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AL MAN:' UA L IC N EC H WVARDEPARTMENT T

CARUSLE BARRACKS, PA 17013-5008

' ¼-"TON 4 x 4 TRU:CK

(WILLY S -. OV.ERL MODEL MB- And FORD MODEL- :GPW)

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SORY INStTrrE
US. ARMY MAR CARUSLE BARRACKS. PA 17013-5008
WAR DEPARTMENT TECHNICAL MANUAL

*TM 9-803

14-TON 4 x 4 TRUCK (WILLYS- OVERLAND MODEL MB and FORD MODEL GPW)

WAR DEPARTMENT
22 February1944

*This manual supersedes TB 9-803-4, 5 January 1944. For supersession of Quartermaster Corps 10-series technical manuals, see paragraph 1.

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WAR DEPARTMENT Washington 25, D. C., 22 February 1944

TM 9-803, %4-ton4 x 4 Truck (Willys-Overland Model MB and Ford Model GPW), is published for the information and guidance of all concerned.

[A. G. 300.7 (17 November 43)1
BY ORDER OF THE SECRETARY OF WAR:

G. C. MARSHALL, Chief of Staff.

OFFICIAL:

J. A. ULIO, Major General,
The Adjutant General.

DISTRIBUTION: C & H (1).

(For explanation of symbols, see FM 21-6)

TM 9-803

1/4-TON 4x 4 TRUCK (WILLYS-OVERLAND MODEL
MB and FORD MODEL GPW)
CONTENTS
PART ONE-OPERATING INSTRUCTIONS
Paragraphs Pages

SECTION

Introduction .................. Description and tabulated data.. Driving controls and operation.. Operation under unusual conditions .................. V First echelon preventive maintenance service.......... VI Lubrication .................. VII Tools and equipment stowage on the vehicle .................

I II III IV

1 2-3 4-6 7-11 12-16 17-18 19-21

5-9 10-12 13-20 21-27 28-36 37-48 49-51

PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS SECTION VIII IX X XI XII XIII Record of modifications ....... Second echelon preventive
maintenance ................ New vehicle run-in test........ Organization tools and
equipment.................. Trouble shooting ............. Engine--description, data,
maintenance, and adjustment
in vehicle ................... Engine--removal and installation Ignition system .............. Fuel and air intake and exhaust
systems .................... Cooling system ................ Starting system., .............. Generating system ............. 3
22 23 24-26 27-28 29-49 52
53-67
68-72
73
74-103

XIV XV XVI XVII XVIII XIX

50-59 60-61 62-69 70-78 79-86 87-90 91-94

104-115
116-117
118-125
126-136
137-143
144-145
146-149

. 95-106 107-112 113-116 117-121 122-125 126-137 138-145 146-152 153-157 158-163 164-175 176-179 150-166 167-171 172-175 176-178 179-180 181-188 189-192 193-204 205-210 211-215 216-220 221-227 Shipment and temporary storage 180-182 228-232 233-234 235 REFERENCES ............................................................ . Transfer case .. Clutch ...... Radio interference suppression system .................. Rear axle ... Front axle .............TM 9-803 A4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Paragraphs Pages SECTION XX XXI XXII XXIII XXIV XXV XXVI XXVII XXVIII XXIX XXX XXXI XXXII Battery and lighting system.................................. Propeller shafts and universal joints .............. INDEX ............... Steering gear ............... Springs and shock absorbers...... .................................. Transmission ........ .............................. Brakes ............ Body and frame .........

... . or proper in­ structions issued.. this technical manual has been published in advance of complete technical review.TM 9-803 1 PART ONE-OPERATING INSTRUCTIONS Section I INTRODUCTION Paragraph Scope 1. 5 .. The manual is divided into two parts. Part Two. and care of the mate­ riel. 15 January 1943.. this manual supersedes them: (1) ' TM 10-1103.. contains vehicle maintenance instructions to using arm personnel charged with the responsibility of doing maintenance work within their jurisdiction.. Any errors or omissions will be corrected by changes or.. contains vehicle operating instructions. Together with TM 9-1803A and TM 9-1803B. (2) "TM 10-1207.... In addition to a description of the ¼%-ton 4 x 4 Truck (WillysOverland model MB and Ford GPW).. In all cases where the nature of the repair.. the respon­ sible ordnance service should be informed so that trained personnel with suitable tools and equipment may be provided. (3) -TM 10-1349..... 20 August 1941... c. This manual includes operating and organizational mainte­ nance instructions from the following Quartermaster Corps 10-series technical manuals. 1 SCOPE. sec­ tions VIII through XXXII. if extensive. a. including radio suppres­ sion and shipment and temporary storage information. Part One. 3 January 1942. . This technical manual* is published for the information and guidance of the using arm personnel charged with the operation and maintenance of this materiel.. or adjustment is beyond the scope of facilities of the unit.. .. *To provide operating instructions with the materiel.. by an early revision....... b.. d.. 20 August 1941. use. sections I through VII... this manual contains technical information required for the identification. modification. Change 1.... (4) 1'M 10-1513.

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TM 9-803 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 0 ax !i 1 S~~~~~~~~~~ v //F - w~~ 8 .

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. 10 .................... under the hood at the front of the vehicle....... The manufacturer's chassis serial number is stamped on a plate inside the left frame side member at the front end...... 49 in...................................A...... and............... 80 in.. DESCRIPTION... ... The U. .. Crew.......... The folding top can be removed and stowed...... a.....combat 16 x 4........ 6 Tire plies ..... or cargo carrier especially adaptable for reconnaisance or command...... 52 in....... and on the name plate.. over-all .... Length........ 6)....... The body is of the open type with an open driver's compartment... It is a four-wheel vehicle with four-wheel drive....... 35 lb Tire pressure (front and rear).00 in....... The engine serial number is stamped on the right side of the cylinder block...... ...... Height... and designated as %-ton 4x 4 Truck..... General physical character­ istics are shown in figures 1 through 4..... Tire size . The engine is a 4-cylinder gasoline unit located in the conventional place. ..... ...... Width.......... 16 x 6.... .......... ........... operating ....... 3).......... a... Type............. Specifications of the vehicle are given under "Data" (par............. -top down ............ personnel....../(fif...... DATA. Vehicle Specifications.... .... 2 5 Passenger capacity including crew .........50 E Wheel size ................ mud and snow Tire type ..... Tread (center-to-center)-front ...................TM 9-803 2-3 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section II DESCRIPTION AND TABULATED DATA Paragraph Description ..... 49 in.... 3... registration number is painted on both sides of the hood.. ...... -69a/ in....... over-all 62 in..... Data .......... and a pintle hook is provided to haul trailed loads.... 2 in.. the windshield tilted forward on top of the hood... Identification........... over-all--top up .... front upper corner.... A conventional three-speed transmission equipped with a transfer case provides additional speeds for traversing difficult terrain.... ... -rear ................. Wheelbase ... ..... A spare wheel equipped with a tire is mounted on the rear of the body.... or opened upward and outward...... ..S........ b.................. 2 3 2....... This vehicle is a general purpose..

........................062 lb Maximum pay load ......... including gas and water .. 3................................ none -rear ...................... 2............................. 65­ Intermediate gear (2nd) ... Kind and grade of fuel (octane rating).....TM 9-803 3 DESCRIPTION AND TABULATED DATA Weights: Road. 11 5 qt 4 qt 3/ q t 2 ..Gasoline (68 min) Approach angle ................ 45 deg Departure angle ..253 lb Shipping (less water and fuel) ..................... 600 rpm Miles per gallon-(high gear-high range) average con d it io n s .... 331 -square feet ........000 lb Ground clearance ........... Towing facilities-front ........ ...... 21 Low gear (lst) ........................................................................... 2.................... 3... } c....... Performance...................................................453 lb Gross (loaded) .... ....... 800 lb Maximum trailed load .................................... 12 Reverse gear . --refill .... 21 in........... Engine crankcase capacity-dry .......... Pintle height (loaded) .................... Maximum allowable speeds (mph) with transfer case in "HIGH" range: High gear (3rd) ........................ 33 Intermediate gear (2nd) .......... ......... 9 Maximum grade ability ............... :....................................337 lb Boxed gross ..................... pintle hook Maximum draw-bar pull .................................... 1..................... Cruising range-(miles) average conditions ............... 1....... 35 deg Shipping dimensions-cubic feet .............. 17X2 ft Maximum fording depth ......... 57 b................ Capacities................. 60 pct Minimum turning radius-right.. 41 Low gear (1st) ................................................................... 21 in... ft -left ........... 24 Reverse gear ........................930 lb Engine idle speed ...................... 18 Maximum allowable speeds (mph) with transfer case in "LOW" range: High gear (3rd) ................................. 83/4 in.... Transmission capacity ............ Transfer case capacity ...

.............. The generator is driven by a V-belt from a power take-off unit on the rear of the transfer case...... Communications. 14 qt- Front axle steering knuckle universal joint .. 55-ampere auxiliary gen­ erator is furnished on some vehicles................. 1-I qt Rear axle capacity (differential) ..... A 12-volt.................... 11 qt Brake system (hydraulic brake fluid) .. % qt Shock absorbers--front ........ 12 ........ 53/4 oz d................................ 15 gal Cooling system capacity .... 5 oz -rear .....................TM 9-803 3 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Front axle capacity (differential) ..... (2) AUXILIARY GENERATOR..... %/ qt Air cleaner (oil bath) ........... Y4 qt Steering gear-housing ..... (1) RADIO OUTLET Box............ Instructions for operation and care accompany those vehicles.................... 5/8 qt Fuel tank capacity ...... This outlet is located against the body side panel at the right front seat.............. A radio outlet box is provided on the later vehicles to use the vehicle battery (6-volt current supply)...................

...AD W A B C D E F G H I J K L M N O P Q V UT S... The fuel gage on the instrument panel 13 ... R Q P O N M L K J I R WHEEL STEERING S HORN BUTTON T WINDSHIELD WIPERS U WINDSHIELD ADJUSTING ARMS V AMMETER W HAND BRAKE X WINDSHIELD CLAMPS Y CAUTION PLATE Z NAME PLATE AA PLATE SHIFT AB LEVER TRANSMISSION GEAR SHIFT LEVER-FRONT AXLEDRIVE AC SHIFT CASE TRANSFER AD LEVER-AUXILIARY RANGE SHIFT CASE TRANSFER AE STARTING SWITCH AF GAGE TEMPERATURE AG FOOT REST ACCELERATOR AH SPEEDOMETER (FOOT ACCELERATOR THROTTLE) GAGE OIL PRESSURE GAGE FUEL PEDAL BRAKE INSTRUMENT PANEL LIGHT SWITCH PEDAL CLUTCH FUEL TANK FIRE EXTINGUISHER STRAP SAFETY CONTROL) HEADLIGHT FOOT SWITCH (BEAM BLACKOUT LIGHT SWITCH BLACKOUT DRIVING LIGHT SWITCH REAR VISION MIRROR CHOKE CONTROL IGNITION SWITCH HAND THROTTLE RIFLE HOLDER RA PD 334753 Figure 5-Instruments and Controls 4............... A B C 4 5 6 AH N D AE . ...... a... The ammeter on the instrument panel indicates the rate of current flow when the generator is charging the battery..... Use of instruments and controls in vehicular operation ...... Towing the vehicle . 5)......TM 9-803 4 Section III DRIVING CONTROLS AND OPERATION Paragraph Instruments and controls .......... INSTRUMENTS AND CONTROLS.. (1) AMMETER (fig.. (2) FUEL GAGE (fig.... Instruments.................... 5). and also indicates the amount of current being consumed when the engine is idle....

~~1 -hf lt RA PD 305162 RA PD 305161 Figure 7--Caution Plate Figure 8--Shift Plate 14 .TM 9-803 4 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Figure6-Name Plate RA PD 330838 Fiue7Cuio | _ltiue .

· SERVICE STOP LIGHT (ONLY) SERVICE OFF ~ ~ ~LOCKING BUTTON BLACKOUT RA PD 64586 Figure 9-Blackout Light Switch Operating Positions (2) BLACKOUT L4GHT SWITCH (fig. 5). push in black­ out driving light switch knob. 15 . The oil pressure gage located on the instrument panel indicates the oil pressure when the engine is running. 5). first pull the blackout light switch button to the first position. When the control knob is pulled out to the first position.TM 9-803 4 DRIVING CONTROLS AND OPERATION is an electrical unit which indicates the fuel level in the tank. The speedometer on the instrument panel indicates in miles per hour the speed at which the vehicle is being driven.O. Controls. b. on the back of the switch. To switch off the light. DRIVE) on the instrument panel controls the blackout driving light located on the left front fender. and closes when the thermostatic element cools. A trip indicator (in lower part of speedometer face) gives distance covered on any trip. (3) OIL PRESSURE GAGE (fig. including the instrument panel litglts. blackout driving light. A circuit-breaker type fusie. 5). then pull black­ out driving light switch knob. (5) TEMPERATURE GAGE (fig. The blackout driving light switch (B. The odometer (in upper part of speedometer face) registers the total number of miles the vehicle has been driven. 5). 9). The temperature gage registers the temperature of the solution in the cooling system. Set trip indicator by turning the knurled con­ trol shaft extending through back of the speedometer. and stop lights. (4) SPEEDOMETER (fig. and only registers while the ignition switch is turned on. to furnish additional light during blackout periods. 5). the blackout headlights and blackout stop and taillights are turned on. opens when a short circuit occurs. The light switch is a four-position push-pull type with a safety lock (fig. (1) BLACKOUT DRIVING LIGHT SWITCH (fig.controls the entire lighting system. To operate light. The knob on the instru­ ment panel (LIGHTS.

control knob travel is automatically locked in this position by the lock-qut button to prevent accidentally turning on of the service (bright) lights in a blackout area. To operate extinguisher. 5). push in on lock-6it control button on the left side of the switch. To remove. and pull control knob out to the last or stop light position to cause only the regularstop light to function. and the panel lights can be turned on by pulling out on the knob (PANEL LIGHTS). To obtain service lights. located on the instrument panel. hold body ifi one hand and with the other. 5). controls the lights to illuminate the panel instruments and controls. RA PD 305165 Figure 10-Generator Brace (3) PANEL LIGHT SWITCH (fig. service stop and taillights are turned on.TM 9-803 4 1A4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) The switch. The panel light switch knob (PANEL LIGHTS). Read instructions on fire extinguisher plate. turn handle to left one-quarter turn. which releases plunger lock. b (2) above) must be in service (bright light) position for this switch to control the panel lights. (4) FIRE EXTINGUISHER (fig. and pull out control knob to second position. The fire extinguisher is mounted inside the left cowl panel. CAUTION: When driving during the day. Use pumping action to force liquid on base of fire. press in lock-out control button. pull outward on the clamp release lever. 16 . When switch is in this posi­ tion service headlights. The blackout light switch (subpar.

(9) OTHER INSTRUMENTS AND CONTROLS. 4 b (2)). check temperature gage reading. The brake is released by turning the handle one-quarter turn. The generator brace can be pulled up to release tension on the fan belt and stop the fan from throwing water over the engine when crossing a stream. 8). 5). (1) For daytime driving turn on service stop light (par. Release switch as' soon as engine starts. (3) Pull out choke button all the way. The windshield clamps are located on the lower part of the windshield. (9) Check ammeter for charge reading.? b. USE OF INSTRUMENTS AND CONTROLS IN VEHICULAR OPERATION. (2) Pull out hand throttle button about 3/4 inch to 1 inch. 5. 5). Pull the handle out in a vertical position when the vehicle is parked. at idle speed the indicator hand should show at least 10 on the gage. (11) In extremely cold weather refer to paragraph 7. (10) After engine has operated a few minutes. The hand brake is applied by pulling out on the handle at the center of the instrument panel.TM 9-803 4-5 DRIVING CONTROLS AND OPERATION (5) HAND BRAKE (fig. (7) WINDSHIELD CLAMPS (fig. To open windshield. (5) Depress clutch pedal to disengage clutch. NOTE: Choking is not necessary when engine is warm. c. CAUTION: Be sure fan belt is on pulleys. Before-operation Service. (6) WINDSHIELD ADJUSTING ARMS (fig. (8) Check oil pressure gage reading. (8) GENERATOR BRACE (fig. Other instruments and controls are of the conventional type. Perform the services in paragraph ( 13 before attempting to start the engine. (4) Turn ignition to "ON" position. a. Check fuel gage for indication of fuel supply. Placing Vehicle in Motion. loosen knobs and push forward on lower part. (2) Place transfer case right-hand shift lever in rear position to 17 . and are shown in figure 5. then set by tightening the knobs. Pull gen­ erator out to running position as soon as possible thereafter.. . Pull up on both clamps and unhook them. and it will lock in place. Normal operating temperature is between 160 0F and 1850 F. after which the windshield can be lowered on top of the hood. and hold pedal down while engine is started. The windshield adjustment arms are mounted on each end of the windshield frame. 10). To start the engine proceed as follows: (1) Put transmission gearshift lever in neutral position (fig. As engine warms up. (6) Step on starting switch to crank -again. Starting Engine. using the holddown catches on both sides of the hood. (7) Adjust choke and throttle control buttons to obtain proper idling speed. push choke button all the way in. 5). Be sure to hook down the windshield.

" 2. or by both front and rear axles. 7). and accelerate. move front axle drive shift lever to "IN" position. (c) Disengaging Front Axle when Transfer Case is in "LOW. Disengage front axle when operating on average roads under normal conditions. follow the same procedure as outlined above in order to shift into high (3rd) gear. (5) Slightly depress accelerator to increase engine speed. Move front axle drive shift lever to "OUT" position. The selection of gear ratios depends upon the road and load conditions. the low gear provided by the transfer case further increases the number of speeds provided by the transmission. (b) Disengaging Front Axle with Transfer Case in "HIGH" Range. (1) FRONT AXLE ENGAGEMENT. and then into second gear. (3) Depress clutch pedal. Shift gears in the transfer case in accordance with the shift plate. 8). No double clutching is required. and observe the instructions on the caution plate (fig. 8). and at the same time release pressure on accelerator. Shift to a lower gear before engine begins to labor. make sure that the engine speed is synchronized with vehicle speed before clutch is engaged." 1. increase engine speed. NOTE: During the following operationsperform proceduresoutlined in para­ graph 14. then place center shift lever in forward posi­ tion to disengage front axle (fig. (6) Increase speed to approximately 10 miles per hour. and move transmission shift lever toward driver and backward to engage low (lst) gear (fig. shift to next lower gear. 8). Shift front axle drive lever into "OUT" position. 8). steep grades. increasing pressure on accelerator as clutch engages and vehicle starts to move. Front axle should be engaged only in off-the-road operation.TM 9-803 5 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) engage "HIGH" range. and at the same time slowly release clutch pedal. then shift transfer case lever into "HIGH. release clutch pedal slowly. as follows: Depress clutch pedal quickly. Move transmission shift lever out of low gear into neutral. Shifting to Lower Gears in Transmission. Depressing the clutch pedal will facilitate shifting. The transfer case is the means by which power is applied to the front and rear axles. Release clutch pedal and accelerate engine. In addition. Vehicle may be driven by rear axle. (7) After vehicle has attained a speedof approximately 20 miles per hour. With transfer case in "HIGH" range. (a) Engaging Front Axle with Transfer Case in "HIGH" Range. The transmis­ sion gearshift does not in any way affect the selection or shifting of the transfer case gears. depress clutch pedal. The front axle cannot be driven independently. d. 18 . Depress the clutch pedal to facilitate shifting. (fig. Shifting Gears in Transfer Case (fig. slippery roads. When shifting to a lower gear at any rate of vehicle speed. or during hard pulling. moving the gearshift lever straight back. (4) Release parking (hand) brake. Depress clutch pedal. e.

apply parking (hand) brake." This shift (3) can be made regardless of vehicle speed. g. Engage front axle drive (subpar. Stopping the Engine. To attach tow line. To tow vehicle attach the chain. 11). 8). Towing to Start Vehicle. and apply brakes by depressing brake pedal. f. (b) Release clutch pedal. Do not tow from the middle of the bumper. and accelerate engine to desired speed. depress clutch pedal and move transmission shift lever to "N" (neutral) position (fig. pull out throttle knob about 1 inch. Depress clutch pedal and engage transmission in high (3rd) speed. NOTE: Before a new or reconditioned vehicle is first put into service. Depress clutch pedal and move transfer case shift lever into (a) "HIGH" position. (2) When vehicle has come to a complete stop. (d) Depress clutch pedal again and move transfer case shift lever forward into "LOW" position. and accelerate as load is picked up. (c) Release clutch pedal and accelerate engine. After 19 . 6. e (1) above). rope or cable to the front bumper bar at the frame side rail gusset (fig. rope. loop chain. Attaching Tow Line. To shift into reverse speed. or cable over top of bumper. (e) Release clutch pcdal. and back on opposite side of frame. (1) When vehicle speed has been reduced to engine idle speed. Release clutch pedal and accelerate engine to desired speed. Reversing the Vehicle. To stop the engine turn the ignition switch to "OFF" position. (1) Depress clutch pedal. (3) Release clutch pedal slowly. (2) ENGAGING TRANSFER CASE LOW RANGE. a.TM 9-803 5-6 DRIVING CONTROLS AND OPERATION 3." pull out choke control knob (if engine is cold). (2) Move transmission shift lever to the left and forward into "R" (reverse) position. and accelerate engine to desired speed. release parking (hand) brake. and tow vehicle. (a) (b) Depress clutch pedal and move transfer case shift lever into "N" (neutral) position. TOWING THE VEHICLE. then hook or tie. bring tow line up across front of bumper. and release clutch and brake pedals. make run-in tests as outlined in sec­ tion 10. RANGE) shift lever of towed vehicle to the rear ("HIGH"). Remove foot from accelerator. Place transfer case (aux. h. b. ENGAGING TRANSFER CASE-"LOW" to "HIGH. Stopping the Vehicle. first bring the vehicle to a complete stop. Place front axle drive shift lever in "OUT" (forward) position. Transfer case LOW range cannot be engaged until front axle drive is engaged. Switch ignition "ON.

being careful to avoid overrunning towing vehicle or tow line. (e) If rear propeller shaft only is damaged. (1) ALL WHEELS ON GROUND. Place front axle drive shift lever in "IN" (rear) position and this will allow front axle drive to propel vehicle under own power. Figure 11-Chain Tow RA PD 305106 (c) If the front axle differential or propeller shaft is damaged. nuts. release clutch pedal slowly. (b) If transfer case is damaged. remove front axle shaft driving flanges. When towing a disabled vehicle exercise care so that no additional damage will occur. remove as described in step (d) above. Place front axle drive shift lever in "OUT" (forward) position and drive vehicle under own power. (d) If the rear axle differential is damaged. and races in the glove compartment. 20 . TOWING VEHICLE WITH FRONT OR REAR WHEELS OFF (2) GROUND. rollers. disconnect both propeller shafts at the front and rear axles by removing the universal joint U-bolts. being careful not to lose the bearing races and rollers. If vehicle is to be towed in this manner be sure that transfer case shift lever is placed in "N" (neutral) position and front axle drive shift lever is placed in "OUT" (disengaged) position.and FORD MODEL GPW) vehicle is under way. remove rear propeller shaft at rear universal joint U-bolts and front universal joint snap rings in forward flange. Place bolts. As engine starts. regulate choke and throttle controls and disengage clutch. (a) If transfer case is not damaged.TM 9-803 6 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB . then drive out bearing cups. Towing Disabled Vehicle. Securely fasten the shafts to the frame with wire or remove dust cap and pull apart at the universal joint splines. c. shift transmission and trans­ fer case into neutral position and follow steps (c) and (d) below. remove the rear axle shafts.

.... dirt.. (5) If possible.... if possible....... Operation in sand ........ Winter grade of gasoline is designed to reduce cold weather starting difficulties. 7 8 9 10 11 OPERATION IN COLD WEATHER... this water will form ice crystals that will clog fuel lines and carburetor jets........ Due to condensation of moisture from the air...... (4) Be sure that all containers are thoroughly clean and free from rust before storing fuel in them............. drums.. unless means are provided to ground the electricity..... Operation in landing . The more fuel there is in the tank... b........ Operation of automotive equipment at subzero temperatures presents problems that demand special precautions and extra careful servicing from both operation and maintenance person­ nel.. (6) Keep all closures of containers tight to prevent snow......... Operation in hot weather ...TM 9-803 Section IV OPERATION UNDER UNUSUAL CONDITIONS Paragraph Operation in cold weather ..... water will accumulate in tanks......... Purpose.. after filling or moving a container....... Decontamination .. Storage and Handling of Gasoline. 21 ... the smaller will be the volume of air from which moisture can be condensed....... Grade 3....... a. and containers............ c. and other foreign matter from entering... unless the following precau­ tions are taken: (1) Strain the fuel through filter paper.... to the fuel tank each time it is filled.. Gasoline. At low temperatures..... d. allow the fuel to settle before filling fuel tank from it... (1) TRANSMISSION AND DIFFERENTIAL........... (3) Add /2 pint of denatured alcohol... if poor performance and total functional failure are to be avoided.. the winter grade motor fuel should be used in cold weather operation. (2) Keep tank full. (7) Wipe all snow or ice from dispensing equipment and from around fuel tank filler cap before removing cap to refuel vehicle.. to assure an effective ground. CAUTION: Gasoline flowing over a surface generates static electricity that will result in a spark............... Always provide a metallic contact between the container and the tank... or any other type of strainer that will prevent the passage of water. 7............ ice...... This will reduce the hazard of ice formation in the fuel. therefore... Lubrication..

Lubricate chassis points with general (2) ' purpose grease. If consistent temperature below 0°F is anticipated. Dilute make-up oil in the same proportion before it is added to gear cases.for use at temperatures as low as -. refill with clean water. Refill with uni­ versal gear lubritant. Protect the system to at least 100 F below the lowest temperature expected to be experienced during the winter season. compound. and main­ tain engine speed at fast idle for 5 minutes. if possible. and pet cocks and tighten if necessary. Protect the system with. If Grade 75 universal gear lubricant is not available. clean the cooling system. Drain housing. drain the gear cases while warm. (b) After engine has been warmed up.n iversal gear lubricant. (2) CLEAN COOLING SYSTEM. Inspect all hose clamps. Otherwise the system should be cleaned with cleaning compound. Repair all radiator leaks before adding antifreeze compound. fill the system with water to about one-third capacity. using the proportion of antifreeze compound to the cooling system capacity indicated below. anti­ freeze compound (ethylene-glycol type) for operation below +32°F. and again drain. and refill with Grade 75 universal gear lubricant. Dilute make-up oil in the same proportion before it is added to the housing. CHASSIS .TM 9-803 7 14-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (a) . This will heat gear lubri­ cants to the point where normal operation can be expected.200 F. if not available. (4) ADD ANTIFREEZE COMPOUND. Inspect all hoses. in the proportion of one part fuel to six parts universal gear lubricant. If the cool­ ing system has been cleaned recently. SAE 80. e. Grade 75. Before adding antifreeze. (4) OILCAN POINTS. SAE 80 universal gear lubri­ cant diluted with the fuel used by the engine. is suitable. 22 . Correct all leakage of exhaust gas or air into the cooling system. or. Put transmission in low (first) gear. No. and completely free it from rust. USE ANTIFREEZE COMPOUND. 0. and drive vehicle for 100 yards. may be used. SAE 80 universal gear lubricant diluted with fuel used in the engine. (1) Protection of Cooling Systems. use lght lubricating. being careful not to stall engine. engage clutch. (3) ST RING GEAR HOUSING. When the cooling system is clean and tight. preservative oil. where specified on figure 14. in the proportion of one part fuel to sx parts SAE 80 universal gear lubricant. Then add antifreeze compound. or until gears can be engaged.. (3) REPAIR LEAKS. which is suit­ able for operation at all temperatures below +32 0 F. it may be necessary only to drain. For oilcan points where engine oil is pre­ scribed for above 0°F. or use suction gun t/r emove as much lubricant as possible. The following instructions apply to use of new antifreeze compound.POINTS. and replace if deteriorated. plugs.

...... if necessary..... (5) SPARK PLUGS.. (2) WIRING. 0 . and clean or replace points..... See that the commutators are clean. Check the brushes........ If rusty.. Clean and adjust or replace.. In cold weather. (1) GENERATOR AND CRANKING MOTOR.. (a) Antifreeze compound is the only antifreeze material author­ ized for ordnance materiel... (d) Do not spill antifreeze compound on painted surfaces..... (b) It is essential that antifreeze solutions be kept clean... If it is difficult to make the engine fire...... rust... inspect the coolant weekly for strength and color... -30 0 F .. clean... adding antifreeze compound if required. -20°F ............. and add new solution of the required strength.. Electrical Systems.. 23 ....... (7) INSPECT WEEKLY. (3) COIL. and bearings.. To test a hydrometer. slightly pitted points may prevent engine from starting. After adding antifreeze compound. use one part antifreeze compound to two parts water. then start and warm the engine to normal operating temperature. 67 b)..... This solution will pro­ duce a hydrometer readingof O0F..... and oil..... Check the points frequently. In service........TM 9-803 7 OPERATION UNDER UNUSUAL CONDITIONS ANTIFREEZE COMPOUND CHART (for 11-quart capacity cooling system) Temperature Antifreeze Compound (ethylene-glycol type) + 10°F ..... This will make ignition more effective at reduced voltages likely to prevail... f..005 inch less than that recommended for normal operation (par..... drain and clean cooling system thor­ oughly. -40 0 F .. Check......... and tighten all connections...... Care should be taken that no short circuits are present.. Clean thoroughly. commutators. Stop the engine and check the solution with a hydrometer. reduce the gap to 0.... fill with water to slightly below the filler neck. (4) DISTRIBUTOR.... Check coil for proper functioning by noting quality of spark.. 3 33/4 4% 43/4 5% 6 qt qt qt qt qt qt (5) WARM THE ENGINE.... The large surges of current which occur when starting a cold engine require good contact between brushes and commutators. (6) TEST STRENGTH OF SOLUTION.. Use only containers and water that are free from dirt... (c) Use an accurate hydrometer... °F -10 0 F .. especially the battery terminals... (8) CAUTIONS...

and replace. (7) BATTERY. (1) INSPECT CRANKING MOTOR MECHANISM. Care should be taken that the spark is not unduly advanced nor retarded. Check the butter­ fly valve to see that it closes all the way. or cause them to remain in mesh after the engine starts run­ ning. g. wiring. and becomes practically nil at -. (9) ICE. 24 . Wash screens in dry-cleqning solvent. The oiP will congeal and prevent the easy flow of air. and otherwise functions properly. (5) FUEL SYSTEM. Ice and frost formations on the air cleaier screens can cause an abnormally high intake vacuum in the cafburetorvair horn hose. strainers. If water is added and the battery not put on charge. or other electrical equipment is free from ice. Inspect the lights carefully. Be sure that no heavy grease or dirt has been left on the cranking motor throwout mechanism. The latter will ruin the cranking motor and necessitate repairs.. Check for short circuits and presence of moisture around sockets. daily.300. (4) AIR CLEANERS. Check carefully. Heavy grease or dirt is liable to keep the gears from being meshed. resulting in collapse. the layer of water will stay at the top and freeze before it has a chance to mix with the acid. when turning speeds are reduced to 30 to 60 revolu­ tions per minute. At temperatures below 0°F do not use oil in air cleaners. (2) USE OF CHOKE. unless a warm slave battery is available. see that the spark plugs. Before every start. (3) CARBURETOR AND FUEL PUMP. The carburetor. Be sure the fuel pump has no leaky valves or diaphragm. A full choke is necessary to secure the rich air-fuel mixture required for cold weather starting. with the hydrometer reading between 1. dry. etc. but a fully discharged battery will freeze and rupture at +5 0 F. Do not try to start the engine with the battery when it has been chilled to tem­ peratures below -30 0 F until battery has been heated. (b) Do not add water to a battery when it has been exposed to subzero temperatures unless the battery is to be charged immediately. Starting and Operating Engine. is liable not to operate satisfactorily at low temperatures. (a) The efficiency of batteries decreases sharply with decreasing temperatures. Also drain fuel tank sump daily to remove water and dirt. See that the battery is always fully charged. which will give no appreciable trouble at normal temperatures.275 and 1.TM 9-803 7 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (6) TIMING.400 F. (8) LIGHTS. as this will prevent the fuel pump from delivering the amount of fuel required to start the engine at low temperatures. Remove and clean sediment bulb. A fully charged battery will not freeze at temperatures likely to be encountered even in arctic climates.

Always have a blowtorch handy to warm up these parts. to block the wheels or otherwise prevent movement of the vehicle. (1) BRAKE BANDS. particularly on new vehicles. Chassis. h. if they bind prior to mov­ ing. ~--:· ~''R fin 1 : RA PD 305175 Figure 12-Fuel Pump. the vehicle. (e) Free up engine with hand crank or use slave battery. 25 . Parking the vehicle with the brake released will eliminate most of the binding. Hand Operation (g) Engage clutch to warm up transmission oil before attempting to move vehicle. 13 b (22)). (a) Clean ignition wires and outside of spark plugs of dirt and frost. (b) Free distributor point arm on post and clean points. under these circumstances. (d) Operate fuel pump hand lever to fill carburetor bowl (fig. Brake bands. Observe the following precautions in addition to the normal starting procedure (par. (h) Check engine operation for proper condition (par. 12). Precaution must be taken. (c) Be sure carburetor choke closes fully. or attempting to move. have a tendency to bind when they are very cold. (f) Stop engine if no oil pressure shows on gage. 5 a and b).TM 9-803 7 OPERATION UNDER UNUSUAL CONDITIONS (6) STARTING THE ENGINE.

OPERATION IN SAND. Release clutch pedal slowly so the wheels will not spin and "dig in. Check and replenish oil and water frequently. adjust throttle control. Check the battery solution level fre­ (par. and add water as required to keep it above the top of the plates. Disconnect the oil-lubricated speed­ ometer cable at the drive end when operating the vehicle at tempera­ tures of -30 0 F and below. damp weather or quick changes in temperature. (2) (3) LUBRICATION. add rust preventive solution to the cooling system. gravel. Inspect the vehicle frequently. a. b. 26 ." c. or clean and flush the system at frequent intervals. (1) COOLING SYSTEM. particularly if a tow or winch is available. 8).'. frozen ground causes strain and jolting which will result in screws breaking. wires. 7). is greatly reduced at extremely low temperatures. and sometimes will break. and both inside and outside of distributor cap. Starting the Vehicle. When starting the vehicle in sand. When engine starts. a. Operation of vehicles on hard. do not exceed the speed specified on the caution plate for the particular gear ratio (fig. push choke control in. or nuts jarring loose. In sandy territory clean the carburetor air cleaner more often. engage the front wheel drive (par.TM 9-803 7-9 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (2) EFFECT OF Low TEMPERATURES ON METALS. Clutch. If hard starting is experienced in hot. Racing the engine usually causes the wheels to "dig in" farther. Do not attempt to "jump" or "rock" the vehicle out with a quick engagement of the clutch. Reduce tire pressures in desert terrain if character of sand demands this precaution. Air Cleaner. 9. Rust formation occurs more rapidly dur­ ing high temperatures. due to the excessive drag caused by the high viscosity of the oil with which it is lubricated. therefore. pull the throttle control out. dry the spark plugs. The cable will often fail to work properly at these temperatures. Protection of Vehicle. and. use the cranking motor. Operation. When operating in sand deep enough to cause the use of a lower gear. In extremely hot weather avoid the continuous use of low gear ratios whenever possible. (3) SPEEDOMETER CABLE. quently during hot weather operation. OPERATION IN HOT WEATHER. 8. or resistance against breaking." necessitating a tow or "winch-out. If a flooded condition of the engine is experienced in starting. Lubricate the vehicle for hot weather operation ELECTRICAL SYSTEM. The frequency of cleaning depends upon the severity of the sandy condition. or soft terrain. Shock resistance of metals. d. 5 e (1)).

'and transfer case lubricant for presence of sludge. a. fuel pump. (3) POWER TRAIN. clean the valve chamber.TM 9-803 9-11 OPERATION UNDER UNUSUAL CONDITIONS e. and install a new filter element. Clean the air cleaner and change the oil. drain and clean the oil filter. As soon as possible after completing a landing or operation in water. OPERATION IN LANDING. using a mixture of half engine oil SAE 10 and half kerosene. Before putting in new oil. 27 . ENGINE. 11. renew the lubricant after cleaning the units with a mixture of half engine oil SAE 10 and half kerosene. and see that the air passages of the core do not become clogged. Lubricate the propeller shaft universal joints and spring shackles to force out any water which might damage parts. For additional information on technique of operating the vehicle in sand. a. fuel tank. If sludge is found. flush the engine. Radiator. If water or sludge is found. filter. Inspect the front and rear axle housings. Drain the engine crankcase oil. fuel strainers. wheel bearings. Protection. (1). inspect the vehicle for water in the various units. transmission. DECONTAMINATION. Inspect the carburetor bowl. 10. (2) FUEL SYSTEM.\ Inspection. For protective measures against chemical attacks and decontamination refer to FM 17-59. In desert operation check the radiator coolant supply frequently. f. and lines. refer to FM 31-25.

...... are covered in manual procedures under the items to which they are related. however.. also weekly......... to cover vehicles of all types and models..... These services are arranged to facilitate inspection and conserve the time of the driver..... 48.. To ensure mechanical efficiency it is necessary that the vehicle be systematically inspected at intervals each day it is operated... not chafed or burned... at halt.. After-operation and weekly service .. Form No..... Certain items listed on the form that do not pertain to the vehicle involved are eliminated from the procedures as written into the manual.. Items peculiar to specific vehicles.... 48 that apply to this vehicle are expanded in this manual to provide specific procedures for accomplishment of the inspections and services. Form No.." W. d........ but not listed on W. The items listed on W.. Every organization must thoroughly school each driver in performing the maintenance procedures set forth in manuals.. 48 or not... secure.D. The general inspection of each item applies also to any sup­ porting member or connection. whether they are listed specifically on W........ not bare or frayed.... 28 ..... (1) The inspection for "good condition" is usually an external visual inspection to determine whether the unit is damaged beyond safe or serviceable limits. or excessively worn..... Form No. and after operation and weekly... Form No. correctly assembled.... not dented or collapsed......D.. Certain scheduled maintenance services will be performed at these designated intervals...... 48.....TM 9-803 12 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section V FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE Paragraph Purpose .D... a... during operation. and generally includes a check to see whether the item is in good condition. 48. PURPOSE..D. At-halt service .. Driver preventive maintenance services are listed on the back of "Driver's Trip Ticket and Preventive Maintenance Service Record. not broken or cracked............. are identical with those shown on that form....... not torn or cut................ c............... Form No....... The services set forth in this section are those performed by driver or crew before operation. so that defects may be discovered and corrected before they result in serious damage or failure.. During-operation service .... Before-operation service ....D. 12 13 14 15 16 12....... The term "good condition" is explained further by the following: not bent or twisted... The item numbers.... b..... and are not necessarily in the same numerical order as shown on W.....

TM 9-803
12-13 FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE (2) The inspection of a unit to see that it is "correctly assembled" is usually an external visual inspection to see whether or not it is in its normal assembled position in the vehicle. (3) The inspection of a unit to determine if it is "secure" is usually an external visual examination, a hand-feel, wrench, or prybar check for looseness. Such an inspection should include any brackets, lock washers, lock nuts, locking wires, or cotter pins used in assembly. (4) "Excessively worn" will be understood to mean worn, close to or beyond, serviceable limits, and likely to result in failure if not replaced before the next scheduled inspection. e. Any defects o'r-unsatisfactory operating characteristics beyond the scope of the first echelon to correct must be reported at the earliest opportunity to the designated individual in authority. 13. BEFORE-OPERATION SERVICE. a. This inspection schedule is designed primarily as a check to see that the vehicle has not been tampered with or sabotaged since the After-operation Service was performed. Various combat condi­ tions may have rendered the vehicle unsafe for operation, and it is the duty of the driver to' determine whether or not the vehicle is in condition to carry out any mission to which it is assigned. This operation will not be entirely omitted, even in extreme tactical situations. b. Procedures. Before-operation Service consists of inspecting items listed below according to the procedure described, and correct­ ing or reporting any deficiencies. Upon completion of the service, results should be reported promptly to the designated individual in authority. (1) ITEM 1, TAMPERING AND DAMAGE. Examine exterior of vehicle, engine, wheels, brakes, and steering control for damage by falling debris, shell fire, sabotage, or collision. If wet, dry the ignition parts to ensure easy starting. (2) ITEM 2, FIRE EXTINGUISHER. Be sure fire extinguisher is full, nozzle is clean, and mountings secure. (3) ITEM 3, FUEL, OIL, AND WATER. Check fuel tank, crankcase, and radiator for leaks or tampering. Add fuel, oil, or water as needed. Have value of antifreeze checked. If, during period when antifreeze is used, it becomes necessary to replenish a considerable amount of water, report unusual losses. (4) ITEM 4, ACCESSORIES AND DRIVES. Inspect carburetor, gener­ ator, regulator, cranking motor, and water pump for loose connec­ tions and security of mountings. Inspect carburetor and water pump for leaks. (5) ITEM 6, LEAKS, GENERAL. Look on ground under vehicle for indications of fuel, oil, water, brake fluid, or gear oil leaks. Trace leaks to source, and correct or report to higher authority. 29

TM 9-803
13 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (6) ITEM 7, ENGINE WARM-UP. Start engine, observe cranking motor action, listen for unusual noise, and note cranking speed. Idle engine only fast enough to run smoothly. Proceed immediately with following services while engine is warming up. (7) ITEM 8, CHOKE. As engine warms, push in choke as required
for smooth operation, and to prevent oil dilution.
(8) ITEM 9, INSTRUMENTS. (a) Fuel Gage. Fuel gage should indicate approximate amount
of fuel in tank.
(b) Oil Pressure Gage. Normal oil pressure should not be below 10 with engine idling, and should range from 40 to 50 at running speeds (at normal operating temperature). If gage fails to register within 30 seconds, stop engine, and correct or report to higher authority. (c) Temperature Indicator. Temperature should rise slowly dur­ ing warm-up. Normal operating temperature range is 160 0F to 185 0 F. (d) Ammeter. Ammeter should show high charge for short period after starting and positive (plus) reading above 12 to 15 miles per hour with lights and accessories off. Zero reading is normal with lights and accessories on. (9) ITEM 10, HORN AND WINDSHIELD WIPERS. Sound horn, tacti­ cal situation permitting, for proper operation and tone. Check both wipers for secure attachment and normal full contact operation through full stroke. (10) ITEM 11, GLASS AND REAR VIEW MIRROR. Clean windshield and rear view mirror and inspect for cracked, discolored, or broken glass. Adjust mirror. (11) ITEM 12, LIGHTS AND REFLEICTORS. Try switches in each position and see if lights responds Lights and warning reflectors must be securely mounted, clean, and in good condition. Test foot control of headlight beams. (12) ITEM.13, WHEEL AND FLANGE NUTS. Observe whether or not all wheel and flange nuts are present and tight. (13) ITEM 14, TIRES. If time permits, test tires with gage, includ­ ing spare; normal pressure is 35 pounds with tires cold. Inspect tread and carcass for cuts and bruises. Remove imbedded objects from treads. (14) ITEM 15, SPRINGS AND SUSPENSION. Inspect springs for sagged or broken leaves, shifted leaves, and loose or missing rebound clips. (15) ITEM 16, STEERING LINKAGE. Examine steering gear case, connecting links, and Pitman arm for security and good condition. Test steering adjustment, and free motion of steering wheel.
(16) ITEM 17, FENDERS AND BUMPERS. Examine fenders and

bumpers for secure mounting and serviceable condition.
30

TM 9-803
13-14 FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE
(17) ITEM 18, TOWING CONNECTIONS. Examine pintle hook for

secure mounting and serviceable condition. Be sure pintle latches properly and locks securely. (18) ITEM 19, BODY AND LOAD. Examine body and load (if any) for damage. Be sure there is a cap on front drain hole under fuel
tank. See that rear drain hole cap is available in glove compartment. CAUTION: Rear drain hole cap should be installed when about to pass through deep water. (19) ITEM 20, DECONTAMINATOR. Examine decontaminator for full charge and secure mountings. (20) ITEM 21, TOOLS AND EQUIPMENT. See that tools and equip­ ment are all present, properly stowed, and serviceable. (21) ITEM 23, DRIVER'S PERMIT AND FORM 26. Driver must have his operator's permit on his person. See that vehicle manuals, Lubri­ cation Guide, Form No. 26 (accident report) and W.D. AGO Form No. 478 (MWO and Major Unit Assembly Replacement Record) are present, legible, and properly stowed. (22) ITEM 22, ENGINE OPERATION. Accelerate engine and observe for unusual noises indicating compression or exhaust leaks; worn, damaged, loose, and inadequately lubricated parts or misfiring. (23) ITEM 25, DURING-OPERATION SERVICE. Begin the Duringoperation Service immediately after the vehicle is put in motion. 14. DURING-OPERATION SERVICE.

a. While vehicle is in motion, listen for any sounds such as rattles, knocks, squeals, or hums that may indicate trouble. Look for indi­ cations of trouble in cooling system, and smoke from any part of the vehicle. Be on the alert to detect any odor of overheated components or units such as generator, brakes, or clutch; check for fuel vapor from a leak in fuel system, exhaust gas, or other signs of trouble. Any time the brakes are used, gears shifted, or vehicle turned, con­ sider this a test and notice any unsatisfactory or unusual perform­ ance. Watch the instruments frequently. Notice promptly any un­ usual instrument indication that may signify possible trouble in system to which the instrument applies. b. Procedures. During-operation Service consists of observing items listed below according to the procedures following each item, and investigating any indications of serious trouble. Notice minor deficiencies to be corrected or reported at earliest opportunity, usually at next scheduled halt. (1) ITEM 27, FOOT AND HAND BRAKES. Foot brakes must stop vehicle smoothly without side pull and within reasonable distance. There should be at least 13 reserve brake pedal travel and ¼2-inch free travel. Hand brake must securely hold vehicle on reasonable incline with 1/3 reserve ratchet travel. There must be ¼2-inch clear­ ance (on cable) between relay crank and lower end of hand brake conduit. 31

TM 9-803
14-15 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (2) ITEM 28, CLUTCH. Clutch must operate smoothly without chatter, grabbing, or slipping. Free clutch pedal travel of threequarter inch is normal.
(3) (4) (5) ITEM 29, TRANSMISSION. Gearshift mechanism must operate ITEM 29, TRANSFER CASE. Gearshift mechanism must operate ITEM 31, ENGINE AND CONTROLS. Observe whether or not

smoothly, and not creep out of mesh. smoothly and not creep out of mesh. engine responds to controls, and has maximum pulling power without unusual noises, stalling, misfiring, overheating or unusual exhaust smoke. If radio noise is reported during operation of the vehicle, the driver will cooperate with the radio operator in locating the inter­ ference. See paragraph 178. (6) ITEM 32, INSTRUMENTS. During operation observe the read­ ings of all instruments frequently to see if they are indicating properly. (a) Fuel Gage. Fuel gage must register approximate amount of fuel in tank. (b) Oil Pressure Gage. Oil pressure gage should register 10 with engine running idle, and 40 to 50 at operating speeds. (c) Temperature Indicator. Temperature indicator should show a temperature of 160 0 F to 185 0F after warm-up under normal con­ ditions. (d) Speedometer. Speedometer should show speed of vehicle without noise or fluctuation of indicator needle. Odometer should register accumulating trip and total mileage. (e) Ammeter. Ammeter should show zero reading with lights on, zero or positive (plus) charge with lights off, and slightly higher positive (plus) charge for short time immediately after starting. (7) ITEM 33, STEERING GEAR. Observe steering for excessive pull­ ing of vehicle to either side, wandering, or shimmy. (8) ITEM 34, CHASSIS. Listen for unusual noises from wheel or axles. (9) ITEM 35, BODY. Observe body for sagging springs, loose or torn top or windshield cover, if in use. 15. AT-HALT SERVICE. a. At-halt Service may be regarded as the minimum mainte­ nance procedure, and should be performed under all tactical condi­ tions, even though more extensive maintenance services must be slighted or omitted altogether. b. Procedures. At-halt Service consists of investigating any deficiencies noted during operation, inspecting items listed below according to the procedures following the items, and correcting any deficiencies found. Deficiencies not corrected should be reported promptly to the designated individual in authority. 32

TIRES. (5) ITEM 42. (13) ITEM 50. AXLE AND TRANSFER CASE VENTS. TEMPERATURES. generator. and correct cause or report to higher authority. BODY LOAD AND TARPAULIN. and loose mountings or connections. 33 . and all bond straps for damage. CAUTION: Do not apply oil to element after cleaning. including spare. If radio noise during operation of the engine was observed. FUEL. transmission. and inspect vehicle for damage. for flats or damage. (11) ITEM 48. have coolant tested with hydrometer. (8) ITEM 45. (9) ITEM 46. FENDERS AND BUMPERS. (4) ITEM 41. Observe whether axle and transfer case vents are present. Check fuel supply. If. Inspect tires. mirror. Check around engine and on ground beneath the vehicle for excessive leaks. that fan belt is adjusted to 1-inch deflection. (10) ITEM 47. (3) ITEM 40. suppressors at spark plugs and distributor. APPEARANCE AND GLASS. If dusty or sandy conditions have been encountered. examine all radio noise sup­ pression capacitors. and see that they are not damaged or clogged. or oil leaks. add. PROPELLER SHAFT. (7) ITEM 44. LEAKS. during period when antifreeze is used. examine oil sump for excessive dirt. light lenses. and front and rear axles for over­ heating. Observe whether or not all wheel and axle flange nuts are present andtight. AIR CLEANER.TM 9-803 15 FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE (1) ITEM 38. Look for broken spring leaves or loose clips and U-bolts. transfer case. and add antifreeze if required. an abnormal amount of water is required to refill radiator. WHEEL AND FLANGE NUTS. Investigate any irregularities noted during operation. oil. Examine gear cases for excessive oil leaks. SPRINGS. Inspect pintle hook and trailer light socket for serviceability. Trace to source. Clean windshield. STEERING LINKAGE. (12) ITEM 49. See that fan. Service if required. and for cuts or foreign material imbedded in tread. (14) ITEM 51. and coolant. water pump and generator are securely mounted. Inspect propeller shaft for loose­ ness. for complete operation of vehicle to the next refueling point. regulator. ACCESSORIES AND BELTS. and radio terminal box. damage. Feel each brake drum and wheel hub. see that tarpaulins are properly secured and not damaged. as required. (15) ITEM 52. Examine steering control mechanism and linkage for damage or looseness. (6) ITEM 43. OIL AND WATER. ignition and starting switches. (2) ITEM 39. Inspect vehicle and trailed vehicle loads for shifting. Inspect fenders and bumpers for looseness or damage. TOWING CONNECTIONS. GENERAL. at coil. and is not badly frayed.

