at top and pu II back and
push forward or use a crowbar under tire to lift and lower. If bearing is correctly adjusted, there will
be a very slight movement noticeable between brake drum and backing plate flange.
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VEHICLE
Section III - FRONT AXLE
129. REMOVAL
A. Disconnect front axle propeller shaft from differential carrier mounting flange.
B. Disconnect drag link and both shock absorbers.
C. Disconnect brake and axle vent hoses at hull bulkhead fittings. Plug lines and fittings.
D. Remove two U bolts from each spring.
WARNING: Because of the topheavy condition, the axle assembly will have a tendency to
revolve on its axis into an inverted position. Serious injury could result to personnel under
the vehicle at time of removal.
E. Roll axle out from under vehicle.
1210. DISASSEMBLY (Figure 124)
A. Remove drain plug (44) and drain lubricant from axle.
NOTE: Disassembly of right and left sides of axle are similar except where noted.
B. Remove two cotter pins (33). Loosen two nuts (34) two turns and with a hammer drive
tie rod ends (36) loose from steering knuckles. Remove both nuts and tie rod.
C. Disconnect and remove brakelines from wheel cylinders at rear of backing plates.
D. Remove axle vent line from axle housing.
E. Remove hub drive flange then remove hubs, bearings and drums.
F. Remove ten nuts (12) and lock washers (13) from studs securing oil slinger (14) and
backing plate to steering knuckle. Remove oil slinger and backing plate.
G. Remove spindle (66) from steering knuckle (58). Spindle can be loosened from flange
by tapping on side of spindle with a brass hammer.
H. Pull axle shaft (68) from steering knuckle and axle housing.
I. Remove two screws (28), two screws (22) and lock washers (23) securing brush guard
(29) to steering knuckle. Remove guard.
J. Remove, clean and retain grease fittings (37).
K. Remove two remaining screws (22), lock washers (23), plate (35), sleeve (26) and bushing
(27).
L. Remove four screws (20), brake line bracket (21 and 63), plate (24), steering arm (61),
spacers (25), bushing assemblies (60 and 26) and sleeves (27). Retain steering arm (61) and its
spacer (25) for measurement.
WARNING: Steering arm and its spacer are matched in pairs to each axle. Caution must be
taken not to intermix these parts between axles.
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VEHICLE
Figure 12-4 F rant Axle
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M. Clean and remove any contamination found on the steering arm mating surface and spac-
er and its mounting surface on the steering knuckle.
N. Place the spacer into the mating recess on the steering arm and measure the distance
between surface of arm and of the spacer.
NOTE: Spacer surface may either protrude (Figure 12-5) or be recessed (Figure 12-6). In
the event that surfaces are flush refer to Figure 12-5. Retain this dimension "A" for use at
reassembly.
O. Remove twelve screws (52) and outer boot ring clamp (54). Pull boot (55) and clamp
away from steering knuckle.
P. Remove steering knuckle from axle housing by lifting knuckle until clear of upper knuc-
kle trunnion, tilt knuckle forward and lower until clear of lower trunnion.
Q. Remove screw (62) and nut (56) securing inner clamp (57). Remove clamp boot and out-
er ring boot clamp from housing.
R. Remove washer (48), seals (47) and retainer (46) from axle housing.
S. Remove differential carrier assembly.
12-11. INSPECTION
A. Inspect housing outer ends and steering socket trunnions for excessive wear or damage.
Replace housing if outer ends are excessively worn or damaged. Check filler and drain plug hole
threads for damage. Replace plugs if damaged threads cannot be repaired. Replace broken or
damaged studs. Smooth machined surfaces that are nicked or burred, using a fine stone. Replace
oil seals.
B. Examine axle shaft splines for nicks, cracks or other damage; check shaft for twisted or
bent condition. If either the inner or outer shaft is damaged or excessively worn, install a new axle
shaft assembly. To determine if excessive play or backlash exists in the u-joint, place assembly in
vise in a vertical position with outer shaft pointing upward, and with vise jaws gripping inner shaft
just below the u-joint. Firmly grasp the outer shaft and test the shaft yoke for movement by twist-
ing. Only slight movement should be detected. Next pull straight up and push down keeping shaft
in line. There should be no movement.
C. Inspect front wheel spindle for cracks and nicks and threads for damage. Check bushing
for wear or roughness. Check backing plate for distortion and mounting hole wear. Check slinger
for any damage.
D. Inspect steering knuckles carefully for cracks or distortion. Inspect studs for damaged
threads.
E. Inspect steering arm for distortion or other damaged condition.
F. Inspect steering knuckle boot for wear, cracks, or tears.
G. Inspect steering knuckle upper and lower sleeve bearings (bushing-type) for excessive
wear, rough spots, or damage.
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VEHICLE
1212. ASSEMBLY (Figure 124)
A. Install filler and drain plug using new gaskets.
B. Install differential carrier if removed.
C. Install washer spacer (48), new seals (47) and retainer (46) in axle housing (45).
D. Position outer ring boot clamp (54) and boot (55) over axle housing (45) and inslall
clamp (57) with screw (62) and nut (56). Rotate clamp so that screw is centered at bottom of
housing before tightening screw.
E. Position steering knuckle (58) over end of housing. Make sure trunnions on housing are
aligned with holes in steering knuckle.
F. Position lower sleeve (26) with bushing (27) through steering knuckle and over lower
trunnion on axle housing. Align retainer plate (35) and install the two rear screws (22) and washers
(23). Snug up screws. Do not torque.
G. Left Side Knuckle - Service Kit MPS2560 is required for reassembly. The kit contains
one steering arm, six spacers ranging in thickness from .125 through .175 in increments of .010 of
an inch, plus a lock wire and sealant.
H. Position sleeve (60) with bushing (27) through knuckle and over upper trunnion of axle
housing.
I. Using spacer (25) from disassembly Step L and a new steering arm, measure dimension
"A" (Figure 125 or 126, whichever applies). If dimension "A" is a protrusion the dimension
should be within +0.00 to 0.010 of the old arm and spacer. If dimension "A" is r e ~ e s s e d , the di
mension should be within +0.010 to 0.00 of the old arm and spacer. If so, in either case, proceed
to Step J. If not, select a new spacer from kit MBS2560 and repeat measurement until proper
dimension is achieved.
J. Apply sealant supplied with the service kit to the entire surface "A" on the new steering
arm and to the threads of the six previously used steering arm screws.
K. Position selected spacer (25) and new steering arm (61) over sleeve and insert four screws
(64). Torque screws to 325425 ft. Ibs.
L. Place bracket (63) on steering arm and insert and torque two screws (20) to 2025 ft. Ibs.
M. Replace grease fittings (37) and grease per lubrication chart.
N. Install lock wire (65) through screw heads (64) securing arm (61) to knuckle, using a fig
ure 8 pattern.
O. Right Side Knuckle - Position sleeve (26) with bushing (27) through knuckle and over
upper trunnion of axle housing. Position spacer (25) and plate (24) over sleeve and align four
screws (22) and washers (23). Position the brake line bracket (21) and insert two screws (20).
Tighten screws. Do not torque.
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P. Position boot guard (29) on steering knuckle and install in the upper position with two
screws (28) and washers (23). In the lower position, align guard mounting holes over plate (35) and
secure guard with the remaining two screws (22) and washers (23).
Q. Torque upper and lower sleeve plate screws (22) 116 to 134 ft. Ibs.
R. Pull boot mounting flange forward to knuckle and position ring boot clamp over flange
and secure boot and clamp with twleve screws (52).
S. Use care not to damage oil seal in axle housing and insert axle shaft (differential end)
(68) into housing. Guide splines into splined differential no-spin assembly.
T. Install spindle (66), milled slot up, over axle and knuckle mounting studs (59). Be care-
ful not to damage bushing (67).
U. Install backing plate and oil slinger and secure with ten nuts and lockwashers. Torque
nuts to 95-115 ft. Ibs.
V. Install hub, bearing and drum components. Refer to Section II.
W. Install brake to axle housing and wheel cylinders.
X. Install axle vent line to axle housing.
Y. Install tie rod (40) by positioning each tie rod end (36) into steering knuckle. Secure each
tie rod end with nut (34) and cotter pin (33).
Z. Remove fill plug and fill unit with lubricant as per lubrication instructions.
12-13. INSTALLATION
Install front axle in reverse order of removal.
STEERING ARM
STEERING ARM
I
-t-
SPACER SURFACE "z"
"A" DIMENSION
SPACER SURFACE "Z"
Figure 12-5 Spacer Protruding Figure 12-6 Spacer Recessed
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VEHICLE
Section IV - REAR AXLE
1214. REMOVAL
A. Disconnect brake hose and axle vent line from hull bulkhead fitting.
NOTE: Plug disconnected hoses and fitting with suitable plugs.
B. Disconnect propeller shaft from axle carrier flange.
WARNING: Because of a top heavy condition, the axle assembly will have a tendency to
revolve on its axis into an inverted position. Serious injury could result to personnel under
the vehicle at time of removal. Refer to warning at front of this chapter.
D. Roll axle out from under vehicle.
1215. DISASSEMBLY (Figure 127)
A. Remove filler plug (25), drain plug (26) and drain lubricant from axle.
NOTE: Disassembly of right and left sides of axle are identical.
B. Remove axle shaft, hub and drum assemblies.
C. Remove differential carrier assembly.
D. Disconnect brake lines at backing plates and remove from housing.
E. Remove ten screws (13), lock washers (12) and nuts (27) securing backing plates to axle
housing (24).
1216. INSPECTION
A. I nspect housing, flanges and all welds for breaks or cracks.
B. I nspect backing plates for distortion and mounting hole wear.
NOTE: Replace any questionable part or component and damaged mounting hardware.
1217. ASSEMBLY (Figure 127)
A. Install backing plates with ten screws (13), lock washers (12) and nuts (27).
B. Install brake lines and connect to wheel cylinders at rear of backing plates.
C. I nstall differential carrier assembly.
D. Install hubs, drums, bearings and axle shaft.
E. Install drain plug (26) and fill axle with lubricant. Install filler p l u ~ (25).
386

15
17 16 \
10 \ \ ar' If!

27

VEHICLE
,
"
16
,
,
"
15
9
14
- xploded View
Figure
ear Axle E
387
VEHICLE
1218. REMOVAL (Figure 128)
A. Carrier Drive.
1. Remove nuts (2) and lockwashers (3) attaching housing to carrier (1). Remove and
replace stud (4) only if threads are damaged during disassembly.
2. Break carrier loose from housing with rawhide mallet.
3. Pull carrier straight out of housing with chain fall, boom, or "A" frame. A small pinch
bar may be used to straighten the carrier in the housing bore. However, end must be rounded to pre
vent indenting the carrier flange.
4. Scrape off RTV silicone sealer from carrier and housing with a suitable scraper or
blade.
1219. DISASSEMBLY (Figure 129)
A. Carrier Drive.
1. Mount drive unit in suitable repair stand.
2. Center punch one differential carrier leg and bearing cap to correctly identify for
proper reassemb Iy.
Figure 128 Removing or Installing Differential
388
I .
i
1
II
I
I,
, .
VEHICLE
Fo 129 DOlfferential _0 Exploded View Igure .
389
VEHICLE
3. Remove bearing caps, bearings and bearing cups.
4. Lift out differential and gear assembly.
NOTE: Do not attempt further disassembly of carrier drive until differential lock unit is
securely bolted together. Construct a holding fixture from two flat washers, one screw long
enough to pass through the carrier drive and one nut (Figure 12-10). Secure differential lock
unit together before proceeding with further disassembly.
5. Place differential in a vise.
6. Using a punch, put an index mark on each half of the differential case and on each
side of gear to assure original position when assembling.
7. Remove nuts from bolts protruding through differential case. Drive bolts from case
assembly with drift.
8. Remove the right and left sides of the differential case and remove the differential
lock unit.
9. Press bearing cone from each half of the differential case.
B. Top Cover and Inspection Cover.
1. Remove top-toside cover lockwire.
2. Remove eight screws and washers from top cover and remove cover.
3. Remove wire and inspection cover (a soft mallet may be necessary).
C. Through Shaft.
'1. Remove nut and washer. Using suitable puller, remove companion flange from input
shaft.
FLAT WASHER
FLAT WASHER
Figure 12-10 Differential Lock Unit - Holding Fixture
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2. Remove capscrews and washers and secure input bearing cage. Remove cage and shims.
NOTE: Wire the shims removed to the cage for using during assembly.
3. Remove capscrews and washers from rear through shaft plate. Remove plate and bear-
ing spacer from carrier.
4. Remove through shaft by tapping input end of shaft with soft mallet or wood block
until rear inner race is free from housing.
5. Remove bearing retainer snap ring from end of through shaft.
6. Remove rear bearing inner race from shaft using suitable pUller. If required, use puller
and remove rear bearing from carrier.
7. Remove through shaft and pinion assembly by pulling unit through the front open-
ing in the carrier.
8. Using a suitable press, drive the pinion and bearng cone from the shaft. If required,
remove cone from pinion using a press.
9. Remove oil seal from bearing cage and discard. Remove spacer and bearing cone.
10. If wear sleeve requires removal and replacement, remove sleeve by first placing com-
panion flange (yoke) on its side in a vice.
11. Using a cold chisel, notch the wear sleeve slightly to expand the sleeve and permit
its removal from the flange.
CAUTION: Do not completely split or penetrate the wear sleeve and thus cause damage to
the companion flange.
12. Remove the sleeve.
13. If unsuccessful, notch the sleeve in the same location agian. DO NOT SPLIT THE
SLEEVE.
14. Remove the sleeve.
15. If unsuccessful, rotate the flange 180 degrees, notch slightly again and remove the
flange.
D. Cross Shaft Gear.
1. Remove capscrews and washers securing bearing cage cover to carrier. Remove bear-
ing cover and shims from carrier. Tie shims to bearing cover to facilitate adjustment during assem-
bly.
2. Remove screws and cross shaft bearing retainer washer from end of shaft.
3. Install two puller screws into bearing cage assembly. Turn screws alternately and
evenly until bearing cage is free of carrier housing. Remove and tie the shims to the bearing cage to
facilitate adjustment during assembly.
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4. Place bearing cage between two iron spacers and drive the inner and outer bearing
cups and inner and outer bearings from the bearing cage using a suitable driver.
5. Next, place two pieces of channel steel across the bed of a ram press. Rest carrier on
steel with teeth of bevel drive gear facing upward.
6. Position two parallel bars beneath bearing spacer and press cross shaft from bevel
drive gear and carrier.
CAUTION: Save the bearing gear spacer/washer for assembly.
7. Lift or tap out bearing and gear assembly from carrier through top opening.
NOTE: Do not remove the bearing sleeve from the drive unit unless replacement of sleeve
is necessary.
8. If sleeve requires removal, drive dowel out of carrier and sleeve. Then, using a suit-
able driver or wood block, tap out sleeve from carrier and discard.
CAUTION: Be careful not to cock the sleeve in the carrier or damage carrier bore during
removal.
1220. INSPECTION AND REPAIR
A. Differential Carrier. Check differential carrier for cracks or distortion. Inspect stud threads
and capscrew hole threads for damage. Replace studs if broken or damaged. Clean up damaged
threads of carrier with a tap. Replace carrier if differential adjusting nut threads are damaged be-
yond repair.
NOTE: Carrier and caps cannot be replaced as separate items.
B. Differential assembly. Replace a spur-driven gear that is chipped, broken, or visibly worn.
Position the lockout assembly in the differential case. If any radial movement is noted, replace
differential lockout and/or case, whichever is at fault. Replace differential case if scored. Replace
differential bearing cones if any of the rollers are missing, pitted, corroded, or discolored, due to
overheating. Replace differential-bearing adjusting nuts if the threads are stripped, or if the nuts are
broken or damaged.
C. Bevel drive and pinion gears. Examine the bevel and pinion gear carefully for being
chipped, cracked, or having scored teeth. Gears with broken, chipped, cracked or excessively worn
teeth must be replaced. Small defects such as nicks, scores, or burrs may be corrected with a fine
stone.
NOTE: The bevel drive and pinion gears are matched gears. If necessary to replace either
gear, both gears must be replaced.
Replace a bevel pinion gear front or rear bearing cone if any of the rollers are missing, pitted, cor-
roded, or discolored, due to overheating. Replace bevel pinion gear front or rear bearing cups that
are cracked, chipped, pitted or discolored, due to overheating. Replace a bevel pinion front bearing
cap if damaged. Replace the oil seals if worn or damaged.
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VEHICLE
D. Cross shaft gear and related parts. Replace a cross shaft gear if the teeth are broken, chip-
ped, or visibly worn. Small nicks may be polished with a fine stone. Replace a cross shaft gear if
the threaded holes in .end of shaft are stripped or damaged beyond repair. Replace outer bearing
cone or cups if worn or damaged. Replace the outer bearing cage if cracked or damaged. Replace
the inner bearing or bearing sleeve if worn or damaged.
E. To install new companion flange (yoke) if removed, use a press and plate or a mallet.
Using a suitable sleeve, drive the wear sle.eve down until the companion flange (yoke) chamfer is
visible. Make sure the tapered end of the wear sleeve faces the flange (yoke) chamfer.
F. Removal of all gaskets including silicone RTV is accomplished by peeling or scraping the
used gasket off both mating surfaces. Application of silicone RTV gasket material is as follows:
1. Remove dirt, grease or moisture from both mating surfaces.
2. Dry both surfaces.
3. Apply thin bead, approximately 1/8" diameter completely around one mating surface
and all fastener holes to assure complete sealing and prevent leakage.
CAUTION: Minor concentration of acetic acid vapor may be produced during application.
Adequate ventilation should be provided when silicone RTV is applied in confined areas.
Further, eye contact with these silicone RTV gasket materials may cause irritation; if eye
contact takes place, flush eyes with water for 15 minutes and have eyes examined by a doctor.
4. Assemble the components immediately to permit silicone RTV gasket material to
spread evenly. When rebuilding any assembly, always use torque values on fasteners as specified.
CAUTION: Failure to use appropriate gasket material will cause axle to leak.
12-21. ASSEMBLY
A. Bevel Pinion Bearing Preload Test.
NOTE: The preload test can be accomplished in the carrier or on a bench. The bench meth-
od is suggested to facilitate assembly.
