DEPARTMENTS OF THE ARMY AND

No. 9-6012 THE AIR FORCE

No. 96A6%41

“h-TON 4 X 4 UTILITY TRUCK

ParcrgroPb
Pwe
CHAPrER

major item.

P
 _

INDeL-- ____-_--_-___--_____---~~~ ____--__--____-__--_~~

 These instructions are published for the use of personnel to
whom this materiel is issued. They contain information on the
operation and organizational maintenance of the materiel as well
as descriptions of major units and their functions in relation to
other components of the materiel.
b. The appendix contains a list of current references, including
supply manuals, forms, technical manuals, and other available
publications applicable to the materiel.
c. This manual differs from TM 9-804, September 1950, as
indicated in (1)) (2)) and (3) below.
(1) Adds information on-
(a) Plate showing “OFF” and “ON” positions under ig-
nition switch, beginning with vehicle serial No. 26273.
(b) A changed submersible starter mounting, beginning
with vehicle serial No. 53262.
Cc) A submersible generator, beginning with vehicle serial
No. 53262.
Cd) A sealed or pressurized bell housing, beginning with
vehicle serial No. 53262.
(e) A waterproof clutch linkage, beginning with vehicle
serial No. 53262.
(f) A l/s-inch hole in crankshaft pulley for timing pur-
poses, beginning with vehicle serial No. 22296.
(9) Vent lines to bell housing, transfer case and trans-
mission case, beginning with vehicle serial No. 53262.
(h) Decalcomania above deep water fording vent valve
control, for locating bell housing drain plug and ford-
ing information, beginning with vehicle serial No.
53262.
(9 New engine rear plate for use with the changed starter
mounting, beginning with vehicle serial No. 78513.
W Decalcomania on fuel tank cap, beginning with vehicle
serial No. 14693.

3
the supporting ordnance maintenance unit should be informed
in order that trained personnel with suitable tools and equipment
may be provided or other proper instructions issued,
Note. The replacement of certain assemblies, that is, engine, transmission,
transfer, and power-take-off assemblies, winch assembly, front axle, rear
axle, and steering gear is normally an ordnance maintenance operation, but
may be performed in an emergency by the using organization, provided
approval for performing these replacements is obtained from the support-
ing ordnance officer. A replacement assembly, any tools needed for the op-
eration which are not carried by the using organization, any necessary
special instructions regarding associated accessories, etc., may be obtained
from the supporting organizational maintenance unit.

General. Responsibility for the proper execution of forms,

records, and reports rests upon the officers of all units maintain-
ing this equipment. However, the value of accurate records must
be fully appreciated by all persons responsible for their compila-
tion, maintenance, and use. Records, reports, and authorized
forms are normally utilized to indicate the type, quantity, and
condition of materiel to be inspected, to be repaired, or to be used
in repair. Properly executed forms convey authorization and
serve as records for repair or replacement of materiel in the
hands of troops and for delivery of materiel requiring further
repair to ordnance shops in arsenals, depots, etc. The forms,
records, and reports establish the work required, the progress of
the work within the shops, and the status of the materiel upon
completion of its repair.
b. Authorized Forms. The forms generally applicable to units
operating and maintaining these vehicles are listed in the ap-
pendix. No forms other than those approved for the Department
of the Army will be used. For a complete listing of all forms,
see DA Pam 310-Z
c. Field Report of Accidents. The reports necessary to comply
with the requirements of the Army safety program are pre-
scribed in detail in the SR 385-1040 series of special regulations.
These reports are required whenever accidents involving injury
to personnel or damage to materiel occur.
d. Report of Unsatisfactory Equipment or Materials. Any sug-
gestions for improvement in design and maintenance of equip-
ment and spare parts, safety and efficiency of operation, or
pertaining to the application of prescribed petroleum fuels, lubri-
cants, and/or preserving materials or technical inaccuracies noted
in Department of Army Publications, will be reported through
technical channels, as prescribed in AR 700-38, to the Chief of

AGO 10167B 5
Ordnance, Washington 25, DC, ATTN: ORDFM, using DA Form
468, Unsatisfactory Equipment Report. Such suggestions are en-
couraged in order that other organizations may benefit.
Note. Do not report all failures that occur. Report only REPEATED or
RECURRENT failures or malfunctions which indicate unsatisfactory de-
sign or material. However, reports will always be made in the event that
exceptionally costly equipment is involved. See also AR 700-38 and printed
instructions on DA Form 468.

Section II. DESCRIPTION AND DATA

4. Description
CL.General. The $&-ton 4 x 4 utility truck M38 is equipped with
one front axle and one rear axle, with four driving wheels. The
design of this vehicle locates the four-cylinder gasoline engine
forward of the driving compartment, under the hood, and pro-
vides a four-passenger, open-type body. The body may be inclosed
with removable canvas top, side curtains, and doors which are
held in place and supported by suitable metal rods, braces, and
canvas straps. The vehicle is used as a general purpose personnel
or cargo carrier especially designed for adaptation to general
reconnaissance, command, communications, or other special duties.
The windshield can be folded forward to lie flat on the hood for
low silhouette and forward firing. The spare wheel and tire are
mounted on the rear of the body. Suitable brackets and com-
partments are incorporated in and on the body for carrying
equipment. The frame is equipped with a towing pintle at the
rear and lifting shackles at the front and rear to permit towing
or lifting the vehicle. General physical characteristics of the
vehicle are shown in figures 1, 2, and 3. The terms “right,” “left,”
“front,” and “rear” are established with reference to the operator
sitting in the driver’s seat. “Right” indicates the side to the right
of the operator. “Left” indicates the side to the left of the opera-
tor. “Front” indicates the radiator end of the vehicle. “Rear”
indicates the end opposite the radiator.
b. Power for the vehicle is supplied by an L-head, four-
cylinder gasoline engine, mounted at three points on cushion
mounts on the frame. The engine, with accessories, is accessible
when the hood is in the raised position.
c. The conventional three-speed, selective-gear
transmission is mounted directly to the rear of the engine and
clutch assemblies. The transmission has three forward and one
reverse speeds as indicated on the shifting instruction plate (fig.
4). These speeds are manually selected by the driver by means
of the transmission gearshift lever. The lever is mounted on top

AGO 10167B
4
Figure 1. X-ton 4 CT4 utility truck M38-left front view-top up.
00
 %-ton 4 1: 4 utility
ro
of the transmission and extends into the driver’s compartment.
d. To supplement the gear ratio of the transmission,
a two-speed transfer is mounted on the rear of the transmission.
The transfer provides additional gear reduction for negotiating
difficult terrain, a power-take-off for the winch, and a means of
transmitting power to the front axle. The transfer is manually
operated by the driver through a set of transfer gearshift levers
on top of the transfer. The levers extend into the driving com-
partment to the right of the transmission gearshift lever.
e. The front axle is a full-floating,
single-reduction-type with hypoid drive gears. Incorporated in
the front axle are constant velocity-type universal joints at the
steering knuckles. A propeller shaft provides a connection from
the front axle to the transfer for the transmission of power.
Power through the transfer is controlled by a transfer gearshift
lever in the driving compartment. Suspension of the front axle
consists of two semielliptic springs, shackled to the frame at the
front of the spring, secured to the frame at the rear of the spring
by pivot bolts, and attached to the front axle by U-bolts.
f. The rear axle is a semifloating,
single-reduction-type with hypoid drive gears. The rear axle is
connected to the transfer by a propeller shaft for the transmis-
sion of power. Suspension of the rear axle consists of two semi-
elliptic springs shackled to the frame at the rear of the spring,
secured to the frame at the front of the spring by pivot bolts,
and attached to the rear axle by U-bolts.
g. The service brakes are actuated hydraulically
using full-floating brake shoes. Service brakes are on all four
wheels and are operated by the brake pedal in the driving com-
partment. The hand brake is a mechanical brake at the rear of
the transfer and is operated by pulling the hand brake handle
outward from the instrument panel. A ratchet holds the handle
in a locked position which can ‘be released by a quarter turn in
either direction.
h. The electrical system furnishes current
for ignition, lights, sending units, etcetera. Current is gener-
ated by a 24-volt, belt-driven generator, and stored in two 12-volt
storage batteries connected in series.

5. Name, Data, Caution, and Instruction Plates

(1) The vehicle identi-

fication plate is located on the instrument panel at the
right of the instrument cluster. The plate includes ve-

AGO 10167B
10
 hicle name, serial number, manufacturer’s name, ord-
nance stock number, part number, model number, con-
tract number, and year manufactured.
(2) The
vehicle servicing data instruction plate is located on the
instrument panel at the right of the instrument cluster.
This plate includes servicing information of the electrical
system, fuel octane, tire inflation pressures, engine, gear
oil, chassis grease, and instructions for cooling system.
If data plate specifies gear oil (GO) grade 90 for tem-
peratures of +40” to -10” F., it should be changed to
grade 75. Tire pressure for highway driving should be
changed from 28 to 25 pounds.
(3) The responsible agency
plate is located on the instrument panel at the right of
the instrument cluster. The plate gives a list of the agen-
cies responsible for maintenance of various parts of
the vehicle.
(4) The vehicle ship-
ping data plate is located on the instrument panel at the
right of the instrument cluster. The plate provides in-
formation on vehicle dimensions, weights, and maximum
towed load.
(5)
The distributor and ignition coil assem-
bly name and data plate is located on the right side of
distributor and ignition coil assembly. The plate includes
manufacturer’s name, model number, and voltage data.
(6) The starter name
and data plate is located on the left side of the starter.
The plate includes the voltage, direction of rotation,
ordnance part number, manufacturer’s name, serial, and
model numbers.
(7) The generator
name and data plate is located on the right side of the
generator. The plate includes the ordnance part number,
voltage, amperage, manufacturer’s name, serial, and
model numbers.
(8) The generator
regulator data plate is located on the left side of the
generator regulator base. The plate gives data on volt-
age rating, capacity and serial, model, and ordnance
numbers.

AGO 10167B 11
Figure 1. Vehicle name, data, caution, and instruction plates.
 (9) The
name, patent, and serial number plate is located on the
inside of the body on the front of right rear wheel
fender well.

Figure 5. Instruction decalcomania and data plates.

(1) The engine serial number

is stamped on the engine cylinder block behind the water
pump and below the thermostat housing at the front
of the engine.

13
 Figure 6. Data plates and engine serial number location.

(2)
The manufacturer’s serial number is stamped at the top
right corner of the transmission case. The name and
model number are cast into the right rear side of the
transmission case.
(3) The manu-
facturer’s serial number (fig. 32) is stamped on top of
the front flange on the left side of the transfer case.
The name and model number are cast into the rear
of the transfer case (fig. 90).
(4) The
carburetor name and model number are cast into the
carburetor float bowl.
(5) The generator regulator name
is stamped on the top of the generator regulator cover.
(6) This plate
is held by two of the screws securing the steering
knuckle oil seal assembly, and identifies the type of joint
used in the front axle.

14 AGO
 (1) The vehicle
road speed caution plate is located on the instrument
panel at the right of the instrument cluster. This plate
gives information on permissible speeds for- various
selected gear positions.
(2) A warning is stamped on
the top of tthe generator regulator cover. This warning
instructs operator to disconnect the battery ground cable
before attempting to remove generator or generator
regulator.

(1) The shifting instruc-

tion plate is located on the instrument panel at the right
of the instrument cluster. The plate gives a shifting dia-
gram for the transmission and transfer and shows the
lever positions for engagement and disengagement of
the front axle. A list of the applicable publications is-
sued for the vehicle also is included.
(2)
The deep water fording vent valve control instruction
plate (fig. 5) is attached to the instrument panel behind
the deep water fording vent valve control (H, fig. 7).
The plate gives instructions for operating the control
when fording.
(3) The
battery cable disconnection decalcomania, providing in-
structions for disconnecting battery cables when working
on electrical units, is located on the cover of battery
“A” at the right front fender.
(4) The igni-
tion switch OFF and ON plate is located on the instru-
ment panel to the left of the instrument cluster around
the ignition switch (G, fig. 7) (MWO ORD G740-W5).
The plate indicates whether the switch is on or off.
(5) The bell
housing drain plug decalcomania is located on the in-
strument panel to the left of the instrument cluster and
above the ignition switch. It gives the location of plug
when not in use, and installation instructions.
(6) The fuel tank cap
is located on the left side of the vehicle. A decalcomania

AGO 10167B 15
 on early production v+icles and a stamping in late pro-
duction vehicle caps warns that the tank is pressurized
and the cap must be removed slowly. See paragraph 127
for description of fuel tank cap.

Capacities :
Cooling system _~_ ~_________I________________ lllh qt
Crankcase (refill) ~_-.___.________________-~~__ 4 qt
Differentials (ea) __~___________________.._____ 2% pt
Fuel tanks ___~~____~~____~____~__~~_~~_~~~_~~- 13 gal
Transfer case ______________~~__. _______~___..__ 3 Pt
Transmission .._____________________~_______--- 2 Pt
Winch _____~__________________~-~__---------- 2 Pt
Crew _____________~__~_____-~______________--____--- 2
Cylinders (in line) ______~__.._____~~~~~______----- 4
Dimensions :
Height (top up) _..~_________~~___~___~___-_--- 74 in.
Height (top down) ~__~~_______~~_~~_~~________ 68 in.
Length _____~_~~~~______________-_..-_--_---_-~ 133 in.
Width ____~___~~__~_~____________~~~__-~_---- 62 in.
Electrical system ____ ~_~~_~~~~~__~~~_~~________..___ 24 v
Engine ___________~_~~~~____~____-_____-~__~-~---~ Model MC
Ground clearance (min) (rear axle) __..________~____ 9% in.
Loading height (empty) (top down) __~___~_____~~__ 44 in.
Number of batteries ______~_____________~_--~~----- 2
Passengers (incl crew) ~~~____________________----~ 4
Pintle height (rear) :
Empty ___________________~_~~___-~--~------.-_ 20 in.
Loaded (cross-country) __. __~_____~_____~______ 18% in.
Loaded (highway) __________~__.._~___~___~~ ___ 17% in.
Tires :
Size and type-Military nondirectional mud and 6 ply, 7.00 x 16
snow.
Pressure :
Highway ~~_~~~~_~~__~~~____~~___~_________ 25 psi
Cross-country _. ___~~__~________________-~- 25 psi
Mud, sand, or snow _____~_______________--- 10 psi
Weight:
Gross :
On highway ________..___~ ____ __________.-__ 3,950 lb
Off highway _ ~_~~~_________~_~~_________-- 3,550 lb
Net _______~~~~~__~~___________---_-------____ 2,750 lb
Pay load:
On highway ____ _____________________..~-- $200 lb
Off highway _____________________--___-__- 800 lb
Wheelbase _______________________-___--_---___-___ 80 in.