(4) ITEM 57. (6) ITEM 59. or vibration that might indicate worn parts. HORN AND WINDSHIELD WIPERS. Check coolant and oil levels. and At-halt Serv­ ices. If this schedule is performed thoroughly. 34 . Operate both windshield wipers. Be sure fire extinguisher is full. nozzle is clean. AFTER-OPERATION AND WEEKLY SERVICE. a. AND WATER. GLASS AND REAR VIEW MIRROR. loose mountings. to the designated individual in authority. FUEL. have hydrometer test made of coolant if loss from boiling or other cause has been considerable. INSTRUMENTS. Observe whether or not lights operate properly with the switch in "ON" positions. even in extreme tactical situations. Examine for secure mounting and damage. The Afteroperation Service should never be entirely omitted. is then necessary only to ascertain whether the vehicle is in the same condition in which it was left upon completion of the After-operation Service. See that blades contact the glass effectively throughout full stroke. and add as needed. and that extinguisher is mounted securely. and corrects those he is permitted to handle. (5) ITEM 58. Clean lenses and warning reflectors. to the bare fundamental services outlined for the At-halt Service. the results of his inspection. if necessary. The Beforeoperation Service. OIL. LIGHTS AND REFLECTORS. faulty fuel mixture. Inspect all instruments to see that they are securely connected. the procedures for which are indicated in step (b) of each applicable item. Clean glass of windshield and rear view mirror. b. FIRE EXTINGUISHER. DECONTAMINATOR. Add anti­ freeze with water if required. the vehicle should be ready to roll again on short notice. When performing the After-operation Service the driver must remember and consider any irregularities noticed during the day in the Before-operation. (1) ITEM 54. During-operation.TM 9-803 16 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 16. He should report promptly. (3) ITEM 56. (8) ITEM 61. noise. \Fill fuel tank. After-operation Service is particularly important because at this time the driver inspects his vehicle to detect any deficiencies that may have developed. but may be reduced. Test horn for sound. ENGINE OPERATION. and go out when switch is off. See that stop light operates properly. Procedures. Examine decontaminator for good condition and secure mounting. and not damaged. Listen for misi. The After-operation Service consists of inspecting and servicing the following items. (7) ITEM 60. Those items of the After-operation Service that are marked by an asterisk (*) require additional Weekly Service. Refill spare cans. or faulty ignition. backfire. During period when antifreeze is used. if tactical situation permits. (2) ITEM 55. See that horn is securely mounted and properly connected. with a few exceptions.

(b) Weekly. Remove plug from bottom of dash-mounted fuel filter. cranking motor. and hose corinec­ tions. (16) ITEM 69. and does not leak. clean. Remove battery caps. Clean posts and terminals if corroded. Fill cup to indicated oil level (approximately s/8 qt). Do not apply oil to element after cIoning. Aline springs. (b) Weekly. (10) ITEM 63. and not leaking.TM 9-803 16 FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE (9) ITEM 62. (b) Weekly. *FUEL FILTERS. Clean element and refill oil cup as required. (b) Weekly. Examine belt for good condition. *ELECTRICAL WIRING. Be sure plug is replaced tightly. bond straps. *BATTERY. and add water to '2 inch above plates. Allow water and sediment to drain out. Timing hole cover must be closed and tightened. regulator. (13) ITEM 66. (a) See that all ignition wiring and accessible low voltage wiring is in good condition. it must not be frayed. (b) Weekly. Tighten all loose wiring connections or electrical unit mountings. drinkable water. (a) Examine springs for sag.. (Use distilled water if available. *AIR CLEANER. wear. (a) Test fan belt for deflection of 1 inch. broken or shifted leaves. (b) Weekly. Clean cables as required. Tighten all accessories such as carburetor. Tighten hold-down assembly. Tighten terminals as needed.) CAUTION: Do not overfill.-Examine engine controls for ITEM 68. CAUTION: Do not apply oil to element after cleaning. (a) See that battery is clean. *SPRINGS. Replace badly worn or otherwise unserviceable tires. *TIRES. wear or disconnected linkage. and spark plug and distributor suppressors. *ACCESSORIES AND BELTS. (11) ITEM 64. (a) Inspect tires for cuts or abnormal tread wear. 35 . (12) ITEM 65. Inspect electrolyte level. Pay particular attention to radio noise suppression units such as: capacitors. cracking. which should be /2 inch above plates with caps in place and vents open. inflate to 35 pounds when tires are cold. remove foreign bodies from tread. gener­ ator. (a) Examine oil in air cleaner oil cup to see that it is at proper level. or presence of oil. ENGINE CONTROLS. or shackles. if not use clean. fan. Rem0qve. (b) Weekly. and tighten U-bolts and shackles as required. and dry air cleaner element and oil cup. clean. Clean battery carrier if corroded. (a) Examine fuel filter for leaks. securely mounted. examine fan belt for fraying. and apply light coat of grease. and not excessively dirty. (14) (15) ITEM 67. water pump. correctly and securely assembled and mounted. loose or missing rebound clips. Clean top of battery.

tie rod. GEAR OIL LEVELS. (b) Weekly. Wash vehicle if possible. and windshield cover for damage and proper stowage. (22) ITEM 76. or damage. (28) ITEM 85. also points that experi­ ence and operating conditions indicate need lubrication. Check under hood and beneath \the vehicle for indications of fuel. Observe gear cases for leaks. Fenders and bumpers must be in good condition and secure. Remove. (19) ITEM 72. and replace vents. (27) ITEM 84. 36 . *TIGHTEN. Make sure rear drain below fuel tank is open. (a) Inspect pintle hook and towed-load connections for looseness or damage. TOOLS AND EQUIPMENT. BODY AND TARPAULINS. (26) ITEM 83. *AXLE AND TRANSFER VENTS. (b) Weekly. wipe off thoroughly. (a) Tighten any loose wheel. Inspect body. *CLEAN ENGINE AND VEHICLE. or brake fluid leaks. (b) Weekly. LEAKS.TM 9-803 16 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (17) ITEM 70. and steering arm to see if they are bent. PROPELLER SHAFT. Inspect propeller shaft and universal joints for loose connections. Examine steering wheel column. (25) ITEM 82. After units have cooled. (20)' ITEM 73. lubrication leaks. FENDERS AND BUMPERS. clean engine. Observe latest lubrication directives. if lubrication is needed. (18) ITEM 71. STEERING LINKAGE. (a) Clean dirt and trash from inside of body. (21) ITEM 74. Remove excessive dirt or grease from exterior of the engine. and spring U-bolt nuts. GENERAL. clean. axle drive flange. (a) Lubricate spring shackles and steering linkage. *LUBRICATE AS NEEDED. loose. (23) ITEM 77. Check to see that all tools and equipment assigned to vehicle are present and secure. and secure. (a) See that axle and transfer case vents are in good condition. and that cap is in glove compartment. Pitman arm. top. Tighten pintle hook mounting bolts. or inadequately lubricated. and lubricate pintle hook as required. Keep sump under fuel tank cleaned of dirt and water. (b) Weekly. clean. drag link. (24) ITEM 78. (b) Weekly. Lubricant should be level with bottom of filler hole. gear case. inspect differential transmission and transfer unit lubricant levels. *TowING CONNECTIONS. If not possible. Tighten all vehicle assembly or mounting nuts or screws that inspection indicates require tightening. water. oil. Lubricate points indicated on current vehicle Lubri­ cation Guide as requiring weekly attention.

Operate lubricating guns carefully and in such manner as to insure a proper distribution of the lubricant.... Be sure to clean this equipment both before and after use.. 13 and 14) prescribes lubrication maintenance for the Y4-ton 4 x 4 truck.. any one of which may quickly destroy the protective qualities of the lubricant and require servicing in order to prevent malfunctioning or damage to the materiel... Determine the time to change grades of lubricants by maintain­ ing a close check on operation of the vehicle during the approach to change-over periods. oilers and oil holes make them readily identifiable on the vehicle. the using arm shall immediately requisi­ tion a replacement from the Commanding Officer. a. d.. continued operation in sand or dust.... In the event the vehicle is received without a Guide... +320 F to 0°F.. b. Wipe clean such lubricators and the surrounding surface before lubri­ cant is applied.. b... and below 0°F. Points of Application. (1) Red circles surrounding lubrication fittings... c.. above +32 0 F. unless malfunctioning occurs sooner due to lubricants being too thin or too heavy.... 501 (figs.... Lubrication instructions on the Guide are binding on all echelons of maintenance and there shall be no deviations from these instructions.. War Department Lubrication Guide No.. e...... prolonged periods of high speed. Ordinarily it will be necessary to change grades of lubri­ cants only when air temperatures are consistently in the next higher or lower range... grease cups. or exposure to moisture.. Reduce these intervals under extreme conditions such as excessively high or low temperatures... DETAILED LUBRICATION INSTRUCTIONS.. 37 .. Lubricants are prescribed in the "Key" in accordance with three temperature ranges..... LUBRICATION GUIDE.... 17 18 17. Be particularly observant when starting the engine.. A Lubrication Guide is placed on or is issued with each vehicle and is to be carried with it at all times. Fort Wayne Ord­ nance Depot. Service intervals specified on the Guide are for normal oper­ ation conditions..... Detroit 32. Sluggish starting is an indication of thickened lubricants and the signal to change to grades prescribed for the next lower tempera­ ture range.. a Lubrication Equipment.. Each piece of materiel is supplied witz lubrication equipment adequate to maintain the materiel. immersion in water. Mich. 18.TM 9-803 17-18 Section VI LUBRICATION Paragraph Lubrication Guide ........ Detailed lubrication instructions ....

TM 9-803 18 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) !2 l u u! ! l2 E EC Ii. -. ltl. ._ ii.O 0 0 0 _ i: o zgz C - - 0 3 8 a< - 38 . -. .

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TM 9-803 18 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) O 0B z z a eI if i b--PC4 20 0 0 ii i 40 .

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After ompleting iW. Keep oil up to FULL mork. Totel oilers-one. removethe oil pan and clean floating oil intake creen. Use oil con for oiler and lubricote sporingly wick and posl. refill four quaorr. ENGINECRANKCASE DRAININGRemoe droin plug to droin. AIR CLEANER-OE Oneoir cleoer. E DISTRIBUTOR--or E IIF CRANKING MOTOR--OE One distributor. Copocity fie quarl. Use oil can. To replace element remove drain plug. Checklevel ot lelt doily.11.TM 9-803 18 '/-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) ENGINE CRANKCASE-Of Oil leel indicator inl filler pipe. Copocity % quort.. Oil ond reploce cover. RA PD 305166 Figure 15-Engine Lubrication Points 42 . filter cover then element. push side oil hole coer. OIL FILTER-OE One filter--Remoe drin plug to droin. greose com tightly. Total ploces--four. At et once o year. Clean cleoner ond refill rese. nginse few minutesond refill cronkcoseto FULL mark on oil level indicotor.oir to indicated tI el.ti.

Us. CAUTION: Do not use high pressure greose gr becouseof domoge to seIl- Two sip oint Totol til go .inos-two Use pressuregun on fnings RA PD 305167 Figure 16-Pedal Shafts and Power Train LubricationPoints 43 .- TRANSMISSION-GO One tronsmission. Totol plugs-two (filler ond drain). Drain and refill to bottom of filler plug hole. Totol flttings-one. Copocity V. TRANSFERCASE-OO On tronsfer cose. Droin nd refill to bottom of filler plug hole. Totol fittings-four. Use pressure gun on fitting until greose shows E '~F PROPELLER SHAFT SLIP JOINT-CS PROPELLER SHAFTUNIVERSAL JOINTS-CO Four uniersol joints. Usepressure gun (hond) with odoptor. shoA.. Use ger oil pump. Copoaily Is/ quorts. Totol plugs-two (filler ond drain). TRANSFER CASESHIFTLEVERSHAFT-CO One shift leer shoft. f.TM 9-803 18 LUBRICATION CLUTCHAND bRAKEPEDALSHAFT-CO One pedol .ho. gor oil pump. quart.h1ft Totol lngl-two Ufe pressuregun on fittings -util. gr .

Use. oil pump.. inspect boaring roces. STEERING GEAR HOUSING-GO One housing. and Steering Gear Housing LubricationPoints 44 . Total plugs-to. Use presoure gun (hond) and fill I hoing slowlyuntil full.lhub. T_ I PINTLENOOK--O One hook-With an oil con lubricate pin. Total plugs-four (filler and drain). Wheel. C' FRONT AXLE UNIVERSAL JOINTS-CO Two universal joints. Apply grease also around outsid of cage nd roller. U. I B WHEEL BEARINGS-WS Fourwheels. Pintle. Copacity 1 / quart. RA PD 305168 Figure 17-Axle. D arn and refill to bottom of filler plug hole. putthree ounces of grease in eaochhub. Total bearings-eight. Cleanout whee.sand sldiing urfaces.se pressure gun (hand) and fill housing slowly to level of filler plug hole. connection. LINKAGECLEVISPINS-OE All clevis pins and hood and windhield cotches. Totol plugs-one. Ue oil can and apply in proper qanfity.TM 9-803 18 A/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) A AXLE HOUSING$S-GO gear Two axle housjg. Usebearing lubricotor or hand pck thoroughly.

RA PD 305169 Figure 18-Steering Gear and Spring Lubrication Points 45 . Use pressuregu on fittings until nfwl grease how. until grease s. D SPRINGSHACKLES-CO Four spring h. Usepressure gun n fitting until greoseshos. Use presore gun on fitting until greoas slows. Totol fttings--oight. Totl fitting--one. E SPRING BOLTS-CO Four spring bolts.klN. Totl fiings--four. Totl until greoase shows. C STEERING TIEROD-CO "t. Usepressuregun on fitting TORQUEREACTION SPRINGBOLT-CO ehilos equipped with One spring bolt.ho . Usepresure gun on fittings until groose shows. Total fittings-four. ttflings--o.. Two tie rods. Total fittings--one (on this sprnlg on th lft front spring). Use pressuro gun on fittings STEERING BELLCRANK-CO One bollcron.TM 9-803 18 LUBRICATION DRAG LINK-CO STEERING One drog link.

d. apply new lubricant until the old lubricant is forced from the vent. All note references in the Guide itself are to the paragraph below having the corresponding number. Master Cylinder. Cleaning. c. Use of gasoline for this purpose is pro­ hibited. Coot with greose. Removeond cloon if necessory. rill reservoir to / inch from top. or OIL. it bove plotes. Checkcondition. Totol rubber b. BATTERY-CO One botery. fuel.TM 9-803 18 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) / BUSHIGS--HB SHOCK ABSOR1Efl abrorbers. dry all parts thoroughly before applying lubricant. Use SOLVENT. Four shock luid to preserve rubber. Totol terminls--two. and Battery Lubrication Points (2) Where relief valves are provided. Lubrication Notes on Individual Units and Parts. 46 . to clean or wash all parts.uhings-eight. Apply broke BRAKESYSTEM--HB. dry-cleaning. Cleon top of broke moster cylinder and removeplug. Diesel. The fol­ lowing instructions supplement those notes on the Lubrication Guide which pertain to lubrication and service of individual units and parts. Checkwoatr level to keep RA PD 305170 Figure 19-Shock Absorber. After washing. Exceptions are specified in notes on the Lubrication Guide.

Clean before applying lubricant. remove and wash all parts. SAE 30 above +320 F or SAE 10 from +320 F to 0°F.) (7) GEAR CASES. clean inside and renew element. Drain only when engine is hot. etc. and to slip joint until it shows at the end of spline. inspect and refill to plug level. check level and refill oil reservoir to bead level with used crankcase oil or OIL. CAUTION: Be sure pressure gage indicates oil is circulating. drain filter. Use hand gun only.000 miles. water. rough rmads. Every 6. This permits the removal of the axle spindle. dry-cleaning. engine. check level with truck on level ground and. remove plug at rear and add GREASE. remove.000 miles. CAUTION: Lubricate chassis points after washing truck and trailer. 47 . snow. check crankcase level. Weekly.TM 9-803 18 LUBRICATION (1) FITTINGS. For extreme conditions of speed. general pur­ pose. (6) OIL FILTER. Refill to "FULL" mark on gage. Every 1. above +32°F. and dry. sand. (SAE 30 above +320 F. or OIL. mud. (2) INTERVALS. use FLUID. (c) Clean and repack upper and lower steering spindle bearings within the universal housing and reassemble entire unit. (4) AIR CLEANER. No. (9) UNIVERSAL JOINTS AND SLIP JOINTS. to "FULL" mark on gage. Daily. 1 above +320 F or No.. SOLVENT. to level of filler plug hole. 0 below +320 F. Run engine a few minutes. refer to OFSB 6-11. will be used to clean or wash all parts. add lubricant to plug level.000 miles. dry. or more if conditions warrant. Drain only after operation. or No. SAE 10 from +320 F to 0°F. Drain and refill at intervals indi­ cated on Guide. All parts will be thoroughly dry before relubri­ cation. (b) Wash the axle shaft and universal joint thoroughly in SOL­ VENT. Lubricate until new lubricant is forced from the bearing. 1. dry-cleaning.000 miles or more often if filter becomes clogged. light. drain sediment. the complete axle shaft. add OIL. Intervals indicated are for normal service. engine. Care should be taken not to injure the outer oil seal assembly in the housing. to joints until it shows at joint cross. daily under extreme dust conditions. skid plate must be removed to reach drain plug. unless otherwise specified. Diesel. and the universal joint assembly. shock-absorber. (a) Remove brake tube and brake backing plate screws. Use of gasoline for this pur­ pose is prohibited. From 0°F to -40 0 F. Every 6.000 miles. Below -40 0 F. (8) UNIVERSAL JOINT AND STEERING KNUCKLE BEARINGS. Run engine a few minutes and recheck oil level. Every 1. fuel. On early Willys models. No. (3) CLEANING. 0 below +320 F. clean. Check only before operation while lubricant is cold. Every 1. below 0°F. heat. reduce interval by one-third or one-half. gen­ eral purpose. dust. remove oil and operate dry. if necessary. (5) CRANKCASE. Apply GREASE.

lubricating. e. above +320 F.TM 9-803 18 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (10) DISTRIBUTOR. Wet the spindle and inside of hub and hub cap with GREASE. proper lubricants used. engine. 0. 1.G. (13) RUBBER BUSHINGS. general purpose.000 miles. engine. with a packer or by hand. Inspect bearing races and replace if necessary. 17.. Reports and Records. No. below +320 F. brake. 15. remove core and coat lightly with GREASE. A complete record of lubrication servic­ ing may be kept in the Duty Roster (W. +32 0 F to 0°F. apply FLUID. Every 1. shock absorbers and linkage on all Ford and early Willys models. 1 above +32 0 F and No. 16. lubricating. and satisfactory results are not obtained. 2.000 miles. hydraulic. 6). Unscrew linkage eye and refill with FLUIDj shockabsorber. special. f. (14) OILCAN POINTS. SAE 0 10 from +32 F to 0°F. (16) POINTS TO BE SERVICED AND/OR LUBRICATED BY ORDNANCE MAINTENANCE PERSONNEL ONLY. general purpose. 48 . above +320 F or No. A. (17) WHEEL BEARINGS. Remove bearing cone assemblies from hub and wash spindle and inside of hub. OIL. 18. fan. 0. Wash bearing cones and grease seals. No. special. water pump. below 0°F. light. remove and disassemble the shock absorbers. Inspect and replace if necessary. No. clean and coat with GREASE. preservative. Lubricate bearings with GREASE. below OOF. brake and throttle linkages. (12) SPEEDOMETER CABLE. Every 1. lubricate all carburetor. Do not fill hub or hub cap. No. CAUTION: Do not use oil.000 miles. These are the shock absorbers (late Willys). Every 6. clutch. (15) POINTS REQUIRING NO LUBRICATION SERVICE. pintle hook and hand brake cable with OIL. preservative. SAE 30 above +32 0 F. wipe distributor breaker cam lightly with GREASE. Use extreme care to protect bearings from dirt and immediately reassemble and replace wheel.000 miles. general purpose. Any excess might result in leakage into the brake drum. speedometer cable.D. The lubri­ cant in the bearings is sufficient to provide lubrication until the next service period. Every 6. Localized Views. These are the clutch release bearing. and lubricate breaker arm pivot and wick under rotor with 1 to 2 drops of OIL. (11) TRAILER BRAKE CABLES. No. Every 6. make a report to the ordnance officer responsible for the maintenance of the materiel. SAE 10. slide cable con­ duit forward. generator (late models). SAE 30. and 19) supplement the instructions on the Guide and in the notes. 2.000 miles. Every 6. to a maximum thickness of 1/6 inch only to retard rust.000 miles. 0 below +320 F. The localized views of lubrication points (figs. general purpose. to shock absorber linkage. OIL..O Form No. general purpose. If lubrication instructions are closely followed. kneading lubricant into all spaces in the bearing.

%6.... engineer's open-end............... w/handle .. WRENCH... drain plug . 16 oz . screw type... hydraulic brake...... screw fluted.. JACK......... PULLER..... wheel hub ..... combination... Vehicle equipment .... ..x 25/3 2 -in . yz............. engineer's open-end........ /8..x 7/ 6 -in. 19 20 21 19. l1 -ton.. Where Carried HAMMER.... ...................... WRENCH...... wheel stud nut... hex . Unless the vehicle is equipped with extra tool equipment. 2/ 8 -in..........TM 9-803 19 Section VII TOOLS AND EQUIPMENT STOWAGE ON THE VEHICLE Paragraph Vehicle tools ....... WRENCH... ....... VEHICLE TOOLS..........x 1% 2 -in....... ........... socket.x ll6-in .. engineer's open-end..... ................. adjustable... a.. WRENCH. socket...... 3/8.... engineer's open-end. WRENCH... WRENCH... the following are supplied (one of each unless otherwise specified): Federal Tool Stock No.. PLIERS......... 11-in. slip joint.....x 7/8-in.... WRENCH.... WRENCH. 4 %4 -in... ball peen........ auto type........... spark plug. 3/4.............. w/handle ... bleeder screw ..... WRENCH... Vehicle spare parts ..... WRENCH.. WRENCH. engineer's open-end... WRENCH... 41-H-523 41-J-66 41-P-1650 41-P-2962-700 41-W-1962-50 41-W-991 41-W-1003 41-W-1005-5 41-W-1008-10 41-W-1012-5 41-W-1596-125 41-W-449 41-W-2459-500 41-W-3335-50 41-W-3825-200 41-W-3837-55 49 Tool bag Tool compartment Tool bag Tool compartment Tool bag Tool bag Tool bag Tool bag Tool bag Tool bag Tool bag Tool bag Tool bag Tool bag Tool compartment Tool compartment . machinist's. hex..... 6-in ..... wheel bearing nut.......

EXTINGUISHER. pt.... ... tire valve (boxed)...........00 x 16 . friction.... list..... left side Parts bag Parts bag APPARATUS.... CRANK...... CONTAINER... 8-B-11 33-B-76 8-C-650 8-C-6750 50 Glove compart­ ment Parts bag Parts bag (5) Parts bag (5) . w/chuck ................... CORES. MANUAL.... iron... flexible tube .. .... COVER. windshield . Unless vehicle is equipped with special equipment. Where Carried ADAPTER.. 58-E-202 8-G-615 41-G-1330-60 TM 9-803 COVER......... fire .... roll .. 13-0-1530 PUMP..... rd... a. left Tool compartment Tool compartment Glove compart­ ment Front of dash Behind rear seat On dash Body. spare parts ............. BELT........ BAG...... . nom. Unless the vehicle is equipped with a special assortment of parts...... a.TM 9-803 20-21 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 20.. OILER... ord. CHAINS...... 17-T-805 WIRE. starting ........ tool . VEHICLE EQUIPMENT........................... Y2-pt................ fan ....... Ax. D-handle. tire valve (boxed) ........... Tool bag Driver's compart­ ment Body left side Tool compartment Glove compart­ ment Tool compartment (4) Bracket on rear Under right seat (2) Under right seat Under rear seat Inside cowl............... 6.... CATALOG... Where Carried BAG..... 22-W-650 21......... roll . the following are supplied (one of each unless otherwise specified): Name of Spare Part Federal Stock No.. 41-S-3170 TAPE........... tire... lubr. NOZZLE........... single-bit ..... CAPS...... . headlight ...... the follow­ ing are supplied (one of each unless otherwise specified): Tool Federal Stock No. std.... gun . 5-gallon .. SHOVEL........... 8-P-5000 RIFLE .... VEHICLE SPARE PARTS. technical .......... GAGE.......... straight spout.... tire.... decontaminating.. GUN.. chopping.. lubr............... hand-type .... 12 qt . 41-A-1277 41-B-15 SNL-G-503 8-C-2358 ............... tire pressure ..

3 cp blackout. 17-L-5215 8-L-421 8-L-415 8-L-419 42-P-5347 17-P-5365 Parts bag Parts bag Parts bag Parts bag Parts bag Parts bag 51 .. service tail and stop..TM 9-803 21 TOOLS AND EQUIPMENT STOWAGE ON THE VEHICLE Name of Spare Part Federal Stock No.... sealed. 6-8V. 6-8V singtung-fil. LAMP-UNIT. blackout... 3 cp (MZ63) . s. split. LAMP-UNIT. sealed.. PLUG. 6-8V. 21-3 cp PIN. 3 cp LAMP-UNIT. cotter...... spark.. with gasket . LAMP.... Where Carried elec. 6-8V. sealed.. 4 opngs. one opng.. incand. tail... type B boxed ass't. stop.....

are replaced.. transfer cases. and information pertinent to the work accom­ plished. transmissions.. record the date. This form in­ cludes spaces for the vehicle name and U. 478 which provides a means of keeping a record of each MWO completed or major unit assembly replaced.S. main­ tenance personnel will record the MWO numbers of modifications applied prior to the date of A. 22 22. and MWO number. MWO AND MAJOR UNIT ASSEMBLY REPLACEMENT RECORD.O. and nomenclature of the unit assembly. c. Form No. such as engines. 478.. When major unit assemblies..G. instructions for use. Description. Upon receipt by a third or fourth echelon repair facility of a vehicle for modification or repair. 52 . Early Modifications. Instructions for Use.. Every vehicle is supplied with a copy of A. hours and/or mileage. It is very important that the form be used as directed. Form No. and must initial the form in the columns provided. a.A.. Minor repairs and minor parts and accessory replacements need not be recorded. When each modification is completed. registration number..O. hours and/or mileage. record the date. b.G. and that it remain with the vehicle until the vehicle is removed from service.TM 9-803 22 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) PART TWO VEHICLE MAINTENANCE INSTRUCTIONS Section VIII RECORD OF MODIFICATIONS Paragraph MWO and major unit assembly replacement record . Personnel performing modifications or major unit assembly replacements must record clearly on the form a description of the work completed.

.. Regular scheduled maintenance inspections and services are a preventive maintenance function of the using arms and are the responsibility of commanders of operating organizations. however. SECOND ECHELON PREVENTIVE MAINTENANCE SERVICES. the vehicle should not be washed or wiped thoroughly clean. since certain types of defects... If instructions other than those which are contained in the general procedures in step (4). correctly installed. a coating of the lubricant should be wiped over the sealing surface of the lip of the seal. (a) When new or overhauled subassemblies are installed to cor­ rect deficiencies. (4) GENERAL PROCEDURES. and usually includes a check to see 53 .. and dusty or sandy terrain. or a designated individual in authority should be consulted. it should be soaked in engine oil SAE 10 (warm if practicable) for at least 30 minutes. such as cracks. it should be dry and not caked with mud or grease to such an extent that inspection and servicing will be seriously hampered. When the new seal is a leather seal. NOTE: The second echelon personnel must be thoroughly trained in these procedures so that they will apply them automatically. or in the specific procedures in step (5) which follow. a. The frequency of the preventive maintenance services outlined herein is considered a minimum requirement for normal operation of vehicles. The drivers should ac­ company their vehicles and assist the mechanics while periodic sec­ ond echelon preventive maintenance services are performed. Ordi­ narily the driver should present the vehicle for a scheduled preven­ tive maintenance service in a reasonably clean condition: that is. and loose or shifted parts or assemblies are more evident if the surfaces are slightly soiled or dusty.. the leather lip should be worked carefully by hand before installing the seal..TM 9-803 23 Section IX SECOND ECHELON PREVENTIVE MAINTENANCE Paragraph Second echelon preventive maintenance services . Under unusual operating conditions such as extreme temperatures. (c) The general inspection of each item applies also to any sup­ porting member or connection.. (1) FREQUENCY... 23 23. (3) INSTRUCTIONS. leaks. (2) FIRST ECHELON PARTICIPATION.. then. The lip must not be scratched or marred. care should be taken to see that they are clean. other sections of the vehicle operators' manual pertain­ ing to the item involved. and properly lubricated and adjusted. These general procedures are basic instructions which are to be followed when performing the services on the items listed in the specific procedures. it may be necessary to perform certain maintenance services more frequently. are required for the correct performance of a preventive maintenance service or for correction of a deficiency. (b) When installing new lubricant retainer seals.

The special serv­ ices include: 1. lock nuts. not dented or collapsed. Adjust. All tightening operations should be performed with sufficient wrench-torque (force on the wrench handle) to tighten the unit according to good mechanical practice. not chafed or burned. not torn or cut. 1. an item number in one or both columns opposite a Tighten procedure means that the actual tightening of the object must be performed. since this material is not a good lubricant. 4. correctly assembled. These are indicated by repeating the item numbers in the columns which show the interval at which the serv­ ices are to be performed. Clean. locking wires. Clean units of the vehicle with dry-cleaning solvent to remove excess lubricant. draining and refilling units with oil. or other current directives. After the parts are cleaned. This usually consists of performing special operations. not bare or frayed. Clean the protective grease coating from new parts. 3. close to or beyond serviceable limits. For example. Take care to keep the parts clean until reassembled. 4. Serve. and be certain to keep cleaning fluid away from rubber or other mate­ rial which it will damage. (d) Special Services. This applies both to lubrication oper­ ations that do not appear on the vehicle Lubrication Guide and to items that do appear on such charts. 2. lock washers. dirt. rinse them in clean fluid and dry them thor­ oughly. or a pry-bar check for looseness. Such an inspection should include any brackets. and changing the oil filter cartridge. not broken or cracked. secure. Do not overtighten. 3. Use torque-indicating wrench where specified. and show that the parts or assemblies are to receive certain mandatory services. "Excessively worn" will be understood to mean worn. and likely to result in a failure if not replaced before the next scheduled inspection. The inspection of a unit to see that it is "correctly assembled" is usually an external visual inspection to see if it is in its normal assembled position in the vehicle. special bul­ letins. The inspection for "good condition" is usually an external visual inspection to determine if the unit is damaged beyond safe or serviceable limits. 2. 5. and other foreign material. a hand-feel. wrench. but which should be performed in connection with the maintenance operations if p4rts have to be disassembled for inspection or service. The mechanics must be thoroughly trained in the following explanations of these terms. such as replenishing battery water. as this may strip 54 . Tighten. Special lubrication. The inspection of a unit to determine if it is "secure" is usually an external visual examination. The term "good condition" is explained further by the following: not bent or twisted. or cotter pins used in assembly. Make all necessary adjustments in accordance with the pertinent section of the vehicle operator's manual.TM 9-803 23 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) whether or not the item is in good condition. or excessively worn.

perform those items which require little Mile MilI or no movement of the vehicle. 4. (e) Conditions. See. lock nuts. over varied terrain if possible. 6.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE threads or cause distortion. (5) SPECIFIC PROCEDURES. Perform Before-operation Service as outlined in paragraph 13. / ROAD TEST MAINTENANCE NOTE: When the tactical situation does not permit a soso oao full road test. perform the operations indi­ cated opposite the number. and cotter pins provided to secure the tightening. look down the column corresponding to the maintenance due.000-mile and the 1. In order to determine which procedure to follow. 10. namely. 9. 5. then zero or slight positive (plus) reading above speeds of 12 to 15 miles per hour with lights and accessories off. Each page of the chart has two columns at the left edge corresponding to the 6.G. Very often it will be found that a particular procedure does not apply to both scheduled maintenances.000-mile (6-month) main­ tenance procedures are described in the following chart. that speedometer indicates vehicle speed.D. they can sometimes be handled in sections. the numerical sequence of items on the work sheet is followed in the manual procedures. items 3. All available time at halts and in bivouac areas must be utilized. A. but not more than 10 miles. and wherever an item appears. Certain items on the work sheet that do not apply to this vehicle are not included in the procedures in this manual. but in some in­ stances there is deviation for conservation of the mechanic's time and effort. Observe instruments frequently during road test. items with special services in the columns should be given first consideration.000-mile (monthly) and 6. Zero reading is normal with lights and accessories on. In general. if necessary.O. 1 1 Before-operation Service. The procedures for performing each item in the 1. 3 3 Dash Instruments and Gages. and that odometer registers accumulating trip and total mileage correctly. 55 . 461. Form No. When conditions make it difficult to perform the complete preventive maintenance procedures at one time. SPEEDOMETER. Ammeter should show high charge for short time after starting. and 14.. operates without excessive fluctuation or noise. which is the Preventive Maintenance Service Work Sheet for Wheeled and Half-track Vehicles. planning to complete all oper­ ations within the week. Make a full road test of 5. AMMETER. to assure that main­ tenance operations are completed. When limited by the tactical situation. if possible. (f) The numbers of the preventive maintenance procedures that follow are identical with those outlined on W.000-mile maintenance respectively. Tightening will always be understood to include the correct installation of lock washers.

There should be V2-inch reserve clearance between hand brake relay crank and lower end of hand brake cable conduit. Brakes must not squeak or require excessive pedal pressure. tactical situation permitting. which should be /2 inch. Adjust mirror. and inspect for broken or discolored glass. Temperature indicator should0 gradually increase to normal operating range 0 of 160 F to 180 F. Listen for detonation and "ping. or other noises that might indicate need for engine repair. Unusual Noises." misses. Test brakes for smooth. or rattle. Transmission and Transfer Case. Clutch must have free pedal travel of threequarter inch. or improperly adjusted wheel bearing. and Windshield Wiper. Listen for noises that would indicate dry or defective release bearing or pilot bushing. Steering. Brakes. Hand brake must hold vehicle on a reasonable grade. spitting. Horn. damaged. Engine. Feel brake drums and wheel hubs for abnormally high temperatures.TM 9-803 23 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE TEMPERATURE sou Mile Mai looo 4 4 5 5 6 6 7 7 8 8 9 9 10 13 10 13 INDICATOR. Test horn for proper operation and tone. accelerate and decelerate engine. popping. Mirror. or side pull. even stop. grab. Overheated brake drum or wheel hub may indicate dragging brake or defective. Examine blade for good condition and full contact with glass throughout entire stroke. Clutch. There should be no excessive free play with wheels in straightahead position. FUEL GAGE. noting any unusual noises or tendency of levers to slip into neutral. Shift through en­ tire range of transmission and transfer. noting whether the levers move easily and snap into each position. Test pedal free travel. gear clash. or loss of pedal pressure when brakes are held on. Test acceleration and pulling power in each transmis­ sion speed. "spongy" pedal. wan­ der. Test clutch for slip. With shifting levers in each position. Temperatures. Fuel gage must indicate the approximate amount of fuel in tank. Wiper should have sufficient arm tension to stay in "UP" position. excessive pedal travel before application. Examine 56 . Engine must idle smoothly without stalling. dry. Inspect for loose mountings. Steering gear must not bind. Listen for noises that might indicate loose. Test for existence of front-end shimmy. must have positive ratchet action and 1/3 reserve handle travel. or faulty parts.

bolts.G. tighten headscrews to from 65 to 75 foot-pounds. 1/2 quarts. 14 16 16 Leaks. Tighten cyl­ inder head (only if leaks are indicated and after per­ forming item 21) with torque wrench. Form No. Cylinder Head and Gasket. Test specific gravity and voltage. head stud nuts 57 . terminals. With transmission in third gear. 461. and record voltage on W. Clean battery cable terminals. and transfer case for too­ high running temperature. or hydraulic fluid leaks. Perform high-rate discharge test according to instructions for "condition" test which accompany test instrument. front differen­ tial. and differentials. NOTE: Transfer case operates at a higher temperature than other cases. straps. Clean entire battery and carrier. SERVE.. Look for cracks. Inspect cables. transfer case. drain and refill. 3/4 quart. posts. oil. and listen for unusual engine noises. 14 quarts.225 indicate battery should be re­ charged or replaced. Examine lubricant levels of transmission. Battery. Look on ground under vehicle for indications of coolant. 1% quarts..O. 18).D. Observe propeller shaft and universal joints. and may extend /2 inch above plates.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANCE soo 14 Mil M Mile looo differentials. NOTE: Specific gravity must be above 1. inspect bolts for serviceability. Safe level when cold is even with filler plug. front wheel drive engaged. Add clean water to /2 inch above plates. A. fuel. Inspect battery case for cracks and leaks. Tighten termi­ nals and hold-downs carefully to avoid damage to battery.G. rear differential. A. listen for unusual noises in operating units. 461. and holddowns for good condition and secure mounting. and in­ dications of water or compression leaks. wheels. Form No. transmission. Capacities: transmis­ sion. proceed as follows: Accelerate and decelerate engine slightly. Specific gravity readings below 1. Inspect cases for leaks. and engine at fast idle.de (par. according to Lubrication iai. MAINTENANCE OPERATIONS Unusual Noises. and record on W. Clean top of battery. and battery posts.D. transfer case. 17 17 22 22 22 22 18 18 CLEAN. With engine running.225 to make this test. grease lightly. If an oil change is due. and axles for excessive vibration and run-out. Gear Oil Level and Leaks.O. Electrolyte level should be above top of plates. and repaint carrier if corroded. terminal bolts and nuts. Cell variation should not be more than 30 percent.