1. Press the inner and outer bearing caps against shoulder in cage. Press inner bearing
cone on drive pinion. Press through shaft into pinion.
2. Assemble bearing cage over pinion and inner bearing cone. Position the preload spac-
er with chamfer facing outward against the inner bearing cone. Position the outer bearing cone on
the pinion over the spacer. Position the companion flange spacer over the bearings.
3. Add the flange nut and tighten to specified torque. Position through shaft in a vice.
Do not install oil seal at this time.
4. Wrap a cord around the cage pilot diameter and pull on a horizontal line with a pound
scale. Using a rotating torque motion during measurement and note the scale reading. Bearing pre-
load must fall in a range from 12 to 18 in. Ibs.
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VEHICLE
NOTE: The bearing spacer located between the bearing cones controls the bearing preload.
To increase preload use a thinner spacer; use a thicker spacer to decrease preload. After prop
er preload has been established set the unit aside for later installation and continue with
assembly.
B. Ring Bevel Gear and Cross Shaft Assembly.
L If removed, tap radial bearing sleeve into carrier using mallet and block of wood. If
desired, a press and steel plate also may be utilized using the cross shaft inspection cover opening
for access.
NOTE: Make sure guide hole in sleeve lines up with dowel hole in carrier.
2. Stake sleeve in position with dowel using brass drift and mallet. Top of dowel should
be flush with carrier top.
3. Press radial bearing in bevel drive gear.
4. Press inner bearing cup in cross shaft bearing cage.
5. Install bearing washer on gear hub against bearing. Install spacers with I.D. chamfer
so that chamfer is next to radius at root of pinion teeth. A large flat washer is used at this location
when the O.D. of the pinion teeth is smaller than the I.D. of the radial bearing.
6. Coat the I.D. of the gear with heavy grease. Install gear, bearing, and spacer assembly
in drive unit sleeve and block up to hold in place.
7. Inspect entering end of cross shaft and remove any nicks or burrs. Coat. O.D. of shaft
and I.D. of gear with heavy grease.
8. Position carrier in suitable press with cross shaft bearing cage side pointing upward.
Insert bevel drive gear into carrier with gear supported on suitable sleeve.
9. Align key in cross shaft with keyway in gear hub and press shaft firmly against gear,
bearing, and spacer. Continue pressing operation to exert 10 to 20 tons pressure in excess of that
required for secure assembly.
10. Install cross shaft, bearing cage with inner cup, and original ship pack (which con-
trols gear position) over cross shaft.
11. Apply collodial graphite lubricant to cross shaft tapered bearing journal and assemble
inner and outer bearing cones and outer cup using suitable sleeves.
12. Install cage and bearing assembly in drive unit, pressing against outer bearing cone
with suitable sleeve. Be sure oil holes in cage are properly aligned with oil holes in drive unit.
13. Assemble bearing retainer plate with two screws. Torque screws 105-135 ft. Ibs.
14. Install bearing cage cover original shim pack (which controls tapered bearing preload)
over cage flange.
15. Assemble bearing cage cover, washers, and screws. Torque large screws 100-130 ft.
Ibs. (136-176 Nml, small cap screws 65-85 ft.lbs. (88-115 Nm).
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VEHICLE
16. Measure cross shaft bearing preload torque. Wrap strong cord around spur pinion and
pull on horizontal line with pound scale. The preload torque specification for tapered roller bearings
mounted close together in the bearing cage is 12 to 18 in. Ibs (new and serviceable used bearings.
bearings.
Example: Assume spur pinon diameter is 4 in.; the radius is 2 in.; and with five
pounds pull on the scale, preload torque is 10 pound inches.
17. Read rotating pounds pull, not starting pounds pull. If preload torque is not within
12 to 18 in. Ibs., add shims between cover and cage to decrease torque, or remove shims to increase
cross shaft bearing preload torque.
C. Through Shaft.
1. Install rear through shaft bearing outer race in carrier to depth where washer will rest
flush with carrier housing.
2. Assemble rear bearing inner snap ring to shaft.
3. Install pinion bearing cage, pinion and throughshaft, and original shim pack in carrier.
Install cage-to-carrier screws and washers and torque to 65-85 ft. Ibs. (88115 Nm).
4. Install rear bearing inner race with sleeve and mallet and gently tap until inner race
seats flush with outer bearing and inner snap ring. Install outer snap ring on through shaft.
5. Apply silicone RTV gasket material to carrier rear plate mounting surface (see In-
spection and Repair Section).
6. Install rear bearing spacer, plate, capscrews and washers.
D. Adjustment.
1. Spiral bevel gear firstreduction assemblies have shim packs between the forward and
rear thru-shaft tapered bearing covers and the carrier to control pinion position. Hypoid gear first-
reduction units have a single shim pack between the pinion cage and carrier or inter-axle differential
housing and carrier to control pinion position. A shim pack between the cross shaft bearing cage
flange and the carrier controls the position of the first-reduction spiral bevel or hypoid gear in all
top-mounted double reduction drive units.
2. Tooth contact may be checked by applying a thin even coat of lightly oiled red lead
with a small brush to both drive and coast sides of a dozen teeth of the gear. When the pinion is
rotated the red lead is squeezed from the gear teeth by pressure of the pinion teeth leaving areas the
exact size, shape and location of the contacts. Sharper, better defined areas of contact can be ob-
tained by applying rolling resistance to the gear providing the gear is not forced out of location
during the checking operation.
3. Use the smallest amount of the lead and oil mixture that will render good impres-
sions. The drier the mixture the better the impressions. Clean the material from the gear and pinion
teeth when the operation is complete. Always judge tooth contact by noting pattern on the drive
side of the gear teeth. The coast side pattern should be correct when the drive side pattern is correct.
4. Set backlash to amount specified on gear O.D. Set backlash to .005".015", when
amount is not specified.
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VEHICLE
ITEM
1 - BEVEL PINION FRONT BEARING CAGE COVER SHIMS
2 - HELICAL PINION OUTER BEARING SHIMS
3 - HELICAL PINION OUTER BEARING CAGE COVER
4 -- HELICAL PINION OUTER BEARING CAGE
5 - ~ BEVEL PINION REAR BEARING COVER SHIMS
ALWAYS ADO OR REMOVE SHIMS OF EQUAL THICKNESS AND NUMBER WHEN
CORRECTING HYPOID DRIVE GEAR AND SPUR GEAR TOOTH CONTACT.
CORRECT TOOTH CONTACT
SHOWS BLUE OVER TWO-THIRDS
OF TOOTH (CENTERED).
INCORRECT TOOTH CONTACT
SHOWS BLUE AT HEEL OF TOOTH
CAUSES TOOTH BREAKAGE.
INCORRECT TOOTH CONTACT
SHOWS aLUE AT TOE OF TOOTH
CAUSES TOOTH BREAKAGE.
INCORRECT TOOTH CONTACT
SHOWS BLUE AT FLANK OF TOOTU
GEARS WILL BE NOISY.
INCORRECT TOOTH CONTACT
SHOWS BLUE AT FACE OF TOOTH
GEARS WilL BE NOISY.
Figure 12-11 Drive and Pinion Gear Adjustment
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VEHICLE
5. With adjustments properly made (pinion at correct depth and backlash set at .010")
the illustrated contacts above and below will be procured. The area of contact favors the toe and is
centered between the top and bottom of the tooth.
6. The hand rolled pattern shown at top (gears unloaded) will result in a pattern center
ed in the length of the tooth when the gears are under load shown at bottom. The loaded pattern
will be almost full length and the top of pattern will approach the top of the gear tooth.
7. The pattern on the coast side of teeth will appear the same width as the drive side
shown below; however, the over-all length will be centered between the toe and heel of gear tooth.
8. A high contact indicates pinion is too far out. Set the pinion to the correct depth by
removing shims under the pinion cage. Slight outward movement of hypoid gear may be necessary
to maintain correct backlash.
9. A low contact indicates pinion is too deep. Set the pinion to the correct depth by
adding shims under the pinion cage. Slight inward movement of the hypoid gear may be necessary
to maintain correct backlash.
10. Set used gears to have tooth contact to match wear pattern. The hand rolled pattern
of used gears will be smaller in area and should be at toe end of wear pattern. 8acklash may slight-
ly exceed the maximum limit of the .005" specification. Do not mix worn and new gears.
11. Mixed or unmatched gears and pinions will probably be noisy in operation and will
not give optimum performance and life. We assume no responsibility for spiral bevel or hypoid
gears serviced in any manner other than matched sets.
12. 8e sure all bearing preloads are within specified limits before checking tooth con-
tacts. Transpose equal amounts of shims between front and rear pinion bearing covers or spiral
bevel drive units to maintain correct bearing preload while adjusting tooth contact. Add or remove
shims between the pinion cage or inter-axle differential housing of hypoid gear drive units to alter
pinion location. Change the location of the spiral bevel or hypoid gear by altering the thickness of
the shim pack between the cross shaft bearing cage flange and carrier.
13. After obtaining a satisfactory tooth contact, especially in relation to the top and
bottom of the tooth, the backlash can be altered within the limits of .005"-.015" to obtain a better
contact position relative to the length of the tooth.
14. A high backlash setting can be used to keep the contact from starting too close to the
toe, and a low backlash setting can be used to keep the contact from starting too far away from the
toe.
15. After correct tooth contact has been established, install adjusting nut locks and cap
screws. Tighten cap screws and lock wire to bearing cap cap screws.
E. Main Differential.
1. Place differential assembly in press and install bearing cones on each side of differen-
tial case.
2. Position differential case halves around differential lock unit and spur gear and align
punch marks.
NOTE: Do not remove retainer bolt, nut and washers on differential lock unit.
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3. Install bolts and secure with washers and nuts. Torque nuts to 150-190 ft. Ibs. (203-
257 Nm).
4. Remove retainer screws, nut and washer from differential lock unit.
NOTE: Bolts go on side of bevel gear stamped "bevel side" and differential is installed in
carrier with "bevel side" towards input shaft side of carrier. Inspect carrier legs and bearing
caps to be sure they are properly relieved (clean of sharp edges) at inside diameter parting
line.
5. Next, install differential in carrier in reverse order of removal.
F. Main Differential Bearing Preload Test.
1. Temporarily install differential with bearings and cups in carrier housing and center
between carrier leg grooves.
2. Insert thin split rings making certain that there is clearance between bearing cup faces
and rings. (Do not instal bearing caps).
3. By means of a dial indicator measure end play of differential assembly by shifting the
assembly back and forth between the rings with a small pair of pinch bars placed between the car-
rier legs and the spur gears.
4. Remove and measure the thickness of the rings. To the total thickness of the two thin
rings add the end play figure plus another .017" to .022" to obtain the total thickness of the two
thicker rings required to obtain proper bearing preload.
NOTE: Hardened split rings are ground to increments of .005".
Example: If temporary thin rings used to measure end play were .290" each for a
a total of .580" and the end play is .005", then .580" plus .005" end play equals
.585" (or zero end play). Here an additional .020" (interference) would be required
to preload the bearings or a total of .605" thicker split rings. The total of .605" may
be divided between the two rings such as .300" and .305".
5. It should be understood that the .017" to .022" interference is not bearing preload
torque but that it is the amount of interference required to establish bearing preload torque within
the desirable limits.
6. I.nsert one split ring in carrier leg groove. Move differential assembly over so that face
of bearing cup is held tightly against inserted ring. Rings should be positioned in carrier leg grooves
so that split portion will locate in center of cap.
7. Install opposite split ring by tapping it into the carrier leg groove by use of a blunt
end drift, tapping on the I.D. of ring opposite the split portion.
8. Position the differential bearing caps in place making sure they are properly aligned.
9. Install carrier leg cap screws and tighten to specified torque.
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G. Inspection Covers.
1. Coat threads of cross shaft cap with RTV silicone sealer (see Inspection and Repair
Section) and install cap.
2. Coat top cover inspection plate mounting surface on carrier with RTV sealer. Install
top cover plate and secure with capscrews and washers. Torque screws to 2035 ft. Ibs.
3. Install lockwire on cross shaft cap and anchor to top cover inspection plate capscrew.
12-22. INSTALLATION (Figure 12-8)
A. Apply RTV silicone sealer to carrier-to-axle mounting surface and assemble in axle.
B. Place carrier on studs and lower carrier to housing until lockwashers and nuts can be
installed on studs under through shaft housing.
C. Install remaining lock washers and nuts. Tighten all nuts to 130-170 ft.lbs.
NOTE: Free rotation of each wheel in both directions will produce a slight indexing sound
indicating that differential has been correctly assembled and is operating properly. If each
driving wheel does not rotate freely in both directions, recheck assembly and/or installation
procedures.
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NOTES
i
. ;
400
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CHAPTER 13
Brakes
This Chapter contains maintenance instructions for the following brake system components:
brake pedal assembly, brake master cylinder, service brake shoes, service brake drums, wheel cylin-
ders, parking brake shoes, drum actuator and cable, and brake boosters. For minor adjustment of
service brakes refer to limited vehicle maintenance chapter.
CAUTION: Use only approved brake fluid. Do no use brake fluid from a container that had
been used for any other liquid. Mineral oil, alcohol, anti freeze or cleaning solvents even in
very small quantities will contaminate the brake system. Brake fluid once removed from the
system must be discarded.
Section 1 - PEDAL ASSEMBLY
13-1. REMOVAL
NOTE: The pedal assembly may be removed as a complete unit or the cylinder can be
removed without removing complete assembly.
A. Remove brake fluid from cylinder reservoir with a suction gun and discard fluid.
B. Disconnect two hydraulic lines from brake master cylinder. Cap lines and plug cylinder
to prevent contamination.
C. Disconnect stop light switch electrical leads.
D. Remove five screws securing pedal assembly brackets to hull and remove assembly.
13-2. DISASSEMBLY (Figure 13-1)
A. Remove spring (4) and disconnect stop light switch linkage (2) from brake pedal.
B. Remove cotter pin (27) and pull mounting shaft (26) from bracket (11). Remove pedal.
C. Remove nut (8), screw (15), push rod (14) and two flanged bushings (6) from each pedal.
D. Remove two screws (25), lockwashers (24) and stop light switch (10).
E. Remove four screws (11), nuts (20), lockwashers (16) and brake master cylinder (21).
13-3. REPAIR
A. Brake master cylinder (figure 13-2).
1. Remove screw (1). cover (2), washer (3) and cover seal (4). Discard seal.
401
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15
Figure 13-1 Pedal Assembly - Exploded View
2. Remove boot (14), snap ring (13), spaCer (12) and piston with cups and spring
assembly (11) discard piston, cups and spring assembly.
3. Remove stop pin (6), piston (9), cup (8) and spring assembly (7). Discard stop pin,
cup, cup from piston and spring assembly.
4. Clean cylinder housing in a suitable solvent cleaner and blow dry with compressed
air.
5. Inspect bore of housing for 'cracks, pitting or scoring.
6. Cylinder bores that have scores or scratches may be honed, providing the diameter is
not increased more than .002 inch.
7. Install new cup on piston and position new spring assembly cup and piston into bore
of cylinder and secure with new stop pin.
402
/ ~
i
,
VEHICLE
' ~
'\ a?(,
10
Figure 132 Brake Master Cylinder - Exploded View
403
VEHICLE
8. Position new piston assembly into bore of cylinder. Install spacer and secure with
snap ring.
9. Install new cover gasket, washer, cover and screw to keep cylinder clean prior to
installation.
13-4. ASSEMBLY
Assemble pedal components in reverse order of disassembly.
135. INSTALLATION
A. Install pedal assembly in reverse order of disassembly.
B. Fill master cylinder with brake fluid. System must be bled.
C. Bleed brake master cylinder at two bleeder screws on cylinder until fluid shows no signs of
air and refill master cylinder.
D. Bleed brake system at each wheel cylinder until fluid show no signs of air at each wheel
cylinder.
NOTE: When bleeding brakes, brake pedal must be pumped up and held under pressure
until the bleeder screws are closed:
Section 1\ - LINES AND HOSES
CAUTION: The brake system figure 13-3 must be bled after performing any work that may
have caused air to enter system. Where there is any doubt, bleed system.
NOTE: Prior to removing or servicing brake lines or hoses, the connectors or fittings should
be cleaned to prevent any foreign matter from entering system.
13-6. INSPECTION
A. Hoses should be inspected for correct length, surface cracking, pulling, scuffing or worn
areas.
B. Lines should be inspected for rust, dents, cuts, deep scratches or damage from battery acid
and leaks.
C. Air strainers must be free of dirt or other foreign material.
13-7. REPAIR
>-.-.
A. The only repair permitted to brake lines other than replacement of a complete line, is the
cutting out of a damaged section and replacing with clean new tubing and fittings.
B. Brake hoses can only be replaced by a hose of the correct length.
WARNING: No repair is permitted to a brake hose.
404
38
37
13
F 21
2Y---
19
27
VEHICLE
3
10 11

26
33
15
17
11
19
20
5
25
14
21
22
23
12
A MASTER CYLINDER
8 RIGHT FRONT WHEEl CYLINDER
C RIGHT REAR WHEEl CYLINDER
D ENGINE VACUUM PUMP
E - REAR BRAKE BOOSTER
F . LEFT REAR WHEEL CYLINDER
G LEFT FRONT WHEEL CYLINDER
H - FRONT BRAKE BOOSTER
Figure 13-3 Brake System
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Section III-WHEEL BRAKES
138. REMOVAL (Figure 134)
A. Remove wheel, hub, bearings and drum.
B. Remove spring (27), two nuts (24), four cups (30) and two springs (23).
C. Remove two C washers (26) and anchor strip (25).
D. Remove both shoe assemblies (21) from backing plate (11).
E. Remove two remaining cups (30) and springs (31).
F. Remove one cotter pin (28) from each pin (29) and remove both pins.
G. Remove hydraulic brake line or hose, two screws (13), lock washers (12), wheel cylinder
(4) and shield (10).
H. Remove nut (14) and lockwasher (15) from each guide pin (32).
I. Remove two nuts (16), lock washers (17) and both anchor pins (19).
J. Remove ten screws, nuts, lock washers and backing plate.
139. DISASSEMBLY
A. Press bushing (22) from each brake shoe with an arbor press.
B. With a brake shoe riveter press rivets (18) from shoes and remove linings (20).
C. Remove two pin assemblies (1), boots (2), pistons (3), cups (2) and spring (33) from
wheel cylinder (4).