16 AGO
 Allowable speed :
1st 2d Sd Rf9JC378t?
Transfer case in high range ___ 21____40 .___60__ 16 mph
Transfer case in low range _~_ 6____12___-22__ 5 mph
Angle :
Approach _______~_____________-------_----.-- 55 deg
Departure _____________________-----_-_-----__ 35 deg
Cruising range (loaded) ____________________---__-- 225 mi at 35 mph
Cruising speed ____________________--__----_-__--__ 55 mph
Engine horsepower (bhp) :
At 2,000 rpm ___~__________~_~_____~_--___---_ 40 bhp
At 4,000 rpm ____________________-~~__-_--_~_-_ 60 bhp
Fording depth (max) (w/fording equipment) ________ 74 in.
Fording depth (max) (w/o fording equipment) _~____ 30 in.
Fuel consumption (loaded) _________~____________-- 17.3 mpg
Grade ascending ability (max) ___________~_________ 66.2 per cent
Recommended towed load :
On highway (max) ____.._____~______________ 2,000 lb
Cross-country (max) ____________________---_-- 1,500 lb
Turning circle (diam) (right or left) (min) ________ 19 ft
Winch capacity ______________________. __-.___________ 3,500 lb
c. Additional detailed tabulated data
pertaining to individual components and systems are contained
in the following paragraphs:
Paragraph

Body and frame _____________________-----------_-----___-____ 258

Brake system _________~_____________----__-_--__-----_---____ 240
Cooling system ____________________--___--_-~_--_-_-----_----- 120
Electrical system :
Battery and lighting system ________~_____________------__ 154
Generating system ~__~__~___~______________________________ 151
Ignition system __________ _____________________----_----_- 140
Starting system ___~_________________________--____---____ 147
Engine _~____________________-----_-----------__-_--_--_---_ 101
Front axle ____________________-___________________-_____-_____ 221
Fuel and air intake system ______________.._________-_____--_-_- 12’7
Propeller shafts and universal joints ~____________________-_____ 208
Rear axle _______________~_~________________________-__----_ 212
Springs and shock absorbers _____________________-----_---___- 248
Steering system ______..__~__~________-----__--__-------_----- 232
Transfer _____________________--_-__-___________-___________- 197
Transmission and power-take-off _~_______________________----_- 203
Wheels and tires ___~__________-_-___--_-___----__------------ 254
Winch___________-_~----_~---------_--_--__--__-_-____---~--- 54

AGO 10167B 17
 Tools, equipment, and spare parts are issued to the using or-
ganization for maintaining the materiel. Tools and equipment
should not be used for purposes other than prescribed and, when
not in use, should be properly stored in the chest and/or roll
provided for them.

Spare parts are supplied to the using organization for replace-

ment of those parts most likely to become worn, broken, or
otherwise unserviceable providing replacement of these parts is
within the scope of organizational maintenance functions. Spare

I-

Figure 13. Special tools.

10167B
48
parts, tools, and equipment for the v!-ton 4 x 4 utility truck M38
are listed in ORD 7 SNL G-740, which is the authority for requi-
sitioning replacements.

64. Common Tools and Equipment

Standard and commonly used tools and equipment having gen-
eral application to this materiel are authorized for issue to 1st
echelon by ORD 7 SNL G-740. Common tools and equipment for
2d echelon are listed in ORD 6 SNL J-7, Sections 1, 2, and 3;
ORD 6 SNL J-10, Section 4; and are authorized for issue by
TA and TOE.

65. Special Tools and Equipment

Certain tools and equipment specially designed for operation
and organizational maintenance, repair and general use with the
materiel, are listed in table I for information only. This list is
not to be used for requisitioning replacements.

References
Item Identifying
No. I- Fig. Par.
Use

ADAPTER, puller, 41-A-18-251 13, 111 239 Removing steer-

steering wheel. ing wheel.
PULLER, water 41-P-2908-240 13, 42 114 Removing water
pump pulley. pump pulley.
REMOVER and RE- 41-R-2374-750 13, 104 230 Removing or in-
PLACER, bearing stalling steer-
cup (spindle pin, ing knuckle
used w/screw 41-S- flange bearing
1047-300). cup.
REMOVER and RE- 41-R-2374-845 13, 100 225 Removing or in-
PLACER, bearing stalling front
cup (wheel, used hub bearing
w/screw 41-S- cup.
1047-330).
SCREW, remover and 41-s-1047-300 13, 104 230 Used w/RE-
replacer (bearing MOVER and
cup) threaded, %- REPLACER
16NF-2, length 6 in. 41-R-2374-750.
SCREW, remover and 41-s-1047-330 13, 100 225 Used w/RE-
replacer (bearing MOVER and
cup) threaded, I%- REPLACER
12NF-2. 41-R-2374-845.
WRENCH, wheel 41-W-3825-200 13, 98 224 Removing or re-
bearing nut, size of placing wheel
opening 2% in., bearing nut.
length 3.56 in.

AGO 10167B
 Section II. LUBRICATION AND PAINTING

66. lubrication Order

Lubrication Order 9-8012 (figs. 14 and 15) prescribes cleaning
and lubricating procedures as to locations, intervals, and proper
materiels for this vehicle. The official lubrication order will be
carried with the vehicle at all times. In the event the vehicle is
received without a copy, the using organization shall immediately
requisition one. See DA Pam 310-4 for lubrication order of cur-
rent date. Lubrication which is to be performed by ordnance
maintenance personnel is listed on the lubrication order in the
“NOTES” (fig. X), and in a few instances are contained in the
pertinent section.

67. General Lubrication Instructions

n. Gencml. Any special lubricating instructions required for
specific mechanisms or parts are covered in the pertinent sections.
6. Usual Conditions. Service intervals specified on the lubrica-
tion order are for normal operation and where moderate tem-
perature, humidity, and atmospheric conditions prevail.
c. I,ub7ication Equipwent. Organizational maintenance tdol sets
contain lubrication equipment adequate for maintenance. Clean
this equipment both before and after use. Operate the lubricating
guns carefully and in such a manner as to insure a proper dis-
tribution of the lubricant.
d. Points of Application.
(1) Lubrication points are shown in figures 16 through 19
and are referenced to the lubrication order. Clean fit-
tings and surrounding surfaces as prescribed in lubri-
cation general notes (fig. 14).
(2) A :jI,<-inch red circle should be painted around all lubri-
cating fittings, oil can points, and refill plug holes.
(3) Clean and lubricate unsealed bearings as in (a), (b),
and (c) below.
(a) Wash all the old lubricant out of the bearings and
from the inside of the hubs with volatile mineral
spirits or dry-cleaning solvent and dry the parts
thoroughly.
Cnutiorc: Bearings must not be dried or spun with
compressed air. See TM 37-265 for care and mainte-
nance of bearings.

50 AGO 10167B
 (b) Pack the bearings by hand or with a mechanical
packer introducing the lubricant carefully between
the rollers. Do not smear grease only on the outside
of the bearings and expect it to work in. Great care
must be exercised to insure that dirt, grit, lint, or
other contaminants are not introduced into the bear-
ings. If the bearings are not to be installed immedi-
ately after repacking, they should be wrapped in clean
oilproof paper to protect them from contaminants.
(c) After the bearings are properly lubricated, pack the
hub with a sufficient amount of lubricant to uniformly
fill it to the inside diameters of the inner and outer
bearing races. Coat the spindles and hub caps with
a thin layer of lubricant (not over % 6 in.) to prevent
rusting. Do not fill the hub caps to serve as grease
cups under any circumstances. They should be lightly
coated, however, to prevent rusting.
Note. For normal operation, lubricate wheel bearings at 12,000
miles or at annual intervals, whichever comes first.
e.
(1) Report unsatisfactory performance of prescribed pe-
troleum fuels, lubricant, or preserving materials, using
DA Form 468, Unsatisfactory Equipment Report.
(2) Maintain a record of lubrication of the vehicle on DA
Form 461, Preventive Maintenance Service and Inspec-
tion for Wheeled and Half-Track Vehicles.

68. lubrication Under Unusual Conditions

Reduce service intervals specified on
lubrication chart, that is lubricate more frequently, to compen-
sate for abnormal or extreme conditions, such as high or low
temperatures, prolonged periods of high speed operation, con-
tinued operation in sand or dust, immersion in water, or exposure
to moisture. Any one of these operations or conditions may cause
contamination and quickly destroy the protective qualities of the
lubricants. Intervals may be extended during inactive periods
commensurate with adequate preservation.
Lubricants are prescribed
in the “Key” in the lubrication order (fig. 15) in accordance with
three temperature ranges; above f32” F., f40” F. to -10” F.
and from 0” F. to -65” F. Change the grade of lubricants when-
ever weather forecast data indicate that air temperatures will be
consistently in the next higher or lower temperature range or
when sluggish starting caused by lubricant thickening occurs.

51
 LC 19-75AAA-8
LoID
$l48ul2 9.804. 26 Ad 19511

TRUCK, %-TON, 4 x 4, UTILITY, M38

Reference.TM 9.804; OK? 7 SNL G-740

F, 16

(Check level)
E, FIG 16
Front
ID&n and refilLCop. ptJ
Eee note

D
(Turn handle cae corn-
plete turn1 (See nc.+e 3)

FIG 16 Crankcar.

AA, HG 15 [Check level)

miles or
annually, remove, dean, Crankcase
(Drain and WilLCap.
dry and repack1

AS, FIG IS - Universal Joint and

Steering Knuckle FIG
Bearings
(See-note 6) FIG 18
I)

‘abc
 obc d

GAA 1
GO

Shaft

(Check level)

refilLCap. ptr)
(See note

Transmission

GAA
o”n”olly, renlove, clean,
dry and repack)

and Level Rew

(Check level)

RA PD 364009
Figure 14.Lubrication order.
Figure 15. Lubrication order key.
AGO 10167B
55
 Figure 17. Localized lubrication points J through T.

56 AC0
 Figure 18. Localized lubrication points U through 2.

No change in grade will be made when a temporary rise in tem-

perature is encountered.
c. Maintaining Proper Lubricant Levels. Lubricant levels must
be observed closely and necessary steps taken to replenish in order
to maintain proper levels at all times.

69. lubrication For Continued Operation Below 0” F.

Refer to TM 9-2855 for instructions on necessary special pre-
liminary lubrication of the vehicle, and to TB 9-2855-3 for in-
structions on installation of the winterization kit.

70. lubrication After Fording Operations I

a. After any fording operation, in water 12 inches or over,
lubricate all chassis points to cleanse bearings of water or grit
as well as any other points required in accordance with paragraph
275, for maintenance operations after fording.

10167B 57
 If the vehicle has been in deep water for a considerable length
of time, or was submerged beyond its fording capabilities, pre-
cautions must be taken as soon as practicable to avoid damage
to the engine and other vehicle components in (1)) (2)) and (3)
below.
(I) Perform a complete lubrication service (par. 66).
(2) Inspect engine crankcase oil. If water or sludge is
found, drain the oil and flush the engine with preserva-
tive engine oil PE-30. Before putting in new oil, drain
the oil filter and perform maintenance operation (par.
111).
If preservative engine oil is not available, engiue lubricat-
ing oil OE-30 may be used.

(3) Operation in bodies of salt water enhances the rapid

growth of rust and corrosion, especially on unpainted

58 AGO 10167B
 surfaces. It is most important to remove all traces of
salt water or salt deposits from every part of the vehicle
or equipment. For assemblies which have to be disas-
sembled, cleaned, dried, and relubricated, perform these
operations as soon as the situation permits. Wheel bear-
ings must be disassembled and repacked (par. 67d (3) )
after each submersion. Regardless of the temporary
measures taken, the vehicle must be delivered as soon
as practicable to the ordnance maintenance unit.

71. lubrication After Operation Under Dusty or Sandy

Conditions
After operation under dusty or sandy conditions, clean and
inspect all points of lubrication for fouled lubricants and re-
lubricate as necessary. Special attention should be given to the
air cleaner and maintenance performed according to lubrication
order (“NOTES,” fig. 15).
Note. A lubricant which is fouled by dust and sand makes an abrasive mix-
ture that causes rapid wear of parts.

72. Painting
Instructions for the preparation of material for painting, meth-
ods of painting, and materials to be used are contained in TM
9-2851. Instructions for camouflage are contained in FM 5-20B.
Materials for painting are listed in ORD 7 SNL G-740.

Section III. PREVENTIVE MAINTENANCE SERVICES

73. General
a. Responsibilities and Intervals. Preventive maintenance serv-
ices are the responsibility of the using organization. These serv-
ices consist generally of daily operator’s services (daily “A”
services) performed by the operator or crew, and of biweekly
services (biweekly “B” services) performed by the crew (under
supervision of the squad, section, and platoon leaders) ; and of
the scheduled services to be performed by organizational mainte-
nance personnel (“C” and “D” services). Intervals are based on
normal operations. Reduce intervals for abnormal operations or
severe conditions. Intervals during inactive periods may be ex-
tended accordingly.
b. Definition of Terms. Inspections to see if items are in good
condition, correctly assembled or stowed, secure, not excessively
worn, not leaking, and adequately lubricated apply to most items
in the preventive maintenance and inspection procedures. Any or

AGO 10167B 59
all of these checks that are pertinent to any item (including sup-
porting, attaching, or connecting members) will be performed
automatically, as general procedures, in addition to any specific
procedures given.
(1) Inspection for “good condition” is usually visual inspec-
tion to determine if the unit is safe or serviceable.
“Good condition” is explained further as meaning: not
bent or twisted, not chafed or burned, not broken or
cracked, not bare or frayed, not dented or collapsed, not
torn or cut and not deteriorated.
(2) Inspection of a unit to see if it is “correctly assembled
or stowed” is usually a visual inspection to see if the unit
is in its normal position in the vehicle and if all its parts
are present and in their correct relative positions.
(3) Inspection of a unit to see if it is “secure” is usually a
visual, hand-feel, pry-bar, wrench, or screwdriver in-
spection for looseness in the unit. This inspection will
include any brackets, lockwashers, locknuts, locking
wires, and cotter pins as well as any connecting tubes,
hoses or. wires.
(4) “Excessively worn” is understood to mean worn beyond
serviceable limits, or likely to fail if not replaced before
the next scheduled inspection. Excessive wear of mating
parts or linkage connections is usually evidenced by too
much play (lash or lost motion). It includes illegibility
as applied to markings, data and caution plates, and
printed matter.
(5) Where the instruction “tighten” appears in the pro-
cedures, it means tighten with a wrench, even if the
item appears to be secure.
(6) Such expressions as “adjust if necessary” or “replace
if necessary” are not used in the specific procedures. It
is understood that whenever inspection reveals the need
of adjustments, repairs, or replacements, the necessary
action will be taken.

74. Cleaning
a. General. Any special cleaning instructions required for spe-
cific mechanisms or parts are contained in the pertinent section.
General cleaning instructions are as shown in (1) through (5)
below.
(1) Nameplates, caution plates, and instruction plates made
of steel rust very rapidly. When they are found to be
in a rusty condition, they should be thoroughly cleaned
and heavily coated with an application of lacquer.
AGO 10167B
 (2) Use dry-cleaning solvent or volatile mineral spirits to
clean or wash grease or oil from all parts of the vehicle.
(3) A solution of one part grease-cleaning compound to four
parts of dry-cleaning solvent or volatile mineral spirits
may be used for dissolving grease and oil from engine
blocks, chassis, and other parts. Use cold water to rinse
off any solution which remains after cleaning.
(4) After the parts are cleaned, rinse and dry them thorough-
ly. Apply a light grade of oil to all polished metal
surfaces to prevent rusting.
(5) Before installing new parts, remove any preservative
materials, such as rust-preventive compound, protective
grease, etc. ; prepare parts as required (oil seals,
etc.) ; and for those parts requiring lubrication, apply
the lubricant prescribed in the lubrication order (par.
66 and figs. 14 and 15).