Oil Filters and Lines. using round gage. insects. Wipe off plugs without removing. hose. Service if required. Plugs with broken insulators. minimum pressure is 70 pounds. Examine air passages and guards for obstructions and clean out any dirt. Clean and adjust plugs to gap of 0. Test compression with:all plugs' re­ moved. 18). using oil test. and report to higher authority. exhaust valve. clean filter case and install new cartridge and gaskets. timing case. 25). Record all readings. and con­ nections for good condition or leaks.014 inch 'when hot or cold. Drain and refill crankcase if change is due. Proper clearances are: intake valve. SERVE. Tighten in correct order (fig. or foreign 58 20 20 21 21 23 23 23 24 24 24 25 25 . NOTE: If sand blast cleaner is not available install new or reconditionedplugs. Adjust valves only if noisy.030 inch. cap and gaskets for good condition and inspect for leaks. Test and record antifreeze value (as climate demands). Radiator. recheck weak cylinders. 0. or trash. must be replaced. Examine coolant for oil. Spark Plugs. SERVE: Remove filter cartridge. ADJUST. inspect for insulator cracks and leakage through insulators and gaskets. See Lubrication Guide (par. Compression. or flywheel housing oil leaks. Observe vehicle for crankcase. Inspect filters. and'with throttle and choke wide open. electrodes burned thin or other­ wise unserviceable. valve cover. Again inspect for leaks with engine running and check oil level after engine is stopped. CAUTION: System operates under 3%/ to 4% pounds pressure (be careful in removing cap). lines. rust. 0. Crankcase. Be sure cylinder head to dash bond strap is in good condition and securely connected. exces­ sive carbon deposits. Check oil level. Stand­ ard pressure is approximately 110 pounds at cranking speed. Observe radiator core.014 inch when hot or cold. Maximum variation between cylinders must not be more than 10 pounds. Check clearance and adjust valves. CAUTION: Do not start engine until completion of item 24. Valve Mechanism. Refill crankcase (5 quarts with new filter cartridge). If variation is greater than 10 pounds.TM 9-803 23 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE o0I logo Mile Mile 19 19 to from 60 to 65 foot-pounds. Correct plug (AN-7).

alinement. In­ spect breaker points for burning. wick and camshaft according to Lubrication Guide (par. Coil and Wiring. and secure connections and attachment. Turn distributor shaft (with rotor). and deterioration. Replace and aline burned or badly pitted points. Drive Belt and Pulleys. Distributor. Pay particular attention to see that spark plug 59 27 27 27 29 29 31 31 31 32 32 . and bond straps from generator and cranking motor. Adjust to deflection of 1 inch between pulleys. and ex­ posed low voltage wiring for cleanliness. Clean and tighten as re­ quired. and adjustment. good condition. Replace generator or cranking motor when commutator is scored. 18). high tension. SPECIAL LUBRICATION. Blow out with com­ pressed air. Tighten hose clamps. TIGHTEN. Replace or adjust belt as needed. Inspect these units to see if they are in good condition. wear. Examine coil. rough. Sparingly lubricate cam sur­ faces. Clean breaker plate assembly. pitting. and release to test centrifugal advance for binding. SERVE. Water Pump and Fan.020 inch. Inspect commutators and brushes for good con­ dition and wear. CAU­ TION: Save and filter coolant if antifreeze is present. movable breaker arm pin. worn. Inspect pump for secure attachment. clean and securely connected or mounted. Clean and flush radiator as needed. Inspect fan belt for fraying. and for leaks. Feel to determine excessive distributor shaft play. particularly radio noise suppression capacitor on generator and starting switch terminal. and Switch. Adjust breaker point gap to 0. if dirty. Loosen fan belt. Clean and remove distributor cap.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANCE MilI material. Inspect pulleys for cracks and misalinement. test water pump shaft and bearing for play. Brushes should be free in holders. Exam­ ine cap and rotor arm for cracks. In­ spect fan for alinement and secure mounting. Inspect radiator cap and gasket for tight seal. corrosion and burned conductors. Cranking Motor. i600 1000 Mile 25 26 26 Add inhibitor and antifreeze if needed. or brushes are less than half their original length. Generator. and have full contact with commutator. Clean commuta­ tors with 2/0 flint paper if needed.

renew gaskets. and -s0 Mile 1000o Mile coil. or hydraulic fluid leaks. Reinstall with new gasket. Examine oil cup. bruises. 40 Leaks. 65). remove and clean filter element. 41 Ignition Timing. 37 Fuel Filter. Examine air cleaner for good condition and secure mounting. TEST. Pressure should be 1%/z to 2/2 pounds with engine running at approximately 30 miles per hour vehicle road speed. Connect low voltage circuit tester and test voltage regulator. and pressure reading. Tighten manifold stud nuts as required to from 31 to 35 foot-pounds. Clean fuel pump screen. 42 Engine Idle and Vacuum Test.-R+emove disk filter element from fuel filter mounted on dash. check ignition tim­ ing. clean element and bowl. fuel. blisters. Inspect tires for cuts. With neon light. irregular and excessive tread wear. and inspect for -" worn parts. Adjust engine to smooth idle. Start engine and observe cranking motor for positive action. Observe fuel pump for leaks. See that regulator and radio noise capacitors are in good condition. and unusual noise. using vacuum gage. CAUTION: Close timing hole cover and tighten screw. nails. Make sure oil pressure gage and ammeter read­ ings are satisfactory. 34 Air Cleaner. If dirty. Inspect valve stems for correct posi­ tion and missing caps. do not apply oil to element after cleaning. Make certain that the choke and throttle open and close fully. Observe if spark advances automatically. and Lines. inspect unit for leaks. Look around engine and on ground under engine for oil. radio noise suppressors. 39 Cranking Motor. Directional and non­ 60 33 . obtain highest possible steady vacuum reading. Remove im­ bedded glass. coolant. Heat control valve must be free and bimetal spring must be in good condition. Inspect for gasket leaks. 38 Fuel Pump. Clean oil cup and refill (5/ qt). secure mounting. current regulator. Adjust timing as required (par. 36 Carburetor. normal speed. and cut-out for output control. Inspect for leaks after unit has been refilled. 47 Tires and Rims. Lubricate linkage. and securely mounted or connected. 43 Regulator Unit. and that all connec­ tions and mounting are secure.TM 9-803 23 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE and coil to distributor wire.terminal capacitor are in good condition. Screens. or stones. 33 34 36 37 38 39 40 41 42 43 47 Manifolds and Heat Control.

and adjust bearings. CLEAN. Tighten all lug nuts securely. Inspect return springs for good action. Take measurements with all tires equally inflated. Lightly lubricate anchor pins. excessive wear. Examine brake hose for chafing. and tighten backing plate bolts. SERVE. secure mounting. and inspect for damage. Observe linings for wear. and scor­ ing. Disassemble wheel bearings and seals. DRUMS AND SUPPORTS. and last on rear tires. without removal. leakage. Replace worn parts 61 . Tires should match on all wheels within 3/4 -inch over-all circumference. Rear Brake Shoes. Tighten brake support and drum mounting bolts securely. Pack wheel bearings. and drums for lubricant or brake fluid leaks. and adjust as for 6. and 0. Front Brake Shoes. install new 53 53 53 54 seals. In­ spect around drive flanges. If contamination of lubricant has occurred. service other wheel bearingslikewise. clean. CAUTION: If it is known that vehicle has operated in deep water which may have entered wheel bearings. Lightly lubricate anchor pins. Remove all wheels and drums. SPECIAL LUBRICATION.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANC directional tires should not be installed on same vehicle. repack. and dry or damaged bearings. Inflate tires to 35 pounds (cold). Inspect brake hose for proper fit and for deterioration. looseness.005 inch at heel. Remove grease and dirt from brake drums and backing plates. open end of chevron should meet ground first on front tires. Inspect drums for damage. and possibility of rivets scoring drum before next 1. al Mlh rons Mile 48 48 49 49 49 52 52 If equipped with directional tires. Inspect wheel cylinders (exterior) for good condition. and inspect for excessive wear or scoring and loose mounting bolts. inspect right wheel bearing for con­ tamination. If lining on right rear wheel requires replacement. and deterioration. and leaks. linings. Inspect wheel for good condition and. Remove. Remove right rear wheel and in­ spect linings for wear. secure mount­ ing. Rear Wheels. and determine if shoes are secure and guided by anchor pins. and dirt. test for evidence of looseness of wheel bearing adjustment. Inspect tire carrier for looseness and damage. and for leaks. Inspect brake shoes. Front Brakes. Clean drums and backing plates thoroughly.000-mile inspection. clean. and anchors for damage or looseness. Adjust brake shoes to 0. brake supports. oil. and dirt. oil. re­ move all wheels for lining inspection.008 inch at toe.000-mile service. Rear Brakes. Tighten drive flange and wheel nuts. and as to type of tread. Inspect wheel cylinders (exterior) for good condition.

Tighten flange yoke bolts. Tighten and adjust assembly mounting nuts and screws. Inspect shock absorbers to see if they are in good condition and secure. Front Shock Absorbers. if bodies are leaking fluid. Inspect universal and slip joints for alinement. Front Springs. Adjust brake shoes to 0. If rubber bushings are hard or cracked. and 0. Inspect front springs for good condi­ tion. Inspect propeller shaft for damage and incorrect assembly. Inspect pinion shaft for end play and grease leaks. TIGHTEN. Inspect steering knuckle housings and oil seals for serviceable condition. apply a film of brake fluid. and lubricant. Front Propeller Shaft. correct alinement. and lubricant leaks. tie rods.leaks. Inspect springs for excessive wear of spring bushing and clips.005-inch clearance at heel. Adjust bearings and test for wheel shake before removing jack. See that engine mount­ ings and bond straps are in good condition and secure. inspect. drag link. and gear. Inspect axle for apparent aline­ ment. and if rubber bushings have deterior­ ated. Replace broken seals or worn parts. wear. Check lubricant for contamination. 55 56 56 57 57 57 58 58 60 60 60 61 61 Front Axle. Refill to bottom of filler hole. NOTE: If fluid is leaking or bodies are defective. and excessive deflection. broken. Inspect for good condition. Remove. 62 62 62 63 63 Engine Mountings and Braces.TM 9-803 23 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE Mile o6000 10D 55 Mile and worn linings. Front Wheels. Pitman arm. and secure mounting. Steering Knuckles. end play. CLEAN AND LUBRICATE. Examine Ushackles and pivot bolts for wear. lubri­ cate. and leakage. Pitman arm. TIGHTEN. Rotate wheels and observe for loose. Tighten U-bolts securely and uniformly. tie rod. Examine front axle housing for good con­ dition and lubricant leaks. excessive wear. Tighten front mountings if loose. or dry bearings. and steering wheel nuts. Adjust rear 62 . and see that vent is open. Observe steering gear. drag link. clean. and replace bearings. Clean dust from linings. and that rubber mountings are not separated from metal backing.008-inch clearance at toe. shock absorbermust be replaced. Steering. security. arms. and steering connecting rods for good condition. correct assembly.

clutch should have free pedal travel of 3/4 inch. Fill master cylinder reservoir to '/4 inch below plug. return spring must be operative. and cap screws. Look for brake fluid leaks. Tighten radio noise suppression bond strap Mile Mile mountings securely. See that drum is not scored or oily. Inspect mounting and assembly bolts and cap screws for looseness. Test control for looseness. Adjust brake pedal free travel to I/ inch.005 inch to 0. ADJUST. clean out filler plug vent. Tighten mounting and assembly bolts and cap screws. Reserve lever travel should be one-third the ratchet range. There must be %-inch reserve clearance (on cable) between relay crank and lower end of hand brake conduit. that lining is not oil-soaked nor worn thin. Inspect master cylinder for good condition and secure mounting. excessive wear. brake should have 1/3 reserve travel. TIGHTEN.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANCE mounting bolts to from 38 to 42 foot-pounds with torque moo 1000 wrench. Brake Master Cylinder. Inspect mounting and assembly bolts and cap screws for looseness. ADJUST. Inspect oil seals and gaskets for leak­ age. 72 73 73 Rear Propeller Shaft. and improper operation. Inspect oil seals and gaskets for leak­ age. Adjust clutch pedal free travel to 3/4 65 66 66 inch. Remove any trash that may be wrapped around shaft or universal joints. return spring must be operative. In­ spect ratchet for positive holding action. brake linkage must be secure and not worn excessively. Clean vent. check master cylinder boot for good condition and correct installa­ tion. Test brake pedal operation. inspect stop light switch for terminal attachment and correct operation. Tighten mounting and assembly bolts. Clutch pedal linkage must be secure and not worn. 64 65 65 Clutch Pedal. Lubricate upper end of conduit tube at cable with engine oil. 66 67 67 71 71 71 72 72 Transfer Case. Transmission. excessive wear. and improper operation. Brake Pedal. 64 64 Parking (Hand) Brake. Inspect 63 . Adjust clearance between drum and lining to from 0. TIGHTEN. ADJUST. nuts. Test controls for looseness.010 inch.

Vehicle Lubricatioo. 18) in this manual.TM 9-803 23 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE n01000 Mile mounting of universal and slip joints for misalinement. If found loose. Frame. worn spots in lines. Inspect tank and lines for good condition. loose spring clips. straight-ahead position. LOWER VEHICLE TO GROUND 73 75 75 77 77 78 80 78 80 81 81 82 82 82 83 83 84 84 85 85 86 86 Toe-in and Turning Stops. Remove fuel tank drain plug briefly. Tighten loose bolts. Inspect tail pipe for stoppage. TIGHTEN. SERVE. report condition to higher authority. wear. rusted condition. Turn front wheels fully in both right and left 64 . or out of alinement. Tighten flange yoke cap screws. Rear Axle. Exhaust Pipe and Muffler. and drain off accumulated water and sediment. damage or leaks. and check toe-in. Normal toe-in range is 3% 4 -inch to 3 / 2 -inch. Observe latest issued lubrication directives. Brake Lines and Connections. or U-bolts. feel for excessive play in pinion shaft. deteriorated or damaged hose and connections. Make sure differential carrier mounting cap screws are tight. cracks. check conduits and grommets for proper position and good condition. Inspect rear axle housing for leaks. use wheel alining gage. With front wheels on ground. Examine frame for loose side rails and cross members. Rear Springs. Tighten spring pivot bolt nut to from 29 to 30 foot-pounds. Lubricate according to Lubri­ cation Guide (par. Inspect in the same manner as for item 58. inspect brake lines for proper mounting. and leaks. and grease leaks. Wiring. tighten U-bolts to from 50 to 55 footpounds. Check springs for shifted leaves due to broken center bolt. leaks. If frame appears to be bent. Rear Shock Absorbers. check cap for defective gasket or clogged vent. Inspect exhaust pipe and muffler for secure mounting. Inspect all wiring for looseness and broken insulation. clean vent. Conduits and Grommets. secure mounting. Fuel Tank and Lines.

Inspect front fenders for good condi­ tion and secure mounting. securely mounted. Front Fenders. Operate stop light by depressing brake pedal. Body Hardware. Inspect rear bumpers and pintle hook to see if they are 65 liesa Ml' 91 Ise Ml' 91 91 92 93 92 93 94 94 95 96 95 96 98 98 101 101 . hav­ ing no holes or tears. and determine if turning stops hold tires clear of all parts of vehicle in these positions. or Boxes. windshield frame and holddown hooks at hood should be in good condition. these must be clean. Latch and Lock Pin. Safety Reflectors. Safety reflectors must be present. Inspect all lights. and securely mounted. fasteners are present. Examine hood for aline­ ment and secure mounting when fastened. instru­ ment. See that radio noise bond straps from hood to dash and grille are secure. reflectors must not be discolored. Seats and upholstery should be clean and undamaged. Hinges and Fasteners. Rear Bumpers and Pintle Hook. noting whether beam is controlled for high and low positions. blackout lights must be in good con­ dition with shield in proper position. secure. clean. arid not ex­ cessively worn or bent. floor drain plugs (2) should be present. Front bumper and grille must be present. or discolored. Lubricate hinges and fasteners lightly. tail. and secure. and blackout lights operate properly. located on main light switch) for pitting or corrosion. body handles should be present.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANCE directions. in good condition. Examine axle for loose turn stops. Circuit Breaker. secure. and in good condition. Hood. Determine that switches for head. top should be clean. and in good condition. lenses must not be broken. safety straps should be present and in place. ADJUST. undamaged. and all grommets must be present and in good condition. Front Bumper and Grille. and undamaged. Replace if cracked or broken. Be sure all radio noise suppression bond straps and capacitor on radio terminal box (if so equipped) are in good condi­ tion and secure. Lights. Windshield should be free from cracks or discoloration. cracked. Test foot switch. see that. Inspect points of thermal circuit breaker (30 amperes. Terminal Blocks. Adjust and aim headlight beams. Inspect body of vehicle according to following standards: Hardware should operate properly and be adequately lubricated.

and secure. and securely mounted. Check against stowage list (par. TOOLS AND EQUIPMENT 131 131 Tools and Equipment. and Shielding). See that all units not covered in the foregoing specific procedures are in good condition. Make latter check by removing filler plug. secure mounting. the radio operator will report the condition to the designated individual in authority. completeness. First Aid Kit. 26 (Acci­ 66 132 133 132 133 14& 143 135 135 . and legibility. Drain and refill with fresh solution every 90 days. Inspect decontaminator for damage. and lock securely. Sharpen cutting tools and darken bright parts of exposed tools in combat areas. Be sure all additional noise suppression bond straps and toothed lock washers listed in paragraph 177. If cleaning and tightening of mountings and connections. make tests in accordancewith paragraph178. 26. Examine gun mounts and covers (if pres­ ent) for good condition.TM 9-803 23 1/4 -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) MAINTENANCE sOU Ie00 present. Decontaminator. Re­ port any deficiency. and full charge. parts. Filters. Inspect paint of entire vehicle for good condition and bright spots that might cause glare or reflection. and equipment must be present. Pioneer tools. 19). and secure attach­ ment. 105 105 Armament. Examine contents of first aid kit for good condition. and 103 securely mounted and connected. cleanliness. Vehicle markings and identification must be legible. and replacement of defective radio noise suppression units does not eliminate the trouble. clean. 103 104 Paint and Markings. Condensers. See that nozzle is clean. Inspect identification plates and their mount­ iigs (if furnished) for good condition. and see that contact surfaces are clean. Form No. in good condition. secure mounting. 104 Radio Bonding (Suppressors. NOTE: Guns. See date of last filling on attached tag. Fire Extinguisher. NOTE: If objectionable radio noise from vehicle has been re­ ported. Publications and Form No. Pintle hook Mile Mile safety latch should be free. Inspect fire extinguisher for full charge and secure mounting. serviceable. See that the vehicle manuals and Lubrication Guide. Standard vehicle tools. and covers are to be referred to armorer or gun commanders for all inspections or service. are inspected for looseness or damage. and satisfactory packing.

Final Road Test. Road test.TM 9-803 23 SECOND ECHELON PREVENTIVE MAINTENANCE MAINTENANCE Mile 000o 1000 Mile dent Report) and W. and properly stowed. and presence of cap on chain. NOTE: Corrector report all defects found during final road test to higher authority..D. Inspect fuel can and bracket for damage. 140 140 141 141 142 142 67 . on Form No. are clean. 136 139 136 139 Traction Devices. leaks. Modifications (Completed). 478 (MWO and Major Unit Assembly Replacement Record). Fuel Can Nozzle and Bucket. A.G. Inspect entire vehicle to be sure all Modification Work Orders have been com­ pleted. Inspect tire chains for broken or worn links. and properly stowed. and differentials for lubricant level and for leaks. are present. Form No. rechecking items 2 to 16. and enter any modifications or major unit re­ placements made at time of this service. 478. transfer case. missing cross chains. Confine this test to minimum distance necessary to satisfactory observa­ tions. legible.O. Recheck transmission. loose mounting. See that fuel can nozzle and bucket are not damaged. or damaged fasteners. Fuel Can and Bracket.

... In addition.... See that portable extinguisher is present and in good condition.. they will perform a run-in test of at least 50 miles as directed in AR 850-15. (2) Refer deficiencies beyond the scope of the maintenance echelon of the using organization to a higher echelon for correction. When a new or reconditioned vehicle is first received at the using organization... OIL.. table III. Test it momentarily for proper operation. Fill fuel tank.. 25. a. AND WATER............... follow instructionson tag before driving the vehicle.. CORRECTION OF DEFICIENCIES. 24 25 26 24. a. Deficiencies disclosed during the course of the run-in test will be treated as follows: (1) Correct any deficiencies within the scope of the maintenance echelon of the using organization before the vehicle is placed in service. Clean fuel pump filter screen and bowl....... and equipment to see that they are in place and correctly adjusted. add oil and coolant as necessary to bring to correct levels.... Allow room for expansion in fuel tank and radiator.. CAUTION: If there is a tag attached to filler cap or steering wheel concerning engine oil in crankcase.... PURPOSE. If any appreciable amount of dirt or water is present.......... subassem­ blies.. (3) FUEL FILTER.. (3) Bring deficiencies of serious nature to the attention of the supplying organization.. (2) FUEL..... Preliminary Service... remove main filter bowl and clean bowl and element 68 ......... Drain sediment bowl... (1) FIRE EXTINGUISHER......... tools.... During freezing weather....... RUN-IN TES'F PROCEDURES.... and mount it Securely.. 26. and secure mountings and connections... paragraph 25... Correction of deficiencies . Check crankcase oil and coolant supply.... test value of antifreeze... assemblies. For this purpose.. Inspect main fuel filter for leaks... Run-in test procedures . it is necessary for second echelon personnel to determine whether or not the vehicle will operate satisfactorily when placed in service..TM 9-803 24-26 I/4-TON 4 x'4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section X NEW VEHICLE RUN-IN TEST Paragraph Purpose ..... and add as neces­ sary to protect cooling system against freezing... according to procedures in paragraph 26 below. inspect all accessories.. a... damage...

See that all tires. distributor. Fill oil cup to indicated level with fresh oil.TM 9-803 26 NEW VEHICLE RUN-IN TEST in dry-cleaning solvent. NOTE: Perform following items (14) through (17) during lubrication. cranking motor. cool. according to instructions on Lubrica­ tion Guide (par. See that accessories such as carbu­ retor. hook for looseness and damage. and that bushings and shackle pins are not excessively loose. and add as necessary to bring to proper levels. Change only if condition of oil indicates the necessity. except gear cases. See that all body mountings are secure. Inspect front and rear springs and shocks to see that they are in good condition. seats. for looseness and damage. Examine fenders and front bumper TOWING CONNECTIONS. (7) ELECTRICAL WIRING. (9) (10) (11) WHEEL AND FLANGE NUTS. Examine towing shackles and pintle axle flange nuts are present and secure. and securely mounted or fastened. (8) TIRES. wheel bearings. and oil filter. Inspect for damage. hardware. (12) BODY. top and frame. Examine carburetor air cleaner to see if it is in good condition and secure. Remove element and wash thoroughly in dry-cleaning solvent. or shiny surfaces that might cause glare. correctly assembled. are securely mounted. 69 . including spare. and remove objects lodged in treads and carcasses. or damaged. grab rails and safety straps. regulator. and add clean water to bring electrolyte 38 inch above plate. Make hydrometer and voltage test of battery. and other units already lubricated or serviced in items (1) to (12). correctly assembled. and that air horn connection is tight. and reinstall securely. Inspect attachments. and adjusted to have 1-inch finger-pressure deflection. or if gear oil is not of proper grade for existing atmospheric temperatures. Check all gear case oil levels. Examine body paint or camouflage pattern for rust. Drain only until fuel runs clean. securely connected. are properly inflated to 35 pounds. Make sure that fan and generator drive belt is in good condition. water pump. generator. (5) AIR CLEANER. 18). (14) SPRINGS AND SUSPENSIONS. (4) BATTERY. drain accumulated dirt and water from bottom of fuel tank. and properly supported. fan. and see that pintle latch operates properly and locks securely. to see if they are in good condition. See that all wheel mounting and FENDERS AND BUMPER. all valve caps present and finger-tight. Examine all accessible wiring and con­ duits to see if they are in good condition. curtains and hood. (6) ACCESSORIES AND BELT. See that vehicle markings are legible. Perform a complete lubrication service of the vehicle. (13) LUBRICATE. Also. secure. Be sure oil cup and body gaskets are in good condition. that stems are in correct position. glass. covering all intervals.

curtain windows. and within engine compartment. and connections are in good condition and secure. Look under vehicle. hot.TM 9-803 26 I/4TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (15) STEERING LINKAGE. current used in starting. open and close all light switches to see if lamps respond properly. Engine temperature should rise gradually during warm-up period to normal operating range. and brake fluid leaks. Observe if engine responds properly to controls. paragraphs 19 and 20. Immediately after engine starts. (c) Temperature Gage. During warm-up. and inspect for looseness and damage. test horn for proper operation and tone. (Normal operating pressure. Adjust mirror for correct vision. Clean lenses and inspect all units for looseness and damage. and if engine has any tendency toward hard starting. (25) LEAKS. at idle. in good condition. Trace to source any leaks found. and that blade contacts glass evenly and firmly. and not clogged. Stop engine if pressure is not indicated in 30 seconds. (19) ENGINE WARM-UP. for indications of fuel. (b) Ammeter. High charge may be indicated until generator restores to battery. Set hand throttle to run engine at fast idle during warm-up. (18) CHOKE. Fuel gage should register "FULL" if tank has been filled. Clean all body glass. coolant. and not leaking excessively. correctly assembled. Examine choke to be sure it opens and closes fully in response to operation of choke button. GENERAL. (20) INSTRUMENTS. rods. at running speeds is 40 to 50 pounds. (21) ENGINE CONTROLS. 70 . If tactical situation permits. and see that they are serviceable. (a) Oil Pressure Gage. and mirror. and if controls operate without excessive looseness or binding. (23) GLASS AND REAR VIEW MIRROR. and that gear case is securely mounted and not leaking excessively. and properly mounted or stowed. observe if oil pressure is satisfactory. and correct or report them to designated authority. oil. See if wiper arms will operate through their full range. to be sure all items are present. (16) PROPELLER SHAFTS. Inspect all shafts and universal joints to see if they are in good condition. (26) TOOLS AND EQUIPMENT. 10 pounds). If tactical situation permits. See that axle housing and transfer case vents are present. and to prevent overchoking and oil dilution. (24) LAMPS (LIGHTS) AND REFLECTORS. See that these items are in good condition and secure. Check tools and On Vehicle Stow­ age Lists. Ammeter should show slight positive (+) charge. (22) HORN AND WINDSHIELD WIPERS. secure. (17) AXLE AND TRANSFER VENTS. alined. reset choke button so that engine will run smoothly. 160 0 F to 185°F (d) Fuel Gage. See that all steering arms. Start engine and note if cranking motor action is satisfactory.

TM 9-803 26 NEW VEHICLE RUN-IN TEST b. overheating. or slippage (under load) when fully engaged. or squeal on engagement. Be on the alert throughout road test for any unusual noise from body and attachments. or wheel tramp. wander. Observe if engine responds properly to all con­ trols. Be on the alert 'for any abnormal engine operating characteristics or unusual noise. that might indicate looseness. and do not engage and disengage new clutch severely or unnecessarily. and note any excessive pull to one side. CAUTION: Avoid long application of brakes until shoes become evenly seated to drums. and observe if pedal has at least I/-inch free travel before meeting push rod-to-piston resistance. (9) TEMPERATURES.. (1) DASH INSTRUMENTS AND GAGES. Cautiously hand-feel each brake drum and wheel hub for abnormal temperatures.reduce the length of the road test to the least mileage necessary to make observations listed below. (4) TRANSMISSION AND TRANSFER. leaving one-third lever ratchet travel in ifeverse. (2) BRAKES: FOOT AND HAND. Run-in Test. CAUTION: Do not ride clutch pedal at any time. backfiring. wear. See that column. or wheels. Do not move vehicle until engine temperature reaches 1350 F. See that pedal has 3/4-inch free travel before meeting resistance. Also see that speedometer registers the vehicle speed. or underinflated tires. and that odometer registers accumulating mileage. without side pull. or squealing. stalling. bracket. Maximum safe operating tem­ perature is 2000 F. (8) HALT VEHICLE AT 10-MILE INTERVALS FOR SERVICES (steps (9) and (10) below). shimmy. (3) CLUTCH. Perform the following procedures. Gearshift mechanism should operate easily and smoothly. steps (1) to (11) inclusive. chatter. inade­ quate lubrication. misfiring. oil temperature. running gear. (5) STEERING. and differential housing for indications of overheating 71 . chatter. (6) ENGINE. CAUTION: Continuous operation of the vehicle at speeds approach­ ing the maximum indicated on the caution plate should be avoided during the test. (7) UNUSUAL NOISE. Test service brakes to see if they stop vehicle effectively. and wheel are secure. Test front axle declutching for proper operation. Examine the transmission. or exces­ sive exhaust smoke. transfer case. and not slip out of mesh. On vehicles which have been driven 50 miles or more in the course of delivery from the supplying to the using organization. should hold vehicle on reasonable incline. Parking brake. such as lack of pulling power or acceleration. during the road test of the vehicle. damage. Observe readings of ammeter. and gears should operate without exces­ sive noise. Observe steering action for binding or looseness. Observe if clutch operates smoothly without grab. and fuel gages to be sure they are indicating the proper function of the units to which they apply. suspen­ sion.

and cooling systems under pressure. Report general condition of vehicle to designated indi­ vidual in authority.TM 9-803 26 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) and excessive lubricant leaks at seals. correct or report any defici­ encies noted. or vents. and fuel. (10) LEAKS. c. Upon completion of run-in test. 72 . gaskets. look within engine compartment and under vehicle for indications of leaks. NOTE: Transfer case temperatures are normally higher than other gear cases. With engine running. engine oil.

27 28 27....... STANDARD TOOLS AND EQUIPMENT..... .. 73 ............ a................. a.... ..TM 9-803 27-28 Section XI ORGANIZATION TOOLS AND EQUIPMENT Paragraph Standard tools and equipment . tappet. 28....X 17/32-in.. The special tools required for the operations described in this manual are listed below: Tool Federal Stock No...... COMPRESSOR. and their availability is determined by the table of equipment for any particular organization. double-end. shock absorber grommet... 41-C-2554-400 WRENCH......... SPECIAL TOOLS............. 41-W-3575 /32 .. The special tools available to second echelon for repair of this vehicle are listed in the Organizational Spare Parts and Equip­ ment List of SNL G-503...... All standard tools and equipment available to second echelon are listed in SNL N-19.... Special tools ..........

..... reference is made to a paragraph where more complete information will be found.......... b..................... and related parts .. Intake and exhaust systems ............. it is assumed the vehicle has received the attention out­ lined in section IV........................................... Body and frame ...... The information in this section applies to operation of the vehicle under normal conditions................ If the remedy is not given................. Brake system .............. A separate list is provided for each unit.................... ......................TM 9-803 29-30 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XII TROUBLE SHOOTING Paragraph General ....................... ENGINE.. a........... Clutch . If extreme conditions are en­ countered.................................................................................... Determine troubles in a general way first as follows: (1).......... Instrum ents . Propeller shafts ....... The following listed possible vehicle troubles and remedies will assist in determining the cause of unsatisfactory operation.................... Diagnosing Troubles................... Transfer case ..... 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 29.... Steering system .......................................... ... Springs and shock absorbers .... Rear axle ..................................... wheel bearings.................. 74 .............. Radio suppression ........ 30. GENERAL................ Ignition system ................................ Engine ................................... Front axle .............. Wheels........................................ a........................CHECK MECHANICAL CONDITION............... Battery and lighting system . ....................................................... Check for mechanical trouble such as broken or deficient parts in engine or cylinder com­ pression............. . Cooling system ............................ Starting and generating systems .................... Transmission ........................... Fuel system ......

Replace or charge battery (par. to determine if fuel is reaching carburetor. 68). Ammeter must show slight deflection from zero to discharge side (with lights off) when cranking motor is operated and ignition switch is on. (3) CHECK FUEL SYSTEM. Cranking motor drive gear jammed in flywheel teeth. (2) AMMETER IS PRESSED. If ammeter drops to zero when starting switch is pressed. 89).TM 9-803 30 TROUBLE SHOOTING (2) CHECK IGNITION SYSTEM. A flooded carburetor and engine may prevail so the spark plugs are shorted. Battery terminals or ground cables loose or corroded. Replace switch (par. 89). Resistance to operation indicates carburetor is empty or no fuel. Replace cranking motor (par. Cranking motor or drive gear faulty. Engine Will Not Start. Rock vehicle backwards or loosen cranking motor (par. Remove spark plug wire at a plug. Cranking Motor Will Not Crank Engine. Poor starting switch contacts. check ammeter operation to determine condition of ignition primary circuit. 75 Turn on fully. (1) AMMETER DROPS TOWARD ZERO WHEN STARTING SWITCH IS PRESSED. 89). If no spark is obtained. Remove cranking motor and clean gear (par." Ignition switch partly on. or battery is discharged. 18). and check for a good spark by having someone turn ignition switch on and operate cranking motor. Ignition switch faulty. (1) No SPARK. Operate priming lever on rear side of fuel pump. Replace switch (par. start­ ing system is defective. if seizure has occurred. 97). b. Clean or replace. Hold terminal end of wire about Y4 inch from a metal part of engine. Remove and clean. Possible Cause Possible Remedy Battery discharged. 90). Change oil to proper grade (par. report to higher authority. Excessive engine friction due to seizure or improper oil. (3) CRANKING MOTOR WHEN SWITCH IS PRESSED. REMAINS UNCHANGED WHEN STARTING SWITCH Battery cable terminal corroded or broken. . no resistance indi­ cates carburetor is full. (a) Ammeter Shows No Discharge (Zero Reading) with Ignition Switch "ON. c. FAILS TO CRANK ENGINE RUNS BUT Cranking motor gear does not engage flywheel.

Reset gaps (par. 64). Spark plug gaps wrong. Short-circuited wire between am. condenser or Repair lead or replace condenser Short-circuited (par. 76 .Replace part (par. Replace condenser (par. Short-circuited secondary circuit Replace coil (par. in coil. or out of terminals. Spark plugs. and connect together. 66). Repair or replace and tightenr Replace coil (par. (c) Ammeter Indicates Abnormal Discharge. Short-circuited condenser. and re­ Radio filter short-circuited. or cranking motor cables broken.TM 9-803 30 I/4 -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Ignition primary wires. wires wet (shorted). put one drop of oil on arm post (par. 64). port to higher authority. Ignition coil primary winding open. Distributor points burned. tributor cap or rotor. 64). or -Dry and clean thoroughly. High tension wire from coil to Repair or replace (par. Clean or replace and tighten. 63).Repair or replace wire. 66). Distributor points not closing. report to higher authority. 65). Ignition wires installed wrong in Put in proper places (par. Set timing (par. Short-circuited primary winding Install new coil (par. Disconnect temporarily. distributor cap. (b) Ammeter Reading Normal. grounded. Open circuit in suppression filter. meter and ignition switch or coil. Clean or replace and adjust (par. Clean and adjust. Loose or corroded ground or battery cable connections. pitted. in ignition coil. 64). or dirty. distributor cap. distributor broken. 66). 69). Test for trouble by removing ignition switch and coil wires. 69). Ignition timing incorrect. Short-circuited or burned dis. broken lead. 67). if filter is faulty. or connections loose.

Fuel does not reach carburetor. replace pump if in­ operative (par. Refill tank (par. (3) GOOD SPARK. Disconnect drain tank and blow out lines. Fuel line pinched. High tension or spark plug wires or distributor cap wet. Replace (par. Repair or replace. Distributor rotor burned or broken. High tension or spark plug wires or distributor cap damaged. Choke control not operating properly. Report to higher authority. Carburetor and engine flooded by excessive use of choke. Lack of compression. Replace (par. Ignition out of time. 76). leave choke control "IN. Dirt or water in carburetor or float stuck. 64). 69). Check for damaged or leaky lines. crank engine with motor. Clean or replace and adjust (par. regulate throttle. air leak into line between tank and fuel pump. Distributor does not operate cam to open points. Fuel pump does not pump. 63). Retime (par. 66). Tighten. 75). Dismantle and clean (par. Replace (par. (4) BACKFIRING. Ignition coil weak. 65). Dirt in fuel lines or tank. (2) WEAK SPARK. Dry thoroughly. 64). Pull out throttle. Fuel tank empty. 69). Distributor condenser weak. Clean or replace and adjust (par. Fuel strainer clogged. 64). 74). when engine starts. Clean screen.TM 9-803 30 TROUBLE SHOOTING Possible Cause Possible Remedy Distributor points not opening. Distributor points pitted or burned. Primary wire connections loose. Report to higher authority. Replace (par. Spark plug wires in distributor cap or at spark plugs. 72). in wrong places Install in proper places (par. Report to higher authority. 77 ." Adjust (par.

Check gaskets (par. 53). / and Spits. 64). Tighten manifold stud nuts or replace gaskets (par. Clean or repair. Free-up and adjust (par 53). Clean screen. Dismantle and clean (par. 54). ° Report to higher authority. Adjust (par. Heat control valve not operating. 52). Partly clogged or pinched fuel line. set gaps (par. Carburetor choke valve sticks closed. Carburetor float level low. Reset (par. Replace (par. e. Low compression. Report to higher authority. Ignition timing too early. or idle mixture incor­ rect. 72). 74). gaps incorrect. 67). Valve springs weak. 65). Improper ignition timing. replace pump. Report to higher authority. 78 . "d. Check idle adjustment (par. Heat control valve faulty. Spark plugs faulty. Engine Runs but Backfires Overheated engine. burned. Replace (par. Reset (par. Dirt or water in carburetor. Excessive carbon in cylinders. Replace carburetor (par. Carburetor throttle valve closes too far. Valve holding open-due. 69). Intake manifold leak. 72). Clean or replace.to lack of compression. Valve sticking or not seating properly. Dirt or water in idle passages of carburetor. I below). Engine Stalls on Idle. 65). or pitted. Free-up and check thermostat spring position (par. Report to higher authority. Remove carbon (par. 52). 72). Free-up and lubricate. Spark plug wires in wrong place in distributor cap. Check (subpar. Fuel pump pressure low. 64). 72). Fuel strainer clogged. Air leak at intake manifold. Carburetor improperly adjusted. Clean and adjust (par. Distributor capcracked or shorted. if faulty (par. Report to higher authority. Install in proper places (par. 76).TM 9-803 30 /4TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Distributor cap cracked or shorted.

64). Leaky cylinder head gasket.TM 9-803 30 TROUBLE SHOOTING Possible Cause Possible Remedy Water leak in cylinder head or gasket. 67). Crankcase ventilator valve stuck open. Reset (par. Reset gap (par. Engine Misfires on One or More Cylinders. Spark plug gap incorrect. Ignition coil or condenser weak. 69). Dirty spark plugs. Spark plug wires grounded. Valve tappet holding valve open. or broken. Dirty spark plugs or gaps too Clean and adjust (par. or improperly adjusted. 59). 66). High tension or spark plug wires Replace. or burned. or Report to higher authority. pressors faulty. Weak or broken valve spring. 54). Wrong type spark plugs. Compression poor-valve trouble. 67). Spark plug wires in wrong places Install correctly (par. dirty Adjust or replace (par. Distributor rotor or cap cracked Replace (par. Leaky cylinder head gasket.Replace (par. Report to higher authority. f. 67). Replace (par. Carburetor adjustment or choke Adjust (par. close. Replace spark plug (par. 54). in cap or at spark plugs. Spark plug or distributor sup. 56). Clean (par. Replace gasket. Cracked cylinder block or broken Report to higher authority. Replace (par. 67). Dirt or water in carburetor. Report to higher authority. Replace with correct type (par. Cracked spark plug porcelain. Replace gasket (par. Distributor points sticking. float level incorrect. not set right. 65). or report cylin­ der head leak to higher author­ ity. 67). Engine Does Not Idle Properly-(Erratic). leaky-cracked insulation. valve tappet or tappet screw. 67). Replace. Clean and adjust or replace (par. 64). g. Report to higher authority. 64). Distributor cap or rotor burned Replace (par. Uneven cylinder compression. 72). 79 . Ignition timed too early. Service (par.

Replace (par.Adjust or replace (par. Dismantle and clean (par. Fuel pump faulty-lack of fuel. I below). Replace distributor (par. Check (subpar. so80 . or burned. 66). Clean screen. 52). Air cleaner dirty. Weak ignition coil or condenser. Ignition coil or condenser weak. system faulty. Check and adjust (par. 66). High tension or spark plug wires Replace (par. Engine Misses On Acceleration. Overheated engine. Crankcase ventilator valve leaks. Incorrect type of spark plugs. Clean. 73). 64). Valves sticking-weak or broken Report to higher authority. dirt in meter­ ing jets or float level incorrect. 64). 59). Carburetor choke not adjusted. Replace (par. adjusted too wide or burned. 64). wide. Wrong type spark plug. Excessive play in distributor shaft bearing. Replace (par. replace faulty pump (par. Clean screen. Replace (par. dirty or improperly ad­ justed. Adjust (par. wire wet or dirty. ing. Leaky intake manifold. 53). Clean and adjust (par. 67).TM 9-803 30 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Pessibe Couse Possible Remedy Fuel pump pressure low. Engine Misses at High Speeds. Weak distributor arm spring. *67). Distributor cap or rotor cracked Replace (par. 67). valve springs. Replace (par. replace pump (par. 74). h. 74). dirty or incorrect gap. Distributor points sticking. 72). Dirty spark plugs or gaps too Clean and adjust (par. spark plugs or Clean and dry thoroughly. Carburetor accelerating pump Report to higher authority. Tighten manifold stud nuts or replace gaskets (par. 64). 69). leaky-cracked insulation. 64). Clean and reoil (par. Spark plugs faulty. Fuel strainer clogged. Clean (par. Heat control valve faulty. 76). i. Distributor cap.. 67). Distributor breaker points stick. adjust or replace (par.

cover radiator.TM 9-803 30 TROUBLE SHOOTING Possible Cause Possible Remedy Valves sticking-weak or broken springs. Drain and use correct fuel (par. 73). Report to higher authority. Use correct gasoline. Ignition system faulty. Old or incorrect fuel. Manifold heat control inoperative. Wrong type spark plug. Insufficient oil or grade. 81 . 67). Reset (par. change oil in reservoir (par. Old or incorrect fuel. 18). Free-up and adjust (par. Leaky gaskets. Engine overheated. Replace. Check valve operation. Distributor automatic spark ad. Fuel supply lacking at carburetor. Choke valve partially closed or throttle does not open fully. 85). 67). Report to higher authority. Spark plug gaps too wide. Report to higher authority. improper Reset (par. Clean and reoil (par. in cold weather. Ignition timing late. k. 65). Replace (par. 53). (par. Carburetor metering rod incorrectly set. Check (subpar. Remove cylinder head and clean (par.Replace distributor (par. Engine Pings (Spark Knock). 53). 3). Clean. Engine too cold. Check (subpar. Overheated engine. Check fuel system (par. 71 a). Excessive carbon formation. -Air cleaner dirty. Reset (par. Check (subpar. 65). vance stuck in advance posi­ tion or spring broken. Free-up and adjust (par. 1 below). Ignition timing early. 64). 73). 54). Use correct grade (par. 72). Adjust (par. 1 below). Air cleaner dirty. Heat control valve faulty. Excessive carbon deposit in Remove cylinder head and clean cylinders. 54). j. Test thermostat (par. see that spring is in proper position (par. 53). c above). Engine Lacks Power. Heat control valve faulty. Oil system failure.

Report to higher authority. 82). p below). Cooling system deficient. Tighten or replace gasket (par. clogged core. 78). Damaged or deteriorated hose or fan belt. Check (subpar. Ignition system faulty. Lack of fuel. air flow through radiator core restricted. 74) check car­ buretor for water or dirt (par. Damaged muffler. Insufficient oil or improper grade. Radiator or water pump leaky. Report to higher authority.Correct driving practice. Loose fan belt. 65). 82 . Clean filter (par. Ignition timing incorrect. 82). 78). Leaky cylinder head gasket. 83). Water low. Replace (par. Engine Overheats.TM 9-803 30 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Exhaust pipe. High engine speeds (unneces. 76) check fuel pump (par. head or core hole plugs leaky. sary and excessive driving in lower gear range). Remove cylinder head and clean (par. Adjust. 83). 73). Service or replace (par. Low compression-broken valve springs or sticking valves or improper tappet adjustment. Service or replace (par. Clean and renew oil (par. 54). clean from engine side. Poor compression or valve timing wrong. clean or replace radiator (par. 85). 81). Reset (par. Low Fuel Mileage. or generator brace not hooked (par. Replace (par. Replace (par. 1. muffler or tail pipe damaged or clogged. Water pump impeller broken. 54). Inoperative thermostat or radiator cap. Cylinder block. Oil system failure (clogged screen). bent or clogged exhaust pipe. 72). Use correct grade (par. 18). Air cleaner restricted. Excessive carbon in cylinders. m. Replace pump (par. Report to higher authority. Check (subpar. c above).

Choke partially closed. Tighten or replace. Leaky fuel pump bowl gasket. Low compression. 58). 74). Oil filter clogged. 74). Engine running cold. sary and excessive driving in- low gear ranges. Replace fuel pump (par. Clean and renew oil (par. 73). Loose engine mountings permitting engine to shake and raise fuel level in carburetor. 72). I above). 18). Free-up and lubricate. Clean.Correct driving practice. 64). Clean or replace (par. Ignition timed wrong. if damaged replace. 1 above). Report to higher authority. Adjust (par. 67). Replace gasket (par. Check thermostat (par. Service or replace (par. Replace (par. Spark plugs dirty. 85). replace element (par.TM 9-803 30 TROUBLE SHOOTING Possible Cause Possible Remedy Air cleaner clogged. accelerating rod. Improper grade or diluted oil. Clogged muffler or bent exhaust pipe. Replace distributor (par. Report to higher authority. Overheated engine. 78). Reset (par. excessive temperature and thin­ ning of oil. Carburetor parts worn or broken. Metering pump not properly adjusted. 53). 65). Free-up and put spring on bracket (par. 72). Tighten. Low Oil Mileage. cover radiator. n. High engine speeds or unneces. Fuel pump pressure too high or leaky diaphragm. Carburetor float level too high. 83 . Engine idles too fast. 72). Adjust carburetor throttle stop screw (par. Carburetor controls sticking. Oil leaks. 64). Replace carburetor (par. Fuel line leaks. Replace leaky gaskets. Check (subpar. Weak coil or condenser. Spark advance stuck. Overheating of engine causing Check (subpar. Heat control valve inoperative. Use new oil of proper grade (par.

or rings or rear Report to higher authority. Change oil. Adjust tappets (par. o. 57). I above). sticking or burned valves. ex­ cessive clearance of intake valves in guides. excessive bearing clearance. High oil temperature causing oil to be thin. Report to higher authority. Report to higher authority. piston ring grooves worn or rings worn. 56). cylinders scored or worn excessively. 57). sticking tappets. Leaky. Check (subpar. 58). Oil screen clogged. check crankcase ventilator (par. Report to higher authority. Insufficient oil supply. broken or stuck. t Floating oil intake loose or gasket leaky. check for water in oil by inspecting dip stick. Oil too heavy (funneling in cold weather). Incorrect tappet adjustment. Inspect and service. Dilute engine oil (par. q. cylinder bores worn (scored. Remove oil pan and clean screen (par. Improper grade of oil or diluted oil foaming at high speeds. 56). misalined connect­ ing rods. tighten (par. 59).TM 9-803 30 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Faulty pistons. 84 . Low Oil Pressure. reportto higher author­ ity. C X Check oil level. Faulty Valves. Adjust (par. Faulty_oil pump regulator valve stuck closed or improperly adjusted. Oil filter restriction hole too large. valve springs weak or broken. valve stems and guides worn. Other valve troubles. Faulty oil pump or pressure regulator valve stuck or spring broken. Renew gasket. Incorrect tappet adjustment. bearing oil return clogged. Oil leak causing lack of oil. p. out-of-round. Poor Compression. Replace oil filter (par. tapered). Oil pressure too high. 18).

110 and 111). Check (subpar. Other abnormal engine noises. in bracket. Adjust pedal free play (par. (pars. improper clutch lever (finger) adjustment. Possible Cause Possible Remedy Loose fan. Clutch Grabs or Chatters. fan pulley or belt. 110 and 111). Tighten or service. c. driven plate crimped or cushion flattened out. 31. just taut. worn. 110 and 111). Adjust pedal free travel (par. Report to higher authority. Sticking pressure plate. 52 and 54). . Overheated engine. Free-up and lubricate. worn. 85 . Pressure plate or flywheel face scored or rough. plate Report to higher authority. Tighten. Weak pressure spring. Control linkage binding. Report to higher authority. or binding on splined shaft. Clutch Slips. Abnormal Engine Noises. clogged exhaust system. Replace clutch driven (pars. Release linkage binding. improper finger ad­ justment. b. 109). pressure plate broken. excessive looseness in power train. Pressure plate warped or binds Report to higher authority. Driven plate warped. Improper pedal adjustment. Loose engine mountings. 109). 1 above). Free-up and lubricate. a. Replace clutch driven plate (pars. heat control valve. Engine stay cable not adjusted. or oilsoaked.TM 9-803 30-31 TROUBLE SHOOTING r. cylinder head gasket or spark plug. Clutch facings burned or worn. Remove obstruction from muffler tail pipe. CLUTCH. Too much pedal play. torn loose from plate. Report to higher authority. Adjust. Facings burned. or loose on driven plate. Leaky intake or exhaust manifold or gaskets. or noisy generator brush. facings Replace clutch driven plate torn or loose. Replace or tighten (pars. Clutch Drags. excessive friction in flywheel bushing.