1310. INSPECTION AND REPAIR
A. The braking surface of the drum must be smooth and free from galling, ridges and heat
checks.
B. Use a drum gage to determine if drum is out of round or tapered. The diameter of a new
drum is 16.50 inches.
C. Measure drum out of round with a dial indicator, out of round should not exceed .006
inch. If drum is beyond limits the drum must be refaced.
CAUTION: Do not remove more than .060 inch over the size of a new drum. Removing
more than .060 inch will cause overheating of brakes, severely weaken drum and shorten
lining life.
406
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10
28
21
U/
! 29
~
13 4 Service Brake A Figure -
407
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D. Inspect backing plate for warpage, cracks, loose or damaged hardware. If any damage is
found replace backing plate.
E. Inspect all pins, bushings, cups and mounting holes for elongation or worn areas.
NOTE: All brake components must be a snug fit. No play is permitted in any components.
F. I nspect brake shoes for warpage, heat damage, worn anchor pin bushing holes or worn
yoke pin contacting surface. Replace shoes if damaged.
G. Check linings for wear, replace lining if surface of lining is within .0825 inch to the near-
est surfacing rivet head. Replace linings that are greased or oil soaked.
H. Inspect all springs for worn areas or distortion. Replace if necessary.
I. Inspect wheel cylinder bore for scoring or pitting. A bore that has light scratches or
corrosion, can be cleaned with crocus cloth. Deep pits or scratches may require honing. When hon-
ing, the bore must not be increased more than .002 inch, if more than .002 inch is removed replace
complete cylinder.
13-11. ASSEMBLY
kit.
A. With a brake liner, rivet new lining (20) to shoes (21) and rearc shoes to brake drums.
B. Press new bushing (22) into brake shoe.
C. Assemble wheel cylinder (4) in reverse order of disassembly using a wheel cylinder repair
NOTE: Dip wheel cylinder, spring retainer, cup and piston in brake fluid prior to assembly
for lubrication.
13-12. INSTALLATION
A. Position backing plate (11) to axle housing and secure with ten screws, lock washers and
nuts.
B. Install shield (10) and wheel cylinder (4) to backing plate with two lock washers (12)
and screws (13). Connect brake line to cylinder.
C. Install two guide pins (32) and secure with lock washers (15) and nuts (14).
D. Position anchor pins (19) into backing plate with punch marks together and wrench flats
in line vertically. Install lock washers (17) and nuts (16). Tighten nuts but do not torque.
E. Install spring return pin (29) to each brake shoe (21) and secure with two new cotter pins
(28) each.
F. Install two springs (31), two cups (30) and position both brake shoes on anchor pins.
G. Position anchor (25) onto anchor pins and secure with two new C washers (26).
H. Install two cups (30), spring (23) and nut (24) to each guide pin.
408
VEHICLE
I. Install shoe return spring (27).
J. Install drum, bearings and hub. Adjust bearings.
13-13. MAJOR ADJUSTMENT (Figure 13-5).
NOTE: For mi nor brake adjustment refer to limited vehicle maintenance chapter.
A. Bleed brake system at each wheel cylinder to be certain that system is free of all air.
B. Remove inspection cover from outside of brake drum. Rotate drum until opening is l-Y,
inches from bottom end of front brakeshoe. Insert 0.010 inch feeler gage between drum and bot-
tom end of brake shoe. Loosen nut on anchor pin. Hold nut with one wrench and turn anchor pin
clockwise on left side, counterclockwise on right side, with second wrench until 0.010 inch clear-
ance is obtained. Tighten nut to 120-150 ft. Ibs. torque. The anchor pins are eccentric to adjust
brake shoes to drum.
C. Rotate drum until opening is lY, inches from top end of front brake shoe. Insert a 0.020
inch feeler gage and turn adjusting cam until 0.020 inch clearance is obtained. Check lower clear"
ance again. Repeat above steps until proper clearances are obtained.
D. Repeat steps 2 and 3 on rear brake shoes.
NOTE: Anchor pin on rear brake shoe must be turned counterclockwise on left side, clock-
wi'se on r i g h ~ side, to tighten brake.
E. Install inspection cover on drum and install wheel.
F. Repeat operations 2 through 5 above on remaining three wheels.
FEELER
GAGE
Figure 13-5 Brake Adjustment Major
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Section IV - BRAKE VACUUM BOOSTERS
NOTE: The brake vacuum booster is a self contained unit and requires that complete unit
be replaced if defective.
13-14. REMOVAL (Figure 13-6)
A. Open rear engine hatch and engine access door. Remove exhaust outlet grille and fording
shroud.
B. Remove batteries to prevent accidental shorting.
C. Loosen air inlet hose clamps at engine and air cleaner. Remove hoses.
D. Remove two thumb screws securing air cleaner clamps. Lower clamp halves and remove
air cleaner.
E. Disconnect hydraulic lines from vacuum brake booster, cap and secure ends.
F. Disconnect vacuum line from brake booster, protect end connector.
G. Remove top mounting screw and lockwasher, two nuts, and lockwasher securing booster
to fan shroud plate. Remove rear booster.
NOTE: The front brake system booster is located in forward hull wall near brake pedal
assembly. Remove by disconnect lines and attaching screws in same manner as rear booster.
13-15. INSPECTION
A. Inspect outside of booster for dents, cracks or rust. Booster must be replaced if any dam-
age is found that could impair its operation.
B. Inspect all connectors, lines, hoses and fittings for any damage, replace if necessary.
C. Check that engine vacuum pump is operating properly.
13-16. INSTALLATION
A. Position vacuum brake booster on fan shroud plate and secure with one screw and lock
washer and two nuts and lock washers.
B. Connect vacuum line to brake booster.
C. Connect hydraulic lines to vacuum brake booster.
D. Position air cleaner and lower clamp halves and secure clamp halves with two thumb
screws.
E. Install air cleaner hose and tighten hose clamps.
F. Replace exhaust outlet grille and fording shroud.
NOTE: Install brake vacuum booster for front system in similar manner.
G. Bleed brake system.
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Section V - VACUUM PUMP
13-17. REMOVAL (Figure 13-6)
A. Cylinder Head.
NOTE: Cylinder head may be removed for repair or replacement without removing pump
assembly from engine.
1. Disconnect vacuum line from cylinder head cover.
2. Disconnect water inlet and outlet lines from cylinder head.
3. Disconnect air return line from cylinder heads.
4. Remove capscrews and washers securing head cover. Lift off cover and discard gasket.
5. Remove cylinder head and discard gasket.
B. Pump Assembly.
1. Drain cooling system.
2. Remove radiator and shroud assembly.
3. Remove fuel pump assembly.
4. Remove capscrewssecuring vacuum pump to accessory drive housing.
5. Remove vacuum pump.
AIR RFTIJRN
VACUUM LINE
CONNECTION
Figure 13-6 Vacuum Pump
411
WATER IN & OUTLET
VEHICLE
1318. DISASSEMBLY
A. Cylinder Head.
1. Remove nut, copper washer and stud from center of cylinder head cover.
2. Lift intake valve seat from cylinder head.
3. Remove intake valve and spring from cylinder head.
4. Press exhaust valve assembly from underside of head with thumb pressure.
5. Remove 0 rings from exhaust valve seat.
6. Remove exhaust valve from exhaust valve seat.
B. Crankcase Assembly.
1. Install gear puller and pull drive gear.
2. Remove gear key.
3. Remove capscrews, lockwashers and lockplates securing support to crankcase. Remove
support and gasket. Discard gasket.
4. Rotate crankshaft and remove from crankcase and connecting rod.
CAUTION: Do not damage rod bearing in removal and assembly.
5. Clean carbon from worn ridge at top of crankcase bore, then push piston and rod
assembly out top of crankcase.
6. Remove piston rings from piston. Discard rings.
7. Remove the piston pin snap rings.
8. Place piston in hot water to expand piston pin bore.
9. Push piston pin from piston and remove rod.
CAUTION: Do not drive pin from piston, as this will distort piston.
10. Place parts in a pan or rack to prevent them from getting damaged.
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VEHICLE
13-19. CLEANING
1. Immerse cylinder head in a cleaning solvent that is not harmful to aluminum. Remove
all carbon from valve cavities as well as rust and scale from water cavities. Use compressed air to blow
dirt from all cavities.
CAUTION: Do not use screwdriver to remove carbon and scale as this may damage the sealing
surfaces.
2. Clean oil drillings in crankshaft and support with clean, dry compressed air. Remove
drill out oil restrictive orifice, fig. 13-7.
13-20. INSPECTION AND REPAIR
A. Cylinder Head.
1. Check for visible cracks, breaks or mutilation in the cylinder head and head cover.
2. Check exhaust valve seat height, see fig. 13-8. If height is less than 0.485 inch (12.32
mm l. discard seat.
Figure 13-7 Cleaning Oil Orifice
413
VEHICLE
3. Check intake valve seat height, see Fig. 13-9. If height is less than 0.270 inch (6.86
mm). discard seat.
4. Apply "bluing" to exhaust and intake valve seating surfaces to check seats. If seating
surfaces are not 100% true they may be lapped. If lapping will reduce valve seat height beyond wear
limits, discard valve assembly.
5. If lapping is necessary to acquire a good valve seat:
a. Apply "bluing" to surface of exhaust valve to be lapped and allow to dry.
b. Apply lapping compound to exhaust valve and place valve on seat.
c. Insert exhaust valve seat in lapping block.
d. Using a standard hand valve lap per and rubber suction cup, lap valve till a good seat
is acquired. Add additional lapping compound as necessary.
e. Valve must be flat within 0.001 inch (0.0254 mm) total indicator reading.
f. Clean parts thoroughly to remove all lapping compound.
6. Lapping intake valve:
a. I nstall rubber buffer to top of exhaust valve seat.
b. Apply "bluing" to intake valve. Allow to dry.
c. Apply lapping compound to intake valve. Place intake valve seat on intake valve and
lap until a good seat is acquired. Valve must be flat within 0.001 inch (0.0254 mm) total indicator
reading.
.485"
112.32 mm)
Figure 13-8 Checking Exhaust Valve
414
.270"
(6.86mm)
Figure 13-9 Checking Intake Valve
VEHICLE
d. Remove all lapping compound before assembly.
7. Test intake and exhaust valve springs on spring tester that is capable of very accurate
measurements of spring length and load by means of standard and dial indicator gauges. Spring data
is given in Table 13-1.
8. Check head for water leakage.
a. Assemble cylinder head cover to head using new gasket.
b. Assemble cylinder head to crankcase using new gasket. Tighten capscrews alternately
to a final torque of 15 to 17 ft. Ibs. (20 to 23 Nm).
c. Plug the water outlet and apply water under 20 to 30 psi (138 to 207 KPa) pressure
through water inlet.
d. Check for leaks. Discard parts as necessary. Release pressure from inlet. Remove
plug from water outlet and replace water outlet fitting.
e. Remove head cover.
Table 13-1 Spring Data
Pounds Load Required to Compress
Approx.
Free
Length No. Wire Dia. Length New New Worn
Spring Use In. (cm) Coils In. (em) In_ (cm) Min. (kg) Max. (kg) Limit (kg)
Exhaust Valve .670 3 .080 .280 8.8 10.2 8.3
(1.7018) (.2032) (.7112) (3.9917) (4.6267) (3.7649)
I ntake Valve .500 2.75 .062 .280 .65 1.10 .55
( 1.2700) (.1575) (.7112) (.2948) (.4989) (.2495)
B. Crankcase.
1. Check crankshaft for scratches, scoring and wear. Replace if worn beyond replacement
limits given in Table 13-2.
2_ Check front support for scratches, scoring and wear. Replace if worn beyond replace-
ment limits given in Table 13-3.
3. Check support bearing for scoring and wear. If 1.0. exceeds 1.252 inch (31.80 mm),
replace support.
4. Check connecting rod bearings for scoring or wear. If 1.0. exceeds 1.935 inch (49.263
mm) at crankshaft end or .689 inch (17.50 mm) at piston pin end connecting rod must be scrapped.
Connecting rods are available in .010 inch (0.25 mm) undersize for reground crankshaft.
415
VEHICLE
Table 132 Crankshaft Dimensions
Front Support Journal Connecting Rod Journal Engine Gear Case Journal Rear Coupling Journal
Min. Max. Worn Min. Max. Worn Min. Max. Worn Min. Max. Worn
In. (mm) In. (mml Limit In. (mm) In. (mm) Limit In. (mm) In. (mm) Limit In. (mm) In. (mm) Limit
1.872 1.8n 1.811 1.9345 1.9355 1.9330 1.1415 1.1485 1.1465 1.872 1.813 1.811
141.551 141.511 147.521 149.1361 149.162 149.0981 141.551 144.511 141.521
Table 133 Support Dimensions
Distance Between Thrust Faces Bearing Inside Dimension
New Dimension
Min. In. (mm) Max. In. (mm)
Worn
Replacement New Dimensions
Limits In. (mm) Min. In. (mm)
Worn
Replacement
Max. In. (mm) limits In. (mm)
1.694 (43.03) 1.696 (43.08) 1.674 (42.52) 1.8740 (47.600) 1.8760 (47.650) 1.8775 (47.688)
5. Check connecting rod for bend and twist. Bend must not exceed .002 inch (0.05 mm)
or twist .004 inch (0.10 mm).
6. Check gear for excessive wear and scoring.
7. Check piston pin outside diameter with micrometer. New pin outside diameter is .6875
to .6876 inch (17.46 to 17.465 mm), if worn smaller than .6872 inch (17.45 mm) pin should be
replaced.
8. I nspect piston for scoring, cracks, wear or other damage.
9. Measure piston wear one inch below and at right angle to the piston pin bore. If skirt
diameter is less than 3.6165 inch (91.860 mm) at 70 degrees F discard piston. New skirt diameter is
3.619 to 3.620 inch (91.92 to 91.95 mm).
10. Measure piston pin bore at 70 degrees F with inside micrometer. New piston pin bore
is .6875 to .6880 inch (17.463 to 17.475 mm), if worn larger than .6885 inch (17.488 mm) replace
piston.
11. Checking ring groove wear:
a. Install a new ring in groove of piston. (Not Teflon ring).
b. I nsert a .004 inch (0.10 mm) feeler gauge between ring and piston groove.
c. Compress ring in piston groove. If ring is below piston land surface with feeler
gauge in place, wear is excessive and piston must be scrapped.
12. Check piston ring gap:
a. Insert ring (one at a time) in cylinder, seating it squarely with a piston head in an
unworn portion of cylinder bore.
416
VEHICLE
b. Measure with feeler gauge, gap should be .010 to .020 inch (0.2540 to 0.5080 mm).
13. Visually inspect cylinder bore for scoring. Hone oversize as needed.
14. Check crankcase cylinder bore for out-of-roundness and wear with a dial bore gauge.
Bore and hone cylinder bore to accommodate 0.010, 0.020 or 0.030 inch (0.25,0.50 or 0.76 mm)
oversize pistons and rings with 150 grit stone if:
a. Out-of-roundness exceeds 0.0015 inch (0.038 mm).
b. Bore is worn beyond 3.6285 inch (92.164 mm) (3.6295 [92.189 mmJ for 215378).
15. New crankcase cylinder bore is 3.625 to 3.626 inches (92.08 to 92.01 mm) (3.626 to
3.627 inches [92.10 to 92.13J for 215378).
16. Check crankcase bushing in crankcase, if worn larger than 1.8780 inch (4.7701 em),
bushing must be replaced.
17. Replacing crankshaft bushing in crankcase.
a. Press out old crankshaft bushing.
CAUTION: Support crankcase while removing or installing bushing.
b. Lubricate bushing bore in crankcase and press in new bushing until flush with bore
surface.
13-21. ASSEMBLY
A. Cylinder Head.
1. Coat valve assembly with high detergent lubricating oil (No.1 0, 20 or 30 wt.) prior to
assembly in head.
2. Place exhaust valve on exhaust valve seat; install new small and large 0 rings on exhaust
valve seat.
3. Install exhaust valve unit in head. Apply pressure with thumbs to seat exhaust valve.
4. Install intake valve spring on top of exhaust valve seat.
5. I nsert intake valve on top of seat.
CAUTION: Lapped surface of valve must be up.
6. I nsert intake valve seat on top of intake valve.
7. Install cylinder head cover with gasket to cylinder head.
8. Secure with flatwashers, lockwashers and capscrews. Torque to 15-17 ft. Ibs. (20 to
23 kPa).
9. Install valve screw into center of head cover and torque screw to 5 in. Ibs. (.6 Nm).
CAUTION: Over torquing of screw'will cause air and water leakage.
417
VEHICLE
10. Install copper washer and locknut on valve screw and tighten to secure valve screw.
11. Install air and water fittings.
12. Install air and water lines to cylinder head.
B. Crankcase.
1. Heat piston in hot water to expand piston pin bore and install piston pin through
piston and connecting rod.
CAUTION: Do not drive piston pin in piston pin bore. Driving piston pin into piston will
distort piston.
2. Secure piston pin with snap rings.
3. Install piston rings on piston. Stagger piston rings.
CAUTION: Keep word "Top" on compression rings up (toward crown of piston). Do not
scratch piston when installing rings. Do not clamp rod in vise unless rod is protected by soft
wood.
4. Lubricate piston rings and crankcase bore.
5. Install piston and rod assembly in crankcase using a standard ring compressor.
6. Lubricate crankshaft journals and install crankshaft through connecting rod and the
crankcase bushing.
7. Install drive gear key in crankshaft when used.
8. Support crankshaft with support block.
CAUTION: Do not let crankcase rest on table.
9. Press drive gear on crankshaft, with sleeve or pipe, until against shoulder.
10. Check crankshaft end clearance. Clearance must be within limits shown in Table 13-4.
Table 134 Crankshaft End Clearance
Cold Min.
Inch (mm)
.006 (0.15)
13-22. BENCH TEST
A. PUmp Assembly.
Cold Max.
Inch (mm)
.010 (0.25)
Worn In. (mm)
Replacement
.030 (0.76)
Hot Min.