Dry-cleaning solvent and volatile mineral spirits are

inflammable and should not be used near an open flame.
Fire extinguishers should be provided when these mate-
rials are used. Use only in well ventilated places.
(2) These cleaners evaporate quickly and have a drying ef-
fect on the skin. If used without gloves, they may cause
cracks in the skin or a mild irritation or inflammation.
(3) Avoid getting petroleum products, such as dry-cleaning
solvent, volatile mineral spirits, engine fuels, or lubri-
cants on rubber parts as they will deteriorate the rubber.
(4) The use of diesel fuel oil, gasoline, or benzene (benzol)
for cleaning is prohibited.

75. Preventive Maintenance by Driver or Operator(s)

To insure efficient operation, it is necessary that
the vehicle be systematically inspected at intervals every day
it is operated and also biweekly, so defects may be discovered and
corrected before they result in serious damage or failure. Certain
scheduled maintenance services will be performed at these desig-
nated intervals. Any defects or unsatisfactory operating char-
acteristics beyond the scope of the driver or operator(s) to cor-
rect must be reported at the earliest opportunity to the designated
individual in authority.
b. Services. Driver or operators preventive-maintenance serv-
ices are listed in table II. Every organization must thoroughly
school its personnel in performing the maintenance procedures
for this vehicle as set forth in this manual.

AGO 10167B 61
 Services.

Intervals
Daily “A”

Procedure

-
Caution: Place all tags describing condition
of vehicle in the driver’s compartment in a
conspicuous location so they will not be over-
looked.
X %el, oil, and Check the amount of fuel
in the fuel tank (par. 26) and note any indi-
cation of leaks. Add fuel if necessary and
check the spare fuel containers. Check en-
gine oil level and add oil if necessary. Check
coolant level in the cooling system and note
any indication of leaks. When water is added
(par. 121) during period that antifreeze is
in use, a hydrometer test must be made and
antifreeze added, if necessary, to provide safe
operation to meet lowest anticipated tempera-
tures (TM 9-2855).
X _-_- ___~ Tires. Gage all tires, including spare, for correct
pressure (par. 6a).
X Remove all penetrating objects such as nails or
glass. Examine tires for signs of low pressure,
abnormal tread wear, cuts or missing valve
caps.
Look under the vehicle and in
engine compartment for indications of fuel,
engine oil, gear oil, water or brake fluid leaks.
X Visually inspect fire extin-
guishers and make sure vehicle publications
and necessary forms are present and in good
condition.
3ee that fire extinguishers are charged.
3perate lights, horn (if tactical situation per-
mits) , and windshield wipers. Visually inspect
mirrors, reflectors, lights, body, towing con-
nections, paulins, tools, etc.
Check for any tampering or damage that may
have occurred since last inspection.
Observe for normal readings dur-
ing warm-up and during operation of vehicle.
Caution: If oil pressure is zero or excessively
low, stop engine immediately and investigate
cause (par. 782).
X __-_ General Be alert for any unusual
noises or improper operation of steering,
clutch, brakes, or gear shifting.

AGO 10167B
62
 Intervals
Daily “A”

Procedure

faults. Investigate and correct or re-

port any faults noted during operation.
Springs Look at springs and
shock absorbers to see if they have been dam-
aged.
Oil filter. On Cuno-type filter, turn the handle
one complete turn. Check filter for leaks.
Remove drain plug and drain sediment.
Lubricate items specified on lubrica-
tion order (par. 66).
Clean. Clean glass vision devices and inside of
vehicle. Wipe off exterior of vehicle.
Wash vehicle, clean engine and engine compart-
ment. .
Clean, check water level, inspect ter-
minals for corrosion, tightness, and coating
of grease (TM 9-2857).
Inspect assemblies such
as carburetor, generator, starter, coil, dis-
tributor, water pump, and hose for loose con-
nections or mountings. Check adjustment of
drive belts (par. 123).
Check all accessible electrical
wiring, conduits, and shielding to see that it
is securely connected and in good condition.
Inspect for clogging.

The indicated frequency of the prescribed preven-

tive-maintenance services is considered a minimum requirement
for normal operation of vehicle. Under unusual operating con-
ditions, such as extreme temperatures, dust or sand, or extremely
wet terrain, it may be necessary to perform certain maintenance
services more frequently.
The drivers or operators
should accompany vehicle and assist the mechanics while periodic
organizational preventive-maintenance services are performed.
Ordinarily, the driver should present the vehicle for scheduled
preventive-maintenance service in a reasonably clean condition.

AGO 1016’7B
 c. These are indicated by the item numbers
in the columns which show the interval at which the services are
to be performed, and show that the parts or assemblies are to
receive certain mandatory services. For example, an item number
in one or both columns opposite a “Tighten” procedure means
that the actual tightening of the object must be performed. The
special services are as shown in (1) through (5) below.
(1) Make all necessary adjustments in accordance
with instructions contained in the pertinent section of
this manual, information contained in changes to the
subject publication, or technical bulletins.
(2) Clean the unit as outlined in paragraph 74 to
remove old lubricant, dirt, and other foreign material.
(3) This applies either to lubrication
operations that do not appear on the vehicle lubrication
order (par. 66) or to items that do appear but which
should be performed in connection with the maintenance
operations if parts have to be disassembled for inspec-
tion or service.
(4) Service. This usually consists of performing special
operations, such as replenishing battery water, draining
and refilling units with oil, and changing or cleaning
the oil filter, air cleaner, or cartridges.
(5) All tightening operations should be performed
with sufficient wrench torque (force on the wrench
handle) to tighten the unit according to good mechanical
practice. Use a torque-indicating wrench where specified.
Do not overtighten, as this may strip threads or cause
distortion. Tightening will always be understood to in-
clude the correct installation of lockwasher, locknuts,
locking wire, or cotter pins to secure the tightened nut.
d. When conditions make it difficult to per-
form the complete preventive maintenance procedures at one
time, they can sometimes be handled in sections. Plan to complete
all operations within the week if possible. All available time at
halts and in bivouac areas must be utilized, if necessary, to assure
that maintenance operations are completed. When limited by the
tactical situation, items with special services in the columns
should be given first consideration.
e. DA Form 461. The numbers of the preventive maintenance
procedures that follow are identical with those outlined on DA
Form 461, Preventive Maintenance Service and Inspection for

AGO 10167B
Wheeled and Half-Track Vehicles. Certain items on the form that
do not apply to this vehicle are not included in the procedures
in this manual. In general, the sequence of items on the form is
followed, but in some instances there is deviation for conserva-
tion of the mechanic’s time and effort.
f. Procedures. Table III lists the services to be performed by
the organizational mechanic or maintenance crew at the desig-
nated intervals. Each page of the table has two columns at its
left edge for designated intervals of every 1,000 miles (“(7’
service) and 6,000 miles or 6 months whichever occurs first
(“D” service). Very often it will be found that a particular pro-
cedure does not apply to both scheduled intervals. In order to
determine which procedure to follow, look down the column cor-
responding to the maintenance procedure and wherever an item
number appears, perform the operations indicated opposite the
number.

Organizational Mechanic or Maintenance Crew “C” and “D”

Preventive Maintenance Services.

Interval
“D”
“C” (6 montha or Procedure
(every 1,000 6,000 miles
miles) whichever
oeeum Amt)

INSPECTION AND ROAD TEST

Note. When the tactical situation does notpermit
L full road tit, perform only those items that re-
pire little or no movement of the vehicle.
BEFORE OPERATION: Fuel, oil, water,

Perform the services

listed in table II.
3ash and gages, oil
pressure,
ignitjon
Note generator output on the am-
meter immediately after starting engine,
before generator regulator has reduced the
charging rate. Observe all instruments for
normal readings. Notice if ignition switch
operates freely and makes positive contact,
and check all other controls for normal op-
eration (figs. 7 and 11).
Horns, mirrors, and Sound
horn to see if signal is normal (if tactical
situation permits). Test windshield wipers
for satisfactory operation. Examine mirrors
and reflectors.

AGO 10167B 65
 Procedure

INSPECTION AND ROAD TEST-Con.

In
warming up the engine, observe if it starts
easily and if action of choke control and
throttle control (CC and BB, fig. 7) are
satisfactory. Notice if idling speed is cor-
rect. Listen for any unusual noises at idle
and higher speeds. When operating the
vehicle, notice if it has normal power and
acceleration in each speed. Listen for any
unusual noises when the engine is under
load.

(par. 99). With

the vehicle moving straightahead, see if the
steering wheel has excessive free play and
if there is any tendency to wander, shimmy,
or pull to the side. Turn the steering wheel
through its entire range and note any bind.
Examine steering gear jacket and wheel.
drag, noise, grab,
if clutch pedal has specified free
travel (par. 196) and if action of pedal
return spring is satisfactory. Note whether
clutch disengages completely or has a tend-
ency to drag. Observe smoothness of en-
gagement and tendency to chatter, grab,
or slip and any unusual noise. With trans-
mission in neutral, depress and release
clutch pedal (EE, fig. 7) listening for de-
fective release bearing.
Brakes (service and

hand 96). See if

brake pedal has specified free travel and if
action of return spring is satisfactory. Ob-
serve if pedal goes too close to floor. Make
several stops noting side pull, noise, chat-
ter, or any other unusual conditions. Ob-
serve if ratchet of hand brake holds and if
the handle requires more than three-quar-
ters travel for full application. Stop the
vehicle on an incline and apply the hand
brake to see if it holds the vehicle or if
application of hand brake at a speed of 10
mph stops the vehicle within a reasonable
distance.

66 AGO
 INSPECTION AND ROAD TEST-Con.
8 8 Generator starter and switch-action, noise,
speed (pars. 82 and 85). Notice if the
starter switch requires only normal pres-
sure, and if the starter engages smoothly
without unusual noise and turns the engine
with adequate cranking speed. Examine
generator brushes and clean commutator.
9 9 Transmission and transfer-lever action, de-
clutching, vibration, noise. Shift transmis-
sion and transfer into all speeds, observing
any unusual stiffness of the shift levers,
tendency to slip out of speed, unusual noise,
or excessive vibration. Make similar ob-
servations with transfer front wheel drive
gearshift lever (par. 47).
10 10 Unusual noises - attachments, body and
wheels, power train. At all times during
the road test, be alert for unusual or ex-
cessive noises that might indicate loose-
ness, defects, or deficient lubrication in
these components.
11 Lamps-head, tail, body, running, stop, and
blackout. During stops in the road test,
test the operation of these exterior and in-
terior lights and light switches. Notice if
headlights appear to be properly aimed
(figs. ‘71 and 73). Note condition of lights
and safety reflectors.
AFTER ROAD TEST
26 25 Temperatures - brake drums, hubs, axles,
transmission, transfer, and differentials.
Immediately after the road test, feel these
units cautiously. An overheated wheel hub
and brake drum indicates an improperly
adjusted, defective, or dry wheel bearing
or a dragging brake. An abnormally cool
condition indicates an inoperative brake
(par. 96). An overheated gear case indi-
cates internal maladjustment, damage, or
lack of lubrication (par. 66).
Note.

Dhced upon

AGO
 “D”
“C” (6 montlla or Procedure
(every 1,000 6,000 miles
mile% ) whichever
oceum first)

AFTER ROAD TEST-Continued

26 Inspect propeller shafts (figs. 91 and 92).
Tighten universal joint assembly and flange
units (par. 92).
26 26
transmission,

Make general observations in the engine

compartment and underneath the vehicle
for oil, water, fuel, and exhaust leaks. Look
at spark plug, manifold, and cylinder head
gaskets.
Caution: Do not tighten the cylinder head
or manifold unless there is evidence of
looseness or leakage.
If cylinder head requires tightening, use a
torque indicating wrench and tighten in
the sequence (fig. 25) and to the torque
specified in paragraph 103.
27 27 accordance
lubrication order (par. Coordi-
nate with inspection and disassembly op-
erations to avoid duplication.
27 27 During lubrication, inspect tires for unusual
wear, penetrating objects, and proper
matching.
27 Rotate and match tires according to tread
design and degree of wear (par. 255). See
TM 31-200 for acceptable limits in match-
ing tires. Tighten axle flange nuts.

MAINTENANCE OPERATION
28 28 Make hydrometer
test of electrolyte in each cell (TM 9-2857)
and record specific gravity in space pro-
vided on DA Form 461.
29 29 Perform a high-rate dis-
charge test according to instructions in TM
9-2857 or accompanying test instrument.
Record voltage of each cell in space pro-
vided on DA Form 461.
29 After battery test, clean top of battery, coat
terminals lightly with grease, repaint car-
rier if corroded. Look to see if battery re-
quires water.
If distilled or approved water is not available,
clean water. preferably rain water, may be used.

68 AGO 10167B
 (6 months or Procedure
6,000 milea
whichever
occllrs first)

MAINTENANCE OPERATION-Continued
30 Compression. Test compression in each cylin-
der (par. ) , with throttle and choke
wide open, and record in s’pace provided on
DA Form 461. It is preferable to make com-
pression test with engine at operating tem-
perature.

31 cleaner,
Clean and inspect air cleaner, crank-
case ventilator, and control valve (par.
107).

31 Clean and service these items in accordance

with the lubrication order (par. 66), or in-
structions in the pertinent section of this
manual.

32
Inspect these items, noticing particularly
if the radiator core is clogged with foreign
matter or if fins are bent. Test the opera-
tion of the pressure cap. Observe coolant
level (par. 121) and examine coolant for
contamination. In cold weather, test coolant
with a hydrometer to see if it contains suf-
ficient antifreeze.

32 :f need is indicated, drain radiator and block

(fig. 40), clean, flush, refill (par. 121),
and add rust inhibitor, unless antifreeze,
which contains inhibitor, is used. Tighten
radiator mountings and hose clamps.

33 pump, fan, drive

Inspect pulleys and fan for aline-
ment and drive belts for proper tension
(par. 123 and fig. 42). Notice if water
pump is leaking.

34 mechanism-clearance, cover
Gage intake and exhaust valve tappet
clearance (par. 105) and look for broken
or weak valve springs if need is indicated
by engine performance, low compression, or
tappet noise. If clearance is found in-
correct, adjust (par. 105), and recheck en-
gine compression (par. ) . Inspect
cover gaskets.

AGO 10167B 69
 (6 months or Procedure
6,000 miles
whichever
occurs a73t)

MAINTENANCE OPERATION-Continued
35 Spark
points,
Remove
and inspect spark plugs (par. 145). In-
spect distributor cap, rotor, and breaker
points and test operation of centrifugal
and vacuum advance mechanism by hand.
Test distributor shaft for looseness by
hand feel. Test ignition coil and distribu-
tor capacitor with high-tension ignition-
circuit tester, if available, according to
instructions accompanying the test instru-
ment. Using neon timing light, observe
if ignition timing (figs. 58 and 59) is
correct (par. 142) and if spark advances
automatically as engine is accelerated.
Test generator regulator with a low-volt-
age circuit tester following instructions
accompanying the test instrument.

35 Zlean spark plugs and adjust gaps (par.

145). Check distributor breaker points
and adjust gap (par. 143), (figs. 57 and
61). If points are badly pitted, repIace
both points and capacitor.

36 and heat Inspect these

items. Look particularly for signs of
leakage at manifold gaskets. If heat con-
trol is automatic, see if shaft operates
freely and if bimetal spring controls it
properly. If it is manually controlled,
check seasonal adjustment.

37 37 linkage
lines. Inspect these items notic-
ing particularly if the shafts and linkage
operate freely and are not excessively
worn. Observe if the choke valve plate
opens fully when the choke control is
released and if the throttle valve plate
opens fully when the accelerator is fully
depressed.

37 ffake an engine vacuum test (par. 79c(6) ),

and adjust carburetor idle mixture (par.
129). Test fuel pump pressure (par.