Fuel tank cap not functioning. Fuel Reaches Carburetorbut Does Not Enter Cylinders. inspect for proper operation. Fuel line air leak between tank Locate and correct. Low Fuel Mileage. clogged. Driven plate springs broken. Tires improperly inflated. worn driven plate hub on splined shaft. FUEL SYSTEM. hand-tighten fuel pump dome nut. Worn pressure plate or broken return springs at driving lugs. 30 m above). worn release bearing. a.TM 9-803 31-32 ¼/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) d. Clutch Rattles. 3). fingers improperly ad­ justed. Release fork loose on ball stud. 76). Fuel filter clogged. Adjust clutch pedal free travel to 3/4 inch (par. Service fuel filter (par. Reduce to 500 pounds if possible. 109). pilot bushing worn in flywheel. Report to higher authority. 18). Free-up and lubricate. Replace or connect. Fuel line clogged. No fuel in tank. Air leak in fuel lines. Replace. Check (par. b. Replace cap. and fuel pump. Possible Cause Possible Remedy Clutch pedal return spring is broken or disconnected. Carburetor float valve stuck Report to higher authority. Replace (pars. Inflate (par. 32. Lubricant in power train too heavy. Disconnect and blow out lines. d. Vehicle overloaded. Tighten connections. Use correct lubricant (par. 72). c. 86 . Fuel Does Not Reach Carburetor. 110 and 111). Worn release bearing. closed. Low Fuel Pressure. repair if damaged. Fuel passages in carburetor Replace carburetor (par. Fuel pump inoperative. Fill tank. Choke does not close. Engine at fault.

52). diaphragm broken. COOLING SYSTEM. exhaust pipe kinked or tail pipe plugged. Replace (par. Intake System. Improper carburetor throttle adjustment. Fuel lines clogged. Clean or replace lines. Heat control valve inoperative. 78). Control return spring weak. install spring in place on bracket (par. Exhaust System. 33. Loose hose connection. Muffler leaks or rattles. Abnormal conditions.TM 9-803 32-34 TROUBLE SHOOTING Possible Cause Possible Remedy Fuel pump faulty. 34. Replace. valves leaky. Fuel Gage Does Not Register. causing miss on acceleration or slow warm-up. Overheating. Tighten. Replace (par. Free-up. Service or replace parts. Service and/or replace (par. b. linkage worn. 72). a. Damaged or deteriorated hose. 52). Loose wire connection at instru. Leaky crankcase ventilator valve. Carburetor control sticking.Tighten connection. 53). Check (par. 78). sand hole or crack in manifold. 75 and 77). Loss of Cooling Solution. 87 . Replace fuel pump (par. 74). a. Leaky gaskets. 59). Leaky gaskets. unit inoperative. Adjust throttle stop screw (par. INTAKE AND EXHAUST SYSTEMS. Exhaust system or muffler restricted. Instrument panel unit or tank Replace (pars. e. Replace. Replace (par. ment panel or tank units. sand hole or crack in manifold. b. 30 1). Free-up and lubricate. f. Replace (par. Engine Idles Too Fast. Exhaust pipe and connections loose or leaking.

Replace (par. Replace filter (par. Check against wiring diagram (par. Timing incorrect. . 35. Distributor faulty. Ignition switch "OFF. Noises. No spark. Replace switch (par. Filter unit open or grounded. 62 and fig. Water pump faulty. Refer to subparagraph c below. Radiator cap inoperative.TM 9-803 34-35 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Leaky radiator. Refer to subparagraph b below. 67). coil. Service. Ignition System Troubles. Turn "ON" fully. or spark plugs. Clean and tighten. 82). Weak spark. 88 Ground strap connections (engine to frame) loose or dirty. Replace (par. broken. a. 30). Fan blades striking. Coil faulty. c." Ignition switch does not make contact. Frayed or loose fan belt. Primary or secondary wiring wrong: Refer to paragraph 30 e (1). or grounded. 68). Replace (par. Cover radiator. 83). 7). Engine Running Too Cool. d. refer to oper­ ation under unusual condi­ tions (par. refer to paragraph 30 j for other causes. Primary or secondary wiring loose. 65). Aline blades. Refer to paragraph 30 c (2). Replace (par. 85). Low air temperatures. Replace. Dry and clean thoroughly with cloth dampened with carbon tetrachloride. Thermostat stuck open. Spark plug or distributor suppressors faulty. Moisture on distributor wires. 81). 69). Replace or adjust (par. install secondary wires correctly in distributor cap and on spark plugs. IGNITION SYSTEM. Retime ignition (par.

18). rotor does not turn.TM 9-803 35-36 TROUBLE SHOOTING b. 36. 64). Spark plugs dirty. Replace or recharge (par. 64). Install in correct place (par. Possible Cause Possible Remedy Connections loose. 64). Spark plugs wrong type. Engine oil too heavy. Replace with correct type (par. Battery low. Battery cell shorted. gaps incorrect. Distributor cap or rotor shorted. Spark plug porcelain cracked or broken. Distributor. 64). Replace spark plug (par. Clean or replace and adjust (par. or broken. c. Replace condenser (par. Clean or replace. broken. d. Distributor breaker point arm spring weak. dirty or broken external wire. (1) STARTING AND GENERATING SYSTEMS. 64). wet. Clean and tighten or repair. Replace plug. 67). dry thoroughly. leaky. Coil internal fault. Distributor breaker points dirty or pitted. 66). if "frozen" replace distributor (par. CRANKING MOTOR CRANKS ENGINE SLOWLY. Free-up and lubricate arm on post. 97). Distributor cap cracked or shorted. ­ Cracked. cracked. Lubricate and free up. . Replace breaker point arm (par. or in distributor cap. Spark Plug Troubles. a. Cranking Motor Troubles. 89 Change to proper seasonal grade (par. 67). Distributor breaker points stuck open. Spark plug wires installed on wrong plugs. Replace coil (par. Report to higher authority. 69). Distributor Troubles. set gaps (par. or improper type. gap incorrect. Replace cap (par. 97). Replace battery (par. Replace. Distributor automatic advance faulty. 67). Condenser or lead wire faulty. Ignition Coil Troubles.

97). Regulator faulty. Replace (par. Ground strap (engine to frame) broken. Replace regulator (par. 93). Clean (par. Replace cranking motor. Filter unit faulty. Replace generator (par. weak brush springs. Replace. Adjust (par. . Regulator faulty. tighten loose connec­ tioris. (2) Replace generator (par. 93). starting switch or cables faulty. Replace (par. 4 b (8)). CRANKING MOTOR DOES NOT CRANK ENGINE. b. Regulator faulty. Replace (par. 90 Low OR FLUCTUATING OUTPUT. 94). broken or loose connections. (3) EXCESSIVE OUTPUT. 93). Free-up brush or replace crank­ ing motor (par. generator brace not hooked (par. loose connections. broken. 89). 93). Poor brush contact. worn commutator.TM 9-803 36 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Battery connections corroded. Loose pulley or generator mounting. Poor brush contact. Loose fan belt. 90). Engine oil too heavy. Change to proper seasonal grade (par. 94). Filter unit or suppressors faulty. Cranking motor. or loose. Generator faulty. Starting switch faulty. 93). Replace switch (par. 18). Tighten. Replace generator (par. Loose or dirty connections in charging circuit. or engine ground strap to frame connec­ tions dirty or loose. Dirty commutator. Replace (par. (1) Generator Troubles. (2) Clean and tighten or replace (par. Short circuit between field coil and armature leads. Cranking motor internal fault. No OUTPUT. Clean and tighten. 94). 89). 83). (4) NOISY. Clean (par. Replace. 93). Dirty commutator.

Report to higher authority. TRANSMISSION. Clutch fails to release. c. Insufficient lubricant. b. 109). Slips Out of Gear. Report to higher authority. 91 Correct practice (par. Replace generator (par. Report to higher authority. Tighten. Loss of Lubricant. Transmission loose on bell housing. Gears or bearings broken or worn. c. 116). Incorrect lubricant. Report to higher authority. 37. 18). 115 and 116). Clutch driven plate binds on splines. Use correct lubricant (par. Generator Regulator Troubles. Regulator internal defect. Replace transmission (pars. Shift rods binding in case. Report to higher authority. 93). Tighten. . 18). 115 and 116). Damaged bell housing. Overheated transmission. Clutch shaft pilot binding in bushing case or shift housing damaged. 18). improperly seated brushes. Replace transmission (pars. 94). Loose connections or mounting. Transmission loose on bell housing. d. Transmission gears or bearings worn. Interlock plunger not in place.TM 9-803 36-37 TROUBLE SHOOTING Possible Cause Possible Remedy Faulty bearings. 5). shift fork bent. Clean and tighten. Replace regulator (par. Report to higher authority. Gearshift binding in housing. Check lubricant grade and sup­ ply (par. Report to higher authority. or armature rubbing on field poles. or pressure plate faulty. causing partial gear engagement. Incorrect driving practice. Worn or damaged seals or gaskets. Weak or broken poppet spring. gears worn on splines. Adjust clutch pedal free travel (par. Hard Shifting. Excessive Noise. a. Shift fork bent. Install plunger (par. Lubricate and free-up. Add lubricant (par.

Universal joint yoke loose on Report to higher authority. Loose bolts and screws. end play in sliding gear shaft. 18). Slips Out of Gear. Report to higher authority. Backlash. Gears or bearings worn. Replenish supply. Oil Leaks. Clean. Drain to proper level. Incorrect lubricant. shift fork bent.TM 9-803 37-38 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Overfilled with lubricant. Replace transfer case (pars. Replenish supply. Report to higher authority. Lubricate and free-up. or damaged. Report to higher authority. Report to higher authority. Drain and refill with correct lu­ bricant (par. e. Shift lever seizing on shaft. odd tires on (front and rear) wheels. Shift rod tight in case. Low or uneven tire pressures. Vent on top of unit clogged. Hard Shifting. Overheats. 38. output shaft. d. 119 and 120). gears not fully en­ gaged. Clean. Tighten. Insufficient lubricant. poppet scored or stuck. or parts worn or damaged. TRANSFER CASE. Improper driving practice. Leaks at gaskets or seals. improperly adjusted. Parts damaged or worn. f. Replace transfer case (pars. Lack of lubrication. c. Bearings adjusted too tight. Insufficient lubricant. b. Service. 92 . 5). Shift rod poppet spring weak or broken. Vent on top of unit clogged. Excessive Noise. Lubricant level too high. a. 119 and 120). Reduce to correct level. Use correct procedure (par. shift fork bent. Replenish supply.

Report to higher authority. d. Replace shaft. Tighten. Steering trouble.TM 9-803 38-41 TROUBLE SHOOTING Possible Cause Possible Remedy Transfer case loose on transmission or snubbing rubber. a. 125). b. REAR AXLE. Excessive Vibration or Noise. Universal Joint Leaks. Match arrows on joint and pro- peller shaft (par. Drain excessive lubricant. report to higher author­ ity incorrect caster or camber. 18). 40. Lubrication leaks. Damaged axle. Inflate tires (par. 136 and 137). Lack of lubricant. tighten or replace housing cover gasket. Report to higher authority. Replace fitting. Clean out. a. replace wheel bearing grease seals. Oil seals leak. c. Lubricate (par. PROPELLER SHAFTS. c. Noisy gears or backlash. Noisy gears or backlash. remove excessive grease in wheel hubs. Replace steering knuckle oil seals. Universal joint parts worn. 145). Overfilled. Parts worn or damaged. . Replace axle (pars. 39. e. for other remedies refer to paragraph 41 c. Report to higher authority. Lubrication leaks. Universal joints not in same plane. 93 a. correct toe-in. b. Report to higher authority. 13 b (13)) (do not use front wheel drive ex­ cept where needed). Foreign material around shaft. Refer to paragraph 45. Lubricate correctly (par. b. clean housing vent. Replace axle (par. Damaged axle. Lubricant fitting leaks. 41. or propeller shaft sprung. Abnormal tire wear. 18). FRONT AXLE.

Report to higher authority. or brake anchor pin adjust­ ment faulty. Replace. spring. Brakes improperly adjusted. b. Wheel cylinder pistons or cups faulty. Grease or brake fluid on linings. i/ I Inflate tires (par. 148).Tighten. Weak or broken shoe return Replace spring. Correct leakage. 148). Adjust (par. Possible Cause Possible Remedy Improper pedal adjustment. ing plate loose. Free-up and lubricate lightly. One Brake Drags. Axle spring clips or brake back. Brake shoes binding on anchor Free-up and lubricate lightly. Brake pedal return spring broken or weak. Dirt imbedded in linings or rivet Clean with wire brush. pin. Tires underinflated. e. 128 and 141). clean up and in­ stall new shoes and lining as­ semblies. Replace. Replace wheel cylinder (par. Replace drums and brake shoe and lining assemblies. 13). Rubber parts swollen from use of mineral oil in brake fluid. Replace. Adjust (par. One Brake Grabs (Vehicle Pulls to One Side). Drums scored or rough. Loose or damaged wheel bearings. Clogged master cylinder port. Adjust or replace (pars. Brake shoe return spring broken or weak. 94 . a. Insufficient brake shoe clearance Adjust (par. Replace (par. holes. Tires worn unequally. / Replace. 148). All Brakes Drag. 148). Brake shoe adjustment faulty. Adjust brake pedal free travel (par. 150). BRAKE SYSTEM. Brake hose clogged or pinched. 150). Brake shoe anchor pin tight in shoes.TM 9-803 42 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 42.

clean up and re­ place shoe and lining assem­ blies (par. 148). 151). Adjust (par. 148). Brake pedal lacks free travel. Replace master cylinder (par. Replace cylinder (par. 128 and 141). Improper adjustment of anchor ·bolts. Correct leakage. 152). Tighten. Brakes Locked. Change shoes to proper place and adjust brakes (par. Dirt in brake fluid. d. 148). Adjust or replace (pars. Correct leakage. 148). 150). Wheel cylinder stuck. Clean with wire brush. Brake shoes. Loose brake shoe anchor. Grease or brake fluid on linings. Replace shoe and lining blies (par. . e. Replace shoe and lining assem­ blies in both wheels. 148). Brake lining worn out. Brakes Noisy or Chatter. and re­ assem­ 148). Grease or brake fluid on linings. Brake shoes improperly adjusted. Adjust and tighten (par. Obstruction in brake line. Adjust (par. Loose or broken wheel bearings. Odd kinds of brake lining on opposite wheels. or backing plate distorted. 148). 95 Replace shoe and lining assem blies (par. Improper or loose linings. Replace shoe and lining assem­ blies (par. Brakes frozen to drums (cold weather).TM 9-803 42 TROUBLE SHOOTING Possible Cause Possible Remedy Primary and secondary brake shoes reversed in one wheel. clean up place shoe and lining blies. Clean or replace tube (par. Improper linings. 148). f. Severe Brake Action on Light Pedal Pressure. Break oose by driving vehicle. Dirt imbedded in linings and rivet holes. drums. Bleed hole in master cylinder clogged. assem­ Adjust pedal free travel (par. Flush system (par. 148). Loose spring clips or shackles. Straighten or replace. 150).

Shoes improperly adjusted. 148). Adjust brake eccentrics (par. wheel cylinders. nected from master cylinder). Leaky piston cup in master or Replace cylinder. No Brakes-Pedal Will Pump Up. Brake not properly adjusted. 151). Normal lining wear. h. Excessive Pedal Travel. Brake line leaky or broken. 149). Possible Cause Possible Remedy Adjust brake eccentrics only (par. 149). Replace damaged parts. 148). 148).Connect or replace faulty part (par. 148). 148). Scored brake drums. Pedal goes to floorboard (discon. Replace with correct shoe and lining assemblies. 148). clean up and re­ place shoe and lining assem­ blies (par. Adjust (par. Excessive Pedal Pressure. 148). Grease or brake fluid on linings. Adjust (par. Locate and tighten or replace. Locate and correct. Low fluid level in master cylinder Fill master cylinder and bleed or air in brake system. Correct cause. lines (par. Adjust (par. Brake drums scored or distorted. Obstructed main brake line. Improper pedal adjustment. Warped shoes or improper brake linings. Locate and tighten or repair. Improper brake fluid. Spongy Brake Pedal Action. Lining worn out. lines (par. Air or insufficient fluid in brake Fill master cylinder and bleed system. i. Incorrect brake lining. worn or glazed lining. Brake anchor adjustment faulty. Leaky master or wheel cylinder Replace cylinder. Replace shoe and lining assem­ blies (par. j. piston cup. Brake shoe clearance excessive. 131 and 144). Leaky brake line or hose. 148). Clean system and fill with cor­ rect fluid. Replace shoe and lining assem­ blies (par.TM 9-803 42 1/4-TON 4 x 4 TRUCK (WILLYS'-OVERLAND MODEL MB and FORD MODEL GPW) g. 96 . 148). Adjust (par. Replace (pars.

Reduce load. WHEELS. Wheel bearings run hot (pull ve. Tighten or replace part. WHEEL BEARINGS. 156). a. Wheel out of balance. or Replace worn parts (par. Replace master cylinder 149). 155). Do not lubricate unless rusty. Shock absorbers not adjusted Adjust or replace shock absorbers correctly. Improper handling of vehicle on Use correct practice when pos­ sible (par. Report to higher authority. Excessive or uneven tire wear. Worn shackles. 97 . in.Replace spring (par. 156). bushings. kemount tire correctly. Leaky brake line or hose. Overlubricated springs. Overloaded vehicle. 157). AND RELATED PARTS. SPRINGS AND SHOCK ABSORBERS. Refer to paragraph 45. rough terrain. same in size or wear. Wheel Troubles. Rebound clips off or out of place. bent wheel. Broken Springs. Spring shackle bushing loose. Refer to paragraph 135. Diameter of front tires not the Replace or match up. Wheels misalined. 128 and 141). 44.(par. Noisy Springs.TM 9-803 42-44 TROUBLE SHOOTING k.Adjust (pars. Free-up and lubricate. b. a. Shackles or pivot bolts too tight. (par. 43. Wheel loose on hub. Service. Main leaf broken at end. Pedal Goes to Floor Slowly When Brakes Are Applied. bent. Replace spring (par. at center). Service. replace Wheel wobbles. leaves. 3). pivot pins. or dam(par. 5). lack fluid. Axle clips loose (spring broken Keep clips tight. ner spring eye opened up. Clutch or brakes grab. hide to one side). Tighten. Spring hangers loose on frame. Possible Cause Possible Remedy Leaky master cylinder piston cup. Spring clips loose on axle or Tighten. Check mounting on hub. aged.

e. right. 157). Replace spring (par. 156). Replace bushing (par. d. Rusted spring leaves. Broken spring leaves. 157). Do not lubricate springs. 45. 98 (par. Shock absorber damaged or lacks Replace shock absorber fluid. Lubricate (par. Rebound clips damaged or lost. Overloaded vehicle. Replace shock absorbers (par. adjust. 157). Do not lubricate unless rusty. lack fluid. Reduce load (par.TM 9-803 44-45 1/ -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) Possible Cause Possible Remedy No fluid in shock absorbers. Lubricate and adjust (par. Overflexible Springs. Lubricate. STEERING SYSTEM. 159). Bottomed Springs. Mounting bracket loose. g. Shock absorbers not adjusted right. Rubber bushings worn out. Replace (par. 18). Shock absorber adjustment not Adjust (par. Tight steering gear. Shockl absorber adjustment Adjust (par. Free-up and lubricate. or are broken. Replace spring (par. 157). f. 157). Broken spring. . 159). or bushings worn out. Replace (par. lack fluid or proper adjustment. Service. Inflate (par. misalined front wheels (caster or cam­ ber). Shock Absorber Control Too Stiff or Too Soft. 13). 157). Shackle or pivot bolts too tight. 156). Report to higher authority. a. Lack of lubrication. or bent frame. Overlubrication causes springs to bottom. Replace. Overlubricated springs. Tire pressures low. or replace shock absorbers (par. 157). Tight steering system connections. Repok to higher authority. Noisy Shock Absorbers. c. 3). Stiff Springs. Shock absorbers broken. Steering Difficult. wrong. Shock absorber faulty.

Loose or lost spring clips. 99 . Bent steering connecting parts. c. Adjust (par. Front springs settled or broken. Check tire mounting. Adjust. Lubricate and adjust (par. Adjust (par. Tire pressures low or uneven. Replace bolt. Loose or worn spring shackles or bolts. Inflate (par. Steering Pitman arm loose. Adjust or replace. Replace spring (par. Faulty shock absorbers. Steering gear worn or ourt justment. 135). Axle shifted (spring center bolt broken). Wheels and tires out of balance. 157). Wander or Weaving. Report to higher authority. Tire pressures uneven. 13). 135). Loose wheel or king pin bearings. Tighten. High Speed Shimmy or Tight Wheel (Refer to remedies listed in subparagraph c above). Replace (par. Low Speed Shimmy or Wobble. Straighten or replace. Steering system connections or king pin bearings not properly adjusted. Adjust (pars. Adjust (par. 159). or adjustments too loose. Improper toe-in Improper camber or caster (axle twisted).TM 9-803 45 TROUBLE SHOOTING Possible Cause Possible Remedy Improper front wheel toe-in. Adjust (par. 13). to higher authority. Replace or tighten. Front axle loose on spring (broken spring center bolt). Improper caster or twisted axle. 135). Adjust mounting. Loose wheel bearings. Steering gear worn. Steering gear mounting loose. d. Replace part. Tighten. Inflate (par. Insufficient toe-in. 156). Spring clips or shackles loose. Misalined steering gear mounting.. Report to higher authorit. Report to higher authority. Loose steering connections. b. 128 and 141). Tighten or replace. report other trouble to higher authority. 128).

Broken front spring leaves. Loose wheel bearings. Shock absorbers not effective. Looseness in steering gear. Odd size. shackles. Worn spring bolts. Front springs settled or broken. Worn spring shackles. tire wear.TM 9-803 45 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Wheel run-out. Loose Pitman arm or mounting. Adjust brakes (par. Adjust or replace (par. Replace spring (par. Inflate (par. Report to higher authority. 100 . Tight wheel bearing. 128 and 141). 157). Replace. Check tire mounting. or bolts. Bent steering knuckle arm. Tires not inflated evenly. or bushings. Wheel Tramp (High Speed). Shift tires. Steering gear loose on frame. Bent steering arm or connection. Vehicle Pulls to One Side. 148). Uneven Replace or adjust (par. Switch tires. Unequal caster or camber (bent axle). steering Dive. Tighten. Straighten or replace. 156): Report to higher authority. bushings Replace. 159). Shock absorbers ineffective. Do not lubricate. Adjust. Shock absorbers out of adjustment or faulty. Adjust or replace. Report to higher authority. g. e. Tighten. Report to higher authority. Axle housing or frame damaged. 'Brake drag. Tighten. Front springs too flexible. Adjust (pars. Replace (par. f. 155). Do not lubricate. Tightness in steering connecting parts. Wheels and tires out of balance. 13). report other trouble to higher authority. Road Shock. Steering gear loose in frame. 157). h. or new and old tires on opposite front wheels. Excessive spring flexibility. Adjust (par. Report to higher authority. tire radial runout or wheel camber incorrect.

Report to higher authority. Spring center bolt broken and/or clips loose. report minor damage to higher authority. or excessive use of lights. Spring clips loose. 101 . Loose or dirty connections. Badly damaged fender. Replace. Clean and tighten connections. Windshield wiper faulty. BATTERY (OTHER TROUBLES. report minor damage to higher authority. 162). Body. Battery. a. 46. fan belt and regulator (par. fuel can rack. Service or replace. Pitman arm not installed in Remove and install in correct position (par. Short in battery cell.) Overheated battery. top. Replace. broken cables. Report to . charge battery. replace cables. radiator guard. i. Frame. Battery solution level low. proper position on steering gear. Replace battery (par.TM 9-803 45-47 TROUBLE SHOOTING Possible Cause Possible Remedy Spri~ng:angers loose on frame. Damaged frame. 92). Axle housing on frame damaged. (1) BATTERY DISCHARGED. Badly damaged pintle hook. check for cracked case. Check generator. b. a. BODY AND FRAME. Replace or charge battery. Check for short circuit or exces­ sive generator charge. 47. Unequal Steering (Right and Left). Tune up engine. Drag link bent. Excessive use of cranking motor. or windshield. (2) Add distilled water to bring level above plates. Report to higher authority. BATTERY AND LIGHTING SYSTEM. Worn or damaged seat cushion.higher authority. 97). Idle battery. seats. Generator not charging. broken. bumpers and Replace. Tighten or replace. or lost. Straighten or replace. hood. Replace.

Clean and tighten. Lights Dim. Headlight aim not right. or broken wire or terminal. Replace switch. Replace lamp (par. Fuse (Circuit Breaker). Sounds continuously (short circuit in wiring between horn and horn button). Loose or dirty connection. Trailer Connection Trouble. Replace lamp-unit (par. Lights do Not Light.TM 9-803 47 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Possible Cause Possible Remedy Case bulged or out of shape. Wiring. Clean and tighten. replace or re­ pair wire or terminal. No current supply. 100). or Check for overcharging and too tight hold-down screws. Clean. connect to correct terminals. tighten or replace. Poor switch contact. g. Headlight. Adjust points. 102 . 98). Horn Troubles. Replace switch. Localize and repair. replace broken wire. Wire grounding. Localize and replace (par. Turn switch on fully. Loose or dirty connection or poor ground connection. Replace wire. Adjust lights (par. blackout driving light. Clean and tighten. Replace fuse assembly (par. Blackout headlight burned out. 104). Loose or dirty connections. Clean and tighten. Internal fault. 99). e. broken wire or terminal. Loose or dirty connections. tail or stop light burned out. Switch not fully on. Other troubles. b. Points dirty. tighten cover or bracket screws. Loose or dirty connections broken wire. c. clean and tighten loose or dirty wiring connections. d. Tighten loose wires. Wiring circuit shorted or open. f. h. Switch. 96). Clean. Improper tone.

103 . If defective. Replace (par. or replace cor­ roded distributor cap towers. Dirty or loose connections. a. Charge or replace battery. Faulty Instruments. Tighten radiator and fender supporting bolts. Tighten generator to regulator bond. Check high-tension insu­ lation. Clean and tighten. INSTRUMENTS. Tighten or clean loose or dirty lock washer ground. RADIO SUPPRESSION. 178). replace generator. Check distributor. Check for discharged battery causing high charging rate (par. Tighten braided bonding straps. 48. or holders. 178). Internal defects. Replace instrument. 49. Faulty ignition. Radio Interference. Replace defective switches or gages (par. Tighten loose wiring connections. Broken speedometer cable. a. Battery low. spark plugs. and suppressors. 178). Erratic noises. Install lock washers in correct posi­ tion (par. brushes. Replace horn. 166). Faulty generator.TM 9-803 47-49 TROUBLE SHOOTING Possible Cause Possible Remedy Internal defect. Check for faulty com­ mutator.

............. Engine tune-up ........ Manifold heat control valve .........000 rpm Compression .... (2) Remove spark plugs and clean....... at 185 rpm SAE horsepower .......... Adjust gaps (par......... 20 and 21) is of the conventional 4-cylinder..................... 51..... Oil filter ..................................................... ..... a. 134.... Procedure...... MAINTENANCE........... For identification refer to paragraph 2 b.................................................. 3%/g in................ 1-3-4-2 Tappet clearance-intake and exhaust (hot or cold) ........... 43/8 in...................... 9S ft-lb Firing order .................. AND ADJUSTMENT IN VEHICLE Paragraph Description and tabulated data .... 67). (1) Perform preventive maintenance and corrective operations listed in paragraph 16............................... ENGINE TUNE-UP..2 cu in........... 4 Bore . 0.................. transmission..... 54 at 4... Type ............................. 104 ...... b........ 6..... ........ :....... Stroke .............................. L-head Number of cylinders .......... : .. internal-combustion type... Cylinder head gasket .......... a... ................ Valve tappet adjustment ...014 in............................ Tabulated Data.. Crankcase ventilator valve ...TM 9-803 50-51 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XIII ENGINE-DESCRIPTION. L-head.................... 50 51 52 53 54 55 56 57 58 59 50............... DESCRIPTION AND TABULATED DATA......63 Maximum torque .................. and transfer case is built into a unit power plant which is mounted at four points in the chassis.................................... Compression ratio .. : ........... The engine with the clutch.... The engine (figs.............. 15....48 to 1 Net horsepower ...... Oil pan gasket ...... Description..... Piston displacement .............. Intake and exhaust manifolds .. Valve cover gasket ...... 110 lb per sq in... DATA.........

AA X U FAN V CRANKSHAFT BEARING--REAR LOWER WATER PUMP BEARING AND SHAFT W VALVE TAPPET X CRANKSHAFT WATER PUMP SEAL WASHER WATER PUMP SEAL Y CONNECTING ROD CAP BOLT WATER PUMP IMPELLER Z OIL FLOAT SUPPORT PISTON AA OIL FLOAT PISTON PIN AB CRANKSHAFT BEARING-CENTER LOWER THERMOSTAT AC CONNECTING ROD WATER OUTLET ELBOW AD CONNECTING ROD BOLT NUT LOCK THERMOSTAT RETAINER AE CRANKSHAFT BEARING-FRONT LOWER AF CRANKSHAFT THRUST WASHER EXHAUST VALVE AG TIMING CHAIN COVER INLET VALVE CYLINDER HEAD AH TIMING CHAIN EXHAUST MANIFOLD Al CRANKSHAFT SPROCKET AJ FAN BELT VALVE SPRING VALVE TAPPET ADJUSTING SCREW AK CRANKSHAFT PACKING-FRONT END ENGINE PLATE-REAR AL STARTING. AND ADJUSTMENT IN VEHICLE A BCI F H I K M AN­ AM AL AJ= A ' O A Al A B C D E F G H I J K L M N O P Q R S T U A A A AC A . MAINTENANCE. DATA.TM 9-803 51 ENGINE-DESCRIPTION. CRANK NUT AM FAN AND GENERATOR DRIVE PULLEY CAMSHAFT AN CAMSHAFT THRUST PLUNGER FLYWHEEL RING GEAR AO CAMSHAFT BUSHING-FRONT CRANKSHAFT PACKING-REAR CRANKSHAFT REAR BEARING DRAIN PIPE AP CAMSHAFT THRUST WASHER AQ CAMSHAFT SPROCKET RA PD 305283 Figure 20-Sectional View of Engine 105 .

TM 9-803 51 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) B C 0 A D ISTRIBUTOR OILER OIL PUMP PINION B C D E F G H I J K L M N IGNITION DISTRIBUTOR IGNITION COIL EXHAUST VALVE GUIDE INTAKE MANIFOLD VALVE SPRING COVER HEAT CONTROL VALVE CRANKCASE VENTILATOR BAFFLE EXHAUST MANIFOLD CRANKCASE VENTILATOR DISTRIBUTOR SHAFT FRICTION SPRING OIL PUMP DRIVEN GEAR OIL PUMP ROTOR DISK OILPUMP P Q R S T U V W X Y Z R A AC OIL RELIEFPLUNGER SPRING RETAINER OIL RELIEFPLUNGER SPRING SHIMS OIL RELIEFPLUNGER SPRING OIL RELIEFPLUNGER OIL PUMP SHAFT AND ROTOR OIL PAN OIL PAN DRAIN PLUG OIL FLOAT SUPPORT CRANKSHAFT BEARING DOWEL CRANKSHAFT BEARING CAP TO CRANKCASE OIL FLOAT OIL FILLERTUBE OIL FILLER CAP AND LEVEL INDICATOR SCREW RA PD 305284 Figure 21--Sectional View of Engine 106 .

TM 9-803
51 ENGINE-DESCRIPTION, DATA, MAINTENANCE, AND
ADJUSTMENT IN VEHICLE

_4

RA PD 305176

Figure 22-Manifolds (3) Test cylinder compression with gage. The gage must read more than 70 pounds, and the variation between cylinders remain less than 10 pounds. Normal compression is approximately 110 pounds per square inch at cranking speed. Report lack of compression to higher authority. (4) Make sure that ground strap at engine left front support is in good condition and tight. (5) Remove distributor cap and rotor. Check for cracks and leaks. Clean or replace breaker points and adjust (par. 64). 107

TM 9-803
51 ¼/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW)

A

B

C

D

E

'N
A B C D E F G H I J K L M N

M

L

O
P Q R

EXHAUST MANIFOLD INTAKE TO EXHAUST MANIFOLD GASKET INTAKE MANIFOLD ACCELERATOR SPRING CLIP INTAKE MANIFOLD PLUG INTAKE MANIFOLD TO CARBURETOR STUD INTAKE TO EXHAUST MANIFOLD SCREW LOCKWASHER INTAKE TO EXHAUST MANIFOLD SCREW HEAT CONTROL VALVE BI-METAL SPRING STOP HEAT CONTROL VALVE BI-METAL SPRING WASHER HEAT CONTROL VALVE COUNTERWEIGHT LEVER HEAT CONTROL VALVE LEVER KEY HEAT CONTROL VALVE LEVER CLAMP SCREW HEAT CONTROL VALVE LEVER CLAMP SCREW NUT HEAT CONTROL VALVE BI-METAL SPRING EXHAUST PIPE TO EXHAUST MANIFOLD STUD NUT EXHAUST PIPE TO EXHAUST MANIFOLD STUD HEAT CONTROL VALVE SHAFT RA PD 334754

Figure 23-Manifolds, Disassembled 108

TM 9-803
51-52 ENGINE-DESCRIPTION, DATA, MAINTENANCE, AND
ADJUSTMENT IN VEHICLE
(6) Check ignition timing (par. 65). (7) Check valve tappet clearance (par. 56). (8) Install spark plugs, assemble distributor, start engine, and allow to run until normal temperature is reached; then set throttle valve stop screw so that engine will idle at 600 revolutions per minute (vehicle speed 8 mph). (9) Adjust idle adjustment screw until engine idles smoothly. If carburetor float level, accelerating pump, or metering rod require adjustment, report to higher authority.
WASHER BIMETAL SPRING SPRING STOP

RA PD 305187 Figure 24-Heat Control Valve (10) Tighten cylinder head screws and nuts, using torque wrench (par. 54). (11) Check operation of manifold heat control (par. 53). 52. INTAKE AND EXHAUST MANIFOLDS. a. Description. The intake and exhaust manifolds (figs. 22 and 23) are attached to each other with four screws, making a unit in which a heat control valve is used to regulate the intake manifold temperature (par. 53). b. Remove Intake and Exhaust Manifolds. Remove carburetor air horn at top of carburetor, and disconnect hand throttle, choke, 109

TM 9-803
54

1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB
and FORD MODEL GPW)

RA PD 305138

Figure 2S5-Cylinder Head TighteningChart

A

B C

D

E I

F

I

L K
A B C D E F VALVE SPRING COVER GASKET VALVE SPRING COVER VALVE SPRING COVER SCREW GASKET VALVE SPRING COVER SCREW-REAR CRANKCASE VENTILATOR VALVE CRANKCASE VENTILATOR VALVE ELBOW G H I J K L

IC

H

CRANKCASE VENTILATOR TUBE VALVE SPRING COVER SCREW-FRONT CRANKCASE VENTILATOR BODY ELBOW CRANKCASE VENTILATOR BODY CRANKCASE VENTILATOR BODY GASKET CRANKCASE VENTILATOR BAFFLE RA PD 334755

Figure 26-Valve Spring Cover, Disassembled 110

AND ADJUSTMENT IN VEHICLE and accelerator at carburetor. e. a. and then remove the tube. and spring. Attach fuel line at carburetor. Install ventilator valve. and remove intake to exhaust manifold gasket. 23 and 24) is con­ trolled thermostatically by a bimetal spring. If there is antifreeze in the cool­ ing system. MANIFOLD HEAT CONTROL VALVE. Remove cylinder head and bond­ 111 . Remove all cylinder head screws and nuts. accelerator clip.TM 9-803 52-54 ENGINE-DESCRIPTION. This valve diverts ex­ haust gases around the central portion of the intake manifold during the warm-up period of the engine. and tighten in place with nut and screw. Drain the cooling system by opening the drain cock under the radiator at the left front. Attach in­ take manifold to exhaust manifold loosely. using a new gasket. remove two nuts holding filter to engine. and tighten valve spring cover front screw. and tighten at fuel pump. and remove filter. Separate Intake Manifold from Exhaust Manifold. MAINTENANCE. then start engine. and disconnect at carburetor. Loosen the valve spring cover front screw to relieve any pull on crankcase ventilator tube. Place new gasket on studs in cylinder block. and remove distributor cap from distributor. 53. Loosen fuel line at fuel pump. Disconnect exhaust pipe at the manifold. Tighten the four screws attaching intake manifold to exhaust manifold. Disconnect spark plug wires at the plugs. For replacement follow procedure outlined in paragraph52. a. using new gasket. 54. Description. and choke at carburetor. Removal. and install manifold. Install ventilator tube. and tighten evenly (torque wrench reading 31 to 35 ft-lb). Clean contact sur­ faces of manifolds and cylinder block. Install carburetor. Install washers and nuts with convex side of washers against manifolds. Remove two nuts attaching carburetor to intake manifold. Attach exhaust pipe to mani­ fold. Remove four screws holding intake and exhaust manifolds together. Push controls in on instrument panel (throttle closed and choke fully open). Remove radiator upper tube with hoses attached. hand throttle. CYLINDER HEAD GASKET. Assemble Intake Manifold to Exhaust Manifold. remove manifolds as an assembly. Connect accelerator rod. Disconnect oil filter upper tube. Remove all nuts and washers from manifold studs in cylinder block. The heat control valve (figs. Tighten screws only slightly until manifolds are installed on cylinder block. and remove carburetor with accelerator spring clip. and remove bracket with wires and distributor cap. Remove two nuts on cylinder studs holding air cleaner tube bracket. NOTE: The manifold heat control valve is an integral part of the exhaust manifold. Install carburetor air horn and secure in place. DATA. and remove ventilator valve. d. and check for leaky gaskets. Install Intake and Exhaust Manifolds. drain into a pan so it can be used again. Operate fuel pump priming lever to put fuel in carburetor. c.

and attach spark plug wires to correct plugs. Cement cork gasket to cover. up. Place cylinder head gasket in position on cylinder block. and cylinder block thoroughly. nuts. 65 to 70 ft-lb. 7). using a RA PD 305189 Figure 27-Valve Tappet Adjustment torque-type wrench (screws. Install radiator upper tube. Install cylinder head bolts and nuts. Clean cover and gasket seat on cylinder block. Install rear bonding strap. Fill the cooling system. and discard gasket. Start engine. and check cooling system for leaks. if required (par. and close radiator drain cock. and remove tube and cap. and air cleaner tube bracket. Re­ move crankCase ventilator tube at ventilator valve. Remove front valve spring cover bolt (fig. and slide valve spring cover forward. Tighten cylinder screws and nuts evenly and in sequence (fig. and out over the fuel pump. replenish if necessary. Installation. 55. a. Install cover rear screw and copper gasket. 26). but do not tighten. Installation. taking care not to damage oil filler tube. giving due attention to antifreeze. Connect oil filter tube. Install cover front screw and copper 112 . Removal. b. tops of pistons. 25). b. Position cover on cylinder block by sliding it to the rear over fuel pump. Remove rear valve spring cover bolt. tighten hose clamps. CAUTION: Do not damage oil filler pipe. oil filter. See that cooling solution level has not gone down. 60 to 65 ft-lb). Install cylinder head. Clean cylinder head. install distributor cap.TM 9-803 54-55 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) ing strap. NOTE: The front and rear center studs are pilot studs to correctly position the gasket. Discard gasket. VALVE COVER GASKET.

1 cylinder on compression stroke at~top center. Adustment. MAINTENANCE. then adjust valves in cylinder firing order (par. Adjust the self-locking tappet screws while they are cold (or warm) to 0. FG H A OIL PAN G A OIL PAN GASKET i i i6 C OIL FLOAT e D OIL FLOAT SUPPORT COTTER PIN E OIL FLOAT SUPPORT TO CRANKCASE SCREW F OIL FLOAT SUPPORT TO CRANKCASE SCREW LOCKWASHER. Start engine and check for oil leaks. a. NOTE: The valte tappets will then be on the heel of the cam. 27). 56. replace valve spring cover (par. Connect ventilator tube to valve. AND ADJUSTMENT IN VEHICLE gasket. G OIL FLOAT SUPPORT OIL FLOAT SUPPORT GASKET H I OIL PAN SCREW LOCKWASHER J OIL PAN DRAIN PLUG GASKET K OIL PAN DRAIN PLUG L OIL PAN SCREW A aa 0 Ca 1 | o o ¢ v K L RA PD 334752 Figure 28-Floating Oil Intake and Oil Pan OIL PAN GASKET. 55). Remove oil pan. . 28). a. turning the crankshaft one-half turn for each cylinder. Remove oil pan screws.TM 9-803 55-57 ENGINE-DESCRIPTION. 55). Removal. and tighten both cover screws evenly. starting with No. DATA. exercising care not to lose spacers under fan belt guard. VALVE TAPPET ADJUSTMENT. After adjusting. and gasket. Set tappet screws. 113 57. baffle. Remove the valve spring cover (par.014 inch (fig. Drain oil by removing drain plug in lower left side of oil pan (fig. with ventilator cap. 62 b). then remove gasket.

The oil filter is the military standard type located on the right front side of the engine (fig. The inlet line at the top of the filter connects to the oil distribution line at the 114 . Disassembled RA PD 305275 ing element is a cylindrical replaceable unit which should be changed each 6. and tighten all screws evenly. more often if the oil gets dirty quickly. a. OIL FILTER. clean in dry-cleaning solu­ tion.C dE A B C D E F G H I COVER BOLT COVER BOLT GASKET COVER ASSEMBLY COVER BOLT SPRING COVER GASKET ELEMENT ASSEMBLY CASE ASSEMBLY DRAIN PLUG CLAMP ASSEMBLY G ii Figure 29--0il Filter. Description. Installation. 36).TM 9-803 57-58 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) b. 58. Put oil pan in position. Be sure that spacers under belt guard are in position.000 miles. Check condition of floating oil intake screen and if dirty. First clean oil pan thoroughly. Clean face of oil pan and crankcase where gasket is installed. Part of the oil circu­ lated through the oiling system is sent through the filter. and install screws. The filterA _ . Torque wrench reading must be 10 to 14 foot-pounds. and cement gasket to oil pan.