Inch (mm)
.003 (0.08)
1. Mount the vacuum pump on the proper fixture and connect water, oil and air lines.
418
VEHICLE
2. Start vacuum pump and bring speed to 800 rpm. Run at this speed for 30 seconds dis-
charging to atmosphere.
a. Lubrication: Oil pressure to be maintained between 50 to 60 psi (345 to 414 kPa),
oil temperature not to exceed 210 degrees F.
b. Cooling: Water to be supplied at the rate of 3 gallons per minute (11 l/min.).
3. Check for oil and water leaks, overheated bearings, and excessive noise.
4. Connect vacuum gauge to inlet. Operate the vacuum pump at 1200 rpm. The vacuum
must be a minimum of 26 in. Hg. (660 mm Hg).
5. Increase speed to 2500 rpm. Operate for five minutes. The vacuum must be a mini-
mum of 26 in. Hg. (660 mm Hg) at the end of 5 minutes of operation. Stop the vacuum pump,
disconnect oil and water lines. Remove from stand.
13-23. TROUBLESHOOTING
Complaint Possible Cause
I
A. Vacuum pump fails to 1. Discharge valve leaking.
pull vacuum.
2. Excessive cylinder, piston or ring wear.
3. I ntake valve stuck open.
4. Excessive leakage of intake valve.
5. Leak in vacuum lines between vacuum pump and brakes.
6. Vacuum pump head cover leaking.
B. Noisy operation. 1. Same as Step "2" above.
2. Worn or burned out bearings.
3. Excessive wear on gear.
4. Excessive end play.
C. Vacuum pump head cover 1. Machined surfaces mutilated.
leaking air or water.
2. Gasket material left on surface when rebuilt.
3. Excessive torque on valve assembly retaining screw.
4_
Cracked head or head cover.
1324. INSTALLATION
A. Install pump assembly in reverse order of removal.
419
VEHICLE
Section VI - PARKING BRAKE
1325. REMOVAL
NOTE: Complete removal of the parking brake assembly is obstructed by the gear coupling
and transfer unit when the power train is installed in the vehicle.
If complete brake removal is required, disconnect coupling sleeves and loosen or remove trans
fer unit mounting hardware as necessary to allow lifting of the input side of the transfer unit so it
does not obstruct brake removal. Replacement of the parking brake shoes and cleanup of minor
brake drum scoring or glazing can be accomplished without removing the coupling or moving the
transfer unit.
To remove the parking brake assembly from the transmission with the power train removed
from the vehicle see the power train chapter.
A. Brake Shoes (Figure 1310).
CAUTION: Block wheels of vehicle to prevent movement when brake is inoperative.
1. Place parking brake lever in OFF position.
2. Disconnect clevis from brake actuator lever.
3. Remove eight screws, nuts and lockwashers securing brake drum to flange.
4. Pull brake drum rearward away from brake shoe assembly.
5. Disconnect two return springs. Remove brake shoes.
B. Control Linkage (Figure 1311).
1. Remove nut (9), screw (22), lockwasher (10) and clamp (21) freeing cable from
transmission.
2. Remove screw (16), lockwasher (15) and clamp (14) from front of cable (11).
3. Remove two nuts (12), screws (19), brake lever (20) and spacers from brake lever.
Cable can be removed by tracing the cable routing and releasing it from tie downs.
4. Remove lever (20) from cable by removing cotter pin and clevis pin from cable yoke.
5. Remove yoke (3) and spring (5) from cable by removing nuts (2) and washer (23).
NOTE:- Both ends of cable have permanent collars which prevent further disassembly.
1326. INSPECTION AND REPAIR
A. Inspect drum and rough or scored braking surface, stud holes for elongation. Clean rough
ness from braking surface or replace drum. If holes are damaged replace drum.
B. Inspect backing plate and actuator for cracks, warpage or worn working surfaces. Replace
as necessary.
420
VEHICLE
Figure 13-10 Parking Brake - Exploded View
1\ l 2 3 4 r
1
:) /8
< J(::J
2 21
22

11

,--
11
/
'
, 18
1
1

/
19 r-
Figure 13-11 Parking Brake Control - Exploded View
421
VEHICLE
C. Brake shoes must be replaced if there is less than .030 inch lining to closest surfacing
rivet head. Replace brake shoes as a set.
D. Inspect all control linkage and replace worn or damaged parts.
1327. INSTALLATION
Install all parking brake components in reverse order of removal.
NOTE: Torque flange mounting bolt to 83-100 ft. Ibs. (113-136 Nm). Bend washer tab
against flat of bolt head, stake washer into recess in flange retainer. Torque brake drum screws
31-33 ft. Ibs. (42-45 Nm).
13-28. ADJUSTMENT
A. Back off parking brake lever adjustment to allow maximum adjustment by vehicle driver.
B. Adjustment is made at brake end of cable by adjusting nuts and yoke up or down so that
when released there is no shoe drag on drum as brake will hold vehicle on a 60% incline.
NOTE: Do not twist cable while adjusting yoke.
422
VEHICLE
CHAPTER 14
Steering
The hydraulic steering system, Figure 14-1, consists of a steering wheel, steering gear with
integral power cylinder and control valve, pitman arm, drag link, tie rod, tubing, hoses and fittings.
Hydraulic pressure is provided by an engine driven dual pump which also provides hydraulic pres-
su re to the wi nch.
Section I - STEERING WHEEL
14-1. REMOVAL
A. Remove button in center of steering wheel by pressing down on button and turn
counterclockwise one-quarter turn to disengage button from steering wheel.
B. Remove nut securing steering wheel on steering gear shaft.
C. Place steering wheel puller adapter on end of steering gear shaft. Install steering wheel
puller with hooks engaging puller ring and pull wheel from shaft.
14-2. INSTALLATION
A. With front wheels pointing straight ahead and steering alignment .narks centered, place
steering wheel on steering gear shaft splines with one spoke pointing straight ahead and secure with
nut.
B. Place button in steering wheel recess, press down and turn clockwise until engaged.
423
A WINCH VALVE
8 WINCH MOTOR
C- FILTER
D PUMP
E RESERVOIR
F STEERING GEAR
VEHICLE
31
F
3l
31
30
13
D
Il
16
Figure 14-1 Winch and Steering Hydraulic System
424
VEHICLE
Section II - PITMAN ARM
14-3. REMOVAL (Figure 14-3)
A. Disconnect drag link from pitman arm.
B. Loosen locking screw on nut securing pitman arm in position. Remove nut.
C. Remove pitman arm from output shaft. Use suitable puller if necessary.
14-4. INSTALLATION
A. With steering gear at mid travel, align arrow on output shaft with arrow on pitman arm.
Slide pitman arm onto shaft.
B. Secure pitman arm to sector shaft with nut. Torque to 275 to 295 ft. Ibs. (373-400 Nm).
Torque locking capscrew to 18 to 20 ft. Ibs. (24-26 Nm).
C. Connect drag link to pitman arm.
PITMAN ARM
NUT\r,-__________________________ ~
Figure 14-3 Removing or Installing Drag Link, Cylinder and Pitman Arm
425
VEHICLE
Section III - STEERING GEAR
145. REMOVAL (Figure 144)
A. Remove pitman arm. Use suitable puller if necessary.
B. Place suitable container under steering gear to collect hydraulic fluid that escapes when
hydraulic lines are disconnected.
C. Disconnect both hydraulic lines from steering gear. Turn steering gear completely to the
left and then to the right. This will remove most of the oil from the housing. Plug lines and ports
using suitable plugs.
D. Remove steering wheel.
E. Remove turn signal switch.
F. Remove nuts, cap screws and lockwashers securing steering gear to mounting pad. Discard
"0" on mounting face.
G. Remove steering gear.
146. DISASSEMBLY (Figure 145)
A. Place gear in suitable overhaul stand.
NOTE: When disassembling gear, mark parts so that gear may be assembled to the same ad-
justments.
B. Remove 0 ring from face of gear mounting cover, if still in place.
C. Remove relief valve plungers from both ends of gear.
D. Remove bolts securing mounting cover to gear assembly. Use a soft hammer and tap on
end of output shaft to loosen cover. Remove output shaft and gear assembly along with cover. Ob
serve marks on piston and output shaft gear for correct reassembly.
E. If repairs are necessary, remove roll pin and retaining pin from output shaft gear. Remove
gear from shaft with suitable puller.
F. Make reference marks on gear housing, cylinder head, bearing cap and bearing cap exten-
sion.
G. Remove cyl inder head and gasket.
H. Remove three cap screws securing bearing cap extension to bearing cap. Remove exten
sion. Remove bushing from extension if worn or damaged.
I. Remove ten bolts from bearing cap, then turn the actuating shaft and bearing cap out of
the actuating valve.
J. Remove lock pin from bearing retaining nut.
K. Use a spanner wrench to loosen retainer nut, then remove nut.
426
DIRECTIONAL
SIGNAL
CONTROL
----- NUT 14) .------
14)
VEHICLE
SUPPLY
HYDRAULIC
LINE
Figure 144 Removing or Installing Steering Gear
427
VEHICLE
31


15

33---1:1 "-
34
Figure 145 Steering Gear - Exploded View
428
VEHICLE
L. Press actuating shaft from bearing cap. DO NOT dismantle the actuating shaft as it is only
serviceable as an assembly with bearing.
M. Remove dirt seal and high pressure seal from bearing cap using suitable seal remover tool.
N. Remove seal backup washer, if worn or damaged. Pull piston and valve assembly from
housing.
NOTE: Piston, actuating valve, expander flange and adjusting nuts are available for replace
ment only as part of a complete piston and valve assembly.
The piston ring, relief valve balls, spring and seats, valve positioning pin and 0 ring are also
part of the complete piston and valve assembly, but are available separately for replacement.
O. Remove relief valve seats.
NOTE: Do not lose relief valve balls which are spring loaded.
P. Remove relief valve spring.
O. Remove quad ring seals from output shaft bore of housing and mounting cover.
R. Remove bushing from housing, mounting cover and beaing cap extension if replacement
is required.
14-7. CLEANING, INSPECTION AND REPAIR
A. Cleanliness is of utmost importance. Use clean solvent to wash grease, oil, or dirt from all
metal parts. Clean machined parts individually to avoid damage due to bumping together of parts.
Use lint free cloths, dipped in a clean solvent to clean all machined surfaces. After all parts are clean-
ed, dry parts with compressed air.
B. A careful visual inspection of the steering gear parts is very important. Inspect components
for burrs or nicks, especially on or near the rack (teeth), on the piston.
C. If a raised burr is found on the piston, it should be removed with a fine hand stone. All 0
rings, seals and gaskets should be replaced. Inspect the output shaft bushings for wear.
14-8. ASSEMBLY (Figure 14-5)
A. Install new bushings (if removed) in the gear housing, mounting cover and bearing cap
extension, using a press and a straight line pushing action. The bushing is pushed into the gear hous-
ing, so that the inside face of bushing is flush with inside face of gear housing, figure 14-6_ When new
bushings are pressed into the cover, the face of the bushing must be flush with the inside edge of
bearing surface. When reinstalling bushing in output shaft bore of housing, if it goes in easily and
heavy press resistance is not encountered, carefully remove bushing. Thoroughly cleanbushing of oil
and grease and clean bore of foreign material by scraping with a piece of brass sheet. Bushing and
bore should then be completely washed and dried. Coat exterior of bore and bushing with Loc-
tite high strength retainer compound. Reinstall bushing and allow a minimum of six hours curing
time. When the curing time has elapsed, any excess Loc-tite in quad ring groove or elsewhere should
be removed by washing with naphtha (Fig. 14-6).
429
VEHICLE
B. Install a new quad ring in the groove in the gear housing and mounting cover.
C. Position the relief valve spring and one relief valve ball into the valve bore (if removed).
Then, using a 3/16" Allen wrench, install one of the valve seats. The valve seats must be tight and
flush with or slightly below the end surface of the piston.
D. Install the second relief valve ball seat in the same manner.
E. Install the valve positioning pin in the piston (if removed). Turn pin inward with a screw
driver until it is below the outside surface of the piston. The flats must enter into the piston 1/4"
to engage the mating slot in the valve.
F. Install piston ring (if removed).
G. Install piston and valve assembly using a ring compressor. Be sure piston is installed with
the actuating shaft opening, facing the bearing cap end, figure 147.
NOTE: Before installing piston coat piston and cylinder walls with oil.
H. Using a new gasket, reinstall the cylinder head. The alignment marks will aid in reinstall
ing the head in the correct position. The opening for the plunger must be in alignment with relief
valve in the piston. Torque bolts 33 ft. Ibs. (45 Nm).
I. Press a new oil seal and dirt seal into bearing cap, figures 148 and 149. Press evenly.
J. Lubricate surface between seals before installing actuating shaft assembly.
K. Press actuating shaft assembly into the bearing cap, figure 1410.
L. Install bearing retaining nut. Insert locking pin through the hole in bearing cap and into
the hole in nut. If a new nut is being used, drill a 3/32" hole in nut. The nut must be in place to drill
this hole. Drill through the locking pin hole in the bearing cap and 3/16" into the nut.
BUSHING FACE
FLUSH WITH
GEAR HOUSING
FACE
Figure 146 Bushing Installation
430
BUSHING FACE
FLUSH WITH
COVER FACE
VEHICLE
RING COMPRESSOR
________ PR ESS
-==---=:---
BEARING CAP
ADAPTER
PISTON
Figure 14-7 Installing Piston Figure 14-8 Installing Oil Seal
''---- '- ___ PRESS
BEARING CAP
ACTUATING SHAFT
L..-_- ADAPTER
BEARING CAP
BEARING CAP
DIRT SEAL BEARING
Figure 14-9 Installing Dirt Seal Figure 14-10 Installing Actuating Shaft
431
VEHICLE
M. Using a new gasket on the bearing cap, thread actuating shaft into the valve. Line up punch
marks on gear housing and bearing cap. Turn shaft until cap comes into place on the end of cylinder.
Check plunger hole alignment with valve seat in the piston. Torque bolts 33 ft. Ibs. (45 Nm).
N. Install bearing cap extension. Tighten three attaching screws to 33 ft. Ibs. (45 Nm).
O. Align the timing mark on the output shaft gear with marked spline on the output shaft
and reassemble. Use a press if necessary, figure 14-11.
P. Insert output shaft and gear assembly in gear mounting cover.
O. Install new 0 ring on gear mounting cover. Install mounting cover with shaft and gear
into gear housing.
CAUTION: Be certain gear teeth are properly centered in rack teeth. Marks on output shaft
gear must align with mark on piston.
R. Install mounting cover attaching bolts and lockwashers. Torque bolts 83 ft.lbs. (113 Nm).
S. Install bearing cap and cylinder head plungers, using new 0 rings.
NOTE: Final plunger adjustment is made with the steering gear installed in the vehicle.
OUTPUT SHAFT
GEAR
I ~ ~ . . - - ~ L . . ~ - - - - PRESS
I_----OUTPUT SHAFT
Figure 14-11 Installing Output Shaft
432
VEHICLE
149. INSTALLATION (Figure 144)
A. Position steering gear in vehicle with new 0 ring installed on gear mounting face.
B. Install screws, nuts and lockwashers securing gear to mounting pad. Torque 100120 ft.
Ibs. (136163 Nm).
c. Apply sealant to threads of hydraulic line fittings and install lines in steering gear ports.
D. Install turn signal switch.
E. Install steering wheel.
NOTE: With front wheels parallel with centerline of vehicle and markers on steering gear
housing and shaft aligned, install steering wheel with one spoke parallel with centerline of
vehicle.
F. Install pitman arm.
NOTE: Arrow on pitman arm must align with arrow on steering gear output shaft.
G. Install shaft nut. Torque 275295 ft.lbs. (373400 Nm).
H. Install locking capscrew in shaft nut. Torque 1820 ft. Ibs. (2426 Nm).
I. Connect drag link to pitman arm.
1410. ADJUSTMENT
A. Start engine and allow it to run at fast idle.
B. With full weight of vehicle on all wheels, turn the steering wheel to the left until the relief
valve opens. You can hear the relief valve open. DO NOT force steering wheel.
c. Adjust the plunger in bottom end of steering gear until .12 inch (3 mm) clearance is main
tained at left wheel stop when relief valve opens.
D. Repeat procedure by turning steering wheel to the right and adjusting plunger on top of
steering gear.
NOTE: It may be necessary to adjust length of drag link to achieve proper steering gear
adjustment.
433
VEHICLE
Section IV - HYDRAULIC PUMP - STEERING AND WINCH
The hydraulic pump is a dual vane type providing hydraulic pressure to operate the power
steering system and winch. The pump is mounted in the rear of the engine overhanging the trans-
mission and is driven from the engine gear train. The maximum operating pressure is 1750 psi.
14-11. REMOVAL (Figure 14-12)
pump.
A. Drain hydraulic reservoir.
NOTE: Place suitable container under pump to catch residual hydraulic fluid when hydraulic
lines are disconnected.
B. Remove four hydraulic lines on pump. Plug lines and posts with suitable plugs.
C. Remove two screws and lockwashers securing pump to engine mounting pad. Remove
t+--_ HYDRAULIC
A'i==-- CONNECTIONS
SCREW 12)
LOCKWASHER 12)
Figure 14-12 Hydraulic Pump
434
VEHICLE
14-12. DISASSEMBLY (Figure 14-13)
A. Clamp the p\.lmp body in a vise (not too tightly) cover end up. Remove four cover screws.
B. Note position of cover posts before I ifting off cover and 0 ring. Set cover aside for further
disassembly.
C. Remove pressure plate, 0 ring and vane washer.
D. Note position of rotor ring for correct reassembly. Lift off ring and remove locating pins.
E. Remove rotor and vanes from shaft.
\
F_ Remove inlet body.
G. Remove second pump cartridge in same manner as first.
H. Note position of second pressure plate for correct reassembly. Remove pressure plate,
o ring and spring.
I. Turn outlet body over and remove snap ring retaining shaft in outlet body.
J. Tap shaft out of body with soft mallet.
K. Remove small snap ring from .shaft behind bearing.
L. Support the shaft inner bearing race and press the shaft out of bearing.
M. Pull shaft seal out of body with suitable hooked tool.
N. Remove plug from snap ring side of cover.
O. Remove plug that releases spring and relief valve.
P. Insert suitable tool from snap ring end of bore and remove relief valve subassembly.
O. Remove snap ring from cover.
NOTE: Complete cartridges are available in service kits for rebuilding the hydraulic pump.