AGO 10167B
70
 Interval

“D”
“C” (6 months or Procedure
(every 1,000 6,000 miles
miles ) whichever
occurs first)

tiAINTENANCE OPERATION-Continued
examine fuel lines and connections for evi-
dence of leaks. Clean the filter element
of fuel filter; drain water and sediment
from fuel tank if there is evidence of
contamination, using a container to catch
the drainings.
Inspect; listen
for excessive or unusual noises and look
for exhaust leaks.
righten mountings.

Inspect flexible and rigid brake lines and

test brake linkage for freedom of action.
lemove wheels (par. 256a) and brake drums
(par. (3) and e (3) ) and examine
drums, shoes, linings, guides, anchors,
supports, retractor springs, and cylinders
and cams.
Wheel bearings will be disassembled, cleaned
and repacked (pars. 215~ and c,
and and 67) in every mile
inspection or annually. If the wheel bear-
ings are due for repacking, remove wheels
and hubs and make observations of the
brake internal components as in the pre-
ceding paragraph. Clean the anchor plates
and tighten the anchor-plate bolts. If the
wheel bearings are not due for repacking,
inspect the internal brake components only
on vehicles from which the brake drum
can be removed without removing the hubs
and bearings. Adjust brakes (par. 242).
If wheels have not been disassembled from
brake drums, tighten wheel nuts.

Inspect
these items, paying particular attention
to body mountings and springs. Test op-
eration of windshield, hood hinges, and
fasteners. Observe seat mountings and
upholstery. Make a general inspection of
the body including glass, panels, tops,
fenders, running boards, chains, bows,

AGO 10167B
 Interval

“D”
“c” (6 months or Procedure
(every 1,000 6,000 miles
miles ) whichever
occur* first)

MAINTENANCE OPERATION-Continued
paulins, curtains, and grille guard. Examine
condition of paint and legibility of mark-
ings and identification and caution plates.
Tighten body mounting bolts. Loosen the
steering gear jacket clamp before tight-
ening body mounting bolts and tighten
afterward. Tighten spring U-bolts and
spring leaf clips.
and
Inspect these items including lifting
shackles. Test operation of towing pintle
(fig. 10).
Inspect power-take-
off and winch drive lines (pars. 54 and
202). Test operation of winch. Clean
and oil winch cable in accordance with
lubrication order (par. 66).

This section contains troubleshooting information and tests

for locating and correcting some of the troubles which may de-
velop in the vehicle. Troubleshooting is a systematic isolation of
defective components by means of an analysis of vehicle trouble
symptoms; testing to determine the defective component and ap-
plying the remedies. Each symptom of trouble given for an in-
dividual unit or system is followed by a list of probable causes of
the trouble and suggested~ro@zdures to be followed.
This manual cannot cover all possible troubles and deficiencies
that may occur under the many conditions of operation. If a
specific trouble, test, and remedy therefor are not covered herein,
proceed to isolate the system in which the trouble occurs and
then locate the defective component. Do not neglect use of any
test instruments such as voltmeter, ammeter, test lamp, hy-
drometer, and pressure and vacuum gages that are available.
Standard automotive theories and principles of operation apply
in troubleshooting the vehicle. Question vehicle driver or operator
to obtain maximum number of observed symptoms. The greater

72 AGO 10167B
the number of symptoms of troubles that can be evaluated, the
easier will be the isolation of the defect.

a. Engine Will Not Turn.

(1) Weak or discharged batteries. Test batteries and re-
place if necessary (par. 155).
(2) Loose battery ground cable. Clean and tighten battery
ground cabl’e (par. 155).
(3) Loose or corroded battery terminals. Clean and tighten
battery terminals (par. 155).
(4) Faulty starter switch. Refer to paragraph 82.
(5) Faulty starter. Refer to paragraph 82.
(6) Incorrect oil viscosity. Inspect engine oil. Check records
of oil changes and if found to be improper grade, drain
and refill with correct grade of engine oil (par. 66).
(7) Mechanical seizure of engine parts. Refer to ordnance
maintenance personnel.
b. Engine Turns But Will Not Start.
(1) Lack of fuel. Check fuel gage on instrument panel
with ignition switch turned on, and also check actual
level in fuel tank to be sure there is sufficient fuel for
operation and that fuel gage is operative.
(2) Engine is wet. Although engine is waterproofed, it
is possible for moisture to collect due to seepage, loose
connections, or condensation. Wipe all moisture from
distributor terminal housing, distributor cap, coil, and
spark plugs.
(3) Engine is too hot. If engine is hot, either vapor lock
or “percolation” might exist. Vapor lock is due to the
vaporization of fuel before it reaches the carburetor and
as a result the engine is starved for fuel. “Percolation”
is caused by the fuel vaporizing in the carburetor pas-
sages. The bubbles rise, pushing the fuel above them
into the carburetor throat. Vapor lock may occur when
the vehicle is under load and can slow or completely
stop vehicle. “Percolation” occurs only as the engine
speed is reduced or when the vehicle is standing and
engine is idling. To start a vehicle which has vapor
locked or “percolated,” press the accelerator pedal to
floor board and crank engine until it starts. Do not
pump accelerator pedal as this action will cause flood-
ing of the engine.
(4) Engine is flooded. Press accelerator pedal to floor board
and crank engine until it starts.

AGO 10167B 73
 (5) Refer to paragraph 82~.
(6) of Refer to paragraph 81.
(7) Refer to paragraph 79.
(8) Refer to paragraph 142.
(9) engine compression. Perform an engine compres-
sion test as follows-remove all spark plugs and spark
plug gaskets (par. 145). Block carburetor throttle link-
age in open position to assure a full charge of air in the
cylinders. With ignition switch off and a compression
gage in position in one cylinder (fig. 20), crank engine
with starter until compression gage pointer no longer
rises. Note compression r,eading on gage. Reset com-
pression gage to zero after checking each cylinder.
Record compression pressure for each cylinder on DA
Form 461. Compare the compression pressures of the
cylinders. Normal compression pressure is 135 psi. Mini-
mum compression pressure is 100 psi. Cylinder compres-
sion pressures should not vary more than 20 psi. If
pressures do vary more than 20 psi, or are lower than
100 psi, notify ordnance maintenance personnel.

AGO 10167B
74
 (1) Check
spark plug cables and make sure cables are attached
to correct spark plugs (fig. 54).
(2) Check
spark plug cables at distributor cover and make sure
they are in correct positions (fig. 54).
(3) Remove distributor cap (par.
143) and inspect for cracks or burned contacts. Replace
cap if necessary (par. 143).
(4) Time engine (par. 142).
(5) Re-
move distributor cap (par. 143) and check rotor for
proper seating on distributor shaft. Replace rotor if
damaged (par. 143).

(1) Refer to paragraph 79a.

(2)
Refer to paragraph 81.
e.
(1) Inspect spark
plug cables for cracks which would allow cable to short
out. Replace spark plug cables if necessary. Check spark
plug cables for proper location at distributor cover and
at spark plugs.
(2) Remove distributor cover
(par. 143) and inspect rotor for cracks or evidence of
shorting. Replace distributor rotor if necessary (par.
143).
(3) Adjust carburetor (par. 129).
(4) Replace cylinder head
gasket (par. 103).
(5) Perform an engine compres-
sion test (9) above).
(6) Run engine at idle speed and observe
if any of the valves are noticeably noisy. Adjust valve
clearance if necessary (par. 105).
(7) Refer to ordnance maintenance
personnel.
f.
(1) Examine throttle
linkage for kinks or breaks. Press accelerator pedal to
floor board and note if throttle opens fully. If replace-
ment of throttle linkage is necessary, notify ordnance
maintenance personnel.
AGO 10167B
75
 (2) Inspect choke
control linkage for kinks or breaks. Inspect choke valve
plate to see that it is completely open when choke con-
trol button on instrument panel is pushed in. Choke con-
trol linkage should have enough free play so that normal
movement of the engine on its flexible mounts will not
cause a partial closing of the choke valve plate.
(3) Perform an engine com-
pression test (b (9) above).
(4) Remove, clean, and,
inspect spark plugs, replace if necessary (par.
(5) Test coil by substitution (par. 81).
(6) Refer to para-
graph 79.
(7) Refer to paragraph 79.
(3) Adjust carburetor (par.
129).
(9) Adjust clutch pedal free travel (par. 196).
If clutch must be replaced, refer to ordnance mainte-
nance personnel.
(10) Adjust brakes (par. 242)
and inflate tires to correct pressure (par. 257).
(11) or Re-
place exhaust pipe or exhaust pipe extension (par. 138).
(12) Clogged mufier. Replace muffler (par. 139).
(13) Adjust toe-in (par. 234).
(14) Inspect engine oil. Check records
of oil changes and if found to be improper grade, drain
and refill with correct grade of engine oil (par. 66).
(15) If engine has just received major re-
pairs, it may be tight, and top speed and power will
be reduced until the new parts are run-in and normal
working clearances have been established.
(16) cleaner or Clean air cleaner and
precleaner (par. 132).
(17) Inspect fuel lines for kinks
or pinches, replace lines if necessary (par. 135).
(13) The fuel line from fuel tank to inlet
side of fuel pump is under vacuum when engine is run-
ning. If a small air leak is present, it will reduce quan-
tity of fuel being delivered to fuel pump. Inspect fuel
line and replace if necessary (par. 135).

AGO 10167B
76
 (1) Replace carburetor (par. 129).
Refer to paragraph
Clean, gap, and in-
spect spark plugs (par. Replace spark plugs if
necessary (par. 145).
(4) Perform a compression test (b (9)
above).
(5) Run engine at idle speed and
observe if any of the valves are noticeably noisy. Adjust
valve clearance if necessary (par. 105).

(1) Refer to paragraph 81.

(2) Check valve clearances and
adjust as necessary (par. 105).
(3) Replace cylinder head
gasket (par. 103).
(4) Test fuel pump pressure (par. 79).
Replace fuel pump if necessary (par. 131).
(5) Adjust car-
buretor (par. 129a). If condition is not improved, re-
place carburetor (par. 129).
i.
(1) Refer to paragraph
129.
(2) Refer to paragraph 129.
(3) Clean, adjust, and in-
spect spark plugs. Replace spark plugs if necessary (par.
145).
(4) Refer to paragraph 81.
(5) Time engine (par. 142).
(6) Tighten all
connections in ignition primary circuit.
j.
(1) Refer to (3) above and paragraph
85.
(2) Inspect engine, engine compartment, and ground
beneath engine for indications of oil leakage. Tighten
any leaking connections, repair or replace broken oil
lines, or notify ordnance maintenance personnel.
(3) Refer to above.
(4) Maintain proper oil level. Oil
level may be raised by fuel being forced into crankcase
past carburetor needle valve, through primer pump, or

AGO 10167B
77
 around fuel pump diaphragm when the pressure re-
lief valve in the fuel tank fails and pressure in the tank
is built up at high temperatures. Check for odor of
gasoline on dipstick. Check relief valve (par. 127a).
(5) Inspect en-
gine oil. Check records of oil changes and if found to be
improper, drain and refill with correct grade of engine
oil (par. 66).
(6) Avoid unnecessary and excessive
speeds.
(7) Operate vehicle in proper
gear for desired speed and terrain (par. 45).
k. Refer to (3) above and paragraph 85.
1. Inspect engine oil level and refill as
directed on lubrication order (par. 66) if necessary. If trouble
is not corrected by filling crankcase, piston rings, or connecting
rod bearings, or crankshaft bearings are worn, refer to ordnance
maintenance personnel.

Fuel and Air Intake System

(1) Inspect fuel

and vacuum pump for evidence of leakage. Tighten all
connections. Inspect fuel lines for evidence of leaks.
Replace lines if necessary (par. 135).
(2) Refer to above and paragraph
85.
(3) Remove fuel line
from inlet side of carburetor. With ignition switch in
OFF position, crank engine and observe action of fuel
pump. If fuel spurts from fuel line, the fuel and vacuum
pump is operative. If no fuel is observed spurting from
fuel line, the fuel and vacuum pump is faulty and should
be modified or replaced (par. 131).
Caution: Provide container for fuel, as this is a fire
hazard.

Remove air cleaner,

operate choke, and observe if carburetor choke valve
opens freely. If choke action is faulty, adjust choke
linkage.
(2) Disconnect fuel line
from outlet side of fuel and vacuum pump. Install a
-_ _____
pressure gage (fig. 2i j in fuel and vacuurd piiiiip ixitkt.

AGO 10167B
 With ignition switch in OFF position, crank engine
until pointer on pressure gage no longer rises. Observe
reading on pressure gage. Fuel and vacuum pump pres-
sure is normally 41/i to 5 psi. If pressure is not correct,
replace pump (par. 131). If new pump gives incorrect
pressure, notify ordnance maintenance personnel.

Figure 21. Testing fuel and vacuu,m pump pressure.

(3) Faulty carburetor. Replace carburetor (par. 129).

c. Fuel Mixture Too Lean.
(1) Incorrect carburetor adjustment. Adjust carburetor
(par. 129).
(2) Leaky fuel lines. Inspect fuel lines and fittings. Replace
lines or fittings if necessary (par. 135).
(3) Obstruction in fuel lines. Disconnect fuel line at inlet
side of fuel and vacuum pump. Remove fuel tank filler
cap, and blow compressed air back through fuel line
to remove any obstructions.
(4) Faulty fuel pump. Perform fuel and vacuum pump test
(b (2) above). Replace fuel and vacuum pump if neces-
sary (par. 131).
(5) Faulty carburetor. Replace carburetor (par. 129).

79
 (‘3) Faulty engine vacuum. Peform engine vacuum test as
follows-disconnect fuel and vacuum pump vacuum line
at elbow located on exhaust manifold, and install vacuum
gage adapter in elbow (fig. 22). Start engine and run
at idling speed until minimum operating temperature
(160” F.) is reached. Make sure the carburetor is ad-
justed properly. Adjust if necessary (par. 127). With
engine operating at normal idling speed, vacuum gage
should show a reading of 18 to 21 inches of mercury. A
pointer fluctuating between 10 and 15 inches of mer-
cury may indicate a leaking valve or defective cylinder-
head gasket. An abnormally low reading with the pointer
steady may indicate a leak at the carburetor. Accelerate
and decelerate engine rapidly. Vacuum should drop to
approximately 2 inches of mercury with rapid accelera-
tion, and should rise to 24 inches of mercury as accelera-
tion is decreased quickly.
Note. Above readings are for sea level operation. Vacuum read-
ings will be lowered approximately i inch of mercury for 1,000
feet increase in altitude.

Figure 22. Testing engine vacuum.

d. Fuel Mixture Too Rich.

(1) Incorrect carburetor adjustment. Adjust carburetor
(par. 129).

AGO 10167B
80
 Clean air cleaner
(par. 132).
(3) Remove air cleaner
and observe if choke valve plate is fully open. Make sure
choke linkage has enough free play so that normal move-
ment of the engine on its flexible mounts will not cause
a partial closing of the choke valve plate.
(4) Refer to above.
Replace carburetor (par. 129).
e.
Adjust brakes (par. 242).
(2) Inflate tires to correct pressure
(par. 254).
(3) Re-
place exhaust pipe or exhaust pipe extension (par. 138).
(4) Replace muffler (par. 139).
(5) Adjust toe-in (par. 234).
(6) Remove, clean, and adjust
spark plugs (par. 145).
(7) Refer to paragraph 81.
(8) Time ignition (par. 142).
Clean air cleaner (par. 132).
(10) Perform an engine compres-
sion test (par. ).
(11) Perform a fuel pump
pressure test (2) above).
(12) Adjust or replace carburetor (par.
129).
(13) Make sure brake pedal has
necessary free travel (par. 242).
(14) Adjust valve
clearance (par. 105).