Clean Jilter thoroughly. Mount filter in bracket. 22) is located at the center of the intake manifold. Remove Filter. Remove Element. Install Filter. Tighten valve spring cover front screw. Install cover and tighten in place with cover bolt. d. AND ADJUSTMENT IN VEHICLE plug in the left front side of the engine. The crankcase ventilator valve (fig. and put new-element in filter. The valve is closed when the engine is idling (manifold vacuum high). then lift out element. Drain filter by removing drain plug in lower side. 22). then install drain plug. and replace' if necessary. CRANKCASE VENTILATOR VALVE. and remove ventilator valve (fig. and the valve opens to allow clean air to be drawn from the air cleaner tube through the engine oil filler pip\to ventilate the crankcase. c. Description. The outlet or oil return line connects to the timing chain cover. being careful not to cross threads. b. Start engine. Start the engine and check for oil leaks after which check engine oil level in crankcase and replenish supply to "FULL" mark on gage. 59. and remove filter. and -check filter for oil leaks. If this valve fails to seat properly. Place ventilator valve in a vise and remove top. MAINTENANCE. Remove four bolts holding filter in bracket. c. Remove Valve. and tighten in place. e. Disconnect upper and lower tubes at filter. and reassemble valve.TM 9-803 58-59 ENGINE-DESCRIPTION. a. Loosen valve spring cover front screw. Install valve in manifold and attach tube. Connect tubes. RemaVe­ ventilator tube at valve. Be sure that spring operates freely. 29). Install tube fittings. b. Add enough oil to crankcase to bring level up to "FULL" mark on gage. This valve is spring-loaded. Remove drain plug in lower side of filter to drain filter. exercising care not to damage gasket (fig. Installing Valve. exercising care not to damage them. an engine operating condition will occur similar to a leaky intake manifold. using care not to distort them. Clean the valve and seat. 115 . Unscrew cover bolt in top of unit and remove cover. Installing Element.Inspect cover gasket. and is operated by the intake manifold vacuum. When the engine speed is increased the manifold vacuum is lowered. Install drain plug. Remove tube fittings. DATA.

c... Remove two radi­ ator stud nuts on bottom of radiator. b. and disconnect fuel line at flexible con­ nection on right side of engine. Disconnect oil gage line at upper end of flexible tube on front of dash. On Left Side of Vehicle.. Remove Battery..TM 9-803 60 '/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XIV ENGINE-REMOVAL AND INSTALLATION Paragraph Removal . and at right-front lower corner of cylinder block. g. Disconnect air cleaner flexible hose at cleaner... and lift out battery. Remove Air Cleaner. remove 116 .. Remove two engine front support bolts in frame. Hook or tie hood to windshield to avoid accidental closing. Disconnect Bell Housing...... Remove upper and lower radiator hoses.. Disconnect wires on generator.. Installation .... Remove two wing nuts and washers from hold-down bolts..... Remove radiator stay rod nuts and remove rod. Remove one bolt and one screw to separate exhaust pipe from mani­ fold.back of engine. and pick up weight of engine..... Wrap a rope or cable around front and rear end of engine. Dis­ connect accelerator rod at lower end of bell crank on.. Unhook hood by pulling up catches at forward sides of hood.. Remove nuts on the opposite side.. Remove Radiator. On Right Side of Vehicle. Remove Cranking Motor.. 60 61 60. Underneath vehicle. a. Disconnect ignition switch wire at ignition coil. f.. attach chain hoist.. and one screw in side of crank­ case... e... Unscrew heat indicator unit from cylinder head. Remove battery hold-down frame. Do not lose radiator pads. and lift off radiator.... CAUTION: Do not tip and spill oil from reservoir. REMOVAL.. h.. and remove cleaner......... Open drain cocks at lower left-hand corner of radiator. Remove two bolts in engine rear plate. . Remove bell housing upper bolts. and disconnect bond strap. Remove horn frort bracket by removing two screws. d.. Disconnect battery cables.... Remove fuel line (fuel pump to carburetor).. Disconnect throttle and choke controls at carburetor.... and discon­ nect engine ground strap from frame. Loosen wing nuts on side toward engine. Drain Cooling System. Remove two bolts holding engine front support insulator to frame.. i........ Remove rear center cylinder head stud nut......... Raise hood and lay back against windshield. Remove motor... Loosen fuel tank cap to relieve any pressure.. and detach bond strap.. Open Hood. Disconnect cranking motor wires..

b. Tighten fuel tank cap. Install heat indicator unit in cylinder head. and attach chain hoist. On Left Side of Vehicle. c. Attach ignition coil wire. check for leaks. Wrap rope or cable around front and rear end of engine. Installing Radiator. grease. Insert transmission shaft in clutch driven plate hub. Raise engine and lower into position. Fill radiator. Install cranking motor and attach wires. Raise engine and guide out of frame. and disconnect engine stay cable at the frame crossmember. Run rear adjusting nut up to the bracket. Start engine. Install engine front support insulator bolts in frame. Gasket must be in good condition. Install dowel bolts from engine side. Check engine oil (par. 117 . Drive out two bell housing bolts at side of engine. Attach generator wires and ground strap. Install upper and lower radiator hoses. d. See that radiator pads are in place. Check air cleaner oil in reservoir. Connect flexible fuel line. NOTE: Controls on instrument panel must be all the way in. e. -Install bell housing bolts and tighten. if required. Attach exhaust pipe to manifold with 'bolt and screw. and attach to battery posts. and work engine back into place. and secure in place with hold-down frame and wing nuts. and the choke fully open.. Connect oil gage tube. On Right Side of Vehicle. giving due attention to anti­ freeze. Close hood and hook properly. Install bond strap on cylinder head rear stud. a. 61. Attach horn to bracket. Tighten air flexible connection. Inspection. 9-803 60-61 ENGINE-REMOVAL AND INSTALLATION the remaining bell housing bolts. Install battery. Install carburetor choke and throttle wires. and finally check level of solution in radiator. Attach engine ground strap at left support and bond strap at right support. Install engine stay cable. the throttle in the carbu­ retor in the closed position. Install fuel line between pump and carburetor. 18 c). and install cleaner on dash with wing nuts. Installing Engine.TM. INSTALLATION. and install radiator on frame. and tighten nut to from 60 to 65 footpounds. In­ stall radiator stay rod. tune-up. Clean cable connections. Install accelerator rod with cotter pin. tighten lock nut on the front side of bracket. then with cable just taut.

TM 9-803
62 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XV

IGNITION SYSTEM
Paragraph

Description and data ................ ..................... Maintenance ............................................ Distributor ............................................. Ignition timing .......................................... Coil ......................... ............... Spark plugs ............................................. Ignition switch ........................................ Ignition wiring ........................................

62
63
64
65
66
67
68
69

62. DESCRIPTION AND DATA. a. Description. The ignition system (fig. 30) is a 6-volt system and consists of the spark-plugs, high- and low-tension ignition wires,
BATTERY GROUND CABLE ­ -

!_ r

r

i.BATTERY
BATTERY POSITIVE CABLE

DISTRIBUTOR
E PRIMARYBL

AMMETER

SPARK PLUG
IGNITION SWITCH

RA PD 305191

Figure 30-Ignition System Circuit distributor, coil, and an ignition switch through which it is connected to the electrical system of the vehicle. There are two separate circuits in the ignition system (primary and secondary) which combine to develop the high-voltage current necessary to make a spark jump the plug gaps in the engine combustion chambers, and ignite the fuel mixture. In operation, with the ignition switch turned on, and the distributor points closed, current flows through the primary winding of the ignition coil and builds up a strong magnetic field. When the distributor points open, the magnetic field collapses and induces a high-voltage current in the secondary. winding of the coil. This 118

TM 9-803

62
IGNITION SYSTEM
happens each time the points open. This high-voltage current is delivered to the spark plugs at the correct time by the distributor rotor, cap, and secondary wires. To prevent burning of the distribu­ tor points by current arcing across the open points; a condenser is connected across the points (in parallel). This provides a place (capacity) for current to go until the points open enough to prevent arcing. Discharge of this condenser current back through the primary winding of the coil causes the magnetic field to collapse much faster in developing the high-voltage current for the spark plugs. b. Data. Distributor'
Auto-Lite IAD-4008
Make and model ............. Centrifugal
Type advance ....................... Counterclockwise
Rotation ....................... 1-3-4-2
Firing order ............................. 0.020 in.
Point gap ............................. Brealer arm spring tension ............ 17 to 20 oz
0.18 to 0.26 mfd
Cq~ndenser capacity .............. Ignition coil
Auto-Lite IG-4070L
Make and model ............. 6-8
Voltage ..................................... 5 amps at 6.4 volts
Draw (engine stopped) ......... Draw (engine idling) .................... 2.5 amps.
Spark plugs Auto-Lite AN-7 Make and model ................. Thread size ............................. 14-mm
Gap ................................... 0.030 in.

Ignition switch Make and model ................ Ignition wires Primary (gage) ........................... Secondary (gage) .........................

Douglas No. 6282 No. 14 No. 16

c. Tests. The following procedure will assist in localizing trouble in the ignition system without the use of instruments: (1) First check the brilliancy of the headlights and operate cranking motor, to judge the condition of the battery and connec­ tions as far as the ammeter. (2) Remove an ignition wire at a spark plug and hold about three-eighths inch away from a bare metal part of the engine. A good spark should result when the cranking motor is operated with the ignition switch on. If spark is weak or absent, proceed as follows: (3) Pull coil wire out of center of distributor cap; remove cap and crank engine until distributor points are fully closed. Turn on ignition switch, hold cap end of coil secondary wire about threeeighths inch away from cylinder block, and open breaker points with 119

TM 9-803
62-64 1/ -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) the fingers, or rock the distributor cam. If a good spark occurs, fault is located in distributor cap, rotor, or wires; inspect cap and rotor for cracks or carbon runners and ignition wires for short circuits. To test distributor cap place wire back in cap and operate cranking motor. Short circuit will be evidenced by a spark within or outside the cap. To check rotor, remove from distributor; put end of coil secondary wire in rotor, and hold top against cylinder block; operate distributor points (spark will show where "short" occurs). If no spark occurs in preceding test, proceed as follows: (4) Open distributor points and notice if a slight spark is ob­ tained. If spark occurs, current is reaching points. If no' spark occurs, detach condenser, and repeat above operation. If spark is obtained, condenser is at fault, and must be replaced. If no spark is obtained, . determine if coil primary wires are faulty, as follows:_ (5) Remove switch wire at ignition coil, and strike wire terminal against cylinder block. If no spark is obtained, check wiring up to ammeter for loose connection or open circuit. If spark is obtained, current is reaching coil, and this indicates coil is faulty. Replace coil. 63. MAINTENANCE. a. The distributor requires periodic lubrication at various points (par. 18). Keep coil and distributor wires pushed down in towers. Keep distributor cap and spark plug porcelains free from dirt and grease. All wire terminals must be clean and tight. Replace any wires that are frayed or have cracked insulation. Clean and adjust spark plugs and distributor points (par. 67). 64. DISTRIBUTOR. a. Description. The distributor (fig. 32) is mounted on the right side of the engine. A full automatic spark advance is mechanically governed by two counterweights which advance the spark as the engine speed increases. The distributor is driven by a shaft extend­ ing into the oil pump driven gear, which is driven by a gear on the camshaft. The lower end of the distributor shaft has an offset tongue which must be in correct relation to the oil pump shaft before the two can be assembled. A friction spring on the distributor shaft (fig. 21) engages in the oil pump gear to prevent backlash at this point, and uneven engine performance. b. Removal. After raising hood, remove wires from distributor cap and primary wire from terminal on side of distributor. Remove screw holding advance arm to crankcase, and pull out distributor assembly. c. Installation. Remove distributor cap. Insert distributor in crankcase, pushing it down into place, turn rotor until offset tongue on lower end of distributor shaft fits into oil pump shaft, then push farther down into position. Some resistance will be experienced, caused by friction of the spring on the lower end of the distributor shaft fitting into the oil pump gear (fig. 21). Install screw in advance arm loosely. Attach primary wire to distributor. Set timing (par. 65). Install distributor cap and wires (fig. 32). 120

TM 9-803
64 IGNITION SYSTEM

LOCKING SCREW OILER ; 5 ECCENTRIC ADJUSTMENT SCREW

DISTRIBUTOR POINTS

DISTRIBUTOR
ARM

CONDENSER

RA PD 305194 Figure 31-Distributor Points and Condenser d. Distributor Points. (1) ADJUSTMENT. Slip off the two clips holding the distributor cap in place and remove cap. Lift off rotor. Crank engine until point arm rubbing block is on top of a cam. Loosen lock screw (fig. 31), and turn eccentric screw until point gap is 0.020 inch measured with a thickness gage. Tighten lock screw and recheck gap. Install rotor and cap. Push wires well down into cap. (2) REMOVAL. Slip off the two clips holding the distributor cap in place and lift off cap, then remove rotor (fig. 31). Using a small screwdriver, unscrew condenser lead which will release breaker arm 121

and install breaker arm. and install locking screw loosely. and tighten securely in place. (1) DESCRIPTION. Place stationary breaker point in distributor. Distributor Condenser. and lift out point. Place spring in position with condenser lead. (3) INSTALLATION. To adjust points refer to step (1) above. insert screw. e. Aline points if necessary. The condenser is attached by one screw to the support plate in the distributor.TM 9-803 64 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) RA PD 305195 Figure 32-Distributor Wires spring. The condenser functions to absorb momentarily any current which has a tendency to arc across the points when they open. and connected by a short flexible wire across the distributor points. Remove screw in stationary breaker point. then lift off breaker arm. Lightly lubricate breaker arm pivot pin. The condenser must be firmly attached to the 122 .

TM 9-803

64-65
IGNITION SYSTEM

O

/__

RA PD 305193

Figure 33-Timing Marks (Flywheel) support plate, and the cable in good condition. Refer to paragraph 62 c for tests. Test condenser on a condenser tester, if available. (2) REMOVAL. Slip off distributor cap clips and remove cap. Lift off rotor. Remove screw holding condenser to support plate. Remove screw in lead and remove condenser. (3) INSTALLATION. Position condenser on plate and attach with screw. Attach lead. NOTE: Determine if distributorpoints have been disturbed. Install rotor and cap. 65. IGNITION TIMING. a. To Set Timing without Timing Light. Remove timing hole cover on engine rear plate at right side under cranking motor. Remove distributor cap. Crank engine to No. 1 cylinder firing stroke (distribu­ tor rotor toward lower front corner of distributor). Set flywheel with ignition mark (fig. 33) in center of timing hole. Turn distributor housing so that breaker points are just opening, and tighten screw holding distributor to engine. Install timing hole cover. 123

TM 9-803
65-67 1/ -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) b. To Set Timing with Timing Light. Remove timing hole covet on engine rear plate at right side under cranking motor. Attach one lead of timing light to No. 1 spark plug, without removing the hightension wire, and ground the other lead to the engine. Start engine and run slowly. Hold timing light in position to illuminate timing hole. Observe timing mark on flywheel, as illuminated by light, in relation to timing mark on engine plate. If marks do not coincide, loosen distributor clamp screw, and turn distributor housing in proper direction until marks do coincide. NOTE: Use mirror for a better view. Tighten clamp screw. Accelerate engine speed, and with light observe timing marks. They should separate to indicate that centrifugal spark advance is functioning. 66. IGNITION COIL. a. Description. The ignition coil is mounted on the right side of the engine at the rear (fig. 21). A terminal is provided for the primary wire from the switch, a terminal for the primary wire to the distribu­ tor, and a terminal for the high-tension wire to the distributor cap, and a ground strap connection. The coil steps up the primary cur­ rent, furnished by the battery and generator, to high-tension current of sufficient voltage to cause a spark to jump the gaps of the spark plugs. b. Removal. Remove air cleaner by loosening clamp on flexible tube to carburetor; loosen wing nuts on air cleaner bracket at center of dash, and remove those on the right side. Pull secondary wire out of top of coil. Disconnect primary wires, then remove coil and bracket from engine, after which remove the bond strap. c. Installation. Attach bond strap to coil, and mount coil on engine with bond strap on coil bracket front stud, and tighten securely. Attach primary wires, and push secondary wire into top of coil. Install air cleaner, and tighten hose clamp. 67. SPARK PLUGS. a. Description. Spark plugs (fig. 22) are located in the top of the cylinder head at the left side. The plugs are of the one-piece type. A copper-silver alloy gasket is used on each plug for heat transfer to the cylinder head, and to prevent leakage of compression. Push-on type wire terminals are used with radio filters at each plug. A spark plug insulator cap is fitted on each plug to protect the plugs from water and dirt. No shielding is used on the plugs. b. Adjustment. To adjust the gap, bend the side electrode only, and gage the plug with a round thickness gage to a gap of 0.030 inch. e. Removal. To avoid breakage of the porcelain, remove the plugs with the socket wrench and handle furnished in the vehicle tool equipment. d. Installation. Install new plug gaskets if available. Tighten spark plugs snug so that gasket will compress. 124

TM 9-803
68-69 IGNITION SYSTEM 68. IGNITION SWITCH. a. Description. On the earlier production, a key-type ignition switch was used which has been superseded by an interchangeable lever-type switch (fig. 5). Turn the switch lever clockwise for '"ON" position. b Removal. Disconnect battery positive cable at battery. Unscrew retaining nut against face of instrument panel, and remove switch from panel. Disconnect wires and remove switch. c. Installation. Install the wires on proper terminals, then fit the switch into the hole in the instrument panel, screw on retaining nut, and tighten securely. 69. IGNITION WIRING. a. Description. The ignition wiring (fig. 30) consists of lowtension and high-tension wires. The low-tension, or primary wires, carry the current from the ignition switch, which is connected to the electrical system of the vehicle, to the ignition coil, and from the coil to the distributor. The high-tension or secondary wires carry the high-voltage current generated in the secondary wires of the coil, to the distributor, where it is distributed to the spark plugs. No shield­ ing harness is used. b. Removal. Before removing ignition switch wire, disconnect the battery negative (ground) cable. It is not necessary to disconnect the battery cable to replace the coil-to-distributor primary wire or the secondary wires. Disconnect wires at terminals, and remove wire or harness, opening wire clips on the harness in which the switch wire is a part. When removing secondary wires mark terminal tower in distributor cap for No. 1 cylinder spark plug. Pull wires out of dis­ tributor cap and off spark plug terminals. c. Installation. To install primary wires, run wire or harness through clips, and attach terminals securely. Install secondary wires, for spark plugs, through support bracket. Push terminals down well into the proper distributor towers (fig. 32). Push rubber secondary wire tip down in place on distributor towers. Push terminals down on proper spark plugs. Refer to firing order (par. 62 b).

125

TM 9-803
70 A/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XVI

FUEL AND AIR INTAKE AND EXHAUST SYSTEMS

Paragraph

Description and data .................................... Maintenance ........................................ Carburetor ....................... ................. Air cleaner .............................................. Fuel pump ........................................ ................. Fuel tank ....................... Fuel strainer ............................................. Fuel gage ............................................... Exhaust system ........................................
FUEL FILTER

70 71 72 73 74 75 76 77 78

GASOLINE TANK

a,

FUEL PUMP

CARBURETOR

Figure 34-Fuel System

RA PD 305196

70. DESCRIPTION AND DATA. a. Description. The fuel system (fig. 34) consists of the fuel tank, fuel lines, fuel strainer, fuel pump, carburetor, and air cleaner. In 126

.. Operation. Fuel in the tank is drawn through the fuel strainer by the action of a pump mounted on the forward left side of the engine.. The fuel pump requires periodic cleaning of screen.... Failure to function properly requires replacement of unit....... a. b.. 16).... Electric actuation Fuel gage .. Data.. 4..... Electrical connections must be clean and tight...5 lb at 1. b. MAINTENANCE...... and gasket checked for seat.. Tighten connections which show signs of leakage... Fuel gage requires no attention other than that mounting screws must be tight. and is connected by one wire to a fuel tank unit.... The fuel system must be inspected and cleaned periodically (par. Filler neck screen must be cleaned at regular intervals........ Choke and throttle control clamp screws must be tight... All connections and mounting bolts must be tight.. 71. a.. and replace kinked or damaged lines. Failure to operate requires replacement of unit. Exterior of carburetor must be kept clean. The air cleaner requires periodic check of correct oil level and condition of oil.... Carter WO-539S Carburetor ........... Drain fuel tank periodically to remove dirt and water.... Replace damaged or frayed wires. All connections and mounting bolts must be tight.....800 rpm Fuel pump static pressure ..... All mounting screws must be tight.. In the carburetor.. CARBURETOR. with a throttle operated accelerator pump and economizer device... Fuel lines and vacuum connections must be tight. and be free to operate. d.. Mounting screws and clamps must be tight........ Mounting screws and fuel line connections must be tight. The carburetor (fig. The carburetor is a precision instru­ 127 ............ 35) is of the conventional downdraft.... 72.. Description. All linkage must be lubricated at regular intervals. Air cleaner .. from the oil-bath type air cleaner...... AC1595848 Fuel strainer .. The carburetor requires attention only to the idle adjustment... 15 gal Fuel tank capacity ..... The pump also forces the fuel into the carburetor bowl until the flow is shut off by the carburetor float valve.. Clean fuel strainer at regular intervals..... Type T-2. c. plain-tube type.. f.. by the action of the engine pistons. e... Element must be kept clean and free from dirt..... c.. Gasket must be replaced if damaged. Oakes 613300 AC 1538312 Fuel pump ............... the fuel is proportioned and mixed with air drawn through the carburetor...... Filler cap must be kept clean.TM 9-803 70-72 FUEL AND AIR INTAKE AND EXHAUST SYSTEMS addition to these units an electric-type fuel gage is mounted on the instrument panel...

Install carburetor retracting spring clip. To make the final adjustment. turn the adjustment screw to the right and all the way in. Discon­ nect throttle control rod at throttle lever. then. and tighten clamp screws. 128 . Installation. The idle adjustment screw indicated in figure 35 is the only service adjustment provided on the carburetor. Connect throttle control rod. Install carburetor air horn. and adjust the screw until the engine runs smoothly. if required. Remove throttle and choke control wires. b above). 8 mph). c. Adjustment. and lift off carburetor. Loosen clamp on air horn and flexible air hose. To obtain the approximate correct setting. Removal. and carburetor flange nuts. Disconnect fuel line at carburetor. and remove air horn. d. Inspect condition of gaskets between carburetor and manifold.TM 9-803 72 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) · -~ ~1~~~ ~~RA PD 305197 Figure 35-Carburetor Idle Adjustment ment which delivers the proper fuel and air mixture for all speeds and operating requirements of the engine. and install new gaskets. but do not jam the screw against the seat. warm up the engine. Remove carburetor flange nuts and retracting spring clip. Replace carburetor if it requires other attention. Tighten nuts evenly. b. back out adjustment screw between one and two turns. and throttle and choke wires. Adjust car­ buretor (subpar. Set the throttle stop screw so the engine will idle at 600 revolutions per minute (vehicle speed.

then to the carbure­ tor. passes down and across the sur­ face of the oil.TM 9-803 73 FUEL AND AIR INTAKE AND EXHAUST SYSTEMS FUEL STRAINER AIR CLEANER -li OIL FILTER­ RA PD 305212 Figure 36-Air Cleaner and Oil Filter 73. Air enters through louvers in the dash side of the unit. Removal and Servicing of Air Cleaner. /. clean. b. and mounted on the right-front side of the dash. d. and lift out cleaner assembly. Description. oil cup in place. Loosen the hose clamp and two wing nuts at the center 'of the dash. Remove cup. 129 . Remove two wing nuts on right side of dash. 36) is of the oil-bath type. Place cup in position on bottom of cleaner. and lock with the retaining clamps. Removal of Oil Cup. and refill to indi­ cated oil level. Un­ fasten the two clamps holding. and remove cup (fig. Unscrew element wing bolt in bottom center of cleaner. For servicing of air cleaner refer to subparagraph d below. then dry with compressed air. c. AIR CLEANER. Installation. The air cleaner (fig. and pull out cleaner element. a. 37). up through the filtering element. push up into place. Hold one hand under cup and spring loose the two retaining clamps. Plunge the element up and down in dry-cleaning solvent to wash out any dirt.

Clean and refill oil cup to indicated level. Dry with compressed air. Installation. FUEL PUMP. Install new bowl gasket or turn over old one if serviceable. and tighten air hose clamp in place. in­ stall :and tighten mounting nuts. a. Install the element in cleaner housing. Mount cleaner on dash. A filter screen in incorporated in the fuel bowl. 74. The pump is equipped with a hand lever on the rear side which can be used to operate the pump for priming the carburetor bowl. To Clean Screen. Clean screen with dry-cleaning solvent and small brush. operated by a lever against an eccentric on the engine camshaft. and secure in place with retaining bolt.'and clamp into place on cleaner. Install bowl. Lever must be placed down for camshaft to operate pump. b below). Description. Blow out fuel chamber lightly with compressed air and install screen in place. and should be cleaned periodically (subpar. b. left side of the engine is a diaphragm type. place bail clamp in position and tighten securely. Disassembled e. Unscrew knurled nut on bowl clamp. 38) located on the forward. The fuel pump (fig. swing clamp aside and lift off bowl. ! 130 .TM 9-803 73-74 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD aMODEL GPW) E C D A I~r I FLEXIBLECONNECTION HOSE F BODY AM H A S C D E HOSE CONNECTION FLEXIBLE TUBE AND BRACKET ASSEMBLY BUSHING HOSE CLAMP CARBURETOR AIR CLEANER HORN K F BODY ASSEMBLY G ELEMENT AND WING BOLT ASSEMBLY H CUP I LOWER GASKET J BODY GASKET HOSE CLAMP RA PD 305281 Figure 37-Air Cleaner.

FUEL TANK. and check connections for leaks. b. Remove filler cap. Drain fuel by removing drain plug in left side of tank. Remove the inlet and outlet lines. Install pump in place on crankcase and tighten securely with two screws. pull up on the filler extension. then lift out seat. Inspect gasket and replace if unserviceable. remove two screws holding pump to side of engine and remove pump. 75. To remove the filler extension from the tank turn it to the left and pull up. Attach inlet and outlet lines and tighten. An extension filler neck can be pulled up to facilitate filling the tank from a container. Remove bolts in seat rear flange and front legs. Installation. d. Prime pump by operating priming lever. Removal. Description. Removal. After removing the filler cap.TM 9-803 74-75 FUEL AND AIR INTAKE AND EXHAUST SYSTEMS 'Figure 38--Fuel Pump c. Disconnect fuel gage wire and remove fuel 131 . start engine. The fuel tank (fig. and turn to the right to lock it in place. 39) is located under the driver's seat. a.

Installation. and attach wire to gage. Remove bolt holding tank to wheel housing. Service this unit in accordance with pre­ ventive maintenance procedure (par. 16). FUEL STRAINER. Disconnect fuel line from tank. under vehicle. and install tank in place. and lift out tank. Connect fuel line to tank. 132 . Attach tank straps and bolts. Description. and a settling bowl for dirt and water. a. install cap and check tank and connections for leaks.TM 9-803 75-76 -/4TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) FILLERC d IAPD 303214 Figure 39-Fuel Tank gage unit by taking out five screws. Set seat in position and secure in place with bolts in front legs and seat flange. The fuel strainer (fig. and is mounted on the right-front side of the dash. 41) has a disk-type (laminated) element. Fill tank. 76. c. Clean out fuel tank sump in body. remove bolts in tank straps. Install fuel gage in tank. also bolt holding tank to wheel housing. It is located between the fuel tank and the pump.

Be sure all dirt par­ ticles are removed from between disks of the element. Install cover bolt and gasket. Install element spring and element in bowl. Install gaskets in posi­ tion. and clean thoroughly in dry-cleaning solvent. NOTE: Do not allow fuel to drain onto cranking motor.TM 9-803 76 FUEL AND AIR INTAKE AND EXHAUST SYSTEMS L. 133 . Blow element dry with compressed air. Disassembled b. Wash strainer bowl. Remove element from bowl. Install drain plug. and check for leaks. Do not damage bowl gasket. if damaged. and replace. stop engine. run a few minutes. bowl gasket and cover bolt gasket. but do not use extreme pressure. Check condition of element gasket. Start engine. and dry with clean cloth. and tighten securely.--A M N /D - -C s- C A E F G J HOLD DOWN STRAP TANK ASSEMBLY K FUEL L GAGE L TANK UNIT PROTECTOR M GAGE TO TANK SCREW N GAGE TO TANK SCREW LOCKWASHER O STRAP CLAMP GAGEGASKET HOLD DOWN CLAMP HOLD DOWN STRAP LOCK NUT HOLD DOWN STRAP NUT STRAP CLAMP SCREW RA PD 334756 Figure 40-Fuel Tank. Remove drain plug and allow strainer to drain into a container. and assemble bowl to cover. Unscrew cover bolt and remove strainer bowl and element. To Clean Strainer.

Description.TM 9-803 76-77. Install nuts on bolts through glove compartment. a. and remove mounting bolt nuts. and reinstall on dash. A float in the tank operates a rheostat. which governs the current flowing through the 134 .J U a K RA PD 305282 Figure 41-Fuel Strainer. stop engine. Installation. Open glove compartment door. Disassembled c. Start engine. 36). and a tank unit in the fuel tank. Attach inlet and outlet lines to strainer. for actuating the instrument panel unit. Disconnect inlet and outlet lines from strainer (fig. Place mounting bolts in strainer bracket. The fuel gage consists of an electrical indicating unit located in the instrument panel. I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) B C A B C D F G H I J K PIPE'PLUG COVER CAP SCREW COVER CAP SCREW GASKET PIPE REDUCING BUSHING STRAINER STRAINER STRAINER STRAINER STRAINER STRAINER BOWL GASKET UNIT GASKET UNIT ASSEMBLY UNIT SPRING BOWL AND CENTER STUD ASSEMBLY DRAIN PLUG D E COVER -E G fl * HH 1-'t u . Removal. FUEL GAGE. 77. d. and check for leaks. run a few minutes. then remove strainer.

Install seat. DASH UNIT IGNITION SWITCH CIRCUIT BREAKER RA PD 305198 Figure 42-Fuel Gage Wiring Circuit switch. Removal of Fuel Gage (Instrument Panel). b. and tighten retaining clamp nuts. and replace if dam­ aged. and two retaining nuts on the retaining bracket. 43) consists of the exhaust pipe which. wire from circuit breaker attaches to righthand terminal). Check operation of gage by turning ignition switch to "ON" position. Remove bolts in seat rear flange and front legs. The gage registers only while the ignition switch is on. by unscrewing five screws. The fuel gage wiring circuit is shown in figure 42. EXHAUST SYSTEM. e.TM 9-803 77-78 FUEL AND AIR INTAKE AND EXHAUST SYSTEMS instrument panel gage. for maximum road clearance. Disconnect fuel gage wire. Installation of Fuel Gage (Instrument Panel). gage must register amount of fuel in tank. c. A 135 . Install tank unit. and secure in place with bolts in front legs and seat rear flange. The exhaust system (fig. Remove bracket and take gage out through front of panel. Disconnect posi­ tive terminal cable at battery. passes under the vehicle to the muffler located under the right side of the body. Attach wire to fuel gage. Remove wires on back of gage. Installation of Tank Unit. a. Attach wires (wire to tank unit is attached to left terminal. Turn off ignition BATTERY GROUND CABLE BATTERY BATTERY POSITIVE CABLE AMMETER 'TEFUEL TANK UNIT GA. Take out seat. and install positive cable on battery. d. Place gage in panel. Removal of Tank Unit. 78. Clean terminal. and secure with five screws. and install retaining clamp and nuts. and remove tank unit. Description. Position gage correctly. Inspect gasket.

remove muffler strap and tail pipe clamp. Drop front end of exhaust pipe. Place muffler on exhaust pipe. Removal of Exhaust Pipe. Remove muffler assembly. Remove muffler front support bolt and tail pipe support bolt. Remove bolt and A B C D E F G A B I J MUFFLER SUPPORT INSULATOR PLATE BODY SILLTO MUFFLER SUPPORT BOLT MUFFLER SUPPORT INSULATOR SUPPORT SCREW SUPPORT INSULATOR PLATE SUPPORT CLAMP SUPPORT STRAP MUFFLER ASSEMBLY TAIL PIPECLAMP UNDERFRAME SKID PLATE K L M N O P 0 R S PIPE EXTENSION TO SKIDPLATE PLAIN WASHER EXTENSION TO SKID PLATELOCK WASHER EXTENSION TO SKIDPLATENUT EXTENSION TO SKID PLATEBOLT EXTENSION CLAMP EXHAUST PIPEASSEMBLY CLAMP SCREW NUT CLAMP SCREW CLAMP PIPETO MUFFLER screw in exhaust pipe flange at exhaust manifold. at front end of muffler.TM 9-803 78 -/4TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) flexible section of the exhaust pipe permits movement of the engine in the frame. 136 . Loosen clamp on exhaust pipe. Install bolt in muffler support and flexible mounting. Tighten tail pipe clamp bolt. and attach pipe to manifold with screw and nut. Tighten muffler strap bolt and exhaust pipe clamp. and insert rear end in muffler. To remove the muffler. 'b.-The muffler is mounted on brackets with fabric inserts. and tighten evenly. and attach exhaust pipe shield with three bolts. after which. loosen exhaust pipe clamp. Install bolt through tail pipe clamp and flexible mounting. e. Remove three bolts in exhaust pipe shield at right frame member and remove shield. Installation of Muffler. Remove two exhaust pipe clamp bolts in skid plate under transmission. and remove from the left side of vehicle. d. Loosely install tail pipe clamp and support clamp on muffler. Install pipe in position. c. Attach clamp at muffler. Discard gasket. Installation of Exhaust Pipe. Removal of Muffler. Install exhaust pipe manifold flange gasket.

................................... DESCRIPTION AND DATA........... Fan belt .... ............. Water pump Centrifugal Type ..... Fan belt Drive ........ b............................ fan.......... where it is cooled by the action of the fan drawing air through the radiator core................... 15 in.................... past the thermostat. Length .... pressure-type filler cap.. When in proper condition.................. In oper­ ation the water pump draws the coolant from the bottom of the radiator through the hose connection...... Fan belt Vee Type ........ Diameter ................................................ Temperature gage ...................... There are two drain cocks................................. Cooling system 11 qt Capacity ..................................................................... the units of the cooling system automatically main­ tain the engine at the proper operating temperature.. and temperature gage............. Fan 4 Blades ........................ Description......TM 9-803 79 Sedtion XVII COOLING SYSTEM Paragraph Description and data ..... ther­ mostat............. Maintenance ...... .... Radiator .. 79 80 81 82 83 84 85 86 79....... fan belt............................ a........ Prelubricated ball Bearings ....... 1 Width . Data...... '...................... 44/8 in................ ......... 137 . water pump.... Thermostat ........ and back to the radiator................ The cooling system (fig.............. one in the radiator outlet at the lower left corner................... and the other in the right side of the cylinder block at the forward end.... Radiator Fin and tube Type ....... The system is of the sealed type.......... operating under pressure when the engine is warmed up.............. Fan .................. .. Pressure type Filler cap ............... and forces it through the cylin­ der block......... The filler pipe is in the top of the radiator at the right side... A6 in........... The cooling system capacity is 11 quarts....... 44) consists of the radiator. Water pump ............ 42 deg Angle of Vee ...........

and turn clockwise to tighten.. 138 .. Clean system seasonally as well as before and after using antifreeze solution....... Replace deteriorated or leaky hose.. a. and add water slowly to prevent damage to cylinder block and head.. possibly due to low coolant level in the radiator. MAINTENANCE. hose clamps. Draining and Refilling System.. preferably soft water (water with low alkali content or other substances that promote rust and scale).. or loose hose connections... at temperatures below 32°F. warning personnel about the system being drained... water pump. When draining the cooling system refer to caution plate on the instrument panel (fig.. 7).... Fill radiator to bottom of baffle visible through the radiator filler hole...... start engine... Fill system through radiator filler pipe until level is up to lower edge of baffle visible through filler hole. (3) If engine overheats due to lack of coolant in the system.. and refill system whenever inspection reveals any accumulation of rust or scale. c and d below). flush. 13 and 16)...... (1) Drain the cooling system. If solution is to be saved. (6) Adjust fan belt and replace as required... Fully open .... The air suction test is used to determine if air is entering the coolant.. by opening the drain cocks at the lower left corner of the radiator. The cooling system must be inspected in accordance with pre­ ventive maintenance procedures (pars. and connec­ tions leakproof.. leaky water pump.... If system is not to be refilled immediately... (4) Do not overfill radiator. attach a tag to the steering wheel. add proper quantity of antifreeze solution (par.. when required.. and at the right front corner of the cylinder block.. b.. Start engine and warm up.. Check coolant level in radiator.. catch it in a clean container. (1) Keep sufficient coolant in the system. Install radiator cap.. c...... Air Suction Test. Use clean water available. and add more if required. Let engine cool so that radiator does not boil. 7). (2) Drain.TM 9-803 79-80 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Thermostat Opens .. General maintenance of the cooling system consists of the follow­ ing procedures... (7) Test periodically for air suction and exhaust gas leaking into system (subpars..... To make test... (2) Refill the cooling system by first closing the two drain cocks tightly. Temperature gage type .. (5) Keep cylinder head. Use clean water to which must be added the specified rust inhibitor.. 1450 to 155°F 170°F Capillary 80.... do not add cold water immediately.... Loosen the pressure-type radiator cap to break any vacuum which might prevent proper draining..

possibly due to leaky cylinder block. NOTE: Determine by loosening three screws holding outlet to head. Place tubing in glass container of water. cylinder head. at a moderate speed until warmed up. Replace pres­ sure type cap with plain cap. NOTE: Make this test with engine cold. Continuous appearance of bubbles indicates that air is enter­ ing coolant. The cause will be one of the above. With 139 . Remove fan belt. and must be corrected. or gasket. and fill cylinder head with coolant until level is up to top of head. and without changing engine speed. and tighten securely (airtight). d. Remove water outlet. Run engine. Exhaust Gas Leakage Test. Open radiator drain cock until coolant is below cylinder head water outlet. The exhaust gas leakage test is used to determine if gas is entering the coolant.2RAP0305200 Figure 44-Cooling System fill system to bottom edge of baffle in top of radiator. with transmission in neutral. Attach length of rubber tubing to lower end of overflow pipe (this connec­ tion must be airtight).TM 9-803 80 COOLING SYSTEM R7. watch for bubbles in water.

81. and watch for bubbles in water. Remove radiator stay rod nut at front end. Close drain cocks. Open the drain cock on bottom of radiator outlet and right front corner of cylinder block to drain system. a. Operate engine as directed for prescribed solution. Start engine. Fill radiator. Drain cooling system. Removal. NOTE: A light coating of grease in hose connec­ tions will facilitate assembly. and prevent evaporation of the coolant. Loosen hose connection at water pump. b. Install radiator cap. and fill. "gun" it several times. and a sedi­ ment tank at the bottom. Install hold-down nuts and bond strap. Installation. . Description. When the engine is warm. Replace leaky gasket. run engine until warmed up again. A pressure-type filler cap maintains up to 4¼/-pound pressure to give better engine efficiency. Install stay rod and tighten lock nut. Close drain cocks. Remove the radiator filler cap. 44) consists of the fin-and-tube type core with a coolant tank at the top. install cap. Run engine at moderate speed to stir up loose rust. then remove drain cock and pads. e. report other causes to higher authority. The water pump (fig. Cleaning and Flushing Procedure.engine and completely drain system by opening both drain cocks. c. Description. WATER PUMP. set Tighten upper and lower hose clamps. refill system. or run water through system. fill system with water. No lubrication attention is required. and is packed with lubricant when it is made. RADIATOR. To flush system close drain cocks. check coolant level after engine is warmed up. This procedure is used to clean out loose rust. and check system for leaks. A double-row ball bearing is integral with the shaft. Install drain cock and place pads on bracket. A packless self-sealing gland is used to prevent water leakage. 82. Close radiator drain cock and cylinder block drain cock. and fill system with specified cleaning compound. to proper level. if needed. 140 radiator in place. then completely drain. The radiator assembly (fig. and requires no attention. and add inhibitor corrosion compound to prevent for­ mation of rust and scale. Inhibitor compound must be renewed periodically to be effective. Remove two radiator hold-down nuts and lift off radiator. which must be corrected. It is located in the conventional place at the front of the vehicle. Appearance of bubbles indicates leakage from one of the above conditions. 44) is of the centrifugalimpeller type and is located in the front end of the cylinder block. start engine. The water pump with the generator and fan is driven by a belt from the engine crankshaft fan pulley. Stop. release pressure by turning cap slightly before removal. a. Loosen hose clamp on upper hose at front end.TM 9-803 80-82 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) transmission in neutral.

Install fan belt. water pump. Remove screws holding water pump in cylinder block. and generator. Loosen pump hose clamp and remove hose. and check system for leaks. and remove water pump. a. Description. and pull out generator until brace drops into position. and tighten with screws. and also drain cock in right side of cylinder block at forward end. Open the radiator drain cock in outlet pipe at lower left corner of radiator. Replace if damaged. Pull up on handle of generator brace to loosen fan belt.TM 9-803 82-83 COOLING SYSTEM oo Figure 45-Fan Belt Deflection b. Removal. Check condition of pump to cylinder block gasket. Install fan and screws. Remove radiator filler cap. Fill radiator. and slip off belt. 83. Install pump in cylinder block. The fan belt (fig. FAN BELT. install cap. Start engine and check radiator coolant level after engine is warmed up. Proper adjustment is necessary 141 . ·c. Remove fan blade screws. 45) is of the V-type and drives the fan. Attach hose connection. Installation.

Installation and Adjustment. To adjust fan belt tension. tighten nut. c. A four-blade. Disassembled generator generator one-inch 45). and move gener­ ator toward engine as far as it will go.TM 9-803 83-84 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) for efficient operation and maximum life of belt. It is mounted on the front end of the water pump shaft and is driven from the crankshaft by the same belt which drives the generator. and move generator until fan belt has about deflection midway between fan and generator pulleys (fig. and crankshaft pulleys. 142 . Place belt over fan and crank­ shaft pulleys. pump. 44) draws air through the radiator core. b. 84. FAN. then brace locks in position. causing excessive wear on water pump and generator bearings. Pull up on generator brace handle. loosen brace nut. then over the generator pulley. Description. Remove belt from generator. 15-inch fan (fig. a. Removal. and lift over fan blades. Do not adjust the belt extremely tight. Pull generator out until WATER OUTLET ELBOW CYLOCK WASHER GASKET THERMOSTAT THERMOSTAT RETAINER CYLINDER HEAD CYLINDER HEAD BOLT \ CYLINDER HEAD GASKET I RA PD 305236 Figure 46-Thermostat.

Tighten hose connection. and lift off elbow. 85. Description. It is designed to open between 1400 F and 155 0F. Drain the cooling system by opening drain cock at lower left side of radiator. and located in the water outlet elbow on top of the cylinder head. Installation. Install engine unit. 5) is of the Bourdon­ type with a capillary tube connecting it to an expansion bulb in the right side of the cylinder head. Fill cooling system. 44) is of the bellows-type. and engine unit through hole in panel. to cause valve to operate. Loosen hose clamp at cylinder head water outlet elbow. and fill cooling system. Close radiator drain cock. the whole assembly must be replaced. Place thermostat in water outlet elbow with bel­ lows down. if required. and tighten securely. Installation. so that coolant can reach bellows. Pull out ther­ mostat retaining ring in elbow. mount­ ing bracket. 86. Insert outlet elbow in hose connection. Remove grommet around tube through dash and draw out gage assembly. and dash. Removal. Check condition of gasket and cylinder head surface. The temperature gage (fig. Remove engine unit in right side of cylin­ der head by unscrewing retaining nut in reducing bushing. c. if any difficulty is experienced. Description.TM 9-803 84-86 COOLING SYSTEM b. Install new gasket if necessary. Install outlet elbow on cylinder head. and is fully open at 1700 F. and take out thermostat (fig. THERMOSTAT. and tighten in place with three screws. Removal. The entire system is sealed into one assembly. giving due attention to antifreeze. Place fan in position on fan pulley. and check for leaky connections after engine is warmed up. b. and lift fan out of shroud. Insert grommet in dash. Remove four screws holding fan on fan pulley. 143 . remove three screws. and tighten retaining nut. Install retaining ring with flanged edge against thermostat. Insert engine unit through hole in panel. tighten securely. c. a. Position gage correctly. Removal. Remove two nuts holding retaining bracket on back of gage. install mounting bracket and nuts. Installation. and check for leaks. a. TEMPERATURE GAGE. c. b. tube. 46). install four screws. Drain the cooling system by opening drain cock under left side of radiator. Start engine. The thermostat (fig.

.... R. When the engine starts....... causing the armature to turn..'. 4 Brush spring tension ............. Description. This results in the inertia-type cranking motor gear engag­ ing the teeth on the outer circumference of the flywheel.. As part of the starting system. The drive is transmitted to the engine from an inertia-type gear to the teeth on a removable ring gear on the circumference of the flywheel. Rotation of the cranking motor shaft causes the pinion of the cranking motor drive 144 .. a.. a.......... The cranking motor requires lubrication only at the forward end... 89)...... 185 rpm Make and model .. 89......... Maintenance ..... the battery current energizes the cranking motor.... When the starting switch is pressed with the right foot.. b..... located at the right-rear side of the engine................. Auto-Lite SW-4015 88....................... The cranking motor is a 6-volt........ Check tightness of mounting screws.... The starting system (fig............TM 9-803 87-89 A/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XVIII STARTING SYSTEM Paragraph Description and data ... Auto-Lite MZ-4113 Bearings ...... four-brush type... outboard Bendix Starting switch Make and model .. 42 to 53 oz Drive (direct) ............. Clean the cranking motor drive periodically (par........... Description..... 6 Cranking motor Normal engine cranking speed .................... clean.................... cranking motor.. a... Starting switch ................ Wire terminals must be in good condition....................... MAINTENANCE. 47) is a 6-volt system................ It consists of the starting switch.... Data. :. 87 88 89 90 87............. DESCRIPTION AND DATA.. an d the cables through which they are connected to the battery of the electrical system.... check the battery condition periodically............. Cranking motor ...... the gear is automatically thrown out of engagement with the flywheel teeth.... and tight...........H......... 3 Brushes .......... CRANKING MOTOR. System voltage .....

and remove cables and wires. STARTING SWITCH. Clean cranking motor gear. and remove switch from underneath. Remove cranking motor. Remove cable terminal nuts. 73). After the engine starts. Remove screw from front support bracket. and located to the right of the accelerator treadle on the toeboard (fig._ + A TO RADIO OUTLET BOX TO AMMETER STARTING SWITCH CRANKING MOTOR RA [D 305202 Figure 47-Starting System Circuit 90. The starting switch is a push-button type oper­ ated with the right foot. Install front bracket and place cranking motor in position on engine. place switch in posi­ tion under toeboard. Remove cable terminal nuts on switch. Removal. Insert attaching screws. Do not oil drive. a. e. 73).TM 9-803 89-90 STARTING SYSTEM to advance and mesh with the gear on the flywheel. and connect battery cable to negative post on battery. Attach cable. Description. and tighten in place with two screws. Remove front bracket. Remove two screws holding switch to toeboard. and the speed of the flywheel exceeds that of the cranking motor. A remov­ able cover at the front end of the cranking motor permits inspection of the brushes and commutator. and remove two attaching screws at flywheel. c. and ammeter are attached to top terminal. Installation. and tighten securely. Remove air cleaner (par. the flywheel disengages the pinion automatically. Remove battery cable at negative post of battery. NOTE: Battery positive cable and wires to radio outlet box. 145 . Press the button to close the switch and cause the cranking motor to operate. Install air cleaner (par. 5). Attach cables and wires. also bracket screw. Removal. . b. b. filter. BATTERY GROUND CABLE BATTERY BATTERY POSITIVE CABLE . Installation. Remove cable from motor.

..... 146 ......0 amps..... . 92.............. 40................... Data......... 7.................................. clean........ Generator brace must be in position...... 8...... DESCRIPTION AND DATA........................................... ground-return type.............. 40 amps Clockwise Rotation (drive end) .. 6 Volts ........ Negative Ground polarity ......................6 volts. Brushes . and furnishes current for ignition........ and the requirements of the other electrical units used in the operation of the vehicle....... . Auto-Lite VRY-4203 A Current voltage Type ... Check mounting screws and bracket attached to engine.......0 amps....... Wire terminals must be in good condition..... Properly adjust the drive belt... Regulator ..... 1465 rpm Regulator: Make and model ... Auto-Lite GEG-5101D Negative Ground polarity ... 6 to 8 System voltage .. 1460 rpm 40..... 49) is a 6-volt sys­ tem... single-wire.......................TM 9-803 91-92 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Sedtion XIX GENERATING SYSTEM Paragraph Description and data ...... Maintenance ............... lighting......... 40 Amperes .. The regulator gov­ erns the generator output in accordance with the condition of the battery................... Current voltage regulator Control . MAINTENANCE................... a. and other electrical accessories if the engine operation is sufficient.. The generator requires attention to lubrication of those gener­ ators provided with oilers. Generator ........................ 91 92 93 94 91.................... This system consists of the generator..........6 volts. Generator: Make and model ......... and wires connecting it to the ammeter............... 7.. regulator.... a. For information concerning the battery and lighting system refer to para­ graph 95.... The system develops current to keep the battery charged..... The generating system (fig..... Description...........0 volts... b..........0 amps.... Controlled output ...... .................... 2 8.... 955 rpm Output ..