14-13. INSPECTION AND REPAIR
A. Cleaning. All parts must be thoroughly cleaned and kept clean during inspection and
assembly. The close tolerance of the parts makes this requirement more stringent than usual. Clean
all removed parts, using a commercial solvent that' is compatible with the system fluid. Compressed
air may be used in cleaning, but it must be filtered to remove water and contamination. Clean com-
pressed air is particularly useful in cleaning spools, orifices, and cover passages.
B. Discard the used shaft seal and all 0 rings. Wash the metal parts in a solvent, blow them
dry with filtered compressed air and place them on a clean surface for inspection.
C. Check the wearing surfaces of the body, pressure plate, ring and rotor for scoring and ex-
cessive wear. Remove light score marks by lapping. Replace any heavily scored or badly worn parts_
435
VEHICLE
3
()
Figure 14-13 H d .
y raulic Pump E - xploded V leW
436
I
I
I
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I
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VEHICLE
D. Inspect the vanes for burrs, wear and excessive play in the rotor slots. Replace the vanes
and rotor if the slots are worn.
E. Check the bearings for wear and looseness. Rotate the bearings while applying pressure to
check for pitted or cracked races.
F. Inspect the oil seal mating surface on the shaft for scoring or wear. If marks on the shaft
cannot be removed by .light polishing, replace the shaft.
G. Flow Control Cover: Check the relief valve subassembly for free movement in the cover
bore. Remove burrs from the valve by polishing, but DO NOT round off the corners of the lands.
Do not attempt to rework the valve bore. If the bore is damaged, replace the cover.
14-14. ASSEMBLY
A. Coat all parts with hydraulic fluid to facilitate assembly and provide initial lubrication. Use
small amounts of petroleum jelly to hold 0 rings in place during assembly.
IMPORTANT: During handling and shipping of the precision machined cartridge parts, it is
possible to raise burrs on the sharp edges. All sharp edges on the parts of a new cartridge kit
should be stoned prior to installation.
B. Assembly of Flow Control Cover. Assemble the snap ring in place within the bore (seat
firmly in the groove). Insert the valve in the bore, small land first. Then install the spring and both
pipe plugs.
C. Assembly of Pump. Begin assembly by pressing the shaft into the front bearing while sup-
porting the bearing inner race. Install the small snap ring on the shaft.
D. Before assembling the shaft seal, determine the correct position of the sealing lip. Seals are
assembled with the garter spring toward the pumping cartridge. Press the seal firmly in place and lu-
bricate the lip with petroleum jelly or other grease compatible with the system fluid. Slide the drive
shaft into the body until the bearing is seated. Tap lightly on the end of the shaft if necessary. In-
stall the snap ring.
E. Install new 0 rings in the bodies and cover. Insert the ring locating pins in the body and
assemble the rings so that the arrow on the perimeter points in the direction of rotation. When in-
serting the vanes in the rotor slots, be certain the radius edges of the vanes are toward the cam ring.
F. Check for correct positioning of pressure plates and springs.
G. Install the cover with the outlet port in the correct position. Tighten the cover screws to
75-85 ft. Ibs. (101-115 Nm) torque. Rotate the shaft by hand to insure that there is no internal
binding.
14-15. INSTALLATION
A. I nstall in reverse order of removal.
437
VEHICLE
Section V - TIE ROD
1416. REMOVAL (Figure 1414)
A. Place vehicle of lever surfaces and apply parking brake.
B. Remove cotter pins from tie rod end studs.
C. Loosen tie rod end stud nuts two turns. Hit top of nut with hammer to drive stud loose
from steering knuckle.
D. Remove nuts from each end and remove tie rod.
1417. INSTALLATION
A. Position tie rod in steering knuckles and secure with nut and new cotter pin at each end.
B. Check and adjust toe-in of front wheels if necessary.
TIE
Figure 14-14 Tie Rod
438
COTTER PIN
NUT
TIE ROD
END CLAMP
VEHICLE
Section VI - DRAG LINK
14-18. REMOVAL (Figure 14-15)
A. Remove cotter pin (7) from nut (6) and socket (5). Discard cotter pin.
B. Loosen nut two turns. with a hammer drive socket loose from steering arm. Remove nut
socket from steering arm.
C. Remove cotter pin (13) from drag link (33). Loosen adjusting plug (12) and disconnect
drag link from pitman arm ball stud.
14-19. DISASSEMBLY
A. Remove adjusting plug (12), ball seats (11) and spring (10) from drag link.
B. Remove nut (1), lock washer (2) and screw (8) from clamp (3).
C. Unscrew socket (5) from drag link.
14-20. ASSEMBLY
Assemble drag link in reverse order of disassembly.
14-21. INSTALLATION
Install drag link in reverse order of removal using new cotter pins and check adjustment ..
Lubricate both lubrication fittings.
JJ
Figure 14-15 Drag Link - Exploded View
439
VEHICLE
1422. ADJUSTMENT
stud.
A. Loosen screw and nut securing clamp to drag link.
B. Remove cotter pin and loosen adjusting plug and disconnect drag link from pitman arm ball
C. Adjust length of drag link by screwing tube on or off socket.
NOTE: When drag link is properly adjusted, steering gear will be centered on its high point,
alinement marks on steering housing and sector shaft alined, and front wheels in straight ahead
position.
D. When properly adjusted, tighten clamp screw and nut 60 to 65 ft. Ibs. torque.
E. Connect drag link to pitman arm ball stud and tighten adjusting plug. Secure plug with new
cotter pin.
440
VEHICLE
CHAPTER 15
Electrical
Section I - GENERAL
WARNING: Because of their higher power capabilities, 24-volt systems are more dangerous
than 6 or 12-volt systems. Certain precautions must be observed before beginning any tests on
the 24-volt system. Do not permit a "hot" wire to touch metal parts" of the vehicle at any
time. "Flash" testing by striking a hot wire against a vehicle ground will cause an arc that will
completely destroy the connector on the lead. Accidental contact of metal tools between
battery or starter cables and the frame of the vehicle causes a direct short circuit resulting in
arcing and instant heating of the tool to red hot. This can cause painful burns and serious
damage to tools, vehicle electrical components and batteries. Moreover, the overloaded battery
may explode spraying hot acid and sharp fragments over the surrounding area.
CAUT ION: When removing electrical equ ipment, harnesses, battery cables or starter cables,
disconnect the battery ground cable first. Protect ground cable from accidental contact with
the battery terminal. When work has been completed, connect the battery ground cable last.
This Ghapter contains removal, repair and installation instructions for the following electrical
components: instrument panel, gages and switches, master switch, slave receptacle, batteries; starter",
alternator, head lamp, taillamp, directional signal lamp, flasher and control, horn, dome and map
light, bilge pump, engine oil pressure sending unit, coolant temperature sending unit, wiring harness
and cable connectors. Refer to Figure 15-1 for vehicle electrical schematic.
441
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VEHICLE
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NOTE, SEE TABLE 151 FOR WIRE IOENTIFICATION
Figure 151 Vehicle Electrical - Schematic
442
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VEHICLE
Table151. Schematic Wire Chart
WIRE
NO. CIRCUIT
2
B.O. ORIVE LAMP - LEFT & RIGHT - FRONT
4 SWITCH - STOP LAMP
5 SERVICE DRIVE LAMP - HI BEAM - LEFT & RIGHT FRONT
6
SERVICE DRIVE LAMP - LO BEAM - LEFT & RIGHT FRONT
7 POWER SUPPLY - 24V 30 AMP - TO SERVo LPS. SW'S. & ACC.
MAP LIGHT _. FRONT & BILGE PUMP & REAR DOME LITE POWER
8 BILGE PUMP FRONT -& BILGE PUMP SOLENOID - REAR
9 POWER SUPPLY 24V 15 AMP - TO INSTRUMENT GAGES
10
POWER TACH, ALT., 2 SPEED SWITCH & QUICK START
11 OIL PRESSURE SENDING UNIT
12 WATER TEMPERATURE SENDING UNIT
13 DOME LIGHT - REAR
@14
SERVICE LIGHT SWITCH CONNECTOR TO INSTRUMENT PANEL LIGHTS
15 IGN. STARTER SWITCH, NEUT. SAFETY SWITCH & STARTER SOLENOID
~ y 6
HORN 1
18 NEUTRAL SAFETY SWITCH & STARTER SOLENOID
21 SERVICE DRIVE LAMP - LEFT & RIGHT REAR
22L SERVICE TURN & STOP LAMP - LEFT REAR
22R SERVICE TURN & STOP LAMP - RIGHT REAR
23 8.0. STOP LAMP - LEFT & RIGHT REAR
24 8.0. MARKER LAMP - LEFT & RIGHT- FRONT & REAR
31 STOP LAMP SWITCH DEAD SIDE
33 SERVICE LAMP SWITCH TO CONTROL, TURN SIGNAL
34
SERVICE LAMP SWITCH TO CONTROL, TURN SIGNAL
35
SERVICE LAMP SWITCH TO CONTROL PANEL
37 SIGNAL LAMP - LEFT TURN - FRONT
38
SIGNAL LAMP - RIGHT TURN - FRONT
39
CONTROL, TURN SIGNAL TO FLASHER UNIT - POWER
40 CONTROL, TURN SIGNAL TO FLASHER UNIT - LOAD
41
BATTERY, GROUND TO DISCONNECT SWITCH
42
CABLE, BATTERY JUMPER -102381
43 CABLE, POWER SUPPLY TO POS. BUSS BAR -102380
44
GROUND WIRE, ALTERNATOR ARMATURE - 100660
45 GROUND WIRE, SOLENOID -100727 - 2 REQUIRED
46
CABLE, BILGE PUMP TO SOLENOID - 109384 - 2 REQUIRED
47 HORN, GROUND -101112
48
CABLE SIGNAL LAMP - LEFT & RIGHT FRONT
49
POWER TO BILGE CIRCUIT BREAKER - 1093832 - 2 REQUIRED
50
BILGE SOLENOID TO CIRCUIT BREAKER -1093831 - 2 REQUIRED
51 BUSS BAR TO 15 AMP CIRCUIT BREAKER -109386
52 ENGINE GROUND STRAP
53
LEAO - BI LGE PUMP GROUND - 109446 - 2 REQUIRED
54 FUEL VALVE TO ALTERNATOR
55
ALTERNATOR TO BUSS BAR - 109387
56
CABLE, SOLENOID JUMPER -102383
57 CABLE, DOME LIGHT UNIT
58 CABLE, SLAVE RECEPTACLE - POSITIVE
59
CABLE, SLAVE RECEPTACLE - NEGATIVE
60
CABLE, STARTER TO BUSS BAR -109385
61
CABLE ASSEMBLY - BUSS BAR TO TURRET -105441
63
SPEEDOMETER ADAPTER SIGNAL
64
TACHOMETER/PROBE GROUND
65
TACHOMETER/PROBE SIGNAL
68 QUICKSTART
69 QUICKSTART
71
DISCONNECT SWITCH TO VEHICLE GROUND
72
VACUUM SWITCH POWER
73
NO VACUUM WARNING LAMP - POWER
74 SPARE WIRE
75 SPARE WIRE
78
BUSS BAR TO 30 AMP CIRCUIT BREAKER
79 BUSS BAR TO 30 AMP CIRCUIT BREAKER
80
30 AMP CIRCUIT BREAKER TO TROUBLE LIGHT RECEPTACLE
81
TROUBLE LIGHT RECEPTACLE TO GROUND
443
VEHICLE
Section II - INSTRUMENT PANEL
15-1. REMOVAL
NOTE: Make sure master switch is in the OFF position.
A. Disconnect speedometer cable from rear of speedometer.
B. -Remove five screws securing instrument panel to bracket and hull.
C. Tilt instrument panel, remove harness from two junction blocks and disconnect connector
from vehicle light switch.
15-2. DISASSEMBLY (Figure 152)
A. Vehicle light switch. Remove four screws securing light switch to panel, lift light switch
from rear of panel.
B. Speedometer. Remove speedometer light, two nuts, lock washers, clamp and speedometer,
resistor and two-speed adaptor.
C. Water temperature, transmission oil temperature, engine oil pressure and ammeter gages.
Remove gage light, wire connectors, two nuts, lock washers and retaining clamp. Remove gage from
front of panel.
D. Starter switch. Remove screw, switch lever and nut from front of panel. From back of
panel remove three wires connectors and switch.
E. Dome light, bilge pump and Hi'Lo light switches. Remove thin nut from front of panel.
Remove wires and switch from back of panel.
F. Horn switch. Remove bezel nut wires and horn switch.
G. Panel and Hi beam lights. Remove wire, nut and light socket.
H. Terminal blocks. Tag and remove all wires, two screws, nuts and lock washers and terminal
blocks.
15-3. ASSEMBLY
Assemble instrument panel in reverse order of disassembly.
NOTE: Coat all wire connectors and wire ends with RTV compound.
15-4. INSTALLATION
Install in reverse order of removal and check operation of all gages and switches.
444
Figure 152
VEHICLE
I - Exploded View Instrument Pane
445
VEHICLE
Section III - MASTER SWITCH AND SLAVE RECEPTACLE
CAUTION: Disconnect ground wire from batteries before working on master switch or slave
receptacle.
15-5. REMOVAL (Figure 153)
A. Remove engine compartment lower front side wall to allow access to master switch and
slave receptacle.
B. Remove knob from master switch (12).
C. Remove two nuts securing electrical leads to master switch.
D. Remove two screws (6), nuts (14) and washers'(13) securing master switch (12) and reo
move master switch.
E. Disconnect both electrical leads from slave receptacle.
F. Remove four nuts (14), lock washers (16), flat washers (13), screws (2) and slave recep-
tacle (1).
G. Remove four nuts (11) and screws (9) and trouble light receptacle (7).
15-6. INSTALLATION
Install in reverse order of removal.
11
c
I
10
Figure 153 Master Switch and Slave Receptacle - Exploded View
446
VEHICLE
Section IV - BATTERIES.
WARNING: Battery acid can damage armor, tubing and wiring, flush engine and battery
compartment with water when batteries are cleaned or acid is spilled.
15-7. REMOVAL (Figure 15-4)
A. Open engine hatch and side a c c e s ~ door.
B. Loosen cable clamps and remove cables from battery terminal posts.
C. Remove upper and lower battery clamp wing nuts (6), lockwashers (7), flat washers, and
battery clamps (9).
D. Lift batteries from compartment using handles provided on battery.
CAUTION: Do not use a lifting strap that connects to battery posts.
15-8. INSTALLATION
NOTE: Insure that master switch is in the OFF position.
A. Position batteries in battery supports
10
12
-10
Figure 15-4 Battery Cables and Hold Downs - Exploded View
447
VEHICLE
B. Install upper and lower battery clamps and secure with lock washers and wing nuts.
C. Connect positive battery cable to positive post of upper battery.
D. Connect jumper cable to negative post of upper battery and positive post of lower battery.
E. Connect negative battery cable to negative post of lower battery.
F. Check that level of water is at correct height and batteries are fully charged.
15-9. SERVICING BATTERIES
A. Overall Battery Check. Vehicle batteries should be tested prior to performing any electrical
checks in the vehicle. This vehicle has two 12-volt batteries connected in series, furnishing 24 volts to
the electrical system (Fig. 15-5, A) which uses a negative (-) and a positive (+) power feed to the
electrical components. Turn on the master switch and ignition switch and observe the battery
indicator (Fig. 15-5, B). Start the engine, accelerate to 1200 rpm, and again observe the battery
indicator (Fig. 15-5,C).
B. Specific Battery Tests.
1. Testing specific gravity. The state of charge in each battery cell is determined by the
specific gravity of the electrolyte (acid) in the cell. Do not add water prior to this test. Use a
hydrometer to determine the specific gravity of each cell and then measure the temperature of the
electrolyte. Using the specific gravity temperature correction chart (F ig. 15-6). correct the readings
to 80 degrees F. (Example: Hydrometer indicates 1,280 specific gravity. Electrolyte temperature is 0
degrees F. Referring to the temperature correction chart note that for an electrolyte temperature of
'">ll=""O!)' 24 v
BATTERY -
CONNECT I NG
READINGS HERE
INDICATE THAT
BATTERY IS NEARLY
WORN OUT,
CABLE VEHICLE POWER
CABLE


FRAME BA TTERY

A, BATTERY SYSTEM
READINGS HERE INDICATE
A DEAD BATTERY. COULD
BE UNDERC HARGED. A
SHORT IN ElECTRICAL
SYSTEM OR BATTERY IS
WORN OUT OR DEFECTIVE,
NORMAL READING
CABLE
WITH All ElECTRICAL
UNITS OFF, RUN
ENGINE TO MAXIMUM
CHARGING RATE.
IF VOlTAGE REGULATOR
IS PROPERLY SET, POINTER
Will FAlliN TOP HALF
. OF GREEN SECTION,
READINGS HERE SHOW
BATTERY WAS RECENTLY
CHARGED AT HIGH RATE
(OVERCHARGED)

ENGINE RUNNING AT
1200 RPM FOR SEVERAL
MINUTES, AND POINTER
RESTS HERE, MEANS BATTERY
IS NOT CHARGING. CHECK
VOLTAGE REGULATOR. IF OK,
CHECK ALTERNATOR.
ENGINE RUNNING AT
MAXIMUM CHARGING
SPEED LONG ENOUGH TO
CHARGE BATTERY, WITH
All ELECTRICAL UNITS
TURNED ON, POINTER
SHOULD STAY IN GREEN i
SECTION. IF NOT, VOlTAGEI
REGULATOR IS SET TOO lOW"
OR BATTERY IS WORN OUT,
OVERCHARGE
CHECK FOR MALADJUSTED
OR DEFECTIVE VOLTAGE
REGULATOR.
B, BATTERY AT REST IGNITION SWITCH "ON",
C. BATTERY IN USE - ENGINE RUNNING.
Figure 155 Battery Alternator Indicator
448
VEHICLE
o degrees F, the chart indicates 0.032 is to subtracted from the hydrometer reading. Therefore, the
corrected reading is 1.280 - 0.032 ~ 1.248). Check the correct hydrometer reading against the chart
(Fig. 15-6) to determine the state of charge in each cell. The readings for all cells should be uniform;
if they differ by more than 0.025, replace the battery. If the corrected readings are uniform, but are
below 1.225, charge the battery.