(1) Replace muffler

139). (par.
(2) A leak-
ing intake and exhaust manifold gasket may be noted
by carbon streaks on the cylinder block around the
manifold or by the rush of exhaust gases felt against
the hand. Tighten exhaust manifold or replace mani-
fold gasket (par. 109).
(3)
Replace exhaust pipe or exhaust pipe exten-
sion (par. 138).

AGO 10167B 81
 b. Odor of Exhaust Fumes in Driver’s Compartment. Leak in
exhaust system. Replace defective parts (a above).
Replace defective exhaust system parts immediately,
as exhaust gas (carbon monoxide) is poisonous.

81.
a. No Spark (Ammeter Registers Zero When Ignition Switch
Is Turned On).
(1) Low or faulty batteries. Test batteries (TM 9-2857) and,
if excessively low, replace (par. 155).
Loose or corroded battery cables. Clean cable terminals
and tighten bolts (par. 155).
(3) Faulty ignition switch. Check ignition switch circuit
with suitable test equipment or replace old switch (par.
181) with one known to be operating. If, with switch
on, ammeter now registers a slight discharge, old igni-
tion switch was faulty.
(4) Faulty ammeter. Check ammeter circuit with suitable
test equipment or replace old ammeter (par. 174) with
one known to be operating. If, with ignition switch on,
ammeter now registers a slight discharge, old ammeter
was faulty.
(5) Broken primary circuit from ignition switch to ignition
coil or from ignition coil to distributor. An ammeter
reading of zero while ignition switch is turned on and
engine is being cranked indicates that no current is
flowing in the primary circuit.
(a) With ignition switch in OFF position, disconnect
cable at battery side of ammeter and use test light
or low voltage circuit tester to determine if current
is flowing. If current is not flowing to the ammeter,
check connection and cable for looseness or breaks.
(b) Check wiring circuit for signs of looseness or breaks
from ammeter to ignition switch, and through igni-
tion switch, with switch turned off. Replace cables
if faulty. Clean and tighten all connections.
(c) Check wiring circuit for signs of looseness or breaks
through primary cable from ignition switch to igni-
tion coil and from coil to distributor. If current flows
through primary cable from ignition switch to igni-
tion coil, but not from ignition coil to distributor, re-
place coil (par. 144). If current flows through primary
cable and ignition coil to the distributor, the trouble
lies within the distributor.

AGO 10167B
 (d) If breaker points are faulty, remove distributor cover
and distributor cap (par. 143) and inspect breaker
points for burned or pitted contact surfaces. Replace
points if necessary (par. 143). If points are satisfac-
tory, check gap opening (par. 142).
(e) If capacitor is faulty and a capacitor tester is available,
test capacitor. Reading should be 25 to 26 mfd 2 10
percent. Replace capacitor (par. 143) if reading is not
within these limits. If capacitor tester is not available,
check capacitor by substitution.

If ammeter shows normal discharge with

ignition switch turned on, the primary circuit is functioning and
the trouble is in the secondary circuit.
(1) Remove distributor cap (par. 143)
and inspect for cracks or carbonized paths indicating
current leaks. Inspect all carbon tips in cap for signs of
excessive wear. Replace cap if necessary (par. 143).
(2) Inspect rotor for signs of cracks or extreme
wear. Replace rotor if necessary (par. 143).
(3) Inspect spark plug cables for
cracks, breaks, or corrosion. Replace cables if necessary
(par. 145).
c.
(1) Clean and tighten all con-
nections from starter to distributor and ignition coil as-
sembly.
(2) Check coil by substitution. Obtain
a coil which is known to be operative. Remove coil and
install test coil (par. 144). If spark is now satisfactory,
old coil was faulty.
(3) Refer to (1) above.
(4) Refer to a(5) (e) above.
(5) Refer to a(5) above.
Refer to paragraph 78c, e, and g.
e. Refer to paragraph

(1) Test batteries and charge

or replace if necessary (par. 155).
(2) Clean cable terminals and
tighten bolts (par. 155).

AGO 10167B 83
 (3) Check starter switch circuit with
suitable test equipment or replace old switch (par. 149)
with one known to be operating. If starter now operates,
old starter switch was at fault.
(4) If the above operations have been com-
pleted and the starter still fails to operate, the starter is
faulty and must be replaced (par. 148).

(1) Tighten all attaching parts.

(2) Lack of Lubricate starter (par. 66). If starter
is still noisy, replace (par. 148).
(3) starter. Replace starter (par. 148).
c. Slow
(1) Refer to a(1) above.
(2) Clean and tighten ground
cable.
(3) Inspect engine oil. Check records
of oil changes and if found to be improper grade, drain
and refill with correct grade of engine oil (par. 66).
(4) Replace starter (par. 148).

83.
a.
(1) General. Before performing any generator system tests,
check battery for discharge (par. 155). Some of the com-
mon conditions under which batteries become discharged
are : the battery is worn out and will not hold a charge ;
more current has been used than supplied by the gen-
erator ; battery solution has been allowed to become low ;
accidental discharge of the battery due to light, acces-
sories, or ignition switch left on when generator was not
charging; engine oil too heavy for the prevailing tempera-
tures. Many of the so-called generating system failures
may be attributed to the conditions mentioned above.
(2) Clean cable termi-
nals and tighten bolts (par. 155).
(3) If there is low or no charging
rate with low battery, replace regulator (par. 153).
(4) Check ammeter circuit with suitable
test equipment or replace old ammeter (par. 1’74) with
one known to be operating. If, with engine running,
ammeter now registers a charging rate, old ammeter
was faulty.

a4 AGO 10167B
 Adjust generator drive belts
(par. 123).
(6) If the generating system still fails to
operate properly, replace the generator (par. 152).
Replace
generator regulator (par. 153).

(1) Lubricate generator (par. 66).

(2) Tighten generator mounting
bolts (par. 152).
(3) Adjust drive belts (par.
123).
(4) Replace generator (par. 152).

84. Battery and lighting System

When checking or troubleshooting the battery light-
ing system, refer to the vehicle wiring diagram (fig. 80).
Refer to paragraphs 83a and 155.
c.
(1) Test battery specific gravi-
ty and charge or replace batteries if necessary (par. 155).
(2) Test light switch by substitution.
Remove light switch (par. 182) and install a switch which
is known to be serviceable. If lights now operate, old
switch was faulty.
(3) Notify ordnance maintenance
personnel.
(4) Replace generator regulator
(par. 153).
(5)
Inspect all
cables in lighting circuit (fig. 80) and repair, replace, or
notify ordnance maintenance personnel.
(6) Clean
corroded lamp contacts. Replace all lamps or lamp units
which are broken or damaged (pars. 15’7-160 and 180).

(1) Inspect ground connection and

tighten or repair if necessary.
(2) Replace burned out lamp
unit or lamp (pars. 157-160 and 180).
(3)
Inspect cable for grounded or shorted condition,
frayed insulation, loose
pair, replace, or tighten cable.

AGO 10167B as
 Replace light switch (par. 182).
e.
(1) Dirty Clean light lens.
(2) Test batteries and charge
or replace batteries if necessary (par. 155).
(3) Inspect ground cable or con-
nection and repair or tighten ground cable if necessary
(par. 163).
(4) Clean and tighten terminals
(par. 163).
f.
(1) Replace generator regulator
(par. 153).
(2) Inspect cable for frayed insula-
tion, loose terminals, or breaks. Repair, tighten, or re-
place cables if necessary.
g.
(1) Replace stop light lamp (par. 160).
(2) Replace light switch (par. 182).
(3) Test stop light switch by sub-
stitution. Remove switch (par. 186) and install one which
is known to be operative. If stop light now operates, old
switch was faulty.
(4) Inspect stop light circuit for
grounded or broken cables. Repair or replace cables if
necessary (par. 163).
(5) Clean and tighten terminals
(par. 163).

85. Cooling System

a.
Fill cooling system and idle engine. In-
spect radiator hose and connections for signs of leaks.
Tighten hose connections or replace hose (par. 125) if
necessary. Check area around water pump for damp spots
or rust stains. Tighten water pump or replace (par. 124)
if necessary. Inspect area around cylinder head for damp-
ness or rust stains. Tighten cylinder head or replace cylin-
der-head gasket (par. 103). Inspect radiator core for
dampness or rust spots and if leakage is found, replace
radiator (par. 122). Inspect area around thermostat
housing for evidence of leakage. Tighten thermostat hous-
ing or replace thermostat housing gasket (par. 126).
(2) Adjust drive belt (par. 123).

AGO 10167B
 Inspect exhaust pipe, exhaust
,pipe extension, and muffler for signs of dents, kinks, col-
lapse, or restrictions of any kind. Replace any faulty
parts (pars. 138 and 139).
(4) If air flow through radiator core is
restricted due to insects, leaves, grease, dirt, etc.,
clean fins and air passages by blowing them out with
compressed air.
(5) Time ignition (par. 142).
(6) Adjust carburetor (par. 129).
(7) Inspect radiator hose and replace
any hose that has become soft or collapsed (par. 125).
(8) Replace thermostat (par. 126).
(9) Clogged Flush radiator as directed in TM 9-
2858.
(10) Drain crankcase oil into a suitable con-
tainer and observe if there is water in the oil. (Water
being heavier than oil, will go to the bottom of the con-
tainer. In moderate quantities, it will look like an air
bubble at the bottom of the oil.) If water is found in the
oil, remove the spark plugs (par. 145) and observe if
water is present at the plug holes. Install spark plugs
(par. 145) and refill crankcase with correct grade of en-
gine oil (par. 66). With engine cold, fill radiator. Remove
drive belts (par. 123) so that water pump is inoperative.
Start engine and run at a fast idle for 60 seconds. If
water runs out radiator filler pipe or overflow tube, or
if bubbles come to the surface of the water in the radiator,
leakage exists between one or more of the cylinders and
the cooling system. If leakage is evident from any of
these inspections, check cylinder-head nuts, using a torque
wrench. If the nuts do .not show evidence of looseness,
remove the cylinder head (par. 103) and inspect for a
faulty gasket. Examine cylinder block and head for
cracks, paying particular attention to the area around
the valve ports. Replace cylinder-head gasket (par. 103))
or in the case of a cracked head or cylinder block, notify
ordnance maintenance personnel.

Start engine and allow to idle until temperature is at least normal

(this can be determined by placing the hand on the radiator). If
the gage still reads cold, the gage or sending unit is faulty. Test
the gage and sending unit by substitution. Remove the water tem-
-,.-^L..-^ _^,..^ [par.
~eraUlrt: yzlg;e: I,.... 1”P\ ,.I 11IJlJitll
l,“, anu :,&..-.11“lit:
^_^ I__^____
nll”wll c-.
L” L,. ^_,.. .‘.c:.,,
Lit:“JJalalll”G

AGO 10167B a7
If gage now registers, the old gage was faulty. If gage still does
not register, remove sending unit (par. 187) and install one known
to be operative. If gage now registers, sending unit was faulty.

86. Horn and Horn Button

(1) Refer to vehicle wiring diagram (fig.

80) for wiring arrangement, and connect all cables.
(2) Remove horn (par. 185a) and
clean contacting surfaces. Install horn (par. 185b).
(3) Disconnect main feed cable at
horn switch and ground it momentarily. Note whether a
spark occurs when cable is grounded. If no spark occurs,
there is an open circuit between the main feed cable and
the battery. Inspect main feed wire and make necessary
repairs.
(4) Disconnect main feed cable at switch and
touch end of main feed cable to horn terminal of switch.
If horn now sounds, switch is faulty. Replace horn switch
(par. 184).
(5) If, after the above steps have been per-
formed, horn does not sound, horn is faulty and must be
replaced (par. 185).

(1) Remove
and check horn button and horn switch push rod (par.
184).
(2) Replace horn
switch assembly (par. 184b).

87. Instruments, Gages, Switches, and. Sending Units

(1) Turn off all lights and electrical acces-

sories, start engine and run it at a speed equivalent to a
vehicle speed of 20 mph. If ammeter pointer fails to move
to charge side of for at least the time required to
restore the current used in starting, either the generat-
ing system (par. 83) or ammeter is at fault. Stop engine
and turn on headlights. Ammeter pointer should move
to discharge side of gage. If pointer does not indicate on
either side of gage, replace ammeter (par. 174).
(2) Connect an ammeter which is known
to be nnora+ive
“rU--“-. _ in series with ammeter on vehicle, Start

AGO
 engine and observe ammeter pointer location on each am-
meter. If pointer location varies between the two am-
meters, replace ammeter (par. 174).
(3) Incorrect cable connections. Refer to
instruments, gages, switches, and sending units identifi-
cation diagram (fig. 83) and paragraph 163 for correct
cabIe connecting points.

(1) Refer to instruments, gages, switches,

and sending units identification diagram (fig. 85) and
paragraph 163 for location of cables. Inspect cables for
frayed insulation, loose connections, cracks, or breaks.
Tighten connections or repair cables if necessary.
(2) Test sending unit by
substitution. Obtain a sending unit which is known to be
operative. Remove sending unit (par. 189) from fuel
tank and install sending unit to be used for test. If, with
ignition switch on, fuel gage now operates, old sending
unit was at fault.
(3) Test fuel gage by substitution. Obtain
a fuel gage which is known to be operative. Remove fuel
gage (par. 175) from vehicle and install test fuel gage.
If, with ignition switch on, fuel gage now registers, old
fuel gage was faulty.
c.
(1) Refer to instruments, gages, switches, and
sending units identification diagram (fig. 85) and para-
graph 163 for location of cables. Inspect cables for frayed
insulation, loose connection, cracks, or breaks. Tighten
or repair cables if necessary.
(2) Test sending unit
by substitution. Obtain a sending unit which is known to
be operative. Remove sending unit (par. 187) from ve-
hicle and install sending unit to be used for test. If, with
ignition switch on, temperature gage now registers, old
gage was faulty.
(3) Test gage by substitu-
tion. Obtain a gage which is known to be operative. Re-
move gage (par. 176) and install gage to be used for test.
If, with ignition switch on, temperature gage now regis-
ters, old gage was faulty.