93. Install generator brace spring. Air is drawn in at the back of the generator. BATTERY GROUND CABLE BATTERY . Removal. GENERATOR iLJE x . Install fan belt. report to higher authority. and install bolt through hole. and install washer and bolt in front hole. 10) and slip fan belt off pulley. The generator is located on the right side of the engine at the forward end (fig. remove radio filter and ground strap. and ground strapl Start engine and check charging rate on ammeter in instrument panel (fig. External connecting wires with damaged or cracked insu­ lation must be replaced. e. It has a controlled output of 40 amperes. 147 . and is air-cooled by a fan built into the drive pulley. and discharged at the fan. 83). GENERATOR. and adjust if necessary (par. MOTOR AMMETER + TO LIGHTING SYSTEM RA PD 305203 Figure 48-Generating System Circuit b. and install a drift or pin through front hole as a pilot. shunt-wound. 5). two-brush unit rotating clockwise as viewed from the drive pulley end. Bond straps must be cleaned and securely tightened.TM 9-803 92-93 GENERATING SYSTEM and tight. Remove drift. Installation. If trouble is experienced with the generator. a. filter. Disconnect wires at generator. Attach wires. Description. 49). Install flat washer and bushing at rear support. It is a 6-8 volt. Remove generator brace spring (fig. Place generator in position. Remove two generator support bolts and remove generator. _ I BATTERY POSITIVE CABLE VOLTAGE _ REGU'AREGULATOR I/Il~~~~~~ - J TO RADIO OUTLET BOX TO CRANKING.

49) automatically governs the output of the generator in accordance with the condition of the battery and the current requirements in the operation of the vehicle. and no attempt should be made to adjust it. The regulator is mounted inside the splasher of the right front fender. 148 . and the current regulator. The regulator (fig. REGULATOR. The circuit breaker auto­ matically closes the circuit between the generator and the battery when the generator voltage rises above that of the battery. the voltage regulator. Description.TM 9-803 94 1/ -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) 94. and opens the circuit when the generator current falls below that of the battery. when the battery is low the output is increased. The regulator consists of three separate units: the cut-out or circuit breaker. a. sealed at the factory. and as the REGULATOR -x - E \ ­ - RA PD 2105238 Figure 49-Generator and Regulator battery becomes fully charged the generator develops less current to avoid overcharging. It is a precision instrument. thus.

Removal. and remove four bolts holding regulator to fender. Install battery cable on post. Installation. Remove wires from regulator terminals. Install bond strap. e. Connect wires to proper terminals. Mark wires to assure correct installation. 149 . and tighten securely. Remove battery cable at battery negative post. Start engine and check charging rate of ammeter in instrument panel. The current regulator controls the generator current (amper­ age) output so that it will develop enough to keep the battery charged (providing the engine is run sufficiently). b. and tighten securely with four bolts. Place regulator in position on fender.TM 9-803 94 GENERATING SYSTEM The voltage regulator governs the generator so that it will not de­ velop more voltage than the value for which the voltage regulator is set. Remove bond strap. and also prevent damage to the generator due to an overload.

........................................................................... Panel and blackout driving light switches ........ Wiring system ...... Wiring system: 6 Volts ........ DESCRIPTION AND DATA..... .... Data...... Fig........................................ b..... other light switches such as blackout driving light... Trailer connection ........ Headlights ....... The system consists of two service headlights..... Width ................. ............... The lighting system is protected by a thermal-type fuse-on the back of the blackout switch.......... .............................. Length ......... Auto-Lite-TS-2-15 Willard SW-2-119 6 Volts ... Instrument panel lights ............ Blackout driving light . two blackout headlights.. Description......................... 50) functions on 6 volts supplied by a three-cell storage battery...........TM 9-803 95 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XX BATTERY AND LIGHTING SYSTEM Paragraph Description and data .............................. 150 ............ 15 ............................... Battery: Make and model ..... are controlled by the respective switches.............. Negative Ground terminal . Battery . Blackout (main) light switch ..... 7 in............ stop lights and dimmers........ Maintenance .... ..................... Height ................................ 10 in. ................................................... 85/16 in........................ one blackout driving light....... The lighting system (fig...... 95 96 97 98 99 100 101 102 103 104 105 106 95................... ...... two instrumenf panel lights. Taillights and stop lights ... 50 Wiring identification reference ......... When the blackout light switch is set in the proper operating position................. The entire lighting sys­ tem is controlled by the blackout (main) light switch on the instru­ ment panel............ Blackout headlights ........... 116 Capacity (ampere hours) ............................... instrument panel............. a........ .......... Plates per cell ....... and operating switches and battery......... service and blackout stop and taillights..

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............. Sealed unit Instrument lights .. The battery requires periodic checking of the proper level of electrolyte................. Battery case must be kept clean..... Tighten battery hold-down clamps.. 3544 figure 52­ Headlight RA PD 305216 96.. All light mounting screws and 154 ... a. Keep battery terminals and posts clean and securely tightened................ No..... 51 Trailer connections: Make .........TM 9-803 95-96 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Lamps: i Headlights ....... MAINTENANCE......... Mazda No' 1245 Blackout driving light .. 3604 Plug model ............ . Wagner Socket model .... Sealed unit Taillights and stop lights . No.... Clean battery carrier when corroded. Sealed unit Blackout headlights ... ......... Mazda No... ..... All vent plugs must be tight and breather holes kept open......

In normal temperatures the battery should be recharged when the specific gravity reads 1. c. Disassembled and has the negative (small) post grounded. 36) is a 6-volt. and tighten securely with nuts. and remove hold-down frame. All loose and dirty electrical connections must be cleaned and tightened. Loosen two nuts holding frame on battery. 97.285. Removal. BATTERY. grease and install on bat­ 155 .175 or lower. Lift out battery. The battery (fig.275 to 1. and remove termi­ nals from battery. Place hold-down frame in position. and is fully charged when the specific gravity is 1. NUT LOCK WASHER-4 MOUNTINQ SCREW RETAINER CABLE ASSEMBLY MOUNTING-[ SCREW - GROUND SCREW DOOR SCRE of OL INA HOUSING SUB-ASSEMBLY SEALED UNIT DOOR ASSEMBLY RA PD 305217 Figure 53-Headlight. Bond straps must be clean and securely tightened. Place battery in position with positive post to rear. 116-ampere­ hour storage battery consisting of three side-by-side cells of 15 plates each. Light lenses and reflectors must be kept clean and securely fastened.TM 9-803 96-97 BATTERY AND LIGHTING SYSTEM nuts must be kept clean and tight. b. Loosen bolts in cable terminals. All damaged or frayed wires must be replaced. Installation. if necessary. Description. Headlights must be aimed properly.C The battery is located under the hood at the right side. a. Clean cable terminals.

98. and specific gravity must be 1. Check level and specific gravity of electrolyte in battery. and right-hand 'terminal of the ammeter. and blackout (main) light switch. install retaining clips along wires. A single-wire system is used.. and described in the accompanying legend. a. Description.275 to 1. The wiring system consists of the harnesses and wires which are identified by colors and tracers as shown in figure 50. When necessary to renew wires in the wiring sys­ tem.TM 9-803 97-98 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) tery posts. disconnect wires at terminals. filter. ignition switch. From the left-hand ammeter terminal wires run to the voltage regulator. loosen clips along harness. Electrolyte level must be /2 inch above plates. Note location of wires. Installation. where the horn wire is connected. e. remove grounded (negative) cable at battery. which controls DISTANCE SAME AS LAMP CENTER FROM FLOOR D D ONE-HALF OF DISTANCE BETWEEN CENTERS OF LAMPS OF GREATEST LIGHT INTENSITY 7' 7:<_~~~ / ~ZONE E I CENTEROF BEAMCET LEFT-HAND LIGHT OF BEAM RIGHT-HAND LIGHT ok C' I t STOP BLOCK RA PD 305218 Figure 54-Headlight Aiming Chart all lights in the lighting system. and the negative terminal of the battery is grounded. When installing wires and harnesses see that all connections are correctly located and secure. A single cable connects the battery positive post to the upper terminal of the starting switch. to which are also attached wires running to the radio outlet box. and remove wires. WIRING SYSTEM. Removal. b. 156 . Double-check location and tightness of connections.285 at 800F. The entire vehicle wiring system is shown in figure 50. and the circuits of the lighting system are shown in figure 51.

The upper and lower beams are controlled by the foot-operated dimmer switch. and pull connector from back of unit. b. Each headlight is mounted on a hinged bracket. and lens. 157 . a. HEADLIGHTS. lamp. 53).TM 9-803 99 BATTERY AND LIGHTING SYSTEM 99. The headlights are of the double filament sealed beam-unit type consisting of reflector. which can be RA PD 305219 Figure 55--Blackout Headlight replaced only as a unit (Mazda. 52) are mounted at the front of the vehicle and are protected by the radiator guard. Remove sealed beam assembly. Description. Removal of Sealed Beam-unit. No. The lower beam filament is positioned slightly to one side of the focal point deflecting the beam slightly to illuminate the right side of the road. Two headlights (fig. By loosening the wing nut. Remove door clamp screw and remove door (fig. The headlights light when the blackout lighting switch is in service position. 2400). the light can be swung over and used as a trouble light in the engine compartment.

and secure in place with screw. Mount the headlight on the sup­ port. Tighten headlight mounting nut. Inflate all tires to recommended pressure (par. and adjust other in same manner. Remove clip on radiator grille (two on right headlight wire). Attach connector to back of unit. NOTE: Use a light back­ ground with black center line for centering vehicle on screen. Installation of Sealed Beam-unit. f below). 158 . Aim headlight (subpar. Lower support. aiming screen. and remove headlight. Remove nut on headlight. Installation of Headlight. black wire on top terminal). and fasten with wing nut. stand at rear and sight through wind­ shield down across cowl and hood. Removal of Headlight. Disassembled HOUSING ASSEMBLY ADJUSTING WASHER DOOR ASSEMBLY 1 3 RA2 4 5 220 RA PD 305220 f. Install wire clip on grille (two on right headlight wire).TM 9-803 99 /4. Aiming Headlights. Adjust headlight so that center of bright light area is on intersection of vertical and horizontal lines.-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) c. 3). e. Cover headlight just aimed. Mark screen 7 inches less than the height of centers of headlights. Turn on headlight upper beam. Loosen headlight support wing nut. d. Place unit in position in headlight housing. Set vehicle so headlights are 25 feet away from screen and center line of vehicle is in line with center line of screen. Aim headlights by using headlight aimer. and observe location of upper beam on screen. cover one headlight. Disconnect headlight wires at junc­ tion block on left fender splash under hood. Mark two vertical lines on each side of center line equal to the distance between headlight centers. To deter­ mine center line of vehicle. or wall shown in figure 54. Con­ nect wires to junction block (red wire on bottom terminal. Install door. GASKET DOOR SCREW BULB Figure 56-Blackout Headlight. raise support.

NOTE: The door and lens are in one unit. BLACKOUT HEADLIGHTS. 1245 lamps are used. turn lamp to left and remove. Replace door gasket. DRIVE") in the instrument panel.) Remove mounting nut by reaching in from the rear and lift out headlight.) Attach wire in connector. Remove door screw in lower side of rim and remove door by pulling out on lower side (fig. 101. (Attach three clips for right headlight. if damaged. c. 57) is a hooded light having a sealed unit which throws a horizontal diffused beam to illuminate any vertical object. The blackout driving light 159 .O. e. This light is mounted on the left front fender. a. Removal of Lamp. Insert lamp in socket. Pull wire out of connection just behind left headlight. ' RA PD 305221 Figure 57-Blackout Driving Light d. Description. Removal of Blackout Headlight. (For right headlight remove three clips across bottom of grille. b. Mazda No. Installation of Lamp. Replace door and tighten door screw. The blackout driving light (fig. push in and turn lamp to right. a. These head­ lights are illuminated only when the blackout (main) light switch is in blackout position. and is controlled by a push-pull type switch (marked "B. 55) with lens which permit only horizontal rays to pass through. There are two blackout headlights (fig. Push in on lamp. Description.TM 9-803 100-101 BATTERY AND LIGHTING SYSTEM 100. Put light in position and tighten in place with mounting nut. 56). BLACKOUT DRIVING LIGHT. Installation of Blackout Headlight.

d. HOUSING SUBASSEMBLY MOUNTING RING SEALED BLACKOUT UNIT DOOR ASSEMBLY SCREW _SCREW .. 59) are located in the rear panel of the body. The light is aimed with vehicle on a level surface and loaded. The upper unit consists of 160 . 102. f. Each light consists of two separate units in a housing. Remove screw at bottom of light door (fig. and lift off light. Remove three wire clips. Pull bottom of door forward and up to remove. The left-hand light contains a combination service tail and stop light unit in the upper part. and remove door by releasing mounting ring. e. Installation of Sealed Unit. and mark stick where bright spot appears. and a blackout taillight in the lower part.1 inches lower than mark. Remove mounting nut on bottom of light. and install unit mounting ring. Place sealed unit in door. Disassembled e. attach three clips. and tighten retaining screw. and push wire into connector at dash. a. Install door on housing. Disconnect socket wire. b. Installation of Blackout Driving Light. Description. Two combination taillights and stop lights (fig. Hold a 4-foot wood stick on floor close to the light. Attach wire connection. 58). Pull wire out of con­ nector at dash. and pull wire through fender.01-102 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) can be illuminated only when the blackout (main) light switch is in blackout position. Install light on bracket and tighten nut. TAILLIGHTS AND STOP LIGHTS. run wire through fender and splasher. Adjustment. Removal of Blackout Driving Light. Removal of Sealed Unit.·I~DOOR WASHER LOCK WASHER '2 3 RA PD 305222 Figure 58-Blackout Driving Light.TM 9-803 1. bright spot should be 2. Move stick 10 feet ahead of light.

the unit must be replaced. b. Be sure that unit is correct type. 5) located above instruments and on the outside of the instrument panel. Double contact connector goes in upper socket of left light. a. and a 21-3-candlepower lamp. RA PD 305223 Figure 59--Taillights and Stop Lights d. Installation of Light Unit. gasket. There are two instrument panel lights (fig. These lights are controlled by the blackout (main) light switch.TM 9-803 102-103 BATTERY AND LIGHTING SYSTEM the taillight lens. Pull each unit straight out of socket. 60). Remove two nuts holding light to bracket. Plaqe light in position and secure with nuts. gasket. Removal of Light. and 3-candlepower lamp. and 3-candlepower lamp. The lower unit is the same as the lower unit in the left light. gasket. reflector. When a lamp burns out. 103. reflector. The lower unit consists of blackout lens. The right-hand light contains a blackout stop light unit in the upper part. e. and remove door (fig. push in on connector. Description. Installation of Light. if not. Remove two screws in light door. Install light door and screws. reflector. interchange connectors in sockets. The upper unit consists of the blackout stop light lens. Reach up under body and disconnect wire connector. Attach connectors. and remove light. Turn on blackout (main) light switch to black­ out position to see if right blackout taillight (lower unit) lights. turn counterclockwise and pull connector out of socket. INSTRUMENT PANEL LIGHTS. 161 . and a blackout taillight in the lower part. c. They are controlled by the panel light switch when the black­ out (main) light switch is in service position. Removal of Light Unit. and push into socket.

Put lamp in socket. Removal of Lamp. Installation of Lamp. turn lamp counterclockwise. Push socket into shield. and remove. Disassembled INSTRUMENT LIGHTSHIELD ADAPTER LAMP SOCKETAND CABLE RA PD 305225 Figure 61-instrument Light. Disassembled b. c. press in on lamp. 61). push lamp in. Pull light socket out of shield.TM 9-803 103 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) DOOR STOP-LAMP-UNIT HOUSING SCREW TAIL -LAMP-UNIT 1 2 3 4 5 6 RA PD 305224 Figure 60-Taillights and Stop Lights. Pry off shield by using a sharp tool behind flange (fig. 162 . and push shield into instru­ ment lamp adapter. and turn clockwise.

TM 9-803 103-104 BATTERY AND LIGHTING SYSTEM d. Removal. 5). Press lockout control but­ ton. Removal of Instrument Light. Remove wire and sockets for both lamps under instrument panel. A thermal-type fuse is mounted on the back of the switch having a bimetal spring. The switch controls all the lights. 5 BS T TI BHT1 SIDE VIEW TOP VIEW RA PD 305226 Figure 62-Blackout (Main) Light Switch blackout taillights. With the knob all the way in.establish connection so blackout stop light will function when foot brake is applied. Pull knob out to first (blackout) position to illuminate blackout headlights. Assemble light as outlined in subparagraph c above. when vehicle is oper­ ated during daylight. to cause stop light only to function when foot brake is applied. 62). Loosen set screw in switch knob and unscrew knob. BLACKOUT (MAIN) LIGHT SWITCH. The blackout light switch is a push-pull type (fig. mounted in the instrument panel to the left of the steering gear (fig. e. a. and place sockets through holes in instrument panel. and to establish connections so service stop light will function when foot brake is applied. Disconnect ground cable at negative post of bat­ tery. Attach wire terminal to panel light switch. Disconnect wire on back of light switch. Description. and pull switch knob out to second (service) position to illumi­ nate service headlights and taillight. 104. all lights are off. and dismantle as outlined in subparagraph h above. and. b. Pull knob out to third (service stop light) position. if a short circuit occurs in the lighting system. and has four positions (fig. which causes a set of contact points to open and close. Installation of Instrument Light. Loosen 163 . 9).

.. and take switch out from under panel..... Install knob and tighten set screw.. White-black tr. ....... ... Yellow-black tr. Description. Serviee taillight ........ c. Yellow-black tr.... Blue-white tr.. Attach wires to proper terminals. Installation... Trailer coupling socket............. Blackout headlights Blackout taillights ... and pull off bushing.. Green-black tr.. . Red-white tr. Panel lights .. press lockout control button... mark them for identification.. 105... Remove mount­ ing nut. Blackout driving light ... . The panel and blackout driving light switches 164 ... Blackout driving light... Service headlight .... NOTE: Switch terminals are marked for easy identification. Extra ..... Stop light .. Red-black tr... Install switch in panel and secure in place with mounting nut..A B BHT BS HT S SS SW TT . Green-black tr.. Service stop light.. Blue-white tr.. Black-white tr... a. Attach ground cable to battery.TM 9-803 104-105 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) hexagon head screw at side of switch bushing on front of panel. .. Install bushings and tighten screw. . Blue-white tr.. Trailer coupling socket. . Not used Red-white tr..... Ammeter .. Remove wire terminal -screws. .. Wires are to be attached as outlined below: Figure 63-Light Switch RA PD 305227 Terminal Circuit Wire Coloi .... Blackout stop light .......... .... Red-white tr.. PANEL AND BLACKOUT DRIVING LIGHT SWITCHES.... As wires are removed..... ... ....

Q ( D E A NUT B LOCK WASHER-INTERNAL EXTERNAL C D E __ LOCK WASHER-STANDARD SCREW-LONG SCREW-SHQRT COVER ~o: tC coo r O o l < IF G DUST SHIELD RETAINER H I DUST SHIELD BODY H G F RA PD 305276 Figure 65-Trailer Socket. Disassembled 165 .TM 9-803 105 BATTERY AND LIGHTING SYSTEM STOP LIGHT GROUND TAILLIGHT BRAKES RA PD 305228 Figure 64-Trailer Socket Terminals A B C .

Install knob and secure with set screw so that marking on knob is in correct position. and install lock washers and nuts loosely. Remove wires. opposite the hinge. and remove cover over the terminals. Removal." The panel light switch controls these lights only when the blackout (main) light switch is in the service position.O. The panel light switch knob is marked "PANEL LIGHTS". Install protecting cover. NOTE: Attach green wire to terminal "TL". Installation. and tighten all four nuts holding socket in body panel. Install the lower bolts with the lock washers in correct position. c. Remove equipment from left rear tool compart­ ment. Install socket with drain hole down. attach red wire to terminal "SL". 63). The blackout driving light switch controls that light only when the blackout (main) light switch is in blackout position. and secure with mounting nut. 106. Remove mounting nut. DRIVE.TM 9-803 105-106 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) are push-pull (off-and-on) type (fig. and disconnect wires. Attach wires to switch. Remove four bolts holding socket in body panel. 2). Install ground wire on a lower bolt. Remove screw at top edge of protecting cover. and remove switch from in back of panel. To install socket in body. Attach wires to terminals. Loosen set screw in knob and unscrew knob. Pull out socket. 166 . a. followed by the dust shield with slot in center opening. install in place in panel." Install cover over terminals. Installation. b. NOTE: Toothed lock washers must be installedas directedfor a good ground connection. Place internal-external lock washers on each bolt. the blackout driving light switch is marked "B. c. Remove screws in wire terminals. Description. and secure in place with screw at top edge to complete the installation. install the two long mounting screws in socket cover hinge. The trailer connection is a socket located in the body rear panel at the left side (fig. noting their proper place. b. and remove cover. Place dust shield retainer ring over screws. attach small terminal of black wire to terminal "GR. Place cover against outside of body panel with the two screws through upper mounting holes so that cover opens upward. Removal. The blackout (main) light switch controls the current to socket and trailer lights. TRAILER CONNECTION. As a precaution remove ground cable from battery.

........ 108... 107 108 109 110 11l 112 107....D....... dry-disk type............ adjust the free pedal travel to three-quarters of an inch (fig............ This type clutch has only one service adjustment....... 68)............ Report grabbing or slipping condition of clutch to higher authority..... A ball-type release bearing operates three clutch release levers to control the clutch...... Pedal adjustment .. 66) located between the engine and the transmission is a single plate....... 8 in..TM 9-803 107-109 Section XXI CLUTCH Paragraph Description and data . As the clutch facings wear................................. Prelubricated ball Clutch shaft bushing (in flywheel) size .................... DESCRIPTION AND DATA.... the clutch driven plate which has a spring-center-vibration neutralizer.......... Data..................... inside. Atwood No....... which is bolted to the flywheel. MAINTENANCE.............. unscrew cable until clutch pedal has 3/4 inch free play...... outside Thickness ......... 3 Clutch release bearing type ........ The clutch consists principally of two units.................... The clutch requires attention to pedal adjustment...... and the clutch pressure plate unit............ 0.......... and regulates the amount of free pedal travel. 167 ..... Pedal adjustment must be periodically checked......... 11123 Size .............125) Pressure plate: Make .................... Facings .................... 3/4 in. PEDAL ADJUSTMENT... b........ Description.............. 1 woven and 1 molded Diameter ............ 5'/8 in.................. Borg and Beck No...... a...................... a.. Installation .. I...................... The clutch (fig. The controlled pressure of the driven plate against the flywheel provides a means of engaging and disengaging the engine power to the transmission.. 77/8 in............... TP-2B-7-1 Number of springs ..... 77/ in.......... Dry single plate Torque capacity driven plate ....... · a.... Removal ........ (0........... This adjustment is for the foot pedal........... Clutch pedal adjustment (free play) ..... 67 and 68)........... Maintenance ............................ 132 foot-pounds Make . 109......628 in. Loosen clutch control cable adjusting yoke lock nut (figs.. Adjust Pedal.......... Tighten lock nut.... Clutch release bearing . Type ..... due to the natural wear of lining..... The release bearing is controlled by a rod and cable to the clutch pedal................................... .... Using a wrench........

TM 9-803 109 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) A B C D P 0 A B C D E F G H I FACING-FRONT J CLUTCH CONTROL LEVER DRIVEN PLATE ASSEMBLY K CLUTCH LEVER FACING-REAR L PRESSURE SPRING PRESSURE PLATE M CLUTCH LEVER PIVOT PIN CLUTCH PRESSURE PLATE ASSEMBLY N CONTROL LEVER CABLE RELEASE BEARING 0 ADJUSTING SCREW RELEASE BEARING CARRIER P ADJUSTING SCREW LOCK NUT RELEASE BEARING CARRIER SPRING Q ADJUSTING SCREW WASHER CLUTCH CONTROL LEVER FULCRUM R PRESSURE PLATE RETURN SPRING S PRESSURE SPRING CUP RA PD 305274 Figure 66-Clutch-SectionalView 168 .

TM 9-803 109 CLUTCH r E AC\ i W AA C X A B C D E F G H I J K L M N O P BRAKE PEDAL PEDAL SHAFT ASSEMBLY PEDAL SHAFT COTTER PIN LEVER CABLE LEVER RELEASE BEARING RELEASE BEARING CARRIER RELEASE BEARING CARRIER SPRING LEVER CABLE YOKE END LOCK NUT LEVER CABLE YOKE END LEVER CABLE CLEVIS PIN TUBE WASHER BALL STUD BALL STUD LOCK WASHER TUBE DUST WASHER TUBE FELT WASHER Q R S T U V W X AA AB AC AD AE AF AG AH SPRING TUBE SPRING COTTER PIN LEVER AND TUBE ASSEMBLY PEDAL ROD BALL STUD NUT FRAME BRACKET FRAME BRACKET SCREW PEDAL RETRACTING SPRING PEDAL SHAFT WASHER PEDAL CLAMP BOLT PEDAL CLAMP BOLT LOCK WASHER PEDAL SHAFT HYDRAULIC GREASE FITTING PEDAL TO SHAFT KEY PEDAL PEDAL CLAMP BOLT PEDAL PAD RA PD 305286 Figure 67-Clutch Control 169 .

Use a clutch shaft or clutch pilot arbor to aline driven plate. a. Loosen evenly and remove screws holding pressure plate to flywheel. Install driven plate against flywheel with short end of hub toward flywheel. Mark clutch pressure plate and flywheel to assure correct position when installing.TM 9-803 110-111 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 110. REMOVAL. a. Install small amount of light grease in clutch shaft flywheel bushing. Remove pilot and check adjustment of clutch fingers (fig. 115). Install clutch pres­ sure plate loosely with screws. 60) or transmission and trans­ fer case assembly (par. 111. Clean flywheel and clutch. RA PD 305239 Figure 68-Clutch Pedal Free Travel b. and tighten clutch pressure plate screws evenly. NOTE: The easiest method is to remove the engine assembly. Remove engine assembly (par. remove driven plate. Remove pressure plate. 170 . INSTALLATION.

To adjust clutch fingers. Press carrier out of bearing. loosen lock nut on adjusting screws. Press carrier into bearing. Slip bearing and carrier onto transmission bearing retainer.TM 9-803 111-112 CLUTCH 69). Follow the procedure outlined in paragraph 61 for completion of assembly. Installation. which should be 27/32 inch. a. install release lever on fulcrum. Install engine (par. 61). Figure 69-Clutch Finger Adjustment PD 305229 112. or trans­ mission and transfer case assembly (par. as required. 116). Removal. b. unhook release bearing carrier spring. 171 . and hook spring to bearing carrier. CLUTCH RELEASE BEARING. set lock nuts. and pull off bearing and carrier (fig. and turn screws until measurements from face of fingers (release bearing contacts) to face of clutch bracket measures 27/32 inch. 66). After release bearing can be reached. Follow procedure outlined in paragraph 60 for re­ moving engine.

.. Description.... 3-speed....... j IL A B C D E F G N I J K L MAIN DRIVE GEAR BEARING RETAINER MAIN DRIVE GEAR BEARING SHIFT RAIL-LOW AND REVERSE CONTROL HOUSING ASSEMBLY CONTROL LEVERASSEMBLY CONTROL HOUSING CAP CONTROL HOUSING CAP WASHER CONTROL LEVERSUPPORT SPRING SHIFT PLATE LOW AND REVERSE SHIFT FORK LOW AND REVERSE SLIDING GEAR MAIN SHAFT BEARING Y COUNTERSHAFT M MAIN SHAFT N OIL RETAINING WASHER O MAIN SHAFT SECOND SPEED GEAR ASSEMBLY P COUNTERSHAFT Q REARCOUNTERSHAFT THRUSTWASHER (STEEL) R REARCOUNTERSHAFT THRUSTWASHER (BRONZE) S CASE T SECOND AND DIRECTSPEEDCLUTCH SLEEVE U HIGH AND INTERMEDIATE CLUTCH HUB V MAIN SHAFT PILOT ROLLERBEARING W MAIN DRIVE GEAR X COUNTERSHAFT GEAR ASSEMBLY THRUSTWASHER-FRONT RA PD 305285 Figure 70-Transmission-Sectional View 113. The transmission (fig.....116 ....... Removal .. 70) is a selective.. synchromesh type with synchronized second and high speed gears.. . a......TM 9-803 113 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XXII TRANSMISSION Description and data . Maintenance .... 172 ... DESCRIPTION AND DATA.... Installation Paragraph 113 114 115 ...

Push transmission to 173 .......... Make and model ........ b. Unscrew balls on shift levers. 115....... Place rope around the transmission..... Remove bolts around transmission cover on floor.... 3/4 qt Lubricant grade reference ... For shifting instructions.. Remove transfer case support (snubber) bolt at cross member (fig...... Remove transfer case shift lever pin set screw. a........... Drive out shaft and remove levers...554 Lubricant capacity ..... 2. ...... Third speed is a direct drive through the transmission............ Remove exhaust pipe clamp on skid plate.... and tie propeller shafts up to frame... MAINTENANCE.. 73). Data..... Report transmission gear noise to Sigher authority..-and through the floor at the right of the driver..... clutch.... Mounting screws must be tight.. 1 to 1 Reverse ... a............ Remove transmission shift lever by unscrewing retainer collar at top of shift housing.. Disconnect engine stay cable at cross member. Gearshift ball cap must be removed and cleaned as required... and transfer case............ Vent hole in transmission control housing must be kept clean at all times...... and remove cross member....... Remove radiator upper hose............ and remove hand brake retracting spring. The transmission requires periodic checking of lubrication level... 3. Remove exhaust pipe guard.. Open drain cock at bottom of radiator and drain cooling system.......... Disconnect speedometer cable at transfer case....... Remove frame to cross member bolts at each end. Remove bolts in front and rear propeller shaft universal joint flanges at transfer case end.... Unhook clutch pedal pull-back spring...... The gears are shifted by a lever extending out of the top of the transmission.564 to 1 High (3rd) ... Keep all bond straps clean and securely tightened........ all other speeds are through gears of various sizes to obtain the necessary gear reduction.. 1.... Place jack under engine oil pan......... Raise hood and fasten to windshield to prevent accidental closing. Remove nuts on engine rear support insulator studs in cross member... and remove cover.TM 9-803 113-115 TRANSMISSION It is located in the power plant unit with the engine.. Place a second jack under the transmission...... Warner T-84-J Type ... Remove skid plate. Remove lubricator in right end of shift shaft. Remove clevis pin in clutch release cable yoke at cross tube lever. 3 forward--1 reverse Ratios: Low (lst) . 18 114. Synchromesh Speeds ............. Remove bond­ ing strap on transfer case and transmission... Remove clevis pin in lower end of hand brake cable.665 to 1 Intermediate (2nd) ..... refer to paragraph 5 e... REMOVAL.. par.........

NOTE: Do not lose transmission gearshift interlock plunger (fig. and remove clutch release lever tube from ball joint on transfer case. and remove housing. Remove Transmission from Transfer Case. and attach wire tightly to front of transmission. Slide transmission assembly back until clutch shaft clears bell housing. Pull off main shaft gear and oil slinger. Remove assembly from under vehicle. lowering jack under engine just enough so that transmission will clear floor pan. Remove four bolts holding transmission to bell hous­ ing. Remove cotter pin. nut. b. 174 . Re­ move screws holding rear cover on transfer case. Loop piece of wire around main shaft to the rear of second speed gear. and remove cover and gasket. Support transfer case. Remove core and clutch release fork. Drain lubricant from transmission and transfer case. Remove shifter plate spring. Remove two screws in inspection cover.TM 9-803 115 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) right. and remove jack from under transmission. Remove five screws holding transfer case to rear of transmission. INTERLOCK PLUNGER AND SLOT RA PD 305230 Figure 71--Gearshift Interlock Plunger Remove four screws holding control housing on top of transmission. and washer on rear end of transmission main shaft. Hold weight of assembly with rope. Clean outside of units. and remove shifter plate. and tap lightly on end of transmission main shaft. at the same time draw transfer case away from transmission. 71).

Remove rope. Place jack under transmission to take the weight. Install rear cover with screws and lock washers.TM 9-803 116 TRANSMISSION 116. Assemble Transmission to Transfer Case. Place rope around transmission. Install engine stay cable and adjust so it is just taut. Install transmission skid plate. b. 175 . Attach bond straps. Install transmis­ sion shift interlock plunger in position. Raise transmission. Install radiator upper hose. Run engine until warm. Install clutch release fork on pivot ball. Lower hood and hook into place. Push transmis­ sion to the right. Install lubricator in right end of shaft. 18). Place unit under vehicle. Attach front and rear propeller shafts at transfer case. Connect clutch release cable to lever. Install transmission to bell housing bolts. Install control housing on top of transmission with four screws. Install transmission floor cover. and install bolt through cross member. giving due attention to antifreeze. Raise transmission with jacks. 71).' Push transmission forward into position. and install clutch release cable in end. and wire in place. Put lubricant in transmission and transfer case (par. Install exhaust pipe guard. Install shifter plate and spring. and check coolant supply. INSTALLATION. Remove jack under transmission. and install clutch release tube on ball on transfer case. Install gearshift lever balls. Check cooling system for leaks. using grease to hold it tem­ porarily (fig. Remove jack under engine. Install exhaust pipe clamp on skid plate. Install washer. Attach transfer case to transmission with five screws. if required. Using new gasket. Place transfer case support rubber in place. Adjust clutch release cable for pedal play (par. Instal' transfer case shift levers and springs. Install transmission shift lever in top of housing. 109). install oil retaining washer on transmission main shaft in transfer case. with open face to rear. Fill cooling system. Install shaft lock screw. and cotter pin. Install frame cross member. using new gasket. a. Install engine support insulator stud nuts at cross member. and insert transmission main drive gear shaft (clutch shaft) in hub of clutch plate and flywheel. driving shaft in from right side. Install pedal pull-back spring. Connect speedometer cable at transfer case. Connect hand brake cable and spring. Install in Vehicle. nut. Install main drive gear with small power take-off gear to rear.

..... ................................. Maintenance ............... a.... Shifting levers .............. Removal ....... ................................. Description... 72) is an auxiliary gear unit attached to the rear of the transmission.......... 117 118 119 120 121 117....................TM 9-803 117 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XXIII TRANSFER CASE Paragraph Description and data . Installation ...................... DESCRIPTION AND DATA.......... The transfer case (fig.. The transfer case is essentially a two-speed transmission which provides an additional TRANSFER CASE AP 30 RA PD 305231 Figure 72-Transfer Case-Rear View 176 .........................

....... The transfer case requires lubrication at regular intervals........ All mounting bolts must be kept tight.... -low ........ 73) is operated by two levers on the top of the case...... Spicer-18 Ratio-high ............. L ~~~~~~~ ~~RA ePD 305233 Figure 73-Transfer Case Shifting Mechanism b...................... .......... The shifting mechanism (fig..... ....... Make and model . Data... 14 12...... qt 118..... Universal joint yoke and com­ 177 .. a.TM 9-803 117-118 TRANSFER CASE gear reduction for any selection of the transmission gears........97 to 1 4 --driven gear Lubricant capacity ........... and a hand brake is located on the same housing..... The speedometer drive gear is located in the output shaft housing for the drive to the rear axle..... A power take-off aperture is located at the rear just behind the transmission main shaft. also a means of engaging and disengaging power to drive the front axle. Speedometer teeth-drive gear .. 1 to 1 1................... MAINTENANCE..

and wire in place. 119. and install in vehicle as outlined in paragraph 116. Removal. b. Unscrew accelerator footrest and remove 10 screws holding transmission floor cover. Attach transfer case to transmission. and remove levers (fig. INSTALLATION. Remove covers. Raise hood and secure to windshield. Remove transfer case shift lever set screw and lock wire. 178 . Installation. R~port failure to stay in gear and noisy gears to higher authority. REMOVAL. Install shaft set screw. Unscrew hydraulic fitting from right end of shaft. Install hydraulic fitting in right end of shaft. 121. a. Install transmission floor cover and accelerator footrest. 73). Drive in shaft. SHIFTING LEVERS. also remove two screws holding transfer case shift lever housing cover. Remove transmission and transfer case as an assembly as out­ lined in paragraph 115. Tighten drain and filler plugs. a. a. Bond strap must be clean and tightened securely.TM 9-803 118-121 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) panion flange nuts must be tight. Drive out shaft. Place shift levers and springs in position. 120.

.... ............. Maintenance . at the front of the rear shaft............. The propeller shaft connecting the transfer case to the front axle has U-bolt type joints at both ends... Two propeller shafts are used........... and.............. 74)........... a...L ASNAP.... The trunnion bearings are of the needle bearing type which are lubricated through a hydraulic fitting and an X-channel in the trunnion................................ NOTE: The slip joint is marked with an arrow on the spline shaft and on the sleeve yoke.... 179 .... Description...RING TYPE REAR PROPELLERSHAFT FRONT PROPELLER SHAFT U-BOLT TYPE RA PD 305234 Figure 74-Propeller Shafts and Universal Joints for correct assembly (fig................... The rear propeller shaft has a U-bolt type joint at the rear where it attaches to the rear axle........ DESCRIPTION AND DATA...... A splined slip joint is used at the rear of the front shaft..... and a snap-ring type joint at the'front end..... ... Removal ........ Refer to lubrication instructions in paragraph 18.. Installation .TM 9-803 122 Section XXIV PROPELLER SHAFTS AND UNIVERSAL JOINTS Paragraph Description and data .. Two universal joints are used on each shaft (fig. 122 123 124 125 122... and these arrows must aline .. one to drive each axle. 74)..

........ Remove exhaust pipe shield.......... Remove four bolts in front universal joint yoke flange.......................... REMOVAL. MAINTENANCE.......... Remove propeller shaft and universal joints as a unit.. 1268 123....................... Install propeller shaft and universal joint assembly in position... Propeller shafts Make .. Remove U-bolts from universal joint yoke on axle...... Front Propeller Shaft... Remove two U-bolts from rear universal joint yoke on axle.. Tighten U-bolts evenly...... Snap-ring and U-bolt Model ...... 1268 Rear Universal Joint (front shaft) Type ... Front Propeller Shaft. Attach front universal joint flange at transfer case with four bolts... 180 . 2125/2 in.. Install U-bolts at transfer case......... Lubricate universal joints (par... Install propeller shaft and universal joint assembly in position on vehicle.......... 21%5 in... 1261 Rear Universal Joint (rear shaft) Type ..... Rear Propeller Shaft. Remove U-bolts from universal joint yoke on transfer case.. a....... Rear ...................................................... Install U-bolts at axle...... Attaching bolts and nuts must be securely tight­ ened..... a......... 124........ b... Snap-ring Model ... Install exhaust pipe shield... Data....... and tighten evenly.. 1261 Front Universal Joint (rear shaft) Type ....... Front Universal Joint (front shaft) Type .......... INSTALLATION.... Remove shaft and universal joints as a unit.............. Lubricate universal joints (par..... Trunnion gaskets must be grease-tight....... NOTE: Tighten U-bolts evenly....... 18 e). b.. 125..............TM 9-803 122-125 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) b.. Snap rings must be securely locked in recess....... a............ Spicer Installed length normal load-joint center to center Front ..... Rear Propeller Shaft. Snap-ring and U-bolt Model .... Propeller and universal joints require proper lubrication at regular intervals.. Install U-bolts in rear universal joint.. .... The yokes of front and rear universal joints must be assembled in the same plane....... Snap-ring and U-bolt Model ........ 18 c).......

....... Drive gear ratio ...........TM 9-803 126 Section XXV FRONT AXLE Paragraph Description and data ................................................................ Installation . 126 127 128 129 130 131 132 133..... Wheel alinement (toe-in) ... a..............enclosed within a steering knuckle at the outer end of the axle housing............... The front axle (fig.......................... The differential carrier housing is offset to the right so that the propeller shaft is located to the right of the engine for maximum ground clearance. b................ twopinion differential.................... The differential assembly is the same as used in the rear axle.................... A cover pro­ vides easy access to the differential unit.......................................... Description.......... .......................... Drag link bell crank ............. ........ Wheel grease retainer ..... DESCRIPTION AND DATA.............................................. Power is transmitted by a propeller shaft from the transfer case.................. Wheel hub ....... Steering knuckle housing oil seal .......................... The front wheels are driven by axle shafts........... Maintenance . where a shift lever permits the vehicle operator to engage or disengage the drive................ Spicer--25 Make and model . 134 135 136 137 RA PD 305253 Figure 75-Front Axle 126............... each equipped with a constant-velocity type universal joint.... Brake drums ......88 to 1 181 .... 4.. Steering tie rod ............ 75) is a full-floating type enclosing a front wheel driving unit having a single-reduction.... Wheel bearings ........... Removal ........ and hypoid drive gears................ Data......

.................... Bearings: Differential side ... ................... Differential type .. Tapered roller 182 .......TM 9-803 126 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Drive ......... 1711/32 in.............. to %2 in..... %4 in....... ......... .................... 24¼4 in.... center-to-center ............................ Tapered roller Wheel hub ............. Left-hand length....... 26 deg s-hA........... 87/16 in..... Hotchkiss (through springs) Type ............................ RA PD 305270 Figure 76-Front Wheel Hub Tie rods: Number ................. 2 Right-hand length. 2 pinion Differential drive gears ........................... .................................... Tapered roller Turning angle ................ 1 deg Wheel caster ....... 3 deg Wheel toe-in ................. Hypoid Differential bearings ............... 7/2 deg Wheel camber ........ center-to-center . Tapered roller Pinion shaft ... Steering geometry: King pin inclination ........ . Full floating Road clearance ..........

. Lubricate differential and steer­ ing housings..... 135)... and correct if necessary (par.. 76).. zj i i 7I RA PD 305232 Figure 77-Removing Driving Flange.... Adjustment. Raise front of vehicle so that tire clears floor. Remove axle shaft nut cotter pin... and 183 . Replace damaged brake drums and hubs......... MAINTENANCE. Wheel bearings must be properly ad­ justed (par... Correct any lubricant leakage. WHEEL BEARINGS.............. Steering bell crank .. Keep vent cleared of dirt. and steering control rods (par.. wheel bearings. a..... Lubricant capacity .. 133). Keep all mounting bolts tight.... Report to higher authority any caster and camber trouble.. 128.. or unusual noises.. Tapered roller Tapered roller 1/4 qt 127.. Check wheel toe-in periodically. Using Puller (41-P-2905-60) 18)... nut. a. Pry off hub cap (fig..TM 9-803 126-128 FRONT AXLE Steering knuckle ... and steering control as required (par. 128).

Drive or press out inner bearing along with oil seal. Turn wheel over. Remove lock washer. A slight perceptible shake should be felt in the bearings. nut. Remove driving flange screws and using puller. Remove wheel bearing nut and bearing lock washer. Shake wheel until outer bearing comes free of hub. NOTE: Do not lose flange shims. Measure clearance between nut and flange. and drive or press out outer bearing cup. 184 . Back off nut about one-sixth turn.050-inch thickness gage will go between hub and nut.035 inch. Spin wheel and tighten wheel bearing nut until wheel binds. Lubricate outer bearing cone and roller assembly. WHEEL GREASE RETAINER. Bend lip of nut lock washer away from nut. or more if necessary. With puller. and lift off wheel. Removal. and washer. Install bearing in hub. b. a. Install lock washer and lock nut. e. Remove axle shaft nut cotter pin. Adjust wheel bearings.TM 9-803 128-129 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) washer. and complete installation of parts (subpar. NOTE: Before installation. Check adjust­ ment of bearings by gripping front and rear side of tire and moving it from side to side. and cotter pin. correct thickness of shim pack (with Rzeppa joint disregard these instructions and use 0. Swing wheel to maximum left or right. Press bearing cups solidly into place in hub. and wash all parts in dry-cleaning solvent. 78). Loosen wheel stud nuts. NOTE: Do not lose flange shims. and deduct amount from 0. Install flange shims and flange. Install new hub cap. Bend lip of nut lock washer away from lock nut and remove nut.015 inch or more than 0. Raise front of vehicle so that tire clears floor. 77). Install axle shaft lock washer. pull off flange (fig. Shaft will move in by the amount of end play when end is tapped with soft hammer. b. Remove lock nut with box-type socket wrench (fig. Remove retainer as outlined in paragraph 128 b. Back off nut until 0.soak seal in oil to soften leather. Install wheel on axle. until seal is even with end of hub. Spread 'A6-inch layer of lubricant inside hub to prevent rust. NOTE: Wheel studs have left-hand threads on left side of vehicle. lock washer. NOTE: Bend over lip of lock washer against lock nut. until wheel turns freely.060-inch shim pack).050 inch to determine end play. Installation. Clean lubricant out of hub. a above). Remove wheel stud nuts and remove wheels. If less than 0. Press oil seal into hub (with lip of seal toward bearing). pull flange. Install retainer as outlined in paragraph 128 c. 129. Removal. NOTE: Pack lubricant thoroughly into bearing rollers and cage. Installation. have punch mark on end of axle shaft up or down. nut. Remove driving flange screws. Install outer bearing. Check axle shaft end play by tightening flange nut without the lock washer. Pry off hub cap. Remove lock washer. and nut. Thor­ oughly lubricate inner bearing cone and roller assembly.