2. Testing battery voltage. Use a voltmeter and check each battery individually.
Connect the voltmeter leads to the battery posts, not the connections. Do not disconnect the
batteries for this test. Each battery should measure 12 to 14 volts with no equipment turned on.
Depress the starter button and again measure each battery voltage while the engine is cranking.
CAUTION: Do not crank over 30 seconds. Each battery should measure not less than 9 volts,
and both batteries should be within 2 volts of each other. If a difference of more than 2 volts
exists, replace the battery which has the l.ower voltage reading. If the replacement battery still
reads more than a 2-volt difference in the above tests, replace the remaining battery.
C. Adding Water. The water in the electrolyte solution evaporates because of high temperature
of excessive charging rates. Inspect battery and add distilled water or rain water at intervals required
by service and climatic conditions. Keep batteries filled with water to split ring level.
CAUTION: Keep batteries clean and do not overfill. In cold weather, charge battery
immediately after adding water so that water will combine with electrolyte and not freeze.
1,0"f .0.016
110"1 .1).01]
IOO"f .0.00<1
,,', ,o.ox
HYDROMETER READINGS
Non ... t ~ 00',
CORRECTED SPECIFIC GRAVITY
ro', -0.00.\
1,280 FULLY CHARGED
w', -0.0(<(1
1,250 THREE-FOURTH CHARGED
",', ..1.1.011
1 ,220 ONE-HALF CHARGED
40";
-0.016
1,190 ONE-FOURTH CHARGED
.l(If
-o.O?O
1,160 LITTLE USEFUL CHARGE
,,', _o.w'
1,130 DISCHARGED
10"F -{l.on
", ..{).Oll
+IO"F
-0.03&
20 f -Q.Q40
Figure 156 Battery Hydrometer Readings
449
VEHICLE
D. Placing Dry Charge Batteries into Service.
NOTE: Batteries shipped charged and dry must be filled with electrolyte. Every effort should
be made to give a battery an initial charge up to full charge before putting battery into service.
1. Remove sealing devices from vent plugs and discard. Do not remove plugs until ready
to fi II the batteries.
2. Fill each cell with electrolyte to 3/8 inch above separators. In temperate climates, use
electrolyte of 1.280 specific gravity; temperature of the battery and electrolyte must be above 60
degrees F., but preferably not above 100 degrees F. After approximately 10 minutes, add electl'Olyte
again to replace that absorbed by plates and separaturs.
3. If the battery, which is now ready for use, will not be used within 12 hours after
filling, allow battery to cool to atmosphereic temperature. When charging new batteries watch
temperature closely; if it exceeds 100 degrees F., reduce rate at once. Continue charge until three
hydrometer readings at half-hour intervals show no further rise in specific gravity.
E. Charging Batteries.
1. Fast Charging Batteries. If adequate time for a slow charge is not available, a high
rate (FAST) charge is permissible and will give a sufficient charge in one hour enabling the battery
and alternator to continue to carry the electrical load.
Connect battery charger positive (+) lead to battery positive terminal and negative {-I lead to battery
negative terminal. If battery is not removed from vehicle, be sure master switch is turned off and all
electrical accessories are turned off during charging.
CAUTION: The battery can be damaged beyond repair unless the following precautions are
taken. Battery electrolyte temperature must never exceed 125 degrees Fahrenheit. If this
temperature is reached, battery should be cooled by reducing charging rate or removing
charger from the battery. As batteries approach full charge, electrolyte in each cell will begin
to gas or bubble. Excessive gassing must not be allowed. Do not fast charge longer than one
hour. If battery does not show a significant change in specific gravity after one hour of
"FAST" charge, the slow charge method should be used. Remember to use temperature
correction when checking specific gravity. The manufacturers of high rate charging equipment
generally outline the necessary precautions and some models have thermostatic temperature
limiting and time limiting controls.
WARNING: When batteries are being charged an explosive gas mixture forms beneath the
cover of each cell. Do not smoke near batteries on charge or which have recently been charged.
Do not break live circuits at the terminals of the batteries on charge. A spark will occur where
the live circuit is broken. Keep all open flames away from the battery.
2. Slow Charging Batteries. Many discharged batteries can be brought back to good
condition by slow charging, especially batteries that are sulphated.
Battery should be tested with a hydrometer and a record kept of the readings taken at regular
intervals throughout the charge. When a cell has a specific gravity reading that is 25 points. (.025) or
more below other cells, that cell is faulty and battery should be replaced.
Safe slow charging rates are determined by allowing one ampere per positive plate per cell.
Proper slow charging rate would be 4 amperes for a 53 ampere hour battery; 5 amperes for a 59
amphere hour battery; and 6 amperes for a 70 amphere hour battery.
The average length of time necessary to charge a battery by the slow charge method at normal
rates is from 12 to 16 hours, however, when a battery continues to show an increase in specific
gravity, battery charge should be continued even if it takes 24 hours or more.
450
VEHICLE
NOTE: Watch the temperature of batteries carefully and if the temperature of anyone of
them reaches 100 degrees F., lower the char!ling rate.
Battery will be fully charged when it is gassing freely and when there is no further rise in specific
gravity after three successive readings taken at hourly intervals. Make sure hydrometer readings are
corrected for temperature.
The rate of charge for a sulphated battery should be no more than 1/2 the normal slow rate.
Many sulphated batteries can be brought back to a useful condition by slow charging at half the
normal charging rate from 16 to 100 hours. This long charging cycle is necessary to convert
crystalline lead sulphate into active materials. When a battery takes a full charge, but is returned
several times in need of a recharge, check for a cracked cell partition with a syringe to provide air
pressure; bubbles will appear in an adjacent cell if a crack is present.
F. Cleaning Batteries. The top of the battery must be kept clean. Tighten vent plugs and clean
batteries with brush dipped in a solution of bicarbonate of soda and water. After foaming stops, flush
top of battery with clean water and wipe dry with a clean cloth. Clean terminals and clamps in same
manner. Connect and tighten cable clamps and coat cable terminals with grease. After batteries are
cleaned flush complete engine compartment with clean water to remove any battery acid on floor or
brake lines.
WARNING: Acid fumes and copper sulphate particles can be injurious to the eyes and skin.
Do not allow battery electrolyte to contact flesh; severe burns will result. Upon contact, apply
first aid and obtain medical attention immediately.
451
VEHICLE
Section V - STARTER
15-10. REMOVAL
A. Disconnect ground cable from battery.
B. Remove engine compartment lower rear access panel.
C. Remove electrical leads to starter solenoid.
E. Remove three screws and lock washers securing starter to clutch housing. Remove starter.
15-11. TROUBLESHOOTING
A. Before removing any unit in the starting circuit for repair, the following checks should be
made:
1. I nsure that the batteries have been tested and found to be in good condition and fully
charged.
2. Inspect starter wlrll1g circuit. All wires and cables must be in good condition, all
terminals must be clean and tight.
3. Inspect solenoid, relay and switches to determine condition. Connect a jumper lead
around any component suspected of being defective. If system functions properly with jumper,
replace component being by-passed. If battery, wiring and switches are in good condition and the
engine is known to be functioning properly, remove the starter for testing.
15-12. TESTING
CAUTION: Never operate the starter motor more than 30 seconds at a time. Allow the
motor to cool for at least 2 minutes between each cranking cycle. Overheating, caused by
excessive cranking, will seriously damage the starter motor.
NOTE: Whenever a starter is tested, check for any unusual noises or vibration that might
indicate an unserviceable condition. If either condition exists, further testing should not be
attempted and the starter must be disassembled and repaired.
A. Check armature for freedom of rotation by prying the pinion with a screwdriver.
1. Tight bearings, a bent armature shaft or a loose pole shoe screw will cause the arma-
ture not to turn freely.
2. If armature does not turn freely, the motor should be disassembled without further
testing and repaired.
3. If armature rotates freely, proceed with testing.
B. No-Load, Test (Fig. 15-7).
1. Connect a voltmeter from the motor terminal to the starter frame.
2. Connect a 24-volt battery supply in series with an ammeter between the solenoid
battery terminal and the starter frame.
452
I I
BATTERY
R,P.M.
INDICATOR
VEHICLE
VARIABLE
RESISTANCE

VOLTMETER
STARTER
MOTOR
Figure 157 No Load Test - Wiring Diagram
3. Use an RPM counter to Tl)easure armature speed.
4. Connect a variable resistance across the battery.
5. Energize the circuit by connecting a jumper from the solenoid battery terminal to the
solenoid switch terminal.
6. Obtain the specified voltage (20volts) by varying the resistance unit. Armature speed
should be from 5500 (minimum) rpm to 7000 (maximum) rpm.
7. Check the current draw on the ammeter. Minimum current draw should be 60 amperes
maximum draw is 90 amperes.
C. Interpreting Results of Tests.
1. Rated current draw and noload speed indicates normal condition of the cranking
motor.
2. Low free speed and high current draw indicate:
a. Too much friction - tight, dirty', or worn bearings, bent armature shaft or loose
pole shoes allowing armature to drag.
b. Shorted armature. This can be further checked on a growler after disassembly.
c. Grounded armature or fields. Check further after disassembly.
3. Failure to operate with high current drawn indicates:
a. A direct ground in the terminal or fields.
453
VEHICLE
b. "Frozen" bearings (this should have been determed by turning the armature by
hand).
4. Failure to operate with no current draw indicates:
a. Open field circuit. This can be checked after disassembly by inspecting internal
connections and tracing circuit with a test lamp.
b. Open armature coils. Inspect the commutator for badly burned bars after disassem-
bly.
c. Broken brush springs, worn brushes, high insulation between the commutator bars
or other causes which would prevent good contact between the brushes and commutator.
5. Low no-load speed and low current draw indicate:
a. High internal resistance due to poor connections, defective leads, dirty commutator
and causes listed under Number 4.
6. High free speed and high current draw indicate shorted fields. If shorted fields are
suspected, replace the field coil assembly and check for improved performance.
15-13. DISASSEMBLY (Figure 15-B)
Normally the cranking motor should be disassembled only so far as is necessary to make repair
or replacement of the defective parts. As a precaution, it is suggested that safety glasses be worn
when disassembling or assembling the cranking motor.
A. Note the relative position of the solenoid, lever housing, and nose housing so the motor
can be reassembled in the same manner.
B. Disconnect field coil connector from solenoid motor terminal, and remove solenoid
mounting screws.
C. Remove thru-bolts.
D. Remove commutator end frame from field frame and field frame from lever housing.
E. Remove nose housing attaching bolts and separate nose housing from lever housing.
F. Slide a standard half-inch pipe coupling or other metal cylinder of suitable size (an old
pinion of suitable size can be used if available) onto shaft so end of coupling or cylinder butts against
edge of retainer. Tap end of coupling with hammer, driving retainer towards armature and off snap
ring, figure 15-9.
G. Remove snap ring from groove in shaft using pliers or other suitable tool. If snap ring is
too badly distorted during removal it may be necessary to use a new one when reassembling clutch.
H. Remove the armature and clutch from the lever housing.
I. Separate the solenoid from the lever housing.
454
VEHICLE
Figure 15-8 o ed View Starter - Expl d
455
VEHICLE
CYLINDER
RETAINER
Figure 15-9 Removing Retainer
15-14. CLEANING
The drive, armature and fields should not be cleaned in any degreasing tank, or with grease
dissolving solvents, since these would dissolve the lubricant in the drive and damage the insulation
in the armature and field coils. All parts except the drive should be cleaned with mineral spirits mid
a brush. The drive can be wiped with a clean cloth.
A. If the commutator is dirty it may be cleaned with No. 00 sandpaper. NEVE R USE EM-
ERY CLOTH TO CLEAN COMMUTATOR.
15-15. BRUSHES AND HOLDERS
Inspect the brushes for wear. If they are worn excessively when compared with a new brush,
they should be replaced. Make sure the brush holders are clean and the brushes are not binding in
the holders. The full brush surface should ride on the commutator to give proper performance.
Check by hand to insure that the brush springs are giving firm contact between the brushes and
commutator. If the springs are distorted or discolored, they should be replaced.
15-16. ARMATURE SERVICING
If the armature commutator is worn, dirty, out of round, or has high insulation, the armature
should be put in a lathe so the commutator can be turned down. The insulation should then be
undercut 1/32 of an inch wide and 1/32 of an inch deep, and the slots cleaned out to remove any
trace of dirt or copper dust. As a final step in this procedure, the commutator should be sanded
lightly with No. 00 sandpaper to remove. any burrs left as a result of the undercutting procedure.
The armature should be checked for opens, short circuits and grounds as follows:
A. Opens - Opens are usually caused by excessively long cranking periods. The most likely
place for an open to occur is at the commutator riser bars. I nspect the points where the conductors
are joined to the commutator bars for loose connections. Poor connections cause arcing and burning
of the commutator bars as the cranking motor is used. If the bars are not too badly burned, repair
can often be effected by resoldering or welding the leads in the riser bars (using rosin flux)' and
turning down the commutator in a lathe to remove the burned material. The insulation should then
be undercut except as noted above.
456
VEHICLE
B. Short Circuits - Short circuits in the armature are located by use of a growler. When the
armature is revolved in the growler with a steel strip such as a hacksaw blade held above it, the blade
will vibrate above the area of the armature core in which the short circuit is located. Shorts between
bars are sometimes produced by brush dust or copper between the bars. These shorts can be elimi
nated by cleaning out the slots.
C. Grounds - Grounds in the armature can be detected by the use of a 110volt test lamp
and test points. If the lamp lights when one test point is placed on the commutator with the other
point on the core of shaft, the armature is grounded. Grounds occur as a result of insulation failure
which is often brought about by overheating of the cranking motor produced by excessively long
cranking periods or by accumulation of brush dust between the commutator bars and the steel com
mutator ring.
1517. ASSEMBLY
A. Assemble starter in the reverse of disassembly.
B. The ring and retainer on the shaft can be assembled in the manner shown in figures 1510
and 1511. With the retainer placed over the shaft with the cupped surface facing the end of the
shaft, force the ring over the shaft with a light hammer blow and then slide the ring down into the
groove (fig. 1510). To force the retainer over the snap ring, place a suitable washer over the shaft
and squeeze with pliers (fig. 1511). REMOVE THE WASHER. Assemble all brushes to the brush
arms so the long side of the brush is toward the riser bars.
1518. LUBRICATION
All oil wicks should be saturated with SAE No. 10 oil, and the splines underneath the clutch
should be lubricated with a light coat of SAE No. 10 oil. (Heavier oil may cause failure to mesh at
low temperatures.) Lever housings having a bearing and seal should have the grease cavity between
the bearing and seal filled with lubricant.
Figure 1510 Installing Snap Ring
457
SNAP
RING
WASHER - USE TO
ASSEMBLE RETAINER
OVER SNAP RING,
THEN REMOVE WASHER
Figure 15-11 Installing Retainer
VEHICLE
15-19. PINION CLEARANCE
The pinion should be checked after reassembly to make sure the clearance is within speci-
fications. To check pinion or drive clearance follow the steps listed below.
A. Make connections as shown in figure 15-12.
B. Momentarily flash a jumper lead shown in figure 15-12. The drive will now shift into
cranking position and remain so until the battery is disconnected.
C. Push the pinion or drive back towards the commutator end to eliminate slack movement.
D. Measure the distance between drive and drive stop, figure 15-13.
E. Adjust clearance by removing plug on lever housing and turning shaft nut.
15-20. INSTALLATION
Install starter in reverse order of removal.
BATTERY
SOLENOID
CRANKING
MOTOR
~ I / -
Figure 15-12 Electrical Hookup
458
PLUG REMOVED
tllll
______ SHAFT NUT
V' (TURN TO ADJUST
0 PINION CLEARANCE
:\1J1i ij
PRES90N DRIVE TO
';
-
)1
TA70VEMENT
I
0
D
-
J;)_
-
'"
I----'
Ira J
:Ji
f='
F
'lr-' (---'
~
l
II-
t J ~
'-,
~ ~ ~ ~ ~
=-
<
h
t--
t--
'-- 64 '" 32
Figure 15-13 Pinion Adjustment
VEHICLE
Section VI - ALTERNATOR
15-21. ADJUSTMENT (Figure 1514)
The only adjustment necessary for the alternator is a voltage adjustment.
NOTE: The following procedures for testing and adjusting the alternator are based on the use
of a low-voltage circuit tester or a n)ultimeter with suitable ranges, and an ammeter with a 100
ampere range. The vehicle batteries must be fully charged when adjustment is made.
A. Remove rear panel from engine compartment.
B. Remove socket head plug located adjacent to alternator pulley,. exposing the voltage
adjustment.
C. Attach a voltmeter with a 50-volt scale across battery terminals.
D. Start engine and run until engine and alternator are warmed up to normal operating
temperature.
E. Set engine operation to 1,000 rpm.
F. Turn off all electrical equipment to provide a minimum load on the battery system.
G. Adjust screw until voltmeter reads 27.0 to 27.5 volts. Be sure drive belt is adjusted
properly while making this adjustment.
NOTE: When vehicles are operated in areas where extremely high temperatures are
encountered, it may be necessary to reduce the voltage setting to prevent battery overcharging.
Under these conditions voltage should be reduced to a point where batteries remain charged
but do not overheat or use excessive quantities of water.
TERMINAL POST
UNDER COVER
VOLTAGE
OUTPUT
ADJUSTMENT
UNDER PLUG
Figure 1514 Alternator Adjustment
459
LEAD
STARTER
SWITCH
VEHICLE
H. To adjust drive belt tension, loosen adjusting screw and move alternator until belt can be
depressed a maximum of 1 inch under thumb pressure, figure 15-15.
I. Turn off engine, remove test equipment, and install plug.
15-22. REMOVAL
A, Remove nuts and washers securing wiring harness and terminals to the electrical terminal
posts of alternator. Tag wire for identification when installing.
B. Remove screw, washer and nut securing alternator to upper strap.
C. Remove drive belt from alternator pulley.
D. Remove screw, washers and nut securing ground strap to alternator, Remove ground strap.
E. Remove two screws, washers and nuts securing alternator to mounting bracket. Remove
alternator.
15-23 TROUBLESHOOTING
The most practical method of on-vehicle troubleshooting is the substitution of an alternator
known to be good. If substitution of another alternator results in proper operation, the alternator is
defective.