(1) Refer to instruments, gages, switches and

sending units identification diagram (fig. 85j and para-

89
 graph 163 for location of cables. Inspect cables for frayed
insulation, cracks, breaks, or loose connections. Repair
cables if necessary.
(2) Faulty oil pressure sending unit. Test sending unit by
substitution. Obtain a sending unit which is known to be
operative. Remove sending unit (par. 188) from vehicle
and install sending unit to be used for test. If, with en-
gine running, pressure gage now registers, old sending
unit was faulty.
(3) Fault3 oil pressure gage. Test gage by substitution. Ob-
tain a gage which is known to be operative. Remove gage
(par. 177) and install gage which is to be used for test.
If, with engine running, gage now registers, old gage was
faulty.
e. Speedometer.
(1) Speedometer fails to show either speed or mileage or
pointer fluctuates.
(a) Kinked or broken flexible shaft assembly or core. Re-
fer to ordnance maintenance personnel.
(b) Binding in speedometer. Disconnect flexible shaft at
speedometer. Obtain a short piece of flexible shaft core
about 2 or 3 inches long with a tip to fit the speedometer
socket. Insert the piece of core into speedometer socket
and spin core between the thumb and forefinger in the
proper direction to cause speedometer pointer to indi-
cate speed on speedometer dial. If there is a tendency
for the speedometer to bind, replace speedometer (par.
178).
(2) Speedometer fails to show either speed or mileage or
pointer will not return to zero. Faulty speedometer. Re-
place speedometer (par. 178).
f. Headlight High Beam Indicator Light.
(1) Fails to light.
(a) Lamp burned out. Replace lamp (par. 179).
(b) Faulty wiring. Refer to paragraph 163 for correct cable
and connection. Inspect cable for frayed insulation,
cracks, breaks, or loose connections. Tighten connec-
tions or repair if necessary.
(2) Lamp flickers. Loose cable connections or lamp loose in
socket. Tighten lamp and cable connections.
g. Headlight Dimmer Switch.
(1) Fails to operate.
(a) Loose cable connections or faulty wiring. Refer to
paragraph 163 for correct cables and connections. In-
spect cables for frayed insulation, cracks, or breaks.
AGO
 Inspect cable connections for tightness. Tighten con-
nections or repair cables if necessary.
(b) Faulty switch. Test switch by substitution. Obtain a
switch which is known to be operative. Remove switch
(par. 183) and install switch which is to be used for
test. If, with headlights on, switch now operates, old
switch was faulty.
(2) Switch can be depressed but will not return. Dirty or
faulty switch. Remove switch (par. 183) and clean with
volatile mineral spirits. If cleaning does not correct the
trouble, replace the switch (par. 183).
h. Instrument Panel Lights.
(1) One lamp fails to light.
(a) Burned out lamp. Replace defective lamp (par. 180).
(b) Loose or faulty cable. Inspect cable connections at in-
strument panel light and at light switch for evidence
of loose or faulty cable. Tighten terminal connections
or replace defective cable.
(c) Faulty instrument panel light. If the above conditions
were checked and lamp still does not burn, the light is
faulty and must be replaced (par. 180).
(2) Both instrument panel lamps fail to light.
(a) Burned out lamps. Replace defective lamps (par. 180).
(b) Loose or faulty cable. Refer to (1) (b) above.
(c) Faulty instrument panel light. Refer to (1) (c) above.
(d) Faulty light switch. If the above conditions were
checked and instrument panel lamps still do not operate,
it indicates a faulty switch which must be replaced
(par. 182).
i. Ignition Switch Fails To Operate.
(1) Loose or faulty wiring. Inspect cables for loose connec-
tions, frayed insulation, cracks, or breaks. Tighten con-
nections or repair cables if necessary.
(2) Faulty switch. Replace ignition switch (par. 181).
88. Radio Interference Suppression System
a. Locate Source of Noise. To locate source of radio interfer-
ences emanating from the vehicle, the use of a radio receiver in
the vehicle or adjacent vehicle will be necessary. Determining the
type of interference present in the receiver will heIp to determine
the cause of the trouble. To determine if the noise is coming from
the vehicle or from an outside source, drive the vehicle at least 100
feet from any other vehicle, Turn the ignition switch off and turn
the radio on. Any noise heard in the radio will be coming from an

AGO 91
outside source. Start the engine and any other noise heard in the
radio will be coming from the vehicle itself.
b. Engine.
(1) Start the engine and run it at an idle speed and listen for
noises in the radio receiver. If a crackling or clicking
sound is present, accelerate engine and turn ignition
switch off. If the noise stops immediately, the trouble is
in the ignition circuit (c below). If an irregular click-
ing or chattering sound continues for a few seconds after
the ignition switch is turned off, the trouble is being
caused by the generating circuit (d below). If the inter-
ference is in the form of a whining or whirring sound
which varies with the engine speed, turn ignition switch
off. If the tone of the sound lowers in pitch but continues
for a few seconds after the switch is turned off, it is
caused by the generator (e below).
(2) Start the engine and put the vehicle in motion and note
if there is any interference present in the receiver. If a
clicking or scratching noise is present, stop vehicle but
leave engine running. If the noise stops when the motion
of the vehicle stops, the trouble is caused by loose con-
nections or frayed cable insulation in vehicle wiring (f
below).
c. Ignition Circuit. Make sure the ignition system is functioning
properly (par. 81’). Incorrect spark plug gaps, distributor breaker
point adjustment, or worn parts will affect the suppression sys-
tem, Clean and tighten all electrical connections and engine mount-
ings. Disconnect cable from one spark plug and start engine, note
if interference is reduced or eliminated by this action. Test the re-
maining three spark plug cables. If removal of any one or more
cables eliminates the interference, the trouble is in the spark plug
resistor or the ignition filter. Replace the spark plug (par. i45) or
the ignition filter (par. 143e).
d. Generating Circuit. Check generator regulator mounting bolts
and tighten if necessary. Check wiring harness connecting the
generator to the generator regulator for broken or damaged in-
sulation. Replace generator (par. 152) or generator regulator
(par. 153) if necessary.
e. Generator. Check generator mounting bolts and tighten if
necessary. If noise still persists, replace generator (par. 152).
f. Wiring. Inspect all wiring cables for worn, frayed, or other-
.

92 AGO
89. Clutch

(1) Start engine and run

it at an idle. Depress clutch pedal to full released posi-
tion, and allow clutch time to stop rotating. Shift trans-
mission into first or reverse gear. If the shift cannot be
made without clashing of gears or after engagement of
gears, there is a jumping or creeping movement of the
vehicle with clutch pedal fully depressed, the clutch is
dragging. Adjust clutch pedal free travel (par. 196).
(2) Refer to ord-
nance maintenance personnel.

Adjust pedal free

travel (par. 196).
(2) Refer to ordnance mainte-
nance personnel.
(3) Grease Refer to ordnance
maintenance personnel. Slippage and .failures may be
caused by engine and transmission lubricants that be-
come trapped in the flywheel housing and cover the clutch
components. To eliminate this source of trouble, remove
flywheel housing drain plug and store in map (glove)
compartment. Be sure to install plug before undergoing
fording operations.
(4) Refer to ordnance maintenance person-
nel.
c.
(1) Adjust pedal free travel (par.
196).
(2) Oil or grease Refer to ordnance
maintenance personnel.
(3) Inspect transmission mountings,
propeller shafts, universal joints, and engine mountings
for loose connections. Tighten all connections.

(1) Oil or grease on Refer to ordnance main-

tenance personnel.
Notify ordnance maintenance per-
sonnel.
(3) Dry Refer to ordnance
maintenance personnel.

AGO 10167B
 (1) Lubricate linkage (par.
66).
(2) Refer to ordnance
maintenance personnel.
(3) Refer to ordnance maintenance personnel.

90. Transmission
Shift
(1) Adjust clutch pedal
free travel (par. 196).
(2) If this condition occurs in extreme
cold weather, transmission lubricant may be of incorrect
viscosity. Check records of lubricant changes and if found
to be improper grade, drain and refill with correct lubri-
cant (par. 66).
(3) Refer to ordnance maintenance personnel.
(4) Replace (pars. 206 and
207) or refer to ordnance maintenance personnel.

(1) Check transmission lubricant level and

refill if necessary (par. 66).
(2) Replace (pars. 206 and
207) or refer to ordnance maintenance personnel.
(3) Noises originating in the
vicinity of the transmission are sometimes due to a faulty
transfer. Place transmission shift lever in N (neutral)
position and start engine. If noise is now excessive, trou-
ble is in transmission. If noise is excessive only when
transfer is engaged, trouble lies in transfer. Replace
either transmission (pars. 206 and 207) or transfer
(pars. 200 and 201)) or notify ordnance maintenance
personnel.
c.
(1) Adjust pedal free travel (par.
196).
(2) Refer to paragraph 66 for lubrica-
tion instructions.
(3) Replace (pars. 206 and
207) or refer to ordnance maintenance personnel.

(1) Refer to ordnance maintenance per-

sonnel.

AGO 10167B
94
 shift Replace transmis-
sion (pars. and 20’7) or refer to ordnance mainte-
nance personnel.
(3) Replace transmis-
sion (pars. 206 and 207) or notify ordnance maintenance
personnel.
(4)
Replace transmission (pars. 206 and 207)
or notify ordnance maintenance personnel.
e.
(1) Tighten or replace drain
plug.
(2) Tighten mounting connec-
tions.
(3) Notify ord-
nance maintenance personnel.

91. Transfer
or
(1)
Check lubricant level. Drain and fill transfer with proper
grade of lubricant (par. 66).
Remove
transfer (par. 200), aline, and install (par. 201).
(3) Replace transfer (pars. 200
and 201) or notify ordnance maintenance personnel.

(1) Check lubricant level. Drain and

refill transfer with proper grade of lubricant (par. 66).
(2) Replace transfer (pars. 200
and 201) or notify ordnance maintenance personnel.
(3) Re-
move transfer (par. 200)) aline, and install (par. 201).
(4) Replace either front
or rear propeller shafts (pars. 209 and 210) if necessary.
(5)
(par. 119).
c.
(1) Refer to ordnance maintenance
personnel.
(2) Replace trans-
fer (pars. 200 and 201) or refer to ordnance maintenance
personnel.

95
 Replace transfer
(pars. 200 and 201) or refer to ordnance maintenance
personnel.

(1) Tighten or replace drain

plug.
(2) Tighten attaching parts.
(3) Replace transfer (pars.
200 and 201) or notify ordnance maintenance personnel.

92. Propeller Shafts and Universal Joints

(1)
Replace universal joints or propeller shafts
(pars. 209 and 210) if excessive backlash is noted.
(2)
Tighten companion flange bolts and
U-bolts.

Replace universal
joints (pars. 209 and 210).
(2) Replace propeller
shaft (pars. 209 and 210).
(3) Lubricate universal joints and
propeller shafts (par. 66).
(4) Tighten com-
panion flange bolts and U-bolts.
(5) Re-
place propeller shaft and universal joint sleeve yokes
(pars. 209 and 211) if necessary.

93. Front Axle

Lubricate as prescribed in
paragraph 66.
(2) Adjust steering gear (par. 234).
(3) Refer to ordnance mainte-
nance personnel.
(4) Check and adjust toe-in (par. 234).
(5) Inflate tires to correct pressure
(par. 254).
(6) Notify ordnance maintenance person-
nel.
6. Refer to paragraph

AGO 10167B
 c. Vehicle Wanders.
(1) One tire underinflated. Inflate tire to correct pressure
(par. 254).
(2) Loose or improperly adjusted front hub bearings. Ad-
just or replace hub bearings (par. 225).
(3) Incorrect steering gear adjustment. Adjust steering
gear (par. 219).
(4) Loose or worn tie rods or drag link. Adjust or replace
tie rods (pars. 234 and 235) or drag link (par. 237).
(5) Loose or worn parts in front axle. Replace front axle
assembly (par. 234).
(6) Incorrect steering alinement due to accident. Notify
ordnance maintenance personnel.
(7) Wheel rubs fender or frame on extreme turn. Notify
ordnance maintenance personnel.
d. Excessive Noise On Front Axle.
(1) Vibration due to loose and worn front propeller shaft.
Replace propeller shaft (pars. 209 and 210).
(2) Insufficient lubrication. Lubricate as prescribed in para-
graph 66.
(3) Worn front axle differential gears. Replace front axle
assembly (par. 231).
(4) Worn fron,t axle shafts. Replace front axle shafts or front
axle assembly as necessary (pars. 224 and 231).
(5) Worn or improperly adjusted front hub bearings. Adjust
or replace hub bearings (par. 225).
e. Leaks Lubricant.
(1) Loose or damaged drain plug. Tighten or replace drain
plug.
(2) Faulty steering knuckle flange oil seals. Replace oil seals
(par. 229).
(3) Cracked axle housing. Replace front axle assembly (par.
231).

a. Continuous Rear Axle Noise.

(1) Insufficient lubrication. Lubricate as prescribed in para-
graph 66.
(2) Tires improperly inflated or unequally worn. Inflate tires
to correct pressure (par. 254) or replace worn tires (TM
21300).
(3) Rear axle shaft bearings worn, improperly adjusted, or
inadequately lubricated. Repack, adjust, or replace rear
axle shaft bearings (par. 216).

AGO 10167B
97
 Replace rear axle assembly (par. 220).
(5) Replace propeller
shaft (pars. 209 and 210).

Refer to a(3) above.

(2)
Replace rear axle assembly (par. 220).
c.
(1) Tighten all attaching
parts.
(2) worn or
Replace rear axle assembly (par. 220).

(1) Tighten or replace drain

Plug.
Replace oil seals (par. 215 a(l)-
(9) and c).
(3) Replace rear axle assembly (par.
220).

Service Brakes

(1) Replace master

cylinder (par. 244).
(2) Adjust brakes (par. 242).
(3) Disconnect brake line at master
cylinder and lines at wheel cylinders. Clean brake lines by
blowing out with compressed air. Remove master cylinder
(par. 244) and clean with brake fluid. Install master
cylinder (par. 244)) connect lines at wheel cylinders and
master cylinder. Refill brake system with fluid and bleed
brakes (par. 246).
Note. If brakes are locked preventing movement of the vehicle,
momentarily open bleeder valve (fig. 115) at any wheel cylinder.
A few drops of brake fluid will come out; thus pressure will be
relieved and the brakes freed. This is a temporary measure and
does not correct the cause of the trouble.

(1) Adjust
brakes (par. 242).
(2) Inspect all lines and
connections for signs of leakage. Tighten or replace faulty
lines or connections (par. 245).

AGO 10167B
 Replace master cylinder (par.
244).
(4) Inspect wheel cylinders for evi-
dence of leaks. Replace any faulty wheel cylinder (par.
243).
(5) Bleed brake system (par. 246).
c.
(1) Adjust brakes (par. 242).
(2) Replace brake shoes (par. 242).

(1) Replace brake shoes (par.

242).
(2) Replace brake
shoes (par. 242).
(3) Replace brake drums (par. 242).
(4) Replace retracting
springs (par. 242).

(1) Adjust brakes (par. 242).

(2) Replace brake shoes (par. 242).

Handbrake

(1) Adjust brake (par. 247).

(2) Replace brake shoes (par. 247).
(3) Notify ordnance maintenance
personnel.

(1) Adjust brake (par. 247).

(2) Replace brake shoes (par. 247).
(3) Replace brake shoes (par.
247).
c.
(1)
Be sure brake is completely released before putting
vehicle in motion.
(2) Adjust brake (par. 247).
(3) Replace brake drum (par.
247).

97. Wheels and Tires

(1) Inflate tires to correct pressure

(par. 254).