Removal. Using Wrench (41-W-3825-200) 131. 128 e). BRAKE DRUMS. a. 79). Remove screws holding oil seal in place. Install drum and wheel hub as outlined in para­ graph 130 b. Installation. a. 132. Installation. Install hub on axle and mount wheel (par. Support studs and swedge shoulder over against tapered hole in hub. Remove wheel and hub (par. Remove wheel hub and drum as outlined in para­ graph 130 a. 148). Support b1rake drum inside at hub. and drive out studs. Grease 185 . NOTE: Left-hand thread studs are used in wheels for left side of vehicle. STEERING KNUCKLE HOUSING OIL SEAL. Removal. Raise front of vehicle. a. Adjust brakes (par. Remove brake drum. b. b. 128 b). Installation. Install new wheel studs. NOTE: Before installing new oil seal smooth sphericalsurface of axle with aluminum oxide abrasive cloth. b. :I RA PD 305235 Figure 78-Removing Lock Nut. and remove both halves of oil seal assembly (fig. Assemble brake drum on hub.TM 9-803 130-132 FRONT AXLE 130. WHEEL HUB. Removal.

and tighten in place. Clean all parts in dry-cleaning solvent. a. and stake edge of hole at large end. Remove cotter pin in bell crank stud and remove nut. Drive tie rod ends out of bell crank. Remove slotted adjusting plug (ball seat). and install on stud. remove thrust washer. Removal. a. Drive tapered pin into position. b. 135). Lift rod off bell crank ball. Install seal in place so that ends fit snugly together. Check lubricant level in steering knuckle housing. Installation. and remove dust washers and springs. and secure with nuts and cotter pins. Drive out tie rod ends from steering arms. 18). Lubricate roller bearings. NOTE: Do not lose dust washers and springs. Drive stud up out of axle. Install 186 . Removal. Check wheel alinement. Remove tie rod cotter pins and nuts from tie rod ends (fig. also oil seal. and thrust washer. 133. Remove cotter pin in front end of steering connect­ ing rod. and adjust if necessary (par. STEERING TIE ROD. Install thrust washer on stud. Remove bell crank. To remove bell crank stud. drive stud into axle so that slot will line up with tapered pin hole. Install tie rod ends in steering knuckle arm and bell crank. DRAG LINK BELL CRANK. Installation. b. If bell crank has been removed. 75). RA PD 305240 Figure 79-Steering Knuckle Oil Seal 134. and replenish if necessary (par. dust washer. Remove cotter pins and nuts on tie rod ends at bell crank.TM 9-803 132-134 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) spherical surface of axle. Install dust washers and springs on tie rod ends. and drive out tapered lock pin toward left front wheel.

135. Use straightedge or line against outside of left wheels. :' RA PD 305252 Figure 80--Brake Hose b. c' a. Install tie rod ends in bell crank arm. Check front wheel toe-in. dust washer. set tie rod arm of steering belt~crank at right angles to front axle. and cotter pin. notify higher authority. Caster and Camber. and adjust if necessary (par. nut. 135).TM 9-803 134-135 FRONT AXLE thrust washer. WHEEL ALINEMENT4-TOE-IN). To adjust toe-in. Wheel toe-in is the difference in distance between the front wheels at the front and at the rear of the axle. While bell crank remains at right angle to axle. Adjust left tie rod so that left wheel is straight ahead. Toe-in. If these condi­ tions reauire attention. Caster is the backward tilt of the axle. check right front wheel. Install steering con­ necting rod. as a guide. and secure each with nut and cotter pin. Set toe-in of front wheels at %4 inch to %2 inch by shortening right tie rod approximately one turn. t 187 . and adjust tie rod if necessary. Camber is the outward tilt of the wheels at the top.

Spread spring until axle assembly will clear. Install dust cover on bell crank. Raise front of vehicle. Remove jacks from under springs. Remove spring pivot bolt at rear end of right spring. Remove jacks from under springs. Lubricate front axle universal joints. Attach brake hose at axle. Attach propeller shaft. plates. and remove. 188 . Loosen wheel stud nuts. 128 a). Remove brake hose from axle. and check axle lubricant (par. a. Remove jack from between left spring and frame. 18). INSTALLATION. Fill master cylinder. Remove master cylinder inspection cover on toeboard between foot pedals.nect steering connecting rod at bell crank. Draw universal joint U-bolts up evenly. Lower vehicle to floor. and support underframe side members at rear of spring pivot brackets. Position axle on springs. Install axle assembly on springs. Replace master cylinder inspection cover. Jack up front springs. Connect brake hose at cross member. and nuts. 147). Adjust brakes if necessary (par. Remove wheels. 151). Re­ move universal joint U-bolts at front axle.TM 9-803 136-137 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 136. REMOVAL. Jack up springs. and bleed brakes (par. and install spring clips. Install right spring pivot bolt. Disconnect brake line at front cross member (fig. and attach steering connecting rod. Discon­ . 137. Remove axle spring clip nuts and clips. a. Move axle assembly to the right. Install wheels and adjust (par. 80). Install a jack between left spring and frame.

........................ Rear axle replacement ... Differential type ....... two-pinion differential................ The axle shafts are splined to fit into the differential side gears... .............. 138 139 140 141 142 ............................... 87/1o in.............. The differential carrier housing is offset to the right so that the propeller shaft will have a straight drive from the transfer case........ ........................ Spicer 23-2 4......... b......... Differential bearings .... Hotchkiss (through springs) Type .......................... 81) is a full-floating type enclosing a single-reduction driving unit.... a.................... Wheel bearings ................ and hypoid-drive gears.... A cover provides easy access to the differential............................................................88 to 1 Full floating .. Wheel bearing grease retainer .... Drive ....... Make and model ............... The rear axle (fig............. Road clearance ............. Axle shaft ................. The wheel bearings are adjusted by two nuts threaded onto the axle tube........... Data................... 189 Two-pinion Tapered roller ........................ Drive gear ratio .. Description... 143 144 145 RA PD 305254 Figure 81--Rear Axle 138. and flanged at the outer end where they attach to the wheel hub................. Wheel hub .TM 9-803 138 Section XXVI REAR AXLE Paragraph Description and data .....................unit...... DESCRIPTION AND DATA. Brake drum ........ Maintenance ..

a. Removal. 18). Replace damaged drums and hubs (par. Wheel bearings must be properly adjusted (par. MAINTENANCE. Correct any lubricant leakage. a. Pull out axle shaft (fig.TM 9-803 139-140 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) RA PD 305272 Figure 82-Rear Wheel Hub 139. 141). Report unusual noise to higher authority. Remove six axle shaft flange screws and lock washers. 143). 82). 190 . Lubricate differential and wheel bearings as required (par. Keep vent cleared of dirt. AXLE SHAFT. Keep all mounting bolts tight. 140. and remove flange gasket.

WHEEL BEARING GREASE RETAINER. Press bearing cups solidly into place in hub. b. Install axle flange screws and lock washers. Adjust wheel bearings. WHEEL BEARINGS. 141 a). Install axle shaft (par. 140 a). Installation. Spin wheel. Drive or press out bearing cups from hub. and complete installation of parts (par. Remove wheel stud nuts. Place brake drum on hub. Remove wheel and. and replace if unserviceable. Check brake action. and remove nut with box-type socket wrench (fig. and drive out studs. NOTE: Wheel studs have left-hand threads on left side of vehicle. NOTE: Bend over lip of lock washer against lock nut. 143. hub as outlined in paragraph 141 b. NOTE: Before installation. Remove axle shaft (par. b. Shake wheel until outer bearing comes free of hub. and remove nut with box-type socket wrench (fig. 78). Remove retainer as outlined in paragraph 141 b. Installation. 141. Take care not to damage inner oil seal in axle housing. Remove lock washer. 140 b). and tighten securely. Removal. Press oil seal into hub (with lip of seal toward bearing) until seal is even with end of hub. Clean old lubricant out of hub. Drive or press out inner bearing along with oil seal from wheel hub. Tighten wheel stud nuts securely. Install bearing in hub. Install retainer as outlined in paragraph 141 c. Examine parts for excessive wear or damage.TM 9-803 140-143 REAR AXLE b. Lower vehicle to floor. Install wheel on axle. 141 c). Install axle shaft in axle housing. and raise wheel so that tire clears floor. c. Adjustment. Install hub on axle and mount wheel (par. Installation. Loosen wheel stud nuts. if necessary. Bend lip of lock washer away from lock nut. Remove bearing adjusting nut and bearing lock washer. and wash all parts in dry-cleaning solvent. Remove lock washer. Install outer bearing lock washer and nut. Install new axle shaft flange gasket. and remove wheels. 191 . Check adjustment by shake of wheel. Removal. Thoroughly lubricate inner bearing cone and roller assembly. Back off nut one-sixth turn or more. b. Support studs and swedge shoulder over against tapered hole in hub. WHEEL HUB. 140 a). a. Spread 'A6 -inch layer of lubricant inside of hub to prevent rust. NOTE: Left-hand thread studs are used in wheels on left side of vehicle. Remove axle shaft (par. rotating shaft so that shaft will enter differen­ tial side gear. support brake drum at hub. Install new wheel studs. Install lock washer and lock nut. 142. Lubricate outer bearing cone and roller assembly. 78). Installation.soak seal in oil to soften leather. until wheel turns freely. and tighten wheel bearing nut until wheel just binds. a. NOTE: Pack lubricant into bearing cage. To remove brake drum from hub. Place jack under axle housing. Raise vehicle so that tire clears floor. Removal. a. Bend lip of lock washer away from lock nut. and lift off wheel.

clips. Adjust brakes if necessary (par. place between frame and spring. 145. REAR AXLE REPLACEMENT. and nuts. Attach brake hose at axle. Position axle on springs. a. 148). a. Remove wheel hub and drum as outlined in para­ 143 a. Raise rear of vehicle and support underframe side member just ahead of spring pivot brackets. Tighten nuts securely. and plates. lock washers. Remove jacks from between springs.TM 9-803 144-145 ¾/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 144. Remove axle. sliding it to left until right end clears spring. and spread spring. Install spring clips. Remove jacks from under springs. graph BRAKE DRUM. Remove universal joint U-bolts at rear axle. Check axle lubricant. Attach propeller shaft. Installation. then at frame cross member. 192 . Draw universal joint U-bolts up evenly. then slide to right and remove. Re­ move wheels. Disconnect brake hose at frame cross member. Installation. plates. Removal. and bleed brakes (par. b. 151). Remove master cylinder inspection cover on toeboard between foot pedals. Install axle assembly on springs. Remove brake hose at axle. Install wheels. Loosen wheel stud nuts. Remove jacks from under springs. Replace master cylinder inspection cover. Place jack under each rear spring. graph b. Fill master cylinder. Remove spring clip nuts. Install drum and wheel hub as outlined in para­ 143 b. and place under each spring. Lower vehicle to floor.