Table 15-2 lists malfunctions or warning symptoms of troubles that may develop in the
alternator. Each malfunction is followed by a list of probable causes that must be considered in
determining the corrective action necessary to remedy the malfunction. The probable causes are listed
in their order of probability, and should be checked in that order during troubleshooting.
After the alterna'tor has been removed from the engine, troubleshooting it consists of subjecting
it to tests on a suitable test stand.
Figure 15-15 Alternator Belt Adjustment
460
VEHICLE
Table 152. Troubleshooting - Alternator
Malfunction
Probable cause Corrective action
1.
2.
3.
4.
5.
6.
No output. a. Faulty connector ............ a. Replace connector.
b. Faulty stator ............... b. Replace stator.
c. Loose connection .. . . . '" ... c . Tighten all connections.
d. Worn brushes ............... d. Replace brushes.
e. Brush spring tension weak. . . . . e . Replace brush springs.
f. Contact rings outifround ...... f. Test for outofround
and mach ine lathe,
if necessary.
g. Faulty regulator ............. g. Replace regulator.
Output low. a. All of the causes listed in item 1 a. Refer to corrective action
can cause low output. given for item 1.
b. Faulty rectifier . . . . . . . . . . . . . b. Replace rectifier.
Output erratic. a. Faulty regulator ............. a. Replace regulator.
b. Brush bounce .. . .. .. . . . . . . . b . Replace brush springs.
c. Loose connections ........... c. Tighten all connections.
Overheating. a. Faulty ball bearing ........... a. Replace ball bearing.
b. Faulty fan . . . . . . . . . . . . . . . . . b. Replace fan.
c. Cooling ducts on stator or rotor c. Clean ducts.
plugged.
d. Stator shorted or grounded. . . . d . Replace stator.
e. Rectifier Shorted or faulty. e. Replace rectifier.
Noisy. a. Faulty ball bearing ........... a. Replace ball bearing.
b. Faulty rotor . .. ... . . . . . . . . . b . Replace rotor.
c. Faulty fan . ................ c. Replace fan.
d. Faulty drive coupling ......... d. Replace defective
drive coupling
parts.
e. Stator shorted or grounded ..... e. Replace stator.
f. Rectifier shorted or grounded .. f. Replace rectifier.
Rotor fails to turn. a. Loose rotor windings ......... a. Replace rotor.
b. Faulty ball bearing . , . . . . . . . . b. Replace ball bearing.
c. Bent rotor shaft ............. c. Replace rotor shaft.
CAUTION: When the cause for failure has been discovered, the alternator should be
disassembled and repaired before proceeding with prescribed tests. Additional operational tests
performed on a damaged alternator will only increase the damage.
1524. DISASSEMBLY (Figure 1516)
In the following procedures, it is assumed that the alternator will be disassembled completely.
In some instances, however, breakage of a particular part between normally established repair periods
may not require complete disassembly. In such cases, the alternator should be disassembled only to
the point required to inspect, clean, and replace the damaged component.
NOTE: Discard all packings, gaskets, sealing material, cotter pins, lock washers, brushes, and
o rings as these must be replaced with. new parts during assembly. Prior to disassembling the
alternator, wash external surfaces throughly with dry cleaning solvent and dry with
compressed air.
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Figure 15-16 Alternator - Exploded View
A. Remove nut (45), flat washer (46), spacer (47), and woodruff key (44), securing fan (43)
to shaft of rotor (36). Remove fan.
B. Remove six screws (32) securing regulator assembly (31) to housing (8). Lift regulator
assembly (31) clear of housing and pull five terminal end leads from housing.
C. Remove screw (22), lock washer (12) and clamp (33). Remove regulator assembly (31) and
o ring (52) from housing. Discard 0 ring.
NOTE: Do not attempt disassembly of voltage regulator.
D. Remove three nuts (54) securing capacitor panel (53) to housing (8), disconnect terminals
from stator and terminal assembly (1). Remove capacitor panel.
E. Remove three nuts (48), flat washers (4) and lock washers (12) from stator terminals and
remove all leads from terminals.
F. Remove two screws (22), flat washers (4) and lock washers (12) securing brush holder (21)
to housing (8) and remove brush holder. Remove and discard brushes (20) from brusn holder.
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,
I
I
I
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VEHICLE
NOTE: Further disassembly of alternator is recommended only if inspection indicates that
component parts are defective.
G. Remove six screws (39) and flat washers (38) securing drive end housing (37) to housing
(8) and carefully pull rotor (36) and drive end housing (37) from housing and stator, by tapping
gently with a fibre mallet.
CAUTION: Use extreme care to avoid damage to exposed stator windings. Do not rest
alternator on exposed winding unless suitable protection is provided.
H. Remove two nuts (54) securing capacitor panel (53) and pull stator (1) out of housing.
I. Remove nut (30), lock washer (29) and flat washer (25) securing outpLit lead from capacitor
to stud (27). Remove lead and two insulating washers (24).
J. Remove two screws (26), flat washers (25) insulating washers (24) and insulating bushings
(23) securing positive retifier (5). Remove rectifier.
K. Remove two nuts (30), lock washers (29) flat washers (25) and two ground leads from (55)
from stud (27).
L. Remove two screws (19), flat washers (25), insulating washers (24) and insulating bushings
(23) securing negative rectifier (6). Remove rectifier.
M. Remove two screws (16), lock washers (17) and cover (15).
N. Remove four screws (13), lock washers (12), clamp (1), capacitor (10) and gasket (9).
O. Remove two seals (35) from housing. With a suitable puller remove bearing (34).
P. Remove four screws (42) securing bearing retainer (41) and remove retainer and 0 Ring
(49). Discard 0 Ring and press seal (35) from retainer.
Q. Remove spacer (40) and 0 Ring (50) from shaft. With a suitable puller remove housing
(37) and bearing from rotor. Discard 0 Ring.
R. Press bearing (51) from rear of housing.
1525. CLEANING
A. Clean stator assembly, rotor, and brush holder with a cloth dampened in dry cleaning
solvent. Do not soak parts in solvent. Dry with clean, dry, compressed air; take care not to damage
insulation, cables or windings.
B. Cooling ducts in stator and rotor assemblies should be kept free of dirt and grease. A thin
rod can be us.ed to loosen caked dirt.
C. If contact rings are rough or have minor pits, polish them with No. 000 or finer sandpaper.
Clean rings and rotor with compressed air after polishing ring5.
CAUTION: Do not use emery cloth to polish contact rings. Fragments from emergy cloth
may short-circuit rotor.
D. Clean all other metallic parts with dry cleaning solvent; dry thoroughly.
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VEHICLE
CAUTION: Many parts of these generators are made of aluminum alloys. Do not use a
solvent that will attack aluminum.
1526. INSPECTION
A. Fan. Inspect vanes for cracks or damage.
B. Housings. Inspect for cracks and damage. Check that bearing mating face is not warped.
C. Bearings. Inspect bearings for smoothness of operation, nicks, burrs, discoloration or wear.
NOTE: If there is any doubt as to serviceability of bearings, replace.
D. Brush holder. Inspect for cracks. Inspect terminal studs and screws for looseness and
damaged threads.
E. Brushes. Replace brushes that are worn more than Y, their original length.
F. Rotor.
1. Inspect keys and key sets for damage.
2. I nspect shaft for burred or stripped threads.
3. Place ohmmeter probes on inner and outer contact rings, and measure the rotor coil
resistance. Reading must be between 7.4 to 8.0 ohms figure 1517. If rotor does not meet these
specifications, replace rotor. Also connect an ohmmeter between either slip ring and rotor shaft
figure 1518.
G. Reading on ohmmeter indicates rotor is grounded and must replaced.
H. Stator. Place ohmmeter between each pair of terminals figure 1519. The meter should read
a very low resistance between each phase. If a low reading is not indicated, stator is open. Connect
ohmmeter between each stator terminal and stator core. If a reading is indicated stator is grounded
and must be replaced.
7.4 7.80HM Q
CID
Figure 15-17 Rotor Resistance Test
464
OPEN CIRCUIT
OR INFINITY
READING
Figure 1518 Rotor Ground Test
I
I
VEHICLE
IS:] GROUND
(j]) TEST
Figure 1519 Stator Tests
TEST
POINT
A
STATOR
TERMINALS (3)
TEST
POINT
B
Figure 1520 Diodes and Test Points
NOTE: Diode leads must be disonnected from stator terminals when performing above tests.
I. Rectifiers (figure 1520).
NOTE: If one or more diodes are shorted or open it will be necessary to replace the complete
rectifier. On some volt ohm milliampere meters the positive and negative leads are r e v e r ~ e d
when used as an ohmmeter. Know the lead polarity of your particular meter.
1. Positive Diodes: Connect positive ohmmeter lead to test point B and touch negative
ohmmeter lead to each of three positive diode leads in turn. A high or infinite resistance should be
indicated. If one or more diodes show a low resistance they are shorted. Connect negative ohmmeter
lead to test point B and touch positive ohmmeter lead to each of three' positive diode leads in turn.
A low resistance reading should be obtained. If one or more diodes show a high or infinite resistance
they are open.
2. Negative Diodes: Connect positive ohmmeter lead to test point A and touch negative
ohmmeter lead to each of three negative diode leads in turn. A low resistance should be indicated. If
one or more diodes show a high or infinite resistance they are open. Connect negative ohmmeter lead
to test point A and touch positive ohmmeter lead to each of three negative diode leads in turn. A
high or infinite resistance should be indicated. If one or more diodes show a low resistance they are
shorted;
J. Regulator. There is no method of testing regulators. The regulator should be tested by
installing it in an alternator known to be good.
1527. REPAIR
A. General. The following paragraphs cover only those parts wherein a repqir operation will
return damaged part to serviceable condition. Parts not detailed herein must be replaced when they
fail to pass the required inspection and test.
B. Contact rings. If contact rings are rough or outofround, machine in a lathe and polish with
No. 000 or finer sandpaper.
C. Rotor. Remove minor burrs and nicks from rotor shafts and shaft threads with a fine file.
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VEHICLE
D. Stator and connector assembly. Repair damaged or defective solder connections. Clean up
minor thread damage with a tap of proper size and proper number of threads per inch. Repair
damaged coil insulation with insulating varnish, apply as many coats of insulating varnish to the coil
insulation. Allow each coat to dry until tacky before applying another coat. After sufficient coats
have been applied, place rotor in a drying oven and bake for 2 hours at 193
0
F.
E. End housings. Remove minor nicks and burrs from machined surfaces of end housings with
a stone or fine file.
F. Fan. Remove burs from machined surfaces with a fine file, hone, or stone.
1528. ASSEMBLY (Figure 1516)
A. Press new bearing (34) into housing (8). Pack bearing with BRB-2 grease.
B. Press two new seals (35) into housing. Seals are installed with flat side away from bearing.
After seals have been pressed down into counterbore against shoulder, apply a small amount of
loctite around outer edge of seal.
C. Install gasket (9), capacitor (10), clamp (11) and secure with four screws (13) and lock
washers (12).
NOTE: Apply a small amount of RTV sealant on both sides of insulator around six diode
openings prior to installation.
D. Install insulator (7) and rectifiers (5 and 6). Secure with screws (26 and 19), flat washers
(25), insulation washer(24) and insulation bushing (23).
NOTE: Bushing and washers secure positive rectifier only.
E. To positive rectifier install insulation bushing (28), two insulation washers (24), output
lead from capacitor, flat washer (25), lock washer (29) and secure to stud (27) with nut (30).
F. Install clamp (33), lock washer (12) and screw (22) to secure leads to housing (8).
G. Install regulator leads, brush holder leads and secure with clamp (33), lock washer (12) and
screw (22). .
H. Install nut (30), regulator No. 3 terminal ground lead, brush holder ground lead, flat
washer (25), lock washer (29) and nut (30) to negative rectifier stud (27).
I. Position and install stator (1) to housing (8). Install two flat washers (12), lock washers (4)
and nuts (48) on stator terminal studs.
J. Install flat washers (4), leads (2 and 3) panel (53) and secure with three nuts (54).
K. Install seal (35) in drive end housing (37). Seal should fit flush with real edge of bearing
bore with smooth side facing away from bearing (51). F ill area behind seal with B RB-2 grease. Insert
installing tool into seal from front of housing so that seal lips face rear of housing. Slip housing (37)
and seal onto rotor shaft (36) and remove tool.
L. Press bearing (51) onto shaft and into housing. Install 0 ring (50), sleeve (40) onto shaft
with counterbore of sleeve facing toward bearing.
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VEHICLE
M. I nstall seal (35) in retainer (41) with smooth side of seal facing outside of retainer.
N. Install 0 ring (49) around outer edge of bearing. Position retainer and secure with four
screws (42).
O. Insert pilot tool into housing (8) from regulator side of housing. Fill area behind seal with
B R B- 2 grease.
P. Insert rotor (36) and housing (37) assembly into stator (1) and housing (8) assembly so that
rotor shaft slip rings enter the pilot tool. Push rotor into position, forcing pilot tool out of housing.
This insures that seal lips face toward rotor.
Q. Align housing and install six screw (39) and flat washer (38).
R. Fill area around shaft in front bearing retainer with BRB-2 grease and install key (44), fan
(43), pulley (47), washer (46) and nut (45). Tighten nut to 50-55 ft. Ibs. torque.
S. Insert brushes (20) into brush holder (21) and install brush holder with two screws (22),
lock washers (4) and flat washers (12).
T. Install leads to regulator and end cover (31), observing numbers on leads and regulator.
NOTE: Terminal 6 of regulator is not normally used. If 40 amp maximum output is desired,
connect lead 5 to terminal 6 and do not use terminal 5.
U. I nstall new 0 ring (52) and regulator and cover (31) with six screws (32). Regulator
adjustment screw must line up with adjusting screw hole in housing.
15-29. TESTING
After the alternator has been assembled, test it for proper performance. If the alternator does
not function properly during test described in figure 15-21. disassemble and reinspect for
malfunctioning component.
15-30. INSTALLATION
Install alternator in reverse order of removal and adjust belt tension to 73-92 Ibs .. If a new
belt is installed, run engine for 15 minutes with lights and other electrical equipment on and re-
check belt tension.
IGNITION SWITCH
o
BATTERY
SWITCH
HEAVY LEADS
NO SMALLER
THAN NO.8
WIRE
60AMP LOAD
1. OPEN LOAD BANK SWITCH
2. CLOSE BATTERY SWITCH
3. CLOSE IGNITION SWITCH
4. RUN At. TERNATOR AT APPROX. 2000 RPM
5, ADJUST ALTERNATOR VOLTAGE TO 28 VOLTS
6. CLOSE LOAD BANK SWITCH
7. ALTERNATOR SHOULD PROD,UCE 60 AMPS
AT 27.027.5 VOLTS
8, SHUT DOWN TEST BLOCK
9. OPEN ALL 3 SWITCHES
Figure 15-21 Test Block Wiring
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VEHICLE
Section VII - HEADLAMP
15-31_ REMOVAL
A_ Oisconnect electrical leads at connector inside vehicle under head lamp.
B. Remove three screws and lock washers securing head lamp to hull. Remove head lamp.
15-32. INSTALLATION
Install headlamp in reverse order of removal and test operation of all lights.
Section VIII - TAILLAMP
15-33_ REMOVAL
A. Disconnect four electrical leads at connector inside vehicles at rear corners of hull.
B. Remove sealer from around hole where wires go into hull and pull wire connectors to
outside of vehicle.
C. Remove two screws and lock washers securing taillamp and remove taillamp.
15-34. INSTALLATION
A. Install taillamp in reverse order of removal.
B. Install sealer around wire and hole where wires enter hull.
O. jest operation of all lights.
~ ' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Section IX - DiRECTIONAL SIGNAL LAMP
15-35. REMOVAL
A. Disconnect electrical lead connector at rear of lamp.
B. Remove screw and lock washer securing lamp to hull bracket. Remove lamp.
15-36. INSTALLATION
I nstall lamp in reverse order of removal.
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VEHICLE
Section X - DIRECTIONAL SIGNAL FLASHER
1537. REMOVAL
A. Remove wire harness nut from flasher.
B. Remove two screws and ground wire securing flasher. Remove flasher.
1538. INSTALLATION
I nstall flasher in reverse order of removal.
Section XI - DIRECTIONAL SIGNAL CONTROL
1539. REMOVAL
A. Remove clamp securing control to steering gear jacket tube.
B. Remove wire harness nut from control and remove control.
1540. INSTALLATION
I nstall in reverse order of removal.
Section XII - HORN
1541. REMOVAL
A. Disconnect electrical leads from rear of horn.
B. Remove two screws securing horn to hull and remove horn.
1542. INSTALLATION
Install horn in reverse order of removal.
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VEHICLE
Section XIII - DOME AND MAP LIGHT
1543. REMOVAL
A. Disconnect electrical lead from light assembly.
B. Remove four screws securing light to hull and remove light.
1544. DISASSEMBLY (Figure 1522)
A. Loosen eight screws securing door assembly to light body. Remove screw retaining electrical
lead to switch. Remove door assembly and gasket.
B. Remove screw securing knob to light switch and remove knob. Loosen two screws retaining
two wires to rear of switch and remove wires. Remove front retaining nut and remove light switch,
washer and gasket.
C. Remove two screws from each socket assembly and remove both assemblies.
D. Remove four screws securing partition. Remove partition.
E. Remove seven screws securing lens retaining plate. Remove plate, red lens, gasket, clear lens
and gasket.
1545. ASSEMBLY
A. Post ion lens gaskets, lens, lens retaining plate and partition. Secure with eleven screws.
B. Install light switch and secure with gasket, flat washer and nut. Install switch knob with
screw and lock washer.
C. Install both light socket assemblies with two screws each. Connect both light wires to light
switch.
D. Position gasket into door assembly. Connect electrical lead to light switch and install door
by tightening eight retaining screws.
1546. INSTALLATION
Install dome and map light in reverse order of removal and check operation of lights.
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VEHICLE
9
18
'---9
...------12
~ 1 6
Ii 17
Figure 15-22 Dome and Map Light - Exploded View
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VEHICLE
Section XIV - CIRCUIT BREAKERS
1547. REMOVAL
A. Disconnect two electrical leads from each circuit breaker (front bilge pump, rear bilge
pump, and master switch).