AGO 10167B
 (2) Improper front wheel alinement. Check front wheel
alinement and correct if necessary (par. 234).
(3) Bent wheel. Replace any bent or distorted wheels (par.
256).
(4) Damaged or improperly adjusted front hub bearings. In-
spect hub bearings and adjust or replace if necessary
(par. 225).
(5) Wheel stud nuts loose. Tighten stud nuts (par. 256).
(6) Wheel out of balance. Remove (par. 256) and remount
tire in a different position. If trouble is not corrected,
replace wheel (par. 256) or tire (par. 257).
b. Wheel Wobbles.
(1) Bent wheel. Replace any bent or damaged wheels (par.
256).
(2) Damaged or improperly adjusted front hub bearings.
Adjust or replace hub bearings (par. 225).
(3) Wheel loose on hub. Tighten stud nuts (par. 256).
(4) Wheel out of balance. Remove (par. 256) and remount
tire in different position. If trouble is not corrected,
replace wheel (par. 256) or tire (TM 21-300).
c. Wheel Pounds.
(1) Damaged or improperly adjusted front hub bearings.
Adjust or replace hub bearings (par. 225).
(2) Bent wh,eel. Replace any bent or damaged wheels (par.
256).
(3) Damaged tire. Inspect tire for breaks or bulges, replace
tire (TM 21-300)) if necessary.

a. Insufficient Flexibility.
(1) Lack of lubrication. Lubricate in accordance with para-
graph 66.
(2) Frozen spring shackles. Free shackle and lubricate
(par. 66).
(3) Faulty shock absorbers. Disconnect shock absorbers
(par. 253) and test action by compressing lower section
into upper section. If little or no effort is necessary to
compress shock absorbers, replace (par. 253).
b. Excessive Flexibility.
(1) Over lubrication. Clean excess lubricant from springs
and lubricate in accordance with paragraph 66.
(2) Faulty shock absorbers. Refer to a(3) above.
(3) Broken spring leaves. Inspect springs for evidence of
broken leaves. Replace sprifigs (par. OK:Oi
V"V, if
II noon~~c~arxr
'.ti.db"YULJ.

AGO 10167B
 c. Vehicle Sags to One Side.
(1) Improper load distribution. Check load for correct
weight distribution and relocate load if necessary.
(2) Weak springs. Inspect springs for extreme sag, replace
any weak springs (par. 252).
(3) Broken spring leaf. Inspect springs for broken leaves
and replace (par. 252) if necessary.
(4) Underinflated tires. Inflate tires to correct pressure
(par. 254).
d. Excessive Spring Noise.
(1) Inadequate lubrication. Lubricate in accordance with
paragraph 66.
(2) Worn spring pivot bolts or spring shackles. Use a pry
bar to test wear of shackles and pivot bolts. If excessive
movement is noted, replace shackles (par. 250) or pivot
bolts (par. 251).
(3) Worn or faulty shock absorbers. Replace shock absorbers
(par. 253).
(4) Loose or worn spring center bolt. Replace spring (par.
252).
e. Repeated Spring Leaf Failure.
(1) Loose spring U-bolts. Tighten spring U-bolts.
(2) Overloading or improper operation on rough terrain.
Refer to vehicle shipping data plate (fig. 4) for maxi-
mum load and reduce vehicle speed when driving over
rough terrain.
(3) Spring leaf failure at spring eye. Improperly adjusted
spring shackles or frozen pivot bolts. Free and lubricate
pivot bolts (par. 66) and adjust spring shackles (par.
250).
(4) Spring leaf failure at cerzter section of spring. Loose
spring U-bolts. Tighten spring U-bolts.

99. Steering
a. Vehicle Wanders.
(1) Tight steering knuckle flange cap bearings. Adjust bear-
ings (par. 230~ (5) ) .
(2) Improper tire pressure. Inflate tires to correct pressure
(par. 254).
(3) Steering gear bind. Adjust steering gear (par. 239).
(4) Caster lower than standard. Notify ordnance mainte-
nance personnel.
IK\
(0, flN.-.l”_
“Ui)fitsI“,“““...~“^\7,+:c_.
U,‘G~Vtj,‘.
IY ,.,,J,,,,,
“LllJ “1 --Z-L
UIIcIIIc;t: ^_^Y^^ -^--^^-^-^
Illalll~ellSI.111;t: 1
~ersuIlrlal.
(6) Incorrect toe-in. Adjust toe-in (par. 234).

AGO 10167B 101

 Replace drag link (par.
237).
(8) Replace tie rods (par. 235).
(9) Replace spring (par. 252).
(10) Tighten U-bolts.
(11) Tighten mounting
bolts.
(12) Notify
ordnance maintenance personnel.

(1) Uneven Notify ordnance maintenance personnel.

(2) Inflate tire to correct
pressure (par. 254).
(3) Adjust brakes (par. 242).
(4) Ad-
just or replace hub bearings (par. 225).
(5) Replace any broken or weak
springs (par. 252).
(6) Replace rear axle assembly
(par. 220).
(7) Notify ordnance maintenance per-
sonnel.
(8) steering Notify
ordnance maintenance personnel.
c.
(1) Remount tire in dif-
ferent position (par. 255) or replace tire and wheel
(par. 256 and TM 31-200).
Tighten shock absorber
mountings or replace (par. 253) if necessary.
(3) Replace drag link or tie
rods (pars. 235 and 237).
(4) Tighten mounting
bolts.
(5) Tighten U-bolts.
(6) Replace faulty spring (par.
252).
(7) Inflate tires to prescribed pres-
sure (par. 254).
d.
(1) Inflate tires to correct pressure
(par. 254).
-Adjust bear-
ings (par. 230~ (5) ) .

AGO
 Tighten shock absorber
mounting nuts or replace shock absorbers (par. 253)
if necessary.
(4) Adjust steering gear (par. 239).
(5) Tighten mounting
bolts.
(6) U-bolts. Tighten U-bolts.
(7) Weak Replace faulty spring (par.
252).
e.
(1) Notify ordnance maintenance
personnel.
(2) Adjust drag link (par.
237).
(3) Inspect tires and replace (TM 21-300) if
necessary.
(4) Notify ordnance maintenance person-
nel.
(5) Notify
ordnance maintenance personnel.
(6) Replace steering gear (par. 239).
f.
(1) Inflate tires to correct pressure
(par. 254).
(2)
Adjust bearings (par. 230~ (5) ) .
(3) Replace drag link (par. 237).
(4) Tighten mounting
bolts.
(5) Tighten U-bolts.
(6) Replace faulty springs (par.
252).

Adjust bearings (par. 230~ (3) ) .

Replace drag link (TM 21300).
(3) Replace faulty tie rod ends (par.
235).
(4) Tighten mounting
bolts.
(5) Tighten U-bolts.
 Replace faulty spring (par.
252).
(7) Replace brake drum (par.
228).
h.
(1) Lubricate as prescribed in para-
graph 66.
(2) Inflate tires to correct pressure (par.
254).
(3) Adjust
bearings (par. 230~ (5) ) .
(4) Adjust steering gear (par 239).
(5) Notify ordnance maintenance
personnel.
(6)

paragraph 239.

Be sure valve
is completely turned on.
(2) Free blades from
windshield. Replace blades if damaged (par. 266).
(3) Inspect
for loose connections or broken or cracked lines. Replace
lines or connections if necessary.
(4)
Disconnect line at
fuel and vacuum pump and at windshield wiper motor.
Blow compressed air through line to clear it of any
obstructions. If line cannot be cleared, replace.
(5) Move
windshield wiper handle to loosen paddles. Disconnect
hose at windshield wiper motor and insert a few drops
of engine oil into motor. Work wiper handle to dis-
tribute the oil and connect vacuum line. Start engine and
operate wipers. If trouble is not corrected, replace wiper
motors (par. 265).

Examine hose at connections and along entire

length for nicks, cracks, or breaks. Tighten connections
or replace hose or connections.
._.
(2) Refer to a (5 j above.

104 AGO
 Section V. ENGINE DESCRIPTION AND MAINTENANCE
IN VEHICLE

101. Description and Data

a. The engine is a conventional L-head, four-cylin-
der, four-cycle, liquid-cooled, gasoline-fueled unit. The engine,
transmission, transfer, and radiator are mounted on a subframe
which can be removed and installed as a single unit and which
is termed the power plant (figs. 31 and 32). The electrical sys-
tem is waterproofed. The power plant is sealed and vented for
deep water and underwater fording operation. The oil filler pipe
assembly is a steel tube projecting from the upper portion of
the crankcase on the right side of the engine. The pipe has a
sealed cap, at the top, which is removed to add engine oil. A
bayonet-type oil level gage is fastened to the underside of the
cap. The control valve hose, for deep water fording, is connected
to the oil filler pipe near the top.
b.
Manufacturer ____________________-__---_---__-- Willys Motors Inc
Model ____________________----------__------_-- MC
Engine :
Type ____________________-----------_----__ L-head
Number of cylinders ____________________-__- 4
Bore and stroke ____________________-__----__ 3% x 4%
Piston displacement _________~~_____________ 134.2 cu-in.
Brake horsepower at 4,000 rpm ~_____~_______ 60
Torque at 2,000 rpm _______~_____________--- 105 lb-ft
Compression at cranking speed _______________ 110 psi
Firingorder _~___________________---__----__ l-3-4-2
Valve clearance ________________________-___ 0.016 in.
Weights :
Power plant _____~__________________--_--_-_ 663 lb
c Engine, less accessories _____________________ 351 lb
Engine, with accessories _____________________ 483 lb
Crankcase oil capacity ____________________--_-__ 5 qt
Drain plugs :
Crankcase ____________________-------__----- Left side, front
Transmission ____________________-_-----_--- Left side, front
Transfer _______________________------------ Bottom, right front

102. Operations Performed With Engine in Vehicle

Following is a reference list of engine components and the para-
graphs which cover removal, installation, or maintenance proce-

AGO 10167B
105
 Paragragh

Air cleaner ....................................... 132

Batteries and cables ........................... 155, 156
Carburetor ....................................... 129
Carburetor controls ................................ 130
Clutch linkage adjustment .......................... 196
Cylinder-head gasket .............. : ............... 103
Cylinder-head replacement ......................... 104
Deep-water fording vent metering and control valves ... 107
Drive belts (fan and generator) .................... 123
External lines and fittings .......................... 113
Fuel and vacuum pump ............................ 131
Generator.. ...................................... 152
Generator regulator ............................... 153
Ignition system ................................ 140-146
Intake and exhaust manifolds ................... 108-109
Lines and fittings ............................ 113, 135
Oil filler pipe ..................................... 112
Oil filter ......................................... 110
Oil filter cartridge ................................. 111
Radiator ......................................... 122
Radiatorhose ..................................... 125
Starter and starter switch ..................... 148, 149
Thermostat ....................................... 126
Valve tappet clearance adjustment ................... 105
Valve tappet compartment cover and gasket .......... 106
Water pump, fan, and fan and water pump pulley ..... 124

The key letters noted in parentheses are in figure 24, except where
otherwise indicated.

(1) Drain the cooling system (par. 121).

(2) Loosen hose clamp screws at both ends of the water in-
let hose (P, fig. 23) and remove the hose. Loosen hose
clamp screws at each end of the bypass hose (L, fig. 23)
and remove the hose.
(3) Remove the vent line (C, fig. 23) between the carbu-
retor assembly (J, fig. 23) and the air intake pipe with
vent valve and bracket assembly (B, fig. 23) by un-
screwing the nut at each end of the line. Remove the
vent line (Q) , between the distributor with coil assem-
bly (M) and the air intake pipe, by unscrewing the
nut at each end of the line. Remove the vacuum hose
/P d
\I’, .a& Es), !xhvx!r? the distribute and t.he tee (H;

AGO 1016'7B
106
 Cylinder installation-left side.

fig. 23), by unscrewing the nuts at both ends of the

line and removing the speed nut (E, fig. 23) and clip
(D, fig. 23) on top of the cylinder-head stud nut.
(4) Loosen the setscrew (F) securing the air cleaner con-
trol valve control wire (C) to the swivel (G) and pull
the wire out of the swivel. Loosen the hose clamp screw
(J), on the control valve hose (H), at the crankcase
oil filler pipe assembly
(5) Remove the cylinder-head stud nut securing the air in-
take pipe bracket (R) to the top of the cylinder head.
Loosen the hose clamp screws (G, fig. 23) and slide the
air intake pipe with vent valve and bracket assembly (B,
fig. 23) off the carburetor and at the air cleaner. Lift
the air intake pipe assembly upward, sliding the con-
trol valve hose off at the oil filler pipe connection, and
remove the pipe assembly.

107
 R- moti J - HOSE CLAMP $(cREW
+A10 1NTAKE PIPE WRi VENT VALVE K -~~UNTlN~ BRACKET (ON ENGlNEf
At40 BRACKET ASSY, L-FLAT

CLEANER CONTROL VALVE ASSY UNIT CABLE

IE- CONfRM VALVE LWER F-WATER

D-AIR CLEANUI CONTMOL VAtVE R -AIR

181521

Figure 24. Qylinder head removal and installdtion--right side.

(6) Unscrew the spark plug cable terminal nuts (N, fig.
23) securing the cables to the spark plugs (R, fig. 23).
Remove cables from the plugs and pull them toward the
right side of the vehicle and away from the cylinder
head. Remove the plugs, using a deep socket, and dis-
card the spark plug gaskets. Disconnect the water tem-
perature sending unit cable (N) from the water tem-
perature sending unit (P) by turning the connector
plug on the end of the cable counterclockwise and pull-
ing it out.
(7) Remove the flat washer screw (L) securing the crankcase
oil filler pipe support bracket and the mounting bracket

108 AGO 1016’7B

 (on engine) (K) to the right side of the cylinder head.
Remove the three cylinder-head stud nuts securing the
mounting bracket (on engine) to the cylinder head and
swing the oil filter assembly, with the mounting bracket
attached, toward the front of the vehicle and away from
the cylinder head.
(8) Remove the second cylinder-head stud nut from the
right rear of the cylinder head. Remove the second and
third nuts securing the lifting hook (A) at the rear
center of the head and remove the lifting hook.
(9) Remove the remaining cylinder-head stud nuts and lift
the cylinder head up and off the cylinder block. ,
(10) Remove and discard the cylinder head gasket.
Clean the cylinder-head gasket
contact surfaces of the cylinder block and cylinder head thorough-
ly, checking for, and smoothing any, burs or nicks. Clean carbon
deposits from the cylinder head and the top of the pistons, mak-
ing sure no loose carbon is left on top of the pistons. Check the
cylinder-head studs in the cylinder block for rust or corrosion
and clean if necessary.
c.
(1) Using cylinder-head studs 10 and 12 (fig. 25) as pilot
studs for correct positioning, place a new cylinder-head
gasket over the cylinder head studs. Position cylinder
head on top of gasket being careful not to damage the
threads on the studs.
(2) Start eight %,-inch cylinder-head stud nuts on studs
3, 4, 6, 8, 11, 12, 13, and 14 (fig. 25) and screw the
nuts on fingertight.