Data.. Wheel cylinder .. 9 in... and to limit the release action....... operates a piston in the master cylinder to force brake fluid through the lines to the brake cylinders in the wheels. or as an emergency brake..... Pulling out on the lever draws a flexible cable through a conduit to actuate an external contracting brake band at the rear of the transfer casei the brake cable is of a predetermined length.................... hydraulic Type ...... the brake band lining will be worn to the point where replacement is necessary................................... 1 inch Size .... system is of the hydraulic type with brakes in all four wheels (fig...... Adjustments are provided on the brake to set the band correctly........... or hand brake........ Adjustments are provided to com­ pensate for wear of the brake linings................. 3/4 in.............. forcing them apart to apply the brake shoes against the drums......fluid enters the wheel cylinders between two pistons of equal diameter.. double-anchor type.......... Size ....... The parking......... x 13/4 in............................... The brake pedal.... and cannot be adjusted... Flexible lines............. 193 ... 1 in.... When adjustment is required.... The hand brake is designed for parking the vehicle. b..... Service brakes: Four-wheel........ are of the two-shoe.. Description...... Master cylinder: Combination reservoir and cylinder Type ... rear. The hand brake lever is located at the center of the instrument panel....... Re­ leasing the brake pedal permits the brake fluid to flow back through the lines to the master cylinder........ Parking (hand) brake ...... through a connec­ tion. or foot brake....... The ....... The service........ 146 147 148 149 150 151 152 146.......... Service (foot) brakes .TM 9-803 146 Section XXVII BRAKES Paragraph Description and data ............. I qt Fluid capacity ..... The service. Size .......... hoses and connections .. ........... or foot brakes...... a...... DESCRIPTION AND DATA.......... Wheel cylinders: Straight bore Type ................................... is cable-controlled and mounted on the rear side of the transfer case (fig............ Maintenance and adjustment ... 84).... Front.............. 83).. Master cylinder ................

~~~~~~~~~~~~~~~~~~~~~~~. a~~~~~~~~~~~& Ca o z 0 E~~~~~~~ .TM 9-803 146 'A-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) a Z Mt %~~~~~~~~~~~~~~~ el~~~~~~~~~~~~~~~~ D u _ =v. "~ 2~~~~~~~~~~~~ 0 < < F w~~~~~~ IY . ~04~O ­ ~~~~~~~~~~~~~~~~o~ .U .z 7= I 4 04 04 04 5 V) Z 04 04~~~0 I 0 Lz ~ 0~~~~~~~~~~~~ I J-. I14 ~ 9 194 .

.......... %2 in.. 2 in........ 'MAINTENANCE AND ADJUSTMENT...................................... 189/ 6 in........ The service. 316 in...TM 9-803 146-147 BRAKES CABLE AND CONDUIT HANDLE SUPPORT QUADRANT BAND AND LINING RELEASING SPRING RELAYICRANK RA PD 305256 Figure 84-Parking (Hand) Brake System Brake shoes: Lining length-forward shoe (moulded).. Lining length-reverse shoe (moulded).... 107/32 in... Hand brake: Mechanical Type ........ or foot... a.. Keep master cylinder sup­ 195 .................. brakes require periodic checking of the brake fluid supply in the master cylinder.. Thickness .. Width ....... Thickness ............. 639%4 in.............. Width .................. 147.......................... 13/4 in.......... Lining length (woven) .....

Wheel bearings and brakes must be properly adjusted to provide emergency stops. Place wrenchl on ecCentfic sd 196 . Brake control linkage must be free to operate. Brake back­ ing plate screws and axle spring clips must be kept tight. SERVICE (FOOT) BRAKES. Brake anchor bolt and eccentric adjustment bolt lock nuts must be kept tight. hoses. Raise vehicle until tires clear floor. a. Scored brake drums or saturated brake linings must be replaced. Loosen eccsptriclock nu t on forward shoe of one brake (fig. and connections must be tight and leakproof. Follow procedure outlined in paragraph 148 to adjust brakes when lining has worn so that brake pedal goes almost to the toeboard. 152).TM 9-803 147-148 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) plied with fluid to avoid air entering the lines.'86). Adjustment (minor). NOTE: Do not adjust brakes when drums are hot. RA PD 305260 Figure 85-Wheel Brake b. Brake pedal must have Y2-inch free travel to assure full release of brakes. Clean brake drums when wheels are removed. 148). 148. and should be inspected periodically for condition. Three adjustments are provided on the hand brake (par. All brake lines. Adjustment. Set lock nut securely. Adjust brake pedal free travel by lengthening or shortening brake master cylinder eyebolt so that pedal has I2-inch free play (par. Adjust brake pedal free play to onehalf inch by lengthening or shortening brake master cylinder eye­ bolt.

Lower vehicle to floor. or to the rear. and tighten lock nut.008-inch thickness gage through slot in brake drum. and turn drum so that gage is at upper (toe) end of forward brake lining. and tighten lock nut. Make the same adjustment on the other wheel brakes. until brake drags. and turn wrench handle toward wheel rim. NOTE: Do not adjust brakes when drums are hot. Turn wrench in opposite direction until wheel turns freely. Hold wrench on eccentric. 149). Insert 0. Hold wrench on eccentric. and turn wrench toward wheel rim. and remove wheels from hubs.TM 9-803 148 BRAKES BRAKE SHOE ECCENTRIC BLEEDER SCREW ANCHOR PIN ~~- -~- ~ RA PD 305261 Figure 86-Wheel Brake Adjustment Points that handle extends up. Rotate wheel. or forward. NOTE: Check clearance I inch 197 . b. Replenish brake fluid in master cylinder (par. Rotate wheel. Place wrench on eccentric with handle up. Loosen eccentric lock nut on reverse shoe. Apply brake pedal to test brakes. Raise vehicle until tires clear floor. Adjust brake pedal free play to onehalf inch by lengthening or shortening brake master cylinder eye­ bolt. Turn wrench in opposite direction until wheel turns freely. until brake drags. Set lock nut securely. Remove wheel stud nuts. Adjustment (major).

Place wrench on eccentric so that handle is up. Loosen eccentric lock nut on forward brake shoe.005-inch clearance is obtained by feel of gage. until 0. Turn brake drum so that gage is at lower (heel) end of forward brake shoe _A Ct T C BBH A B C D E F G SHOE AND LINING ASSEMBLY-REVERSE ANCHOR PIN ECCENTRIC ECCENTRIC LOCK WASHER ECCENTRIC NUT RETURN SPRING ANCHOR PIN PLATE H I J K L M N O SHOE AND LINING ASSEMBLY-FORWARD LINING TUBULAR BRASS RIVET LINING-FORWARD ANCHOR PIN CAM ANCHOR PIN LOCK WASHER ANCHOR PIN NUT BACKING PLATE ASSEMBLY LINING-REVERSE RA PD 30527) Figure 87--Wheel Brake Shoes. Place wrench on eccentric so that handle is up. and turn wrench handle toward wheel rim. and turn wrench handle toward wheel rim. until 0. Place wrench on anchor pin with handle down.TM 9-803 148 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) from end of lining.198 . or to the rear. or forward. Place wrench on anchor pin with handle down. .008-inch clearance is obtained by feel of gage. Hold wrench on eccentric. turn wrench toward rim. Turn brake drum so gage is at lower end of reverse brake shoe lining. until 0. and punch mark on end of anchor pin toward other anchor pin. Loosen eccentric lock nut on reverse shoe. and tighten lock nut. turn wrench handle toward rim. Follow same procedure on the other three brakes. or to the rear.005-inch clearance is obtained by feel of gage.008-inch thickness gage. Hold anchor pin and tighten lock nut.005-inch gage in slot. or forward. Check amount of fluid in master cylinder (par. and tighten lock nut.008-inch clearance is obtained by feel of gage. Disassembled lining. Turn brake drum so that gage is at upper end of reverse brake shoe lining. Hold anchor pin and tighten lock nut. and insert 0. Loosen lock nut on anchor pin of forward shoe. Remove 0. Loosen anchor pin lock nut on reverse shoe. and punch marks on ends of anchor pins toward each other. Hold wrench on eccentric. until 0.

Lower vehicle to floor. FILLER CAP SUPPLY TANK CUP RING ­ PISTON STOP INTAKE PORT Y-PASS PORT- ­ RETAINER SPRING . and mount assembly on brake backing plate. Raise hood and disconnect battery ground at battery terminal. Remove wheel hubs (pars. Removal of Brake Shoes and Linings. Install hubs (pars. Remove brake shoes. Install cam in brake shoes. Pull stop light switch wires out of terminal on switch. Remove brake shoe anchor pin cam./' P1 '~/ ISTON PRIMARY CUP CHECK VALVE VALVE SEAT RA PD 305258 SECONDARY CUP BOOT RETURN SPRING Figure 88-Master Cylinder d. Install brake return spring. lock washers. Install anchor pin plate on anchor pins. Remove brake shoe return spring. Installation of Brake Shoes and Linings. 149 b). Loosen eccentric lock nuts (fig. Remove two bolts holding master cylinder shield and re­ move shield. Remove stop light switch. Inspect exterior of wheel brake cylinder for leakage of brake fluid. NOTE: Forward shoe has longest lining. and anchor pin plate from backing plate. Install wheel. replace cylinder assembly (par. Removal. BOOT . If leakage is apparent. Raise vehicle. Install brake cylinder clamp to hold pistons in place. Remove anchor pin nuts. 87). 149. 150). Install brake anchor pin lock washers and nuts. Do not tighten anchor nuts. 128 and 141).TM 9-803 148-149 BRAKES 149). and apply foot brake pedal to test brakes. MASTER CYLINDER. Remove 199 . install pins in brake shoes. c. Make major brake adjustment (par. 128 and 141). anchor pins. Bleed brakes if soft pedal is experienced (par. Remove outlet fitting screw. a. Turn eccentric so that low side is against the shoes. NOTE: Turn brake anchor pins so that punch marks on ends are toward each other. and remove brake cylinder clamp. 151).

WHEEL CYLINDER. 151). Remove brake shoe return spring. 4---" BOOT CYLINDER PISTON ASSEMBLY BLEEDER SCREW I CUPSPRING CYLINDER CUP RA PD 305259 Figure 89-Wheel Cylinder and tighten rear bolt. Install tie bar and rear bolt on master cylinder. Raise vehicle so that tire clears floor. Insert stop light wires in terminals. Install cotter pin in pedal shaft. Lower hood and hook. Remove wheel and hub (pars. Removal. Attach battery ground cable. Install eyebolt link in cylinder.TM 9-803 149-150 ¼/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) master cylinder front screw attaching cylinder to frame. Remove master cylinder and tie bar. Install outlet fitting bolt. 128 and 141). Remove tie bar from master cylinder. b. Install master cylinder shield with two bolts. Install master cylinder front screw. Install master cylinder boot with drain hole down. and install master cylinder in frame with tie bar on pedal shaft. a. Spread shoes until clear of brake cylinder. Disconnect brake tube at 200 . Bleed brakes (par. 150. Remove master cylinder rear bolt nut. Installation. Install stop light switch. Remove master cylinder boot (fig. 88). Remove cotter pin holding master cylinder tie bar on pedal cross shaft. Fill master cylinder with brake fluid.

Apply foot brake pedal to test brakes. Screw brake hose into T-connection on rear axle housing. With screwdriver. Screw brake hose lower fitting into T-connection on axle. Attach brake tube connection.TM 9-803 1'50-151 BRAKES backing plate. s below). Installation of Rear Brake Hose. Installation of Brake Hose at Front Wheels. if soft pedal is experienced. Removal of Master Cylinder to Front Hose Brake Tube. Bleed both rear brakes (subpar. upper end of hose. Remove brake tube connection frame cross member. Remove fitting from bracket. s below). Remove clip on underside of frame rear cross member. Connect tube at master cylinder. Attach brake tube connections. AND CONNECTIONS. Bleed front brakes (subpar. Lower vehicle to floor. Installation. s below). and remove tube. Place cylinder in position on backing plate. HOSES. if soft pedal is experienced. 89). Removal of Brake Hose at Front Wheels. Connect tube at brake hose (frame to front axle). i. bleed all brakes. and drive spring lock into fitting. Disconnect tube from master cylinder connection. c. Replace wheel and hub (pars. if soft pedal is experienced. b. With screwdriver. Attach tube connection. Press brake pedal. Insert hose fitting into frame. s below). Unscrew hose fitting from T-connection on rear axle housing. Installation of Brake Hose at Frame and Front Axle. drive brake hose spring lock off hose fitting. if soft pedal is experi­ enced. and install spring lock. bleed all brakes (subpar. Attach brake tube. Bleed brake (par. Removal of Master Cylinder to Rear Hose Brake Tube. Enter brake shoes in slots of cylinder pistons (fig. Install tube clip at frame. Remove clip from frame. a. Remove hose from frame. Remove brake tube connection at frame bracket. and remove hose. bleed all brakes. Remove clip 201 . Install brake shoe return spring. Place hose in brackets and drive locks into place in the fittings. Insert upper fitting into bracket. FLEXIBLE LINES. Remove two screws holding cylinder to backing plate. f. g. Unscrew brake hose lower fitting from T-con­ nection on axle and remove. 151. and attach with two screws and lock washers. Remove brake tube connections at each end. Installation of Master Cylinder to Front Hose Brake Tube. If soft pedal is experienced. With screwdriver slip hose lock off ends of hose fitting. Press brake pedal. Bleed both front brakes (subpar. h. 151). Removal of Rear Brake Hose. 128 and 141). d. Disconnect tube from brake hose fitting (frame to axle). Press brake pedal. and remove cylinder. e. bleed all brakes. bleed all brakes. remove hose spring lock from fitting at bracket. b. Press brake pedal. Removal of Brake Hose at Frame and Front Axle. Bleed brake.

Withdraw tube to rear of vehicle. Connect tube to master cylinder. m. bleed all brakes. if soft pedal is experienced. Installation of Tee to Front Hose Brake Tube-Right. Press brake pedal. Bleed right front brake (sub­ 202 . k. bleed all brakes. Install tube in frame rear cross member. and install master cylinder shield. Con­ nect brake tube at tee connection. s below). Installation of Tee to Front Hose Brake Tube-Left. Disconnect tube at brake hose fitting and remove tube.EEDER SCREW BLEEDERHOSE RA PD 305263 Figure 90-Bleeding Brakes 1. Remove master cylinder shield. s below). Connect tube at brake hose fit­ ting. Connect tube at hose fitting. Install tube in frame side member. Disconnect tube at tee connection. Installation of Master Cylinder to Rear Hose Brake Tube. Removal of Tee to Front Hose Brake Tube-Right. Install clips and clamps on axle. Disqpnnect tube at master cylinder. Con­ nect brake tube at tee connection. Discon­ nect tube at hose fitting and remove tube. Disconnect tube at rear brake hose. Install tube clips on frame side member and rear cross member. Remove clips and clamps on axle. Removal of Tee to Front Hose Brake Tube-Left. n. and attach to hose fitting. Press brake pedal. if soft pedal is ex­ perienced. A . j. Disconnect brake tube at tee connection. Bleed left brake (subpar. Bleed rear brakes (subpar.TM 9-803 151 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) on frame side member.

Disconnect tube at wheel cylinder and remove tube. Install clamp on axle. Removal of Front Wheel Cylinder to Hose Brake Tube. bleed all brakes. o. s. Attach brake tube to wheel cylinder. Attach tube to hose fitting. if soft pedal is experi­ enced.TM 9-803 151 BRAKES par. Bleeding Brakes. Remove tube clamp on axle. Dis­ connect tube at brake hose. if soft pedal is experienced. r. if soft pedal is experienced. s below). Removal of Tee to Rear Brake Tube-Right. Attach brake to wheel cylinder. bleed all brakes. Remove screws holding brake master cylin­ der inspection cover to toeboard between foot pedals and remove 203 . Bleed brake (subpar. s below). p. bleed all brakes. Installation of Tee to Rear Brake Tube. Bend tube slightly and remove. Press brake pedal. Press brake pedal. BRAKE CAM ANCHOR ~~~~BRACKET BE~~OLT~~ aADJUSTING NUT RA PD 305264 Figure 91-Parking (Hand) Brake q. Disconnect brake tube at tee connection. Installation of Front Wheel Cylinder to Hose Brake Tube. Press brake pedal. Disconnect tube at wheel cylinder. Attach tube to tee connection. s below). Bleed brake (subpar.

Install brake band on drum. Tighten bleeder screw and remove hose. Place hand brake grip in released position. Reach through hole. Loosen adjusting nut so that brake band has approximately 0. Place 0. 90). Remove brake adjusting bolt and spring. the left front brake. 204 . a above). Remove lock wire from anchor adjusting screw (fig. Replace cap temporarily. Remove anchor bolt lock wire. Install retracting spring. Attach bleeder hose to right rear wheel cylinder bleeder screw. Remove bracket bolt. allowing it to return slowly. Replenish master cylinder brake fluid supply. then the left rear. Adjust brake (subpar. a. b. Install anchor bolt. Tighten adjusting nut until brake band is tight around drum. Remove cotter pin from brake cam clevis pin and remove pin. Loosen bracket bolt lock nut and rear nut. Press brake pedal by hand. and adjust screw to secure clearance. Removal of Parking (Hand) Brake Band. and clean around master cylinder filler cap. Install brake release spring and adjusting bolt. 91). Install lock wire. Install filler cap and inspection cover.TM 9-803 151-152 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) cover. Open bleeder screw a three-quarter turn. Remove anchor bolt. Install bracket bolt and nuts. Install cotter pin in clevis pin. and finally. Remove brake band adjusting nut.010-inch clearance on drum. Install brake band adjusting nut. Adjustment. Follow the same procedure on the right front brake. and remove brake band assembly. Clean all bleeder connections at wheel cylinders (fig. Continue action until air bubbles cease to appear at end of bleeder hose. Re­ move retracting spring. Remove cap and fill master cylinder with brake fluid. 152.005-inch thickness gage between band and drum at anchor screw. Install clevis pin in brake cam and head of adjusting bolt. Check brake levers to see that cable is free and released. Installation of Parking (Hand) Brake Band. PARKING (HAND) BRAKE. and place end in a glass jar or bottle so that the end is sub­ merged in brake fluid. Back nut off two turns and set lock nut. c.

.. but RA PD 305265 Figure 92-Left Front Spring have different load carrying ability.. the rear spring is shackled at the rear end............. direct-acting............ The left spring has an "L" painted on the underside of the second leaf at the front end.. 205 . The shock absorbers are of the hydrauliccylinder type.................. two-way control............... adjustable. Four spring leaf clips keep the leaves in alinement.... Spring shackles and bolts .... and refill­ able..................... and hold the leaves together to take the rebound. The left-hand threaded shackle ends and bushings are used in the spring eye of the left front spring and right rear spring.... Shock absorbers .. a............ The shackles are of the threaded U-bolt type with threaded bushings having rightand left-hand threads....... The left-hand threaded bushings have a groove cut around the hexagon head....... Left-hand threaded shackles have a small forged boss on the lower shank of the shackle............ Description... The front spring is shackled at the front end................. 92 and 93) are of the semielliptic type with the second leaf wrapped around the spring eye of the first (main) leaf............. 153 154 155 156 157 153.......... The left front spring is equipped with a torque reaction spring to stabilize the front axle in extremely rough service..........TM 9-803 153 Section XXVIII SPRINGS AND SHOCK ABSORBERS Paragraph Description and data ..... The springs (figs............... Maintenance . DESCRIPTION AND DATA. Springs ..... The front springs appear to be identical.. A spring pivot bolt attaches the opposite end of the spring to the frame...

. Rear Rear Springs 42 in............ 8 ..... Length-center line of eyebolts.......... 9 Number of leaves ............................................. Spring center bolt......... 13/4 in.............TM 9-803 153 1/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) RA PD 305266 Figure 93-Left Rear Spring b........ Width ........... Front Spring eye bushed ......................................... At center Spring center bolt ............... Width .... 13/4 in........ Length-center line of eyes ...... At center Spring eye bushed.......... Number of leaves.... 206 .... Front Springs 36Y4 in................ Data....................................

................................ a......... MAINTENANCE......... SPRING SHACKLES AND BOLTS..... 94).... Spring bushings and shackles must be free to move. Rubber bushings A B A B C D E F COTTER PIN SPRING BOLT NUT REAR SPRING ASSEMBLY-RIGHT SPRING BUSHING SPRING BOLT HYDRAULIC GREASE CONNECTION RA PD 305280 Figure 94-Right Rear Spring Bolt 154... Replace worn or damaged shock absorber mounting bushings (par.... . .... Lubricate springs to prevent breakage... 207 . Remove nut and drive out bolt (fig... 119/6 in.......... 16'/ in. The springs and shock absorbers should be inspected periodi­ cally in accordance with preventive maintenance (par.. Length-extended-rear Adjustable .. Length-compressed-rear ....... Adjust shock absorbers correctly (par.... 18)... Hydraulic Action . Length-compressed-front ..... 155... a.... Yes Mountings ..... Refillable Double 10% 6 in........ 18/ in............................. Removal of Spring Bolt... .. ............ Length-extended-front .. 157)..............TM 9-803 153-155 SPRINGS AND SHOCK ABSORBERS Shock Absorbers Type .............. 23)........ 157). Yes ....... and excessive wear of spring pivot bolts and shackles (par....... Pull cotter pin in spring pivot bolt nut..... Raise vehicle frame until tires just rest on floor.

Insert shackle through frame bracket and eye of spring. Raise vehicle frame until tires just rest on floor. Install nut and cotter pin. Installation of Spring Bolt. Removal of Spring Shackle. Install shackle grease seal and retainer over threaded end. and start upper bushing on shackle. Drive spring pivot bolt into place with oil groove up. Lower vehicle to floor. Installation of Spring Shackle. giving due attention to right. c. and up to the shoulder. d. Lubricate with high pressure grease gun. Line up holes in spring bracket and spring.threads. and lower bushing hexagon 208 .TM 9-803 155 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) B A D i $eF A B C D E F E SHACKLE BUSHING RIGHT-HAND THREAD SHACKLE GREASE SEAL SHACKLE GREASE SEAL RETAINER SHACKLE U-BOLT SPRING ASSEMBLY SHACKLE BUSHING LEFT-HAND THREAD RA PD 305279 Figure 95-Left Front Spring Shackle b. Then alternately tighten bushings until upper bushing is tight against frame bracket. then start lower bushing. Run bush­ ing in about half-way. Remove shackle bushings (fig. Run in about half-way. NOTE: Lefthand threaded bushings are used in spring end of shackles on left front spring and right rear spring.and left-hand. holding shackle tightly against spring eye. 95). Hold shackle tightly against frame.

TM 9-803 155-156 SPRINGS AND SHOCK ABSORBERS head is about 1/32 inch away from spring eye. Raise vehicle. 60 to 65 foot-pounds. and place center bolt in spring saddle on axle. which must be free. Install shackle (par. torque reaction spring bolt. 155 b). SPRINGS. nuts. and lock washers. RA PD 305267 Figure 96-Shock Absorber b. 27 to 30 foot-pounds. or torque spring. 156. 155 d). NOTE: Axle spring clip nut torque wrench readingshould be 50 to 55 foot-pounds. Remove spring plate. and try flex of shackle. Removal. spring pivot bolt nut. Install spring pivot bolt (par. Install axle spring clips and nuts. and pivot bolt lock. If tight. Remove spring shackle and pivot bolt (par. 155). Lubricate bushings. Remove four axle spring clip bolt. 209 . Installation. Remove spring. a. remove bushings and reinstall.

96). Install inner mount­ ing rubber bushing on upper and lower bracket pins. and pull off shock absorbers and rubber bushings (fig.. Install outer bushing and flat washer. NOTE: Turn end clockwise for firmer control. Check shock absorber adjustment. Installation. SHOCK ABSORBERS. then turn end counterclockwise two turns for average adjustment. Turn end in clockwise direction until limit of adjustment is reached. compress shock absorber. allowing faster spring action. and install cotter pin. b. 210 . install sbocl absorber. and turn one end to engage adjusting keys in slots. O'ii'ng 'pressor (41-C-2554-400) to compress bushing. a. and counterclockwise for softer control. Use 'om-. Remove washers. Removal.TM 9-803 157 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 157. Pull cotter pins holding upper and lower washers against rubber bushing on mounting brackets. Spread both ends of cotter pin to hold washer evenly in proper position.

.................... The steering gear (figs.............. ............. Steering connecting rod ........ Maintenance ..................... ................. Description........... 98)......... 97 and 99) is of the con­ ventional type......................... Steering gear ........................... mounted on the left frame side member............ The steering wheel is of the 211 158.................... Steering wheel .... The steering gear is of the cam and lever type with a variable-ratio cam.............. and con­ nected to the front axle steering ball crank by a Pitman arm and steering connecting rod (fig..... 158 159 160 161 162 163 td RA PD 305269 Figure 97-Steering Gear-Phantom View DESCRIPTION AND DATA.. Steering Pitman arm ............ ' . a....TM 9-803 158 Section XXIX STEERING GEAR Paragraph Description and data .

. Make and model ... Variable.. 3-spoke. Cam and twin pin lever Ratio ... 212 .............. 23) to include the Pitman arm and steering con­ necting rod.. The steering connect­ ing rod is of the adjustable. (5) Inspect brakes and shock absorbers. Data.. 18) and periodic inspection in accordance with preventive maintenance F C CDE I KHDAUC GRAE F V I A COTTER PIN F DUST COVER B C D E ADJUSTING PLUG-LARGE BALL SEAT SPRING SAFETY PLUG K HYDRAULIC G DUST COVER SHIELD H CONNECTING ROD ASSEMBLY I ADJUSTING PLUG-SMALL J HYDRAULIC GREASE FITTING GREASE FITTING ...... 159.... Maintenance consists primarily of proper lubrication (par........ Disassembled procedures (par.. Ross T-12 Type .... (7) Check toe-in........... with 1754-inch diameter.. (6) ' Check steering assembly and connecting rod.. (2) Inspect king pin and wheel bearing for looseness.... safety type..... MAINTENANCE. (8) Check toe-out on turns.... safety type... b.TM 9-803 158-159 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 3-spoke... a... 14-12-14 to 1 Wheel ..... RA PD 305278 Figure 98-Steering Connecting Rod........ (3) Check wheel run-out.. 17% in. (4) Check for spring sag. A systematic inspection for steering troubles is as follows: (1) Equalize tire pressures and set car on level floor. ball-and-socket type....

Insert ball seat in other end of rod. Screw plug in firmly against ball. and adjusting plug in order. 160. and lock with cotter pin. Lubricate with high pressure gun. back off one-half turn. and ball seat in this end of rod. STEERING WHEEL. spring. or king pin inclination. If steering difficulty is experienced after checking and-correct­ ing the above items. Screw plug in firmly against ball. 161. Install rod on steering Pitman arm. a.TM 9-803 159-161 STEERING GEAR A B FG H i/ A B CD E F G H I J STEERING WHEEL AND HORN BUTTON NUT HORN BUTTON HORN CABLE UPPER TERMINAL CONTACT WASHER INSULATING FERRULE HORN BUTTON SPRING HORN BUTTON SPRING CUP HORN CABLE ASSEMBLY STEERING COLUMN AND BEARING ASSEMBLY COLUMN CLAMP ASSEMBLY T I k L M N O P Q R S T OIL FILLERPLUG STEERING ARM NUT STEERING ARM NUT LOCKWASHER . b. safety plug. Install second ball seat. Removal. Pull cotter pin at each end of rod. b. STEERING CONNECTING ROD. Unscrew plugs and remove rod. and tape end so it will not ground. report to higher authority. and lock with cotter pin. Install adjusting plug. Disassembled (9) Check tracking of front and rear axle. Correct end of connecting rod to be attached to front axle bell crank will have the lubrication hydraulic fitting to the right.. Install safety plug. remove horn wire at steering post ter­ minal. Installation. back off one-half turn. Install rod on bell crank ball. STEERING ARM COLUMN OIL HOLE COVER HORN WIRE CONTACT BRUSH ASSEMBLY COLUMN BEARING ASSEMBLY COLUMN BEARING SPRING SEAT COLUMN BEARING SPRING STEERING WHEEL K /. Removal. caster. (10) Check frame alinement. Raise hood. " P RA PD 305268 Figure 99-Steering Gear. camber. spring. Remove steering wheel 213 . because the trouble may be due to wheel balance. a.

b. Install steering wheel so that one spoke of wheel is in vertical position above steering post. Check steering gear lubricant. STEERING PITMAN ARM. Install horn wire contact brush. Insert upper end of steering gear through toeboard. retainer. Install steering column floor seal. Install steering connecting rod on Pitman arm (par. Loosen steering column clamp bolt. with horn contact brush onening up. Tighten nut securely. and radiator grille. and lift lower end out over frame side member. and tighten 214 . Remove blackout headlight wire clip on fender. Remove steering column to frame bolts. Installation. Set front wheels straight ahead. Pull cotter pin in rear end of steering connecting rod. b. Remove Pitman arm by using wedge type Pitman arm remover. or as follows: Drive a chisel between the arm and the steering gear case at the front Side. Pull steering wheel off with steering wheel puller. turn wheel to left. attach to steering post terminal. Pull steering wheel with steering wheel puller. Remove bolts attaching fender to body. and lift off horn button. Installation. Install steer­ ing column over tube. Remove' headlight wires from junction block on dash. a. 160 b). Drive wheel down on post. strike rear side of arm to loosen it on the tapered serrations. Turn steering wheel maximum distance to right. try horn. a. and remove adjusting plug. Remove headlight wires from junction block on fender splasher. Remove two screws attaching horn wire contact brush assembly to steering column. Install horn button and steering wheel nut. Removal. 162. replenish if neces­ sary. but do not tighten. Installation.TM 9-803 161-163 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) nut. and remove seal and retainer. unscrew adjusting plug. Remove fender support bolts in frame and remove fender. and position in chassis. Raise hood and tie to windshield. Disconnect blackout driving light wire from slip connector at dash. Removal. Pull steer­ ing column up off tube. and remove from Pitman arm ball. frame. and using a bar. and count turns. Turn wheel to right exactly onehalf of the turns. STEERING GEAR. Install lock washer and nut. Remove steering column bracket. Remove steering wheel nut and horn button. Set front wheels in straight-ahead position. and screws. Tighten steering column clamp. Remove horn from bracket. Install steering gear to frame bolts. Remove battery ground cable at post on battery. Take steering connecting rod off Pitman arm ball. Remove bolts in steering column floor seal. 163. Untape horn-wire. Lubricate connecting rod hydraulic fitting. and lower hood. and install Pit­ man arm on steering gear. Remove cotter pin from rear end of steering connecting rod. Remove Pitman arm nut and lock washer. b. Release headlight bracket wing nut and tilt headlight away from fender. Lower upper end of steering column.

Tighten lock nut. adjust screw for minimum backlash of studs in cam groove. Install steering con­ necting rod (par. With front wheels straight ahead. Attach headlight wires to junction block on fender splasher. Install horn on bracket. Install blackout head­ light wire clip on fender. and radiator grille. Attach headlight wire to junction block on dash. 160 b). Tilt headlight. 161 b). report to higher authority. Attach battery cable. For other adjustments. c.TM 9-803 163 STEERING GEAR screws. Connect blackout driving light wire in slip connector at dash. also screws and bolts to frame. and tighten wing nut. Check operation of horn and lights. Loosen lock nut on side adjusting screw. body. Lower hood and lock. Install steering wheel (par. and tighten steering gear to frame bolts. Install fender and support bolts. Connect blackout headlight wire at slip connector. Attach steering column bracket. 215 . Adjustment.

.. Fenders .......... and can be opened forward or folded down on top of the hood.. and windshield and light covers......... Top .......................... Body type ..... and a radiator guard provide protection against damage.............. A pintle hook at the rear provides a means of hauling a trailed load. The chassis has five cross members............... hand-operated /iwpers...... Folding Driver's position ................. The left front seat cushion can be raised to fill the fuel tank............ There are two individual tubular frame front seats and a rear seat.... Left side Cross members ....... Windshield wiper .... Double drop 216 ............ 164 165 166 167 168 169 170 171 172 173 173 174 175 164................. Hood . Shovel and ax ... can rack.......... Description.... The windshield is equipped with dual.............. Hand grips on the side of the body facilitate lifting............................. trailer connection... The rear seat can be raised to reach the tire pump.............................. A strap and sheath carry a shovel and ax on the left side of the body........... curtains. a..... ............ Box-type. iden­ tified by a name plate located on the instrument panel (figs. Rifle holder .... DESCRIPTION AND DATA.. Data.... 1 to 4) is of the open type.... b......... A fire extin­ guisher and an adjustable rear vision mirror are mounted on the left side of the cowl........ the right front seat can be raised forward for stowage of the vehicle removable top............... A rifle holder is mounted on the lower panel of the windshield over the instrument panel..TM 9-803 164 /4-TON 4 x 4 TRUCK (WiLLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XXX BODY AND FRAME Paragraph Description and data ....... Seats and cushions .. ................. and spare tire and wheel are mounted on the body rear panel......... Safety straps are provided in the entrance ways........................ 5 Chassis frame type.. Open Windshield type ....... 5 and 6)...... Tools and accessories are stowed in two compartments in the rear corners of the body............ The fuel tank sets in a sump in the floor pan under the driver's seat................ The vehicle top is supported by top bows which can be folded down along the body sides to form a hand rail........... reinforced frame side members are used for maximum strength......................... Windshield ...... The body (figs.......... Hood ..... Radiator guard .......................... A fuel..................... Maintenance ...... Instruments ..... Bumpers at the front and rear.......... .... the rear intermediate cross member having a gun platform.....

Place rear seat cushion in position. Place seat in position. and remove seatsback. and install five screws in top side. Remove two nuts holding retaining clamp in place. Remove battery ground cable at battery post as a safety precaution. Place seat cushions in position. Remove bolt in tool compartment holding retainer bracket at seat 217 . c. and remove cushion. Removal. MAINTENANCE. a. and lubrication of wearing parts. stones. when it must be installed.TM 9-803 165-167 BODY AND FRAME 165. Removal of Front Seats. Remove 10 screws holding seat back to frame. Remove five screws in top edge of seat back and two in lower edge. Install retain­ ing clamp and nuts. Chassis maintenance concerns primarily. and remove instrument through face of instrument panel. Remove three screws holding back of driver's seat to floor. Keep the body clean and touch up bare spots to prevent rust. On driver's seat install screws and bolts hold­ ing seat back to floor and wheel housing. General maintenance of the body requires periodic tightening of all loose parts. proper lubrication of connecting parts (par. b. and lift out seat. Lift up back edge of rear seat cushion. Remove two bolts holding front of seat frame to floor. and water. Install instrument in place in panel. Procedure for the removal and installation of the various panel instruments is identical. Place rear seat back in position. Removal of Seat Cushions and Backs. Pull edge of seat back up in place. and turn cushion over into place. Remove five screws holding front seat cushion to frame at rear side. Water in the body can be drained by removing drain plugs in the floor at the side of the cowl. 166. Remove connecting wires or tubes. Install screws. Installation of Seat Cushions and Backs. 167. remove five screws holding front edge of cushion to frame. SEATS AND CUSHIONS. Attach tubes or wires. Removal of Rear Seat. Keep the sump under the fuel tank free of dirt. and remove seat back. and install screws. top side down. Place front seat back in position. and as follows: b. d. c. a. and install screws. Remove screw in wheel housing holding seat. Installation of Front Seats. Install bolts in place at front of seat. INSTRUMENTS. and install two lower screws. and lift out seat. Keep the sump front* drain hole cover on so that dirt and water thrown by the front wheel will not enter. Remove two bolts holding right front seat bracket to floor. 18). Pull up front edge of seat to fold seat. and remove cushion. a. Installation. e. Keep the rear drain hole cover in the glove compart­ ment in the instrument panel except when crossing water.

handles. Remove nuts holding wiper handle. and remove holder (fig. b. at the right end of holder. and nuts. a. WINDSHIELD. Stretch top over bow and down to body back panel. Install seat back bracket and bolts. Unhook windshield clamps on instrument panel (fig. RIFLE HOLDER. a. Install retainer bracket. 5). b. and lower front bow on front seat. and install wing screws at sides of cowl. insert butt end of rifle in holder at the left. Install plain washers. Remove two bolts holding rifle holder to windshield lower panel. and turn bumper to left under rifle. Raise bows out of rear brackets. a. Installation. 218 . On same side remove two bolts holding seat back bracket. and snap flaps around bow. Removal. Slide tubular bows back out of front bracket. Install front ends in rear brackets. and tighten winged screws. Clamp windshield to instrument panel. Swing rifle bumper to the right. Place windshield in position. Raise end of seat and lift out. and remove rifle. Installation of Rear Seat. and remove wiper blades. Loosen the two wing screws at the pivot brackets (fig. a. Place seat in position in brackets. and remove handles. Push rifle up against spring pressure. Remove curtains by releasing snap fasteners. Removal. and lift off windshield. TOP. 168. Remove top from under right front seat. 171. insert bolts. The curtains are attached in the conventional way with snap fasteners. Remove wing screws at sides of cowl. Removal. Raise front bow into position at bow flaps. Unbuckle top straps at body rear panel. 170. Unsnap top at top of windshield. Remove plain washer. stretch top. Tighten rear bracket screws. f. 5). Fold top and stow under right front seat. Removal. b. 4). Attach top to fasteners at top of windshield. Fold front bow against rear bow. and remove. and insert lower ends in front brackets. Place rifle holder in position on windshield panel with butt end to the left. WINDSHIELD WIPER. Place straps in metal loops. b. Installation. and attach to body panel. Loosen wing screws in top rear brackets. and buckle straps. Installation. Installation. Un­ snap bow flaps. 169. Install blades and arms in place through wind­ shield frame. and tighten securely. With barrel up. Allow front bow to drop down over seats. Swing the rifle bumper to the right.TM 9-803 167-171 I/ 4 -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) bracket.

of ax up. Remove blackout headlight wires. Remove rubber shield at headlight. Remove blackout headlight wire clip on left front fender. Install screw through bond strap. Insert handle in front clamp. a.TM 9-803 172-174 BODY AND FRAME 172. over grip. Remove blackout headlight rut and washer. NOTE: This will hold the shovel forward in the strap on the cowl side (fig. Install flat washer. over outside of grip. Installation. Remove headlight hinge bolts. and disconnect bond strap. and tighten to cowl. 219 . Remove wires from slip connector at left front fender. Remove headlight wire clips on guard. Install screw through hinge. or blade. Place hood in position and install hinge screws in cowl. Unhook hood and raise against windshield. through loop. Removal. Remove screws in hinge at cowl. a. Pull up clamp under ax head. Lower hood for alinement. Install washer between hinge and hood. SHOVEL AND AX. RA PD 305271 Figure 100-Shovel and Ax Mounting b. Removal. and strap in place. Release straps and remove shovel or ax individually. and buckle. but do not tighten. through handle. Raise hood and tighten screws. a. Wrap fabric strap. RADIATOR GUARD. Remove guard from chassis. 174. 100). clips. b. Remove fender to guard bolts. between grip and side of body. Installation. and loom. 173. Turn bit. Lower hood and hook down both sides. HOOD. Removal. and remove both light and wire assemblies. NOTE: Install bonded screws last as fol­ lows: Install flat washer on screw. Insert blade in sheath. Raise hood. Turn face of shovel against cowl and place in strap on cowl side.

Lower hood and lock down. and tilt light up. Install blackout headlight wire clip on fender. d. Remove voltage regulator bolts. Install voltage regulator. Install fender to guard bolts loosely. Install hood catch. Remove three bolts in blackout driving light bracket. Installation. Install two wire clips to fender splasher. Install loom on wire.. Tighten fender to guard bolts. Installation of Right Front Fender. Install black­ out headlight wire clip (front) on fender. Removal of Left Front Fender. Install washer and nut. Remove junction block on fender. In­ stall other fender bolts and tighten all. Remove blackout driv­ ing light wire grommet and clips from fender. Install shield over wire. install blackout headlight wire clip on fender. Raise hood. Connect wires to slip connector. and secure with wing nut. Remove fender to radiator guard bolts. Check operation of lights. Remove fuel line clip to fender. Install battery to fender strap. Connect wires to junction block at dash and slip connector. Place headlight in position. Installation of Left Front Fender. Install both blackout headlight. Install battery cable. Check operation of lights. Install one fender to guard bolt. Remove two wire clips on splasher. Place fender on chassis. Remove fender shield to frame bolt. Remove wires from junction block. Lower hood and lock. FENDERS. Install hood catch. and wire assemblies on guard. Install frame bolts in guard. Remove fender bolts in support. e. Install junction block to fender. Remove hood catch assembly. body.TM 9-803 174-175 A/-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) b. Remove head­ light bracket wing nut. Install three bolts in blackout driving light bracket and fender. Install wire grommet in fender. Install all fender bolts loosely. Remove battery ground cable at battery post. Remove blackout driving light clip on top of fender. and tilt lamp up. 175. Position headlight. Install headlight wire clips on guard. Install guard upper bolt. Place fender on chassis. Lower hood and lock down. 220 . and tighten wing nut. Raise hood. Install guard to frame bolt nuts. Remove hood catch. Removal of Right Front Fender. b. Install fuel line clip. spacer. Remove battery to front fender strap. and slip connector at dash. Remove blackout headlight wire clip. Remove bolts between fender and guard support. Remove fender. and frame. Install guard on chassis. Remove fender. body. Install headlight hinge bolts. Install one fender to body bolt. Install blackout driving light wire through fender and splasher. Loosen wing nut on headlight bracket. Install wire clips on loom and clips on guard. and frame. a.

............ the lock washers must be placed between the parts to be grounded.... and spark plugs. 177. . Ignition (both high-tension and primary-circuit suppression).... DATA. or confining them within an area where they cannot be picked up by the antenna of a radioequipped vehicle. but not painted. The sources of electrical noise interference may be basically divided into three groups: the ignition system. the hood and side panels form a box within which radio frequency waves are confined to prevent their acting on the antenna of receiv­ ing equipment.. involves the sup­ pression of these waves at their sources.. Their origin can generally be determined by the nature of the noise heard in the receiver. which produces interfering radio waves... Suppression is accomplished by the use of resistorsuppressors. Description..... or disclose the location of the vehicle to sensitive electrical detectors..... Radio interference suppression.. Data .. and condensers... a.. .... is shielded...17. the hood and other metal parts in the vicinity of the engine are made to form a shield by the use of internal-external toothed lock washers and bond straps.. distributor. or may be given off by the electrical systems during operation of the vehicle... 221 .... These waves are actually radiated as disturbing signals that interfere with any radio receiving apparatus that may be operating in the vehicle or immediate vicinity... and replacement .... the generator system..... In attach­ ing condensers and bond straps. including coil... This is necessary to obtain good connections between the component parts...... removal..... In addition.. 76 177 178 179 176.... resistance 10...... DESCRIPTION. Description .... (1) High-tension suppression is of the resistor-suppressor type and consists of: (a) Coil to distributor high-tension wire at distributor.. Electrical disturbances or radio frequency waves may originate as static discharges between adjoining parts of the vehicle...TM '9-803 176-177 Section XXXI RADIO INTERFERENCE SUPPRESSION SYSTEM Paragraph . Wiring that may carry interfering surges to a point where interference will affect radio reception.... therefore... or elsewhere) creates a surge of electricity. and the wiring........ breaker points.... of electrical disturbances which interfere with radio reception..... including generator and regulator..... Tests .. thus.. and to permit electrical energy to dissipate without causing electrical disturbances.. or minimizing..... a.. Radio noise suppression is the elimination.....000 ohms... Maintenance. Each disturbance (at plugs. and tinned spots must be cleaned. generator brushes.. The suppression components have no effect on engine performance as long as they are maintained in good condition.

101 and 102). (h) Hood ground to grille. Toothed lock washers are supplied from: 222 . (2) Primary circuit suppression is of the capacitive-filter type and consists of: (a) Ignition coil terminal (+) to cylinder block. regulator.01 microfarad. right side (N). ammeter. (1) BOND STRAPS (ground straps) (figs. capac­ ity 0. (c) Cylinder head stud to dash (H). Bond straps are installed from: (a) Hood to dash. Charging Circuits (includes generator. heat indicator) to dash (E). and battery). (2) Regulator suppression is of the capacitive-filter type and consists of: (a) Regulator field terminal (F) to ground. speedometer. (f) Generator to regulator wire shield to ground on generator and regulator (B). c. (i) Hood ground to grille. (b) Starting switch battery terminal to floor. (b) Ignition switch terminal (lower) to instrument panel. capacity 0. d. capacity 0. (4) Front engine bracket to frame. (b) Hood to dash.10 microfarad. (1) Generator suppression is of the capacitive-filter type and consists of generator armature terminal (A) to ground on generator. b. left side (J).TM 9-803 177 l/4 -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) (b) Spark plug high-tension wire at spark plugs. (1) Radio terminal box suppression is of the capacitive-filter type and consists of: (a) Radio box terminal to ground. resistance 10. capacity 0. (j) Radio terminal box to ground wire (F). (b) Regulator field terminal (B) to ground.10 microfarad. left side (I). 101 and 102). capacity 0. capacity 0. capacity 0. Miscellaneous Circuits (including radio box and starting circuits).01 micro­ farad. Bonding. (2) TOOTHED LOCK WASHERS (figs. right side (D).50 microfarad.25 micro­ farad. left side (L).000 ohms.50 micro­ farad. (d) Cables (hand brake. (e) Generator mounting bolt to cranking motor bracket to engine support bracket (A).

utilize a radio-equipped vehicle placed about 10 feet from the vehicle under test.TM 9-803 177-:178 RADIO INTERFERENCE SUPPRESSION SYSTEM (a) Radiator to frame. Electrical disturbances which cause radio interfer­ ence are loose bonds. Determine the circuits causing the noise by checking as follows: (1) Operate engine while listening to radio. right side (U). The radio equipment in the vehicle may. (4) Inspect and tighten all bonds in engine compartment. left side (R). is caused by the ignition circuit. A regular clicking which varies with engine speed. Improper plug gaps. Replace if neces­ sary. right side (Q). Here the cooperation of the radio operator is required. (b) Radiator to frame. broken or cracked resistor-suppressors. or otherwise faulty. left side (T). 223 . (4) Air cleaner mounting (C). (1) Make certain ignition system is functioning properly (section XV). poor adjustment of breaker points. (3) A whining noise which varies with engine speed. Replace filter and test for noise. (c) Body bracket ground to frame. (h) Body hold-down bolts (G). and con­ tinues a few seconds after the ignition is shut off. loose toothed lock washers. (k) Fender to cowl. be used as a test instrument to localize troubles. (d) Body bracket ground to frame. left side (P). and to determine when faulty parts or conditions have been eliminated or corrected. TESTS. and damaged or worn distributor. (f) Fender splasher ground to frame. b. right side (O). late timing. (3) Inspect resistor-suppressor at distributor. a. Make certain mounting bolts are tight. loose connections. (i) Radiator grille to cross member (M). General. will affect the suppression system. If the vehicle has no radio equip­ ment. (j) Fender to cowl. Following are tests which can be made to determine the cause of interference. (5) Inspect capacitive-type filters in primary circuit at ignition coil and ignition switch. is caused by the regulator. (2) An irregular clicking which continues a few seconds after the ignition is shut off. cracked. is caused by the generator. Replace any that are scorched. 178. (e) Fender splasher ground to frame. and ceases the instant the ignition is shut off. right side (S). left side (K). (2) Inspect resistor-suppressors in spark plug leads. Be sure wires are screwed in tightly. or faulty filters. Noise Caused by Ignition Circuit.

General. General maintenance of the radio suppression system (par. f. particularly in regard to spark plugs. (6) Replace field circuit filter attached to regulator (F) terminal.TM 9-803 178-179 I/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) c. (3) Test for noise. (1) Check to make certain there is no excessive sparking at brushes. (3) Inspect ground strap. (7) Replace armature circuit filter attached to generator (A) terminal. (4) Replace filter. (1) Inspect mounting of filter attached to circuit. loose switch con­ tacts. (2) Check capacitive-type filter mounting bolts for tightness and correct placement of lock washers. (3) Test for noise. 101 and 102). MAINTENANCE. Noise Caused by Generator. (5) If noise is still present. and check placement of lock washers. Noise Caused by Regulator. and discharged battery causing high generator charging rate. (2) Inspect filter mounting. but Not When Stopped. Correct if necessary. 23 a (5). (4) Test for noise. Noise Caused by Miscellaneous Circuits (radio box and start­ ing switch). Test for noise. (2) Replace filter. 177 d (2) above and figs. Tighten and test. Test for noise. (2) Inspect and tighten all points where toothed lock washers are used (par. 177 d (1) above and figs. a. (3) Check regulator mounting bolts for tightness and correct placement of lock washers. generator brushes. item 104) must be made in connection with preventive maintenance items. (1) Check all connections to regulator. Noise Observed While Vehicle Is in Motion. d. (1) Inspect and tighten all body bonds (par. e. replace battery circuit filter attached to regulator (B) terminal. distributor and wires. Tighten. 101 and 102). late ignition timing. (5) Test for noise. 179. (8) Test for noise. 224 .

-5 I I i00VW III RA PD 305295 W (!) Figure l1--Lacation of Bond Straps and Fastenings (I Fpte< l zlU Z 2 I .TM 9-803 179 RADIO INTERFERENCE SUPPRESSION SYSTEM uJ M _U :Oc5 Lr1 O O0 0 z X x e. :\ / 0I a ~O~~0 5iOzV l C 0 0-U U oa 0 .

i~~~~~~~U LUo a22 226 . 0~~. g i ~CL sue IL i LU 226 E-j 00 gm 1Q aini WUJ. LU -I I a i W a 1-0 UJII U.TM 9-803 179 14-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) ul L.

(2) Capacitive-filters. Each suppressor must be threaded tightly into end of spark plug wire so that screw enters strands of cable. Bonding. and free of corrosion or dirt. are located at the ignition coil and ignition switch. 227 . and attached to the armature (A) terminal. The filter bracket is located under the left mounting bolt with an internal-external toothed lock washer between the bolt head and the bracket. consist of a high resistance element in an insulated housing. Tinned spots must be clean but not painted. removing mounting nut or screw.TM 9-803 179 RADIO INTERFERENCE SUPPRESSION SYSTEM b. Inspect each suppressor for cracked or broken housing. Wire terminals must be tight. and removing filter. the lock washer must be between the parts to be grounded. The capacitive-filter used in the radio box between the terminal and the ground wire must be tight with the lock washer under the head of the mounting screw. of which there are five (one at each spark plug and one at the distributor). (2) Two capacitive-filters are used on the regulator. Install ignition switch filter with toothed lock washer between filter bracket and panel. refer to paragraph 97. Ignition Circuits. e. (1) A capacitive-filter is mounted on the generator. The mounting screw must be tight with the internal-external toothed lock washer between the filter bracket and the generator housing. Miscellaneous Circuits (radio box and starting circuits). one between the battery terminal and ground. and an internal-external toothed lock washer between the nut and the rear side of the dash. Bonding points indicated in paragraph 117 d must be clean and tight. also between bracket and mounting nut. The mounting screw must be tight with the internal-external toothed lock washer between the filter bracket and the regulator base. of which there are two in the ignition circuit. and the external toothed lock washer under the screw head. (3) For battery removal and replacement. Where bonding is obtained by use of an internal-external toothed lock washer. Replace if faulty by disconnecting wire at terminal. The capacitive-filter in the starting circuit is mounted on the bottom of the starting switch with the connection on the "live" terminal. Charging Circuit. *c. d. (1) Resistor-suppressors. the other between the field coil terminal and ground. Install coil filter with toothed lock washer between filter bracket and mounting nut. well pushed down into place.

a. lubri­ cation. For more detailed information. and for preparation for indefinite storage refer to AR 850-18.. before the vehicle 228 . blocking necessary to secure the vehicle on freight cars.... cinders..... num­ ber of vehicles per freight car.. 181 Loading and'blocking for rail shipment .. test the coolant with a hydrometer..... 180 Preparation\for temporary storage or domestic shipment ... If freezing temperature may normally be expected during the limited storage or shipment period. and properly inflate all tires.. to check on general condition of the vehicle.... 181. Preparation for domestic shipment of the vehicle is the same as preparation for temporary storage or bivouac.... tires requiring retreading or repairing... 182 180.. PREPARATION FOR TEMPORARY STORAGE OR DOMESTIC SHIPMENT.. 18). a.... clean and thoroughly service battery (par. Correct any defects noted in the vehicle operation. GENERAL INSTRUCTIONS.. Wash off immediately any oil.. and other informa­ tion necessary to properly prepare the vehicle for rail shipment. or kerosene which comes in contact with the tires under any circum­ stances..... weight. and tire service....... and add the proper quantity of anti­ freeze compound to afford protection from freezing at the lowest temperature anticipated during the storage or shipping period. Lubricate the vehicle completely (par.. Vehicles to be prepared for temporary storage or domestic ship­ ment are those ready for immediate service but not used for less than 30 days.. If the vehicles are to be temporarily stored or bivouacked... If vehicles are to be indefinitely stored after shipment by rail.... they will be prepared for such storage at their destination.. after the battery.. b. The preparation for limited storage will include a road test of at least 5 miles. Com­ pletely inspect the cooling system for leaks. grease. Check battery and terminals for corrosion and if necessary. 97). (2) COOLING SYSTEM....... (4) TIRES. Clean.. inspect. take the following precautions: (1) LUBRICATION. cooling system. or other surfaces which are soaked with oil or grease... Preparation for shipment by rail includes instructions for loading and unloading the vehicle. Do not store vehicles on floors. gasoline. Replace with serviceable tires. (3) BATTERY. clearance..TM 9-803 180-181 1/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) Section XXXII SHIPMENT AND TEMPORARY STORAGE Paragraph General istructions . (5) ROAD TEST.

into the carburetor throat. Vehicles in limited will be inspected weekly for conditions of tires and battery. Leave rubber mats. and in the case of track-laying vehicles. Make a systematic inspection just before ship­ ment or temporary storage to insure all above steps have been covered. Leave fuel in the tanks except when storing in locations where fire ordi­ nances or other local regulations require removal of all gasoline before storage. Pour 1 pint of medium grade. recharge the with a portable charger. metal tracks. and windshields. Refer to "Before-operation Service" (par. Vehicles equipped with open-type cabs with collapsible tops will have the tops raised. such as floor mats. Coat exposed polished metal surfaces susceptible to rust. Make a list of all missing or damaged items. To prepare the engine for storage. c. and fire extinguishers will remain in place in the vehicle. not rolled or curled up. If added when freezing weather is anticipated. (9) ENGINE. of the latest issue in effect. A written report of these items will then be made to the officer in charge. Release brakes and chock the wheels. Ordnance Department Specification AXS-674. It is not necessary to remove the fuel from the tanks for shipment within the United States. and the wind­ shield closed. (6) FUEL IN TANKS. remove the air cleaner from the carburetor. Then reinstall the air cleaner. open the throttle wide. Close firmly all cab doors. being careful not to choke the engine. (7) EXTERIOR OF VEHICLES. (8)' INSPECTION. Turn off the ignition switch as quickly as possible after the oil has been poured into the carburetor. tire chains. (10) BRAKES. and turn the engine five complete revolutions by means of the cranking motor. 229 storage water is battery Do not . nor to label the tanks under Interstate Commerce Commission Regulations. Make sure paulins and window curtains are in place and firmly secured. or note on a tag attached to the steering wheel. Start the engine. and set the throttle to run the engine at a fast idle. Inspections in Limited Storage. and that the vehicle is ready for operation on call. or remove the battery for charging. and attach it to the steering wheel. all curtains in place. Remove rust appearing on any part of the vehicle with flint paper. With the engine switch off. turn it by hand. Equipment such as Pioneer and truck tools. where provided. If the engine cannot be turned by the cranking motor with the switch off. Repaint painted surfaces whenever necessary to protect wood or metal. attempt to charge the battery by running the engine. such as winch cables. stating the repairs needed or describing the condition present. in an unrolled position on the floor. 13).TM 9-803 181 SHIPMENT AND TEMPORARY STORAGE is stored. or disconnect the high-tension lead and ground it before turning the engine by means of the cranking motor. windows. chains. preserva­ tive lubricating oil. with medium grade rustpreventive lubricating oil.

all blocking will be located against the outside wheel of the dual. The brakes must be applied and the transmission placed in low gear after the vehicle has been placed in position. That portion of the block under the tread will be toenailed to the car floor with two 40-penny nails to each block. Movement from one flat car to another along the length of the train is made possible by cross-over plates or spanning platforms. In case of shipment in side-door cars. using five 40-penny nails to each block. and bouncing. The vehicles will be located on the car in such a manner as to prevent the car from carrying an unbalanced load. of No. Nail the heel of each block to the car floor.TM 9-803 182 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) 182. and then through a stake pocket on the railroad car. whichever type car is the most convenient. must be prevented. black annealed wire "C" around the bumper support bracket at the front of the vehicle. When blocking dual wheels. (2) TIRES. the following preparations and precautions will be taken: (1) EXTERIOR. and the top block to the lower block with three 40-penny nails. an improvised ramp can be made from railroad ties. In securing or blocking a vehicle. side-door box cars. using permanent end ramps and spanning platforms. and tying it back away from the battery. as described below. Perform the same operation at the rear of the vehicle. use a dolly-type jack to warp the vehicles into position within the car. 101 "A"). LOADING AND BLOCKING FOR RIAIL SHIPMENT. a. two wrappings. 8 gage. Pass four strands. lengthwise. 101). (1) METHOD 1 (fig. (3) BATTERY. If no permanent end ramp is available." (6) Ordnance vehicles may be shipped on flat cars. (4) BRAKES. Preparation. (5) All cars containing ordnance vehicles must be placarded "DO NOT HUMP. with a brake wheel clearance of at least 6 inches (fig. This may be accomplished by disconnecting the positive lead. end-door box cars. Nail the lower block to the car floor with three 40-penny nails. Inflate pneumatic tires from 5 to 10 pounds above normal pressure. Locate two blocks "D" against the outside face of each wheel. when ordnance vehicles are prepared for\domestic ship­ ment. Cover the body of the vehicle with a canvas cover supplied as an accessory. taping the end of the lead. b. sidewise. Vehicles may be loaded in gondola cars without drop ends by using a crane. Locate eight blocks "B". In addition to the preparation described in para­ graph 181. three motions. one to the front and one to the rear of each wheel. Securing Vehicles. load and unload vehicles from open cars under their own power. Disconnect the battery to prevent its discharge by vandalism or accident. Whenever possible. Facilities for Loading. There are two approved methods of blocking the vehicles on freight cars. or drop-end gondola cars. c. passing the 230 .

TM 9-803 182 SHIPMENT AND TEMPORARY STORAGE BCKB BKD B2" B ATD CHAMER /' 1 =36" 3" BLOCK-H 2"OCK-D CHAMFER AT 2.4 BLOCK-B BLOC BLOCK--D ~ 4 12" q BLOCK-F F LENGTH TO SUI"T-BLOCK-G RA PD 330839 Figure 103-Blocking Requirements for Securing Wheeled Vehicles on Railroad Cars 231 . /'CONTACT POINT 6" SI.

... Shipping Data......... and the top cleat to the cleat below with three 40-penny nails....... Height.......... Nail the lower cleat to the floor with three 40-penny nails.... this strapping must be applied in a similar fashion... Pass four strands.... two wrappings. as described in Method 1 above.... locate two against blocks "G" to the front of each wheel... Tighten the wires enough to remove slack.TM 9-803 182 A/4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) wire through the opening in the rear bumper. black annealed wire "C" around the bumper support bracket (front). Locate four cleats "H" on the outside of each wheel to the top of each block "G" with two 40-penny nails. and attached to the floor by the use of blocking or anchor plates... These blocks are to be at least 8 inches wider than the over-all width of the vehicle at the car floor.... top down ... Width..... one to the front and one to the rear of each set of wheels.. 101)..... ...25 in.......... 62 in. over-all ....... of No... over-all .. 132............. d... Using sixteen blocks "F"................ 32 in. (2) METHOD 2 (fig. This strapping is not required when gondola cars are used.. . When a box car is used....... Approximate volume ..... Approximate floor area .... and two against blocks "G" to the rear of each wheel........ Place four blocks "G"............ Shipping weight .. Duplicate these two operations on the opposite side of the vehicle..... Length.. 2453 lb 57 sq ft 152 cu ft 4 /2 232 ... and also opening in the rear bumper (rear). 8 gage.. Bearing pressure (lb per sq ft) .

. FM's..................... SNL G-503 SNL K-1 SNL K-2 SNL N-19 TM TM TM TM TM TM 10-580 10-540 38-250 10-460 21-300 1-455 233 ..... TM's. and FB's by serial number and subject) .. OPSR's. T/BA's...... RSD. FS's. ORD-1 IOC Ordnance publications for supply index (index to SNL's) ..... The following publications indexes should be consulted frequently for latest changes to.. and displays) .... and miscellaneous related items ... brazing and welding materials... special oils.......... OSSC's... Automotive electricity ... :....... command reconnaissance (Ford and Willys) ............. EXPLANATORY PUBLICATIONS.............. Cleaning................... MWO's................. models... Tool sets-motor transport ... concerning training) ..... and TB's of interest to Ordnance person­ nel. and OFSB's....... FM 21-8 STANDARD NOMENCLATURE LISTS.. and TR's.. Electrical fundamentals ....TM 9-803 REFERENCES PUBLICATIONS INDEXES....... Includes alphabetical listing of Ordnance major items with publications per­ taining thereto) ... Truck /4-ton................ ASF Cat........ TC's...... devices............ preserving and lubrication materials... Fundamental Principles................. FM 21-6 List of training films.. or revisions of the publications given in this list of references and for new publications relating to materiel covered in this Manual: Introduction to Ordnance Catalog (explains SNL system) ..... re­ coil fluids.......... MTP's. 4 x 4..... OFSB 1-1 List of publications for training (lists MR's. ASF Cat.... Driver selection and training ........... Basic maintenance manual ...... FM 21-7 Military training aids (lists graphic training aids.......... Driver's manual ......................................... ORD-2 OPSI Index to Ordnance publications (lists FM's............................................ S of SR's............ Automotive lubrication ... and film bulle­ tins (lists TF's....... film strips...... Soldering.................. gases and related items ...... TM's.............. T/A's.............

....... AR 850-18 234 .................. FM 5-20 TM FM FM FM FM 3-220 17-59 21-40 31-25 5-25 Storage and Shipment.................. AR 850-15 TM AR TM TM 9-2810 850-20 9-2800 10-570 Maintenance and Repair.. Desert operations ..................... The internal combustion engine ............................. OFSB 6-11 Maintenance and care of pneumatic tires and rubber treads ......... Explosives and demolitions .................. for the United States Army and Navy... TM 9-850 Cold weather lubrication and service of combat vehicles and automotive materiel ..... Camouflage ..... .... group GMajor items ..... TM 10-530 Protection of Materiel.. Storage of motor vehicle equipment... TM. chassis...... Cleaning...................... Decontamination of armored force vehicles ............. TM 9-1828A Tune-up and adjustment ..... materials and equip­ ment .............................. TM 9-1803B Ordnance Maintenance: Electrical equipment (Auto-Lite) ...TM 9-803 /A-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) Military motor vehicles ................ Chemical decontamination........... 9-1803A Ordnance Maintenance: Power train....... ..... lubricating and welding ma­ terials and similar items issued by the Ordnance Department ........ ........................... AR 850-10 Rules governing the loading of mechanized and motorized army equipment..: ......... on open top equipment published by Operations and Maintenance Department of Association of American Railroads.......... Precautions in handling gasoline ............... .. also major caliber guns........................ preserving........ TM 9-1826A Ordnance Maintenance: Fuel pumps ..... TM 31-200 Ordnance Maintenance: Engine and engine acces­ sories for ¼4-ton 4 x 4 truck (Ford and Willys)............................ Ordnance storage and shipment chart.. TM 9-1827C Ordnance Maintenance: Carburetors (Carter) ...................... Motor vehicle inspections and preventive mainte­ nance service ............... Standard Military Motor Vehicles ............ Defense against chemical attack .......... .......... and body for ¼4-ton 4 x 4 truck (Ford and Willys).. TM 9-1825B Ordnance Maintenance: Hydraulic brake system (Wagner) . OSSC-G Registration of motor vehicles ...........

....... care in cold climates... steering gear .... No......... second o echelon . trouble shooting . blackout headlights ...... description .................................. replacement ......... 35 150 155 155 57 24 230 155 116 69 101 155 159 159 163 157 161 154 164 160 166 156 29 111 175 185 181 186 188 183 188 62 185 186 93 187 183 184 185 Blackout driving light adjutment ................. description .. trouble shooting ............. 15-16... Page No.......... front......... 160 159 15 159 163 164 163 25 63 63 61 61 235 . 160 196 128 167 215 113 191 35 33 129 129 47 24 26 129 116 69 60 13 70 Axle shaft installation ........... wiring system ........ Ammeter description ... Before-operation service............ installation ......... 190 .......................................................................... instrument panel lights ..................... .. wheel bearings ........................... run-in test preliminary service........ description and data150 headlights ... preparation for shipment .... ....... description and data........................ Blackout (main) light switch description .............. drag link bell crank.... attery ................. wheel alinement .. Blackout headlights .............. Axle.. 190 echelon maintenance maintenance ................................... removal from engine ... trouble shooting .... valve tappet .............. operation in cold climates. maintenance o n d maintenance ............................ lubrication .......... maintenance .......................... ...... description ...... wheel grease retainer.. operation in cold weather .............. Air cleaner after-operation and weekly service at-halt service .... installation ... brake drum .. clutch pedal . rear. second echelon 93 maintenance ............ 192 189 Brake master cylinder.... second echelon service Assembly intake to exhaust manifold . front brake n-intaillights drums ......... maintenance ........................ ................... installation . ghtg system155 batteryv blackout driving light159 blackout driving light....... ................. wheel hub ..............TM 9-803 INDEX A Page Adjustment blackout driving light ........... from engine ..... rear axle shaft ............... steering tie rod.. description........ Axle............................ wheel bearings (rear axle) ...... second echelon maintenance............. brakes .... 191 190 B Battery after-operation and weekly service data ................... 192 Brake shoes..................... ........... description and data ......... and stop lights ........ wheel bearings ................Brake bands..... panel and blackout driving light switches .. removal and servicing......... carburetor ........... removal ............. removal .... installation ... run-in test preliminary service. wheel hub ... trailer connection ................................ steering knuckle housing oil seal.... blackout (main) light switch............. removal .......................................... 191 Brake shoes......... ..... transmission to transfer case... run-in test preliminary service. .... second echelon maintenance........ operation in sand........................ removal..... maintenance ............ Blackout driving light switch...... second echelon 191 maintenance.........................

......................... 144 protection in cold weather .......... master cylinder . clutch . and installation..... trouble shooting ....... fan belt .............................................. fan .TM 9-803 -/4TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) B -Cont'd Page Brakes description ard data . 193 201 195 199 204 196 94 200 Page No...................................... thermostat ..... Description battery and lighting system ..... description and data............ Crankcase lubrication ........................... flexible lines......................... trouble shooting . 58 Crankcase ventilator valve........................ 59.... .. temperature gage ............... body and frame .... second echelon service .............................. propeller shafts and universal radio interference suppression systeri ................... 128 Circuit breakers................ removal ........ removal............ maintenance ....... 65 171 167 31 170 167 26 167 170 71 56 85 2180 12 137 142 141 138 26 228 22 140 143 143 87 140 236 ..... 75............... 144 description ......................... cooling system....... protection in cold weather ........ 111 D Data........ 146 119 ignition system ...... ......... 89 Cranking motor mechanism..................... 150 216 body and frame ................ 60 removal and installation ...... operation in hot weather ............................. No........... 57 removal ........................ 137 104 engine .......... installation ... starting system . 60 trouble shooting .. transfer case .... maintenance and adjustment. 23 removal and installation .......... parking (hand) brake ........... preparation for storage or shipment .. tabulated battery and lighting system .................................. Clutch clutch release bearing...................... maintenance . run-in test ......... springs and shock absorbers .. Communications ............... 181 front axle .. steering gear ....................... fuel and air intake and exhaust systems ....................... hoses......................................... during-operation .. pedal adjustment ............ 47 maintenance..... 24 Cylinder head gasket installation ........................... Cooling system description and data .......... rear axle ..................... cooling system ............ 193 brakes ....... 116 second echelon maintenance............. 127 operation under unusual conditions.. service (foot) brakes ....... operation in sand............... descrip­ tion.. 221 189 206 144 212 177 173 150 216 193 167 137 120 C Carburetor adjustment .............. 115 Cranking motor data...... second echelon maintenance................................ 167 clutch ... 24 second echelon maintenance.................... brakes ............. transmission ........... distributor ...... and connections ................................................. 112 maintenance ......................................................... 127 generating system .... 145 removal from engine .. 128 description ........ trouble shooting . Cold weather operation .... wheel cylinder ................................................................... inspec­ tion before starting engine . water pump .. radiator .....

.. valve cover gasket. 126 generating system ................. valve tappet adjustment .................... Exhaust system description . instruments .. before-operation service.... Description-Cont'd engine ....................... 144 steering gear ............ lubrication in cold weather ............ Engine crankcase ventilator valve ..... Frame and body description and data.... 186 removal .................................... 176 transmission ............ 189 springs and shock absorbers ................... 120 second echelon maintenance .. seats and cushions .................... removal................... rifle holder .... 85 Drive belt and pulleys........... intake and exhaust manifolds... tune-up ...................TM 9-803 INDEX D-Cont'd Page No. protection in cold weather .... adjustment and installation .......... 221 rear axle ........ Fenders.......................... at-halt service . 59 Driving controls and operation instruments and controls............ 179 radio interference suppression system ..................................... 10 Differential... use of instruments and controls in 17 vehicular operation .................... fenders ......... 118 propeller shafts and universal joints .. 121 lubrication............................ 59 trouble shooting .. 181 fuel and air intake and exhaust systems ...... radiator guard ..... 146 ignition system .................................................................................................... description and tabulated data..120 distributor condenser ................... removal and installation ................. muffler ..................................... second echelon maintenance ................. trouble shooting..... exhaust pipe ..... oil pan gasket .................. 119 description.....137 description .............. preparation for storage or shipment..... installation . No. Fire extinguisher after-operation and weekly service.... cylinder head gasket .......................................................... maintenance .......... shovel and axe........ top ................ oil filter ... windshield wiper .......................................... 26 23 115 111 104 117 109 Page manifold heat control valve ....................... 111 114 113 229 116 74 104 112 113 135 136 136 F Fan data..................... description .................34 run-in test preliminary service........... 3 19 towing vehicle ............................ 122 distributor points .. trouble shooting ................ E Electrical system operation in hot weather ........... 21 Distributor care in cold weather ....... 211 transfer case ......... 172 truck... 48 removal and installation .... 205 starting system ........ 137 142 143 142 14137 14 220 68 34 32 29 31 216 220 219 217 217 219 218 217 219 218 101 218 218 237 ......................... hood .......... removal . 23 data .................................. data........... windshield ........... removal and installation.............................. First echelon preventive mainte­ nance service after-operation and weekly service ..................... during-operation service.. 186 Dragging clutch.. trouble shooting ................................... 104 front axle ........... 89 Drag link bell crank installation ..........................

. Headlights description .............. 130 24 131 60 132124 134 24 27 86 131 131-132 G Gear cases.. installation .. distributor ............................................. and installation ...................... trouble shooting ..................... maintenance .............................. Fuel and air intake and exhaust systems air cleaner ......... removal............. removal and installation ............ fuel pump ...................................... 134 description ............................ Ignition wiring data ... description and data . 47 146 147 146 148 146 147 23 147 59 90 238 ..................... Instrument panel lights description .................................................. 135 removal and installation ......................................... during-operation service ........................... exhaust system ..... Ignition system description and data.... regulator ..................... ... protection in cold weather ............ Fuel system operation in cold climates .................... Fuel filter run-in test preliminary service ..... trouble shooting ........ sealed beam unit ........ Hood.... removal and installation ............................................... description ................................................. .. Instruments and controls controls.......... generator .. Fuel pump description ...... trouble shooting ..... Inspection of vehicle in limited storage .. fuel strainer .......... second echelon service ... ignition switch...... .. instruments. removal and installation ....... carburetor .... maintenance................... removal and installation ........ removal and installation ........... Ignition switch ............ operation in landing .......... 119 124 124 119 125 125 118 120 125 123 125 120 124 88 119 125 229 109 111 109 87 47 161 163 15 13 Fuel gage 13................... operation under unusual conditions .... 17 31 56 157 158 158 158 157 219 I Ignition coil data .................. Intervals of lubrication ...... removal ....... second echelon maintenance . second echelon maintenance ........... removal and installation ............ removal ....... fuel gage ....... sealed beam unit ........... trouble shooting ....................... lubrication .TM 9-803 I/ 4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) F-Cont'd Page No........ second echelon maintenance ................................ 129 127 126 135 134 130 132 131 127 68 60 Hand brake description...... maintenance ................ installation ......... description...... Generating system description and data . H Page No..... ignition timing ....... spark plugs ..... removal and installation . Generator data ..................... Fuel tank description ..... data description .......................... Intake and exhaust manifolds description ......... description removal and installation ...................... Fuel strainer description ...... fuel tank .... ignition wiring ...........................................

. 15 16 panel light .... cooling system .............. O Oil filter (and lines) description ........................... removal and installation ......... 154 217 195 167 138 183 127 146 120 180 224 190 207 144 212 177 173 111 60 193 200 199 52 136 136 52 maintenance... second echelon maintenance...TM 9-803 INDEX L Page No.. Organization tools and equipment.................. . 114 115 115 47 M Maintenance battery and lighting system ..... .. springs and shock absorbers ........ operation in landing..... 15 blackout driving .. data ...... starting system .... second echelon maintenance......... description .... installation ............................... Propeller shafts (and universal joints) description and data......................... 26 in sand 27 in landing .......................... Panel and blackout driving light switches description ........ Master cylinder data ...................... 30 15 description ............. description............ 113 Oil pressure gage before-operation service .... Page No.............. rear axle ....... removal ........................................... transfer case ..... installation ................ 69 37 Lubrication guide .................................... steering........ 21 vehicle for run-in test ..... trouble shooting................... 137 140 N New vehicle run-in test ............ Light switches blackout ..... removal and installation............................................. installation ..... 58 removal.. 48 Oilcan points .......... decontamination ..... removal ............................................. Manifolds................. fuel and air intake and exhaust systems ............. radio interference suppression system ......... R Radiator data .................................. 180 ..................... Power train................... Panel light switch.............. record of ... 204 195 164 166 16 214 27 179 180 180 maintenance.... element ... 22... ignition system .............. ............................................................. 102 Lubrication cold weather ....... Pitman arm............ 62 93 trouble shooting ..... 27 26 hot weather . Operation fuel and air intake and exhaust 127 ............................ clutch ............................... generating system ........................ 68 239 ............ brakes ....... body and frame .... Modifications..... :.................................. systems under unusual conditions 21 cold weather ...... front axle ....... transmission ... description .........115 element.... MWO and major unit assembly replacement record ....... lubrication . 70 run-in test preliminary service... 73 P Parking (hand) brake adjustment .......... Muffler installation .. steering gear .... removal and installation ...................... removal .... Manifold heat control valve....................................................115 Oil pan gasket............... Lighting system... propeller shafts and universal joints ..

.... 146 description ............ data .... description and data................ maintenance ........................................ Shock absorbers and springs description and data ......... Springs and suspension before-operation service............. 48 Rifle holder................ data ......................... 185 removal ........... description and adjustment ....... road test chart ........... shock absorbers ................. Spare parts....... Shovel and ax.......... tools and equipment ....... trouble shooting ......................................... Starting switch data ......... spring shackles and bolts........ Shipment and temporary storage loading and blocking for rail shipment ............ starting switch ... new vehicle correction of deficiencies . Starting system cranking motor . 68 S Second echelon preventive maintenance services maintenance operations . 62 210 207 209 97 219 50 23 119 124 58 89 73 15 55 30 69 144 145 144 144 144 145 89 57 55 66 196 193 199 215 211 32 214 212 213 214 213 230 228 205 207 removal 214 Steering gear housing... 117 maintenance ............. 58 operation in sand ...213 Steering gear adjustment .......... 220 removal ............. 55 Run-in test......................... steering rod ................... 218 Road test chart ......................... 148-149 removal and installation ... maintenance ........... second echelon service ..... maintenance ............ Radiator-Cont'd installation on engine ................TM 9-803 /4-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB and FORD MODEL GPW) R-Cont'd Page No........ Spark plugs care in cold weather ...... 140 removal from engine........................... Steering connecting rod................. trouble shooting ............. description and data ..... 116 Radiator guard installation ....... 185 240 ...................... vehicle.......................... run-in test preliminary service....... 68 procedures .. Speedometer description............ preparation for temporary storage or domestic shipment . 221 description . second echelon maintenance ..... Special tools ...... springs ........... 221 maintenance ...... removal and installation ............................... Steering knuckle bearings....................................... Page second echelon maintenance .................................... 27 removal and installation ..................... steering connecting rod .. lubrication ...... removal and installation .. steering Pitman arm........................... 224 tests .................. Service (foot) brakes adjustment ............. removal and installation. 219 Radio bonding........ 223 trouble shooting ................. No.............. 47 Steering knuckle housing oil seal installation ............................. removal and installation .................. removal and installation of brake shoes and linings ... installation ..... lubrication in 22 cold weather .................. 103 Regulator data .......... maintenance ............................................ .......... trouble shooting ...................... 149 Reports and records of lubrication.... 66 Radio interference suppression system data .... during-operation service ..............................

........... 32 Vehicle specifications .. Steering knuckles................... 33 run-in test ............................ installation and removal and installation ........................... before-operation service ... 166 removal ............... 93 radio suppression .......... Thermostat data .................... : .... 70 Trouble shooting battery and lighting system............. 30 trouble shooting ........ 56.............. : 1............ and related parts ................ second echelon maintenance ... 92 shifting to lower gears in Transmission transmission..... ... 74 removal ........................................ 98 transfer case .. trouble shooting ...... 173 Steering linkage removal ............ run-in test ..................... 91 run-in test preliminary service.. 87 installation ... 62 maintenance . during-operation service ........... 71 placing vehicle in motion .... 177 ments and controls in removal ...... trouble shooting 98-101 Steering tie rod... 112 58 113 10 17 17 19 18 18 17 19 19 241 ...................... 172-173 starting engine ............ removal and installation ............. second echelon lubrication in cold weather ........TM 9-803 INDEX S-Cont'd Page No...... 213 front axle93 T Taillights and stop lights description ....... use of instru­ maintenance .............. 101 Steering system... description.... 50 spare parts ... Transfer case Valve mechanism........... 173 before-operation service ....................... 173 at-halt service .. during-operation service ..... removal and installation ............ Tune-up of engine ... 97 104 47........... shifting levers .. 50 Universal joint lubrication .... 101 installation .... · 89 steering system ... Terminal blocks.......... 97 starting and generating system..... 63 before-operation service ...................... 160 161 143 65 138 fuel system ...... wheel bearings... description ............... maintenance.................................. installation .......... Temperature gage........ 94 clutch . 93 springs and shock absorbers........... 175 stopping the vehicle ............ 87 propeller shafts ........... 32 stopping engine .......................... 56... installation ................. and installation ............. 21 maintenance ............................ 178 shifting gears in transfer case .......... tools ................. 63 reversing vehicle ............ 86 ignition system ... removal. 103 intake and exhaust systems ..................... 174 Vehicular operation................ 103 rear axle ............................................. 186 brake system ................................ 85 Steering wheel cooling system87 cooling system ............ second echelon maintenance... 54 Valve cover gasket. 176 Valve tappet adjustment .. 30 Tools and equipment stowage on vehicle equipment .... . 49 Trailer connections V data ... 88 instruments ........... removal and body and frame .......... description and data . 143 Tires.. 71 after-operation and weekly service 36 second echelon maintenance.............. 214 engine 74 engine ...... 92 transmission91 wheels.................................................................................... Page No...

Wiring system data ...... installation ..TM 9-803 1/ -TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MB 4 and FORD MODEL GPW) W Page No.......... removal and installation ........ removal.................. description ......... Wheel bearings (rear axle). 97 Page No............................................. adjust­ ment......... 141 Wleel alinement ......... 200 Wheel bearings adjustment ..... 187 Wheel cylinder 193 data ............. second echelon service ...... removal and installation 185 Windshield adjusting arms........ description .............. 30 56 150 156 156 242 ..... 183 lubrication .......................................... 48 removal and installation ................ 137 description . 191 Wheel hub.............. 59 removal and installation ....... 184 trouble shooting . 17 Windshield wipers before-operation service ... Water pump (and fan) data .. 201 removal . 140 maintenance ... and installation.................. ...............................