B. Remove two screws securing circuit breaker and remove circuit breaker.
1548. INSTALLATION
Install circuit breaker in reverse order of removal.
Section XV - BILGE PUMP
1549. REMOVAL
A. Turn master switch to OFF position.
B. Disconnect bilge pump electrical connector and discharge hose from bilge pump.
C. Remove four nut,s, lock washers and flat washers securing bilge pump to hull floor.
D. Remove pump from compartment.
1550. DISASSEMBLY (Figure 1523)
A. Remove four screws (1) and washers (2) securing inlet flange (3) and remove with gasket (4).
B. Remove impeller locknut (5), lock washer (6) and impeller (7).
C. Remove two screws (31) securing impeller housing (8). Remove housing and gasket (9).
D. Remove two brush caps (25), brushes (27) and 0 rings (26).
E. Remove two screws (19) that hold the motor together. Tap the drive end bell (11) away
from the stator assembly (28). The rotor (17) and drive end bell will come out together.
F. Press the rotor (17) from the drive end bell (11) and remove 0 Ring (12). Press the shaft
seals (10) from drive end bell. Remove the external snap ring (13) and remove both bearings (14 and
18) with bearing puller.
G. Remove the large bearing (14) from bearing sleeve (14) by removing the internal snap ring.
(15) and pressing bearing from sleeve.
472
VEHICLE
Figure 1523 Bilge Pump - Exploded View
1551. ASSEMBLY
Assemble in reverse order of disassembly.
1552. INSTALLATION
A. Position bilge pump in compartment and install pump outlet hose on pump. Tighten hose
clamp.
B. Connect electrical lead connector to bilge pump.
C. Postion bilge pump in mounting position on hull floor and secure with four flat washers,
lock washers and screws.
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VEHICLE
Section XVI - ENGINE OIL PRESSURE SENDING UNIT
CAUTION: Do not operate engine with NO or LOW oil pressllre gage reading.
1553. TEST
The following test can be performed to determine if the oil pressure sending unit or the oil
pressure gage is defective.
A. Remove electrical connector from sending unit.
B. Turn ON master switch and starter switch.
C. Ground sending unit electrical connector wire to engine. The oil pressure gage must read'
maximum, if reading is maximum replace sending unit, if reading is less than maximum replace oil
pressure gage.
15-54. REMOVAL (Figure 15-24)
A. Remove electrical connector from sending unit.
B. Clean area at block around base of sending unit.
C. Remove sending unit.
1555. INSPECTION
A" I nspect threads in block for being stripped or galled.
B. Inspect threads on sending unit for being stripped, missing and galled.
C. Inspect sending unit for incomplete or broken connection, leaks, breaks and cracks.
15-56. INSTALLATION
A. Install sending unit in rear of engine block.
CAUTION: Do not overtighten sending unit during installation as unit can be easily distorted.
B. Connect electrical connection at oil pressure sending unit.
NOTE: Be sure electrical connection is firmly connected.
C. Check engine oil, start engine check for oil leaks and oil pressure gage operation.
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VEHICLE
OIL PRESSURE
SENDING UNIT
Figure 1524 Oil Pressure Sending Unit
Section XVII - COOLANT TEMPERATURE SENDING UNIT
1557. TEST
The following test can be performed to determine if the coolant temperature sending unit or
the coolant temperature gage is defective.
A. Remove electrical connector from sending unit.
B. Turn ON master switch and starter switch.
C. Ground sending unit electrical connector wire to engine. The coolant temperature gage must
read maximum, if reading is maximum replace sending unit, if reading is less than maximum replace
temperature gage.
1558. REMOVAL (Figure 1525)
A. Open engine petcock and partially drain cooling system.
B. Disconnect electrical connection at sending unit.
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VEHICLE
Figure 1 5 ~ 5 Coolant Temperature Sending Unit
C. Clean area at sending unit.
D. Loosen and unscrew sending unit.
1559. INSPECTION
A. Inspect threads in block for being stripped or crossthreaded.
B. Inspect threads on sending unit for being stripped, chipped and crossthreaded.
C. Inspect sending unit for incomplete or broken connections, leaks, breaks, cracks, and
distortion.
1560. INSTALLATION
A. Coat threads of sending unit with sealer.
B. Install sending unit and tighten securely.
CAUTION: Do not overtighten sending unit during installation as unit can easily be distorted.
C. Connect electrical connection at sending unit.
NOTE: Be sure electrical connection is firmly conn.ected.
D. Fill radiator with coolant. Start engine and check for water leaks. Continue to operate
engine and observe temperature gage.
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Section XVIII - PARKING BRAKE WARNING LIGHT SWITCH
15-61. REMOVAL
A. Disconnect electrical lead from switch.
B. Remove two screws and flat washers securing switch bracket.
C. Remove nut securing switch to bracket. Remove switch.
15-62. INSTALLATION AND ADJUSTMENT
A. Assemble switch to bracket and secure with nut.
B. Position bracket ON transmission and install two screws and flat washers and tighten lightly_
C. Connect electrical lead.
D. Turn master switch and starter switch ON.
E. Insure that parking brake is properly adjusted and fully disengaged.
F. Adjust switch and bracket downward until parking brake warning light j u ~ t goes out. Secure
bracket by tightening mounting screws.
G. Check operation of light by engaging and disengaging parking brake.
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VEHICLE
Section XIX - WIRING HARNESS
15-63. REPAIR (Figure 15-26)
Repair of harnesses, cables, and power plant wIring is lim.ited to replacement of faulty
connectors and the substitution of a jumper for a defective harness wire, or replacing a cable_ When
repair is necessary, free the harness or cable only insofar as necessary to make the repair. This consists
of disconnecting at each end and loosening or removing cable clamps as necessary. Removal of the
complete harness should be avoided.
NOTE: Rubber-to-rubber contacts of bell-type connectors may be lubricated lightly with
silicone compound to assist assembly.
A. Install a jumper wire to substitute a defective wire within a harness.
NOTE: Do not disassemble a wiring harness.
B. Cut and tape ends of defective wire remaining in harness.
NOTE: Refer to electrical schematic figure 15-1 to insure that no internal splices were
bypassed in adding jumper wire. Additional wires may have to be spliced to jumper wire to
complete circuit to additional units or components.
C. Tape a jumper wire of required length to outside of harness and into existing or new
connector.
15-64. TROUBLESHOOTING
A. To assist in troubleshooting the wiring harness, isolate the defective circuit by locating the
inoperative unit or component and disconnect the electrical lead wire or connector and trace circuit
(Table 15-3) to appropriate end.
B. Disconnect electrical lead wire or connector at opposite end. Using a continuity tester, test
circuit. A Reading less than infinity indicates a faulty wire within harness.
478
S5
VEHICLE LIGHT SWITCH
CONTROL PANEL
S3
DIRECTIONAL
SIGNAL
CONTROL
VEHICLE
FI
PANEL
P4 SPARE
P5 SPARE
P31 SPARE
F2
INSTRUMENT
PANEL
LEFT HEADLIGHT
T12 SPEEDOMETER SWITCH
SPEEDOMETER WIRE
::
P42 NEUTRAL SAFETY SWITCH
P41 TRANS CONSOLE LIGHT
P40 NEUTRAL SAFETY SWITCH
SI RIGHT HEADLIGHT
P26 UPI.I<lIH SWITCH
PIO
S4
TURN SIGNAL
FLASHER
P17 B,O. STOP r-
m
P26 RIGHT TURN
SIGNAL
"
P16 SERVICE .:
T3 FLASHER.GROUND PIS B.O. MARKER :'j
T1 BILGE PUMP REAR P2 CIRCUIT BREAKER ______ ......,.
P19 SERVICE TURN=& STOp
(MAP LIGHT) " <;;
P3 CIRCUIT BREAKER
ION)
II =-P12
Y REAR DOME LIGHT
= PI3 OIL PRESSURE
.. c, PI6 WATER TEMP
c:::O P14 ALTERNATOR
T4 STARTER P20 SERVICE TURN & STOP
P21
P22 B,D, STOP
P32 SPARE P33 SPi\RE P23 B.O. MARKER
Figure 15-26 Wiring Harness
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VEHICLE
Table 15-3 Wiring Harnes Continuity Chart
Wire No_ From Connector Pin No_ To Connector Pin No_
2 S-5 D S-l Right Headlamp, S-2 Left Headlamp 2
4 Vehicle Light Switch A P-26'Stop Light Switch -
5 F-l 5 S-l Right Headlamp, S-2 Left Headlamp 1
6 Instrument Panel 6 S-l Right Headlamp, S-2 Left Headlamp 4
S-5 F-l Instrument Panel 7
7 Vehicle Light Switch F P-2 Circuit Breaker, P-7 Map Light
-
8 F-l Instrument Panel 8 P-l Front Bilge Pump, T-l Rear Bilge Pump Solenoid -
9 9 P-3 Circuit Breaker, P-4, P-5 Spare -
10 F-2 10 P-14 Alternator T-ll 2-Speed Speedometer Wire -
11 Instrument Panel .11 P-13 Oil Pressure Sending Unit -
12 12 P-15 Water Temperature Sending Unit
-
13 13 P-12 Dome liGht Rear -
15 F-2 15 P-40 Neutral Safety Switch, PAl Transmission Console Light -
16 Instrument Panel 16 P-l0 Horn -
17 F-l Instrument Panel 3 P-35 Transmission Temperature Sending Unit -
18 T-4 Starter Solenoid - P-42 Neutral Safety Switch -
21 S-3 Directional H P-il Right Taillamp, P-16 Left Taillamp -
22L C P-19 Left Taillamp -
22R E P-20 Right Taillamp -
23 N P-22 Right Taillamp P-17 Left Taillamp -
24 S-5 E S-l Right Headlamp, S-2 Left Headlamp 3
Vehicle Light S w i t c ~ P-23 Right Taillamp, P-18 Left Taillamp -
31 K P-27 Stop Light Switch -
33 C S-3 Directional D
34 J Signal Control G
35 M F-l Instrument Panel 1
37 S-3 B P-24 Left Turn Signal Lamp -
38 Directional A P-25 Right Turn Signal Lamp -
39 Signal F S-4 B
40 Control H Directional Signal Flasher A
63 F-l Instrument Panel 4 T-12 2-Speed Speedometer Switch -
74 P-30 Spare - P-32 Spare -
75 P-31 Spare - P-33 Spare -
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VEHICLE
Section XX - CABLE CONNECTORS
15-65. MALE CABLE CONNECTOR (Figure 15-27)
A. SI ip shell and sleeve over cable.
B. Strip cable insulation 1/4 inch.
C. Insert cable in terminal and secure by crimping or soldering terminal to cable.
D. Slide sleeve over terminal.
E. Pull cable to retract sleeve and terminal into shell.
15-66. FEMALE CABLE CONNECTOR (Figure 15-28)
A. Slide shell over cable.
B. Strip cable insulation 1/4 inch.
C. Insert cable into terminal and secure by crimping or soldering terminal to cable.
D. Install C-washer over cable between shell and terminal.
E. Pull cable to retract C-washer and terminal into shell.
15-67. ELECTRICAL RECEPTICAL (Figlne 15-29)
A. Strip cable insulation 1/8-3/16 inch.
B. Fill pin with solder.
C. Tin cable, with solder.
D. Heat pin and insert tined cable and let cool.
15-68. RECEPTACLE CONNECTOR (Figure 15-30)
A. Slide grommet, housing, coupling ring, ferrule and seal over cables.
B. Strip insulation on cables 1/8 - 3/16 inch.
C. Tin cables and fill pins with solder.
D. Heat pins and insert tined cables and let cool.
E. Slide seal over pins and cables and into connector.
F. Slide ferrule over seal and coupling ring over connector.
G. Screw housing onto connector and slide grommet between ears of housing with rubber lugs
parallel with ears of housing.
H. Install clamps and secure with two screws.
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SHElL
BELL
TERMINAL
TERMINAL
CABLE
SLEEVE
Figure 1527 Male Cable Connector -
Exploded View
PIN
CABLE
RECEPTACLE
Figure 1529 Electrical Receptacle -
Exploded View
482
...
\
CABLE
C-WASHER
Figure 1528 Female Cable Connector -
Exploded View
FERRULE
HOUSING
SEAL
GROMMET
CLAMP
Figure 1530 Receptacle Connector -
Exploded View
VEHICLE
CHAPTER 16
Winch System
The Winch System consists of a hydraulic pump, hand operated directional control valve,
hydraulic motor and winch unit. Hydraulic oil is drawn from main reservoir through a filter and
into pump. Oil is pumped to control valve and then travels under command to hydraulic motor
coupled to winch. It is then directed back to control valve, which has an open center to reservoir
through a return line which is in common with steering system.
The pressure in winch system is proportional to winching requirements and reaches a maxi-
mum of 1500 psi which is limited by pressure relief valve setting within control valve. At 3,300
engine RPM, line speed is 12 feet per minute on bottom layer of cable. .
Section I - WINCH CONTROL VALVE
NOTE: A defective control valve must be replaced. Rebuild of valve is not recommended due
to close tolerances and selective fitting of valve componets.
16-1. REMOVAL (Figure 16-1)
A. Remove four hydraulic lines from control valve. Plug and tag lines for installation.
B. Remove cotter pin and clevis pin from control valve linkage.
C. Remove three retaining screws from control valve and remove valve.
16-2. INSTALLA nON
Install winch control valve in reverse order of removal.
RETURN
LINE
Figure 161 Winch Control Valve
483
SUPPLY
LINE
VEHICLE
14
lOch Mot Figure 16-2 W- or - Exploded View
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VEHICLE
Section II - WINCH HYDRAULIC MOTOR
NOTE: Winch must be removed from vehicle prior to removing winch motor.
16-3. REMOVAL (Figure 164)
A. Remove four mounting screws (19) and lock washer (20) securing motor (26) to adapter
housing (21). Remove motor.
16-4. DISASSEMBLY (Figure 16-2)
A. Remove woodruff key (11) from output shaft (10) key way.
B. Scribe a line across hydraulic motor housing and end caps before disassembly, to act as a
guide for assembly.
C. Remove seven screws (7) and washers (3), attaching motor end cap (6), geroler assembly
(4) to motor housing (8) and plate spacer (2).
D. Remove end cap (6), spacer (5), geroler assembly (4), two 0 rings (3), plate spacer (2) and
geroler drive shaft (1). Discard 0 rings (3).
E. Remove four screws (15) securing mount flange (14) to motor housing (8).
F. Remove mount flange (14), 0 ring (3), bearing race (13) and thrust bearing (12) and out-
put shaft (10). Discard 0 ring (3).
G. Press seal (3) from mount flange and discard seal.
H. Remove housing plug (9) and 0 ring from motor housing (8).
16-5. INSPECTION.
A. Inspect housing and mating components for wear, breaks, stripped threads, uneven and
irregular mating surfaces or out of round bores.
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B. Inspect shafts for straightness, wear, galling and/or distorted keyways and splines.
C. Inspect bearings, bushings and bearing races for wear, scoring or galling.
16-6. ASSEMBLY
Using scribe lines as guides, assemble winch hydraulic motor in reverse order of disassembly,
using new seals and 0 rings.
16-7. INSTALLATION (Figure 16-4)
A. Install woodruff key (25) in to output shaft of motor.
B. Position motor on winch with motor ports in proper orientation for installation of
hydraulic lines.
C. Secure motor with four screws (19) and lock washers (20).
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VEHICLE
Section III - WI NCH
16-8. REMOVAL (Figure 16-3)
CAUTION: Use gloves to protect hands when handling winch cable.
A. Reel winch cable out manually or by power and remove set screw securing cable to drum.
Remove cable from drum.
B. Loosen two oil line nuts and disconnect oil lines from control valve figure 16-1.
NOTE: Plug disconnected oil lines with suitable plugs.
C. Loosen winch motor boot clamp and slip boot off hull flange.
D. Open winch access door, remove four screws, two lock washers, two flat washers and two
nuts securing winch frame to hull. Remove winch assembly from vehicle hull.
16-9. DISASSEMBLY
NOTE: Numbers appearing in parentheses following a component of item name refer to
keyed items in figure 16-4 unless otherwise indicated.
A. Remove drain plug (56) and drain lubricant into a suitable container. After draining
lubricant install drain plug (56) and tighten.
B. Remove four Inounting screws (19) and lock washer (20) securing motor (26) to adapter
housing (21) and remove hydraulic motor.
SCREW (2)
LOCKWASHER (2)
FLAT WASHER (2)
NUTS (2)
SCREWS (2)
LOCKWASHER (2)
\
Figure 16-3 Winch
487
WINCH
HATCH
I
CABLE MOUNTING
SET SCREW
VEHICLE
C. Remove six side cover retaming screws (I) and iock washers (2).
D. Remove side cover (3) and cover gaskets(4).
E. Remove four mounting screws (11) and lock washers (12) securing adapter housing (21)
and bearing container (18) to worm housing (13).
F. Remove drive sleeve (22), drive key (58), adapter housing (21), rear beadng container (18),
and gaskets (17). Remove bearing container seal (16)' bearing and cup (15).
G. Remove bearing spacer (14) from worm shaft (60).
H. Remove four screws (11) and lock washers (12) securing front bearing container (62) to
worm housing (13).
I. Remove front bearing container (62) and gasket (17). Remove bearing and cup (15) from
bearing container (62).
J. Remove bearing spacer (14), from worm shaft (60).
K. Remove worm shaft (60) from worm housing (13). Press shaft out of worm (61) and
remove key (59) from shaft.
L. Remove eight screws (11) and lock washers (12) securing two base angle brackets (32) and
(51) and detent bracket (33) to the worm housing (13) and clutch housing (42). Remove brackets.
Do not lose poppet (36) and poppet spring (35).
M. Remove two screws (11) and lock washers (12) securing steady strap (10) to worm housing
(13) and clutch housing (42). Remove strap.
N. Slide clutch housing (42) and cl.utch (44) from clutch drum shaft (50).
O. Remove two clutch keys (49) and thrust ring (47) from clutch drum shaft (50).
P. Slide cable drum (31) from clutch drum shaft (50).
Q. Remove clutch drum shaft (50) and worm gear (6) from worm housing (13).
R. Remove worm gear spacer (7) from clutch drum shaft (50).
S. Press worm gear (6) from clutch drum shaft (50).
T. Remove two worm gear keys (52) from clutch drum shaft (50).
U.