AGO 109
 (3) Place the mounting bracket (on engine) (K), with
oil filter assembly over cylinder-head studs 9, 10, and
15 (fig. 25) and screw nuts on studs fingertight.
(4) Place the lifting hook (A) over the cylinder-head studs
1, 2, and ‘7 (fig. 25) and screw xc-inch nuts on studs
fingertight.
(5) Position the air intake pipe with vent valve and bracket
assembly (B) in the vehicle. Slide the control valve
hose (H) onto the hose connection on the crankcase oil
filler pipe assembly (S) and place the air intake pipe
bracket (R) over the No. 5 stud (fig. 25) and screw
K,-inch nut on stud fingertight. Tighten the hose clamp
screw (J) securing the control valve hose (H) to the
filler pipe. Slide the air intake pipe hose onto the car-
buretor and the air cleaner. Secure the hose clamp screws
(G, fig. 23) at each end of the pipe assembly.
(6) Slide the air cleaner control valve control wire (C) into
the air cleaner control valve control wire swivel (G)
on the control valve lever (E). Make sure deep-water
fording vent valve control (H, fig. 7) on instrument
panel is pushed all the way in. Position control valve
lever with the swivel toward the front of the vehicle.
Tighten the set screw (F) securing the control wire
to the swivel.
(7) Tighten all cylinder-head stud nuts to torque of 65-
75 pound-feet in the sequence shown in figure 25 to
secure the cylinder head to the cylinder block and the
mounting bracket (on engine), lifting hook, and air
intake pipe bracket to the cylinder head.
(8) Install the 5/le x 54 flat washer screw (L) through the
crankcase oil filler pipe support bracket into the mount-
ing bracket (on engine) (K) and tighten.
(9) Clean, adjust, and install the spark plugs and connect
the spark plug cables (par. 145). Connect the water
temperature sending unit cable (N) by pushing the
connector plug on the end of the cable into the sending
unit receptacle and turning the connector clockwise to
secure it to the sending unit.
(10) Position the vent line (Q), between the distributor
and the air intake pipe with vent valve and bracket
assembly (B), in place and screw the nuts on both ends
of the line into the fittings. Position the vacuum hose (F,
fig. 23)) between the distributor and the tee (H, fig. 23))
in place with clip (D, fig. 23) over cylinder-head stud

110 AGO 10167B

 nut No. 2 (fig. 25). Screw speed nut (E, fig. 23) onto
the stud to secure the clip. Screw nuts at both ends of
the line into fittings. Position the vent line (C, fig. 23)
between the carburetor assembly (5, fig. 23) and the
air intake pipe with vent valve and bracket assembly
(B, fig. 23) and screw the nuts at each end of the line
into the fittings.
(11) Install the bypass hose (L, fig. 23) between the water
pump assembly (K, fig. 23) and the cylinder head (M,
fig. 23) and the water inlet hose (P, fig. 23) between
the radiator and thermostat housing (Q, fig. 23). Tighten
the four hose clamp screws securing the bypass and
inlet hose.
(12) Fill the cooling system (par. 121) and check for water
leaks. Start and warm up the engine until normal op-
erating temperature is reached (par. 120). After warm-
ing up the engine, shut the engine off and tighten
cylinder-head stud nuts again (7) above.

104. Cylinder Head Replacement

ct.
(1) Remove the cylinder head (par.
(2) Remove thermostat housing (Q, fig. 23 and par. 126a).
(3) Remove the water temperature sending unit (P, fig.
24) by unscrewing the unit from the cylinder head.
Clean and inspect (par.

(1) Install the water temperature sending unit (P, fig. 24)
in the cylinder head.
(2) Install the thermostat housing (Q, fig. 23 and par.
Install the cylinder head on the engine (par. 103~).

105. Valve Tappet Clearance Adjustment

(fig. 26)
a. Remove the spark plugs (par. 145).
Remove the valve tappet compartment cover and gasket
(par. 106).
c. When valve adjustment is made, valve must be fully closed.
To be sure both valves of any particular cylinder are closed,
move the piston of that cylinder to top dead center of compres-
sion stroke. This is done as follows-place a thumb over the
spark plug hole and press slightly. Turn the crankshaft by hand.
When pressure is felt against the thumb, the compression stroke
has started. Continue turning the crankshaft, allowing the pres-
sure to escape slowly past the thumb, until the top of the com-

AGO 10167B 111

 Figure 86. Adjusting valve tappets.

pression stroke is reached, at which point, the pressure against

the thumb will cease to build up further. Do not turn crankshaft
beyond this point. Both valves for this cylinder are now fully
closed.
d. Check the clearance between each valve tappet adjusting
screw and the bottom of the valve stem with a feeler gage. The
clearance should be 0.016 inch. If the clearance is not correct,
hold the tappet from turning with an open end wrench and turn
the adjusting screw with another wrench. Turn the screw clock-
wise, as viewed from the top, to increase clearance and counter-
clockwise to decrease clearance. Turn screw only a slight amount
at a time and check clearance after each change. Continue proc-
ess until the clearance of both valves is correct.
e. Repeat operations c and d above for each of the other three
cylinders.
f. Install the valve tappet compartment cover and gasket
(par. 106).
g. Install- the spark plugs (par. 146).
h. Start the engine, warm to operating temperature, and check
for smooth operation. ChGf valve tappet compartment cover for
oil leaks.

AGO 10167B
112
106. Valve Tappet Compartment Cover and Gasket
27).
(1) Unscrew the vent line nut from the elbow on the crank-
case control valve assembly. Remove the front cover bolt
securing the crankcase vent body and valve tappet com-
partment cover to the cylinder block. Remove the vent
body and gasket with the elbow and the vent line con-
necting the compartment cover and the elbow on the
control valve assembly. Discard gasket.

Crankcase

(2) Remove the compartment cover screw securing the cov-

er to the cylinder block at the rear of the cover.
(3) Slide the rear of the cover toward the rear of the
vehicle and down toward the transmission until the front
of the cover has cleared the rear of the intake and
exhaust manifold assembly. Pull the front of the cover
out from the cylinder block to clear the manifold as-
sembly, then pull the cover forward, or toward the front,
to remove from the vehicle ; remove the old gasket.

AGO 10167B 113

 Clean the valve tappet compartment cover gasket sur-
faces on the cylinder block and the cover, removing any
particles of the old gasket. Place a new gasket, secur-
ing it with plastic-type gasket cement, on the cover.
(2) Slide the rear of the cover by the rear of the intake
and exhaust manifold assembly, toward the rear of the
vehicle, and down toward the transmission. When the
front of the cover has cleared the rear of the mani-
fold, push the front toward the cylinder block and be-
hind the manifold and slide the cover forward into posi-
tion on the block.
(3) Install X6 x 2% 6 compartment cover screw through
the cover at the rear end and turn it into the cylinder
block fingertight to secure the cover and the gasket to
the block.
(4) Place a new gasket between the crankcase vent body and
the cover. Slide a new gasket on the front cover bolt and
insert the 5/1s x 3 l l/l6 bolt through the vent body, the
cover, and gasket and screw the bolt into the cylinder
block fingertight. Line up the vent body and gasket on
the compartment cover; the compartment cover and
gasket on the cylinder block, and the vent line with the
elbow and tighten the cover bolt and the compartment
cover screw to secure the vent body and cover to the
cylinder block.
(5) Screw the vent line nut into the elbow on the crank-
case control valve assembly and tighten.

107. Crankcase Control Valve, Air Cleaner Control Valve, and

Crankcase Vent Metering Valve Assemblies

(1)
Loosen the set screw securing the air cleaner control
valve control wire to the air cleaner control valve con-
trol wire swivel and pull the wire out of swivel.
(b) Loosen the hose clamp screw at both ends of the con-
trol valve hose and remove the hose.
(c) Unscrew the air cleaner control valve assembly from
the air intake pipe and remove the valve assembly.
(2)
Screw the air cleaner control valve assembly onto the
air intake pipe with the control valve lever at top,

AGO 10167B
 (5) Remove the vent line (M) between the crankcase con-
trol valve assembly (G) and the crankcase vent body
(fig. 27) by unscrewing nut at each end of the line.
(6) Remove the crankcase control valve and vent metering
valve assemblies (G and E) by unscrewing the pipe
nipple from the intake manifold.
(7) Remove the nut from the bolt and nut (L) from
the stud, connecting the exhaust pipe to the exhaust
manifold.
(8) Remove the four nuts (B) one at the front of the intake
manifold ; one at the rear of the intake manifold ; and
two, with flat washers, at the center securing the intake
and exhaust manifold assembly to the cylinder block.
Remove the three nuts (A) securing the exhaust mani-
fold to cylinder block.
(9) Slide the intake and exhaust manifold assembly away
from the block and off the studs and lift out of the vehicle.
(10) Remove the- four lockwasher screws (J) attaching the
intake and exhaust manifolds (Q and R). Remove heat
control valve spring stop (H) . Remove gasket between
the intake and exhaust manifolds and clean the con-
tacting surfaces. Also clean the gasket contacting sur-
faces on cylinder block and intake and exhaust mani-
fold assembly.
b.
(1) Before installation, the new intake and exhaust mani-
folds must be fastened together. Place the surfaces
which contact the cylinder block on a flat surface or
plate. Insert a new intake-to-exhaust manifold gasket
between the intake and the exhaust manifolds. Place
heat control valve spring stop (H) over one 5//ls x 1
lockwasher screw (J) and screw into the left front
hole fingertight. Start the other three ?$ 6 x 1 lockwasher
screws (J) through the exhaust manifold and into the
intake manifold and tighten all four screws with equal
tension.
(2) Place a new intake and exhaust manifold gasket over
studs on cylinder block. Place intake and exhaust mani-
fold assembly over studs.
(3) Screw the three s/s-inch nuts (A) onto the manifold
studs but do not tighten. Place 1ys2 ID flat washers on
the two center studs and screw on two s-inch nuts (B).
Screw one $&inch nut (B) on stud at front of the intake
manifold and one 3/s-inch nut (B) on stud at rear of the
intake manifold. After all nuts (A and B) are in place
AGO 117
 on the studs, tighten them a little at a time and with
equal tension to secure intake and exhaust manifold
assembly to cylinder block.
(4) Insert a new exhaust pipe flange gasket between the
pipe flange and the exhaust manifold flange. Lift the
exhaust pipe up and over the stud in the exhaust mani-
fold flange and screw s/8-inch nut (L) onto the stud part
way. Insert 3/x x ll/(L bolt (K) through the exhaust mani-
fold flange, gasket, and pipe flange and screw on :j/8-
inch nut. Tighten nut (L) and the nut on the bolt (K)
with equal tension to secure exhaust pipe to the mani-
fold assembly.
(5) Install the crankcase control valve and vent metering
valve assemblies (G and E) on intake manifold by
screwing the pipe nipple into the manifold to the posi-
tion shown.
(6) Insert the crankcase control valve control wire (N)
through the crankcase control valve control wire swivel
(F) and tighten the set screw securing wire to swivel.
Position the vent line (M) between the crankcase con-
trol valve and the crankcase vent body (fig. 27). Screw
nut into the fitting at both ends of the line and tighten.
(7) Position fuel and vacuum pump-to-tee line (D) between
the fuel and vacuum pump and the tee and tighten the
two nuts.
(8) Position fuel and vacuum pump-to-intake manifold line
(C) between the fuel and vacuum pump and the intake
manifold and tighten the two nuts.
(9) Install carburetor (par. 129c).

Replace the intake and exhaust manifold gasket (mani-

fold-to-cylinder block) (par. 108).
b.
Replace intake and exhaust manifold gasket (manifold-to-mani-
fold) (par. 108) except that the old manifolds are used instead
of new ones.

110.
30)
a.
(1) Disconnect the oil filter inlet flexible oil line assembly and
fitting from the oil filter head with cartridge assembly

118 AGO 10167B

 by unscrewing the nut from the fitting and unscrewing
the fitting from the head. Disconnect the oil filter outlet
flexible oil line assembly by unscrewing the nut from
the fitting on the timing gear cover assembly. Remove
the oil filter outlet flexible oil line assembly and elbow
from the head with cartridge assembly by unscrewing
the elbow from the head.

Figure 30. Oil filter assemblp-installed.

(2) Remove the two flat washer screws with large flat wash-
ers, holding the mounting bracket (on oil filter) to the
mounting bracket (on engine), from the two speed nuts.
Remove the oil filter assembly with the mounting bracket
(on oil filter) from the vehicle. Loosen the screw
and nut securing the mounting bracket to the filter
and slide the bracket off the filter.

(1) Screw the oil filter inlet flexible oil line fitting into
the oil filter head with cartridge assembly at the position
indicated by an arrow pointing toward the center of

AGO 10167B 119

 the head. Screw the oil filter outlet flexible oil line elbow,
with flexible oil line, into the oil filter head with cartridge
at the position indicated by an arrow pointing to the
outside edge of the head.
(2) Put the oil filter assembly into the mounting bracket
(on oil filter) but do not tighten the screw and nut in
the bracket. Position the mounting bracket (on oil filter)
on the mounting bracket (on engine). Place a I+&
inch flat washer on each of the two 5/16-10 x s/s (Acme)
flat washer screws. Put the screws through the holes
in the mounting bracket (on oil filter) and screw into
the J-type speed nuts on mounting bracket (on engine).
Position the oil filter in the mounting bracket, alining
the inlet fitting on the oil filter with the inlet flexible
oil line, and tighten the screw and nut securing the
mounting bracket to the oil filter assembly.
Connect the inlet flexible oil line to the oil filter by
screwing the nut on the end of the line into the fitting
on the oil filter. Connect the outlet flexible oil line to
the timing gear cover assembly by screwing the nut
on the end of the line into the fitting in the cover.
Start the engine and run it for a few minutes to fill
the oil filter assembly and check for oil leaks around
the flexible oil line connections and the filter.
Note. The oil filter inlet flexible oil line is slack enough to
permit the engine fan blast to force the line into constant contact
with the manifold elbow. To prevent damage by burning, move
the oil filter clockwise within its mounting bracket to shorten
the line enough to keep it clear of the manifold elbow.

(1) Disconnect the oil filter inlet flexible oil line assembly
and fitting from the oil filter head with cartridge as-
sembly by unscrewing the nut from the fitting and un-
screwing the fitting from the head. Disconnect the oil
filter outlet flexible oil line assembly by unscrewing the
nut from the fitting on the timing gear cover assembly.
Remove the oil filter outlet flexible oil line assembly
and elbow from the head with cartridge assembly by
unscrewing the elbow from the head.
(2) Remove six bolts and nuts securing the head and the
reinforcing ring to the sump and lift the head with
cartridge assembly out of the sump.

120
 Remove the pipe plug from the bottom of the
sump. Drain the sump thoroughly and wipe dry. Wash the oil
filter head with cartridge assembly in dry-cleaning solvent or
volatile mineral spirits. While cartridge is submerged in clean-
ing agent, hold the head and rotate the handle to work all dirt
out of the cartridge. Allow the cartridge to drain.
Caution: Never use compressed air to dry cartridge, as air un-
der pressure can cause serious damage.
c.
Screw the elbow with outlet flexible oil line into the
cartridge head at the position indicated by an arrow
pointing to the outer edge and tighten elbow. Place a new
gasket in the recess of the head. Insert the head with
cartridge assembly in the sump with the outlet pointing
forward as shown in figure 30. Aline the holes in the
reinforcing ring with the holes in the cartridge head,
insert six No. 12 x s/4 bolts through the head and rein-
forcing ring, and screw into the six No. 12 nuts on the
underside of the reinforcing ring. Screw the inlet fitting
into the head and screw the nut on the end of the inlet
flexible oil line into the fitting.
(2) Screw the nut in the end of the outlet flexible oil
line into the fitting in the timing gear cover assembly.
(3) Start the engine to fill the oil filter assembly with
)- oil and check the assembly and flexible oil lines for pos-
sible leaks.

a. Remove the oil level gage with cap assembly

from the crankcase oil filler pipe assembly. Loosen the hose
clamp screws on the control valve hose connecting the oil filler
pipe to the air cleaner control valve assembly and remove the
hose. Remove the flat washer screw securing the oil filler pipe
support bracket to the mounting bracket (on engine) and cylin-
der head, and remove the oil filler pipe.
Note. The fdler pipe is a drive fit in crankcase. Some difficulty may be
experienced in removal. The pipe may be loosened by tapping front and
rear side alternately and, at the same time, pulling straight up on pipe.
Do not install a used filler pipe, as a tight
fit in crankcase is necessary to prevent oil leakage. Insert end
of new pipe in crankcase opening, with the tlat side, at center
portion of pipe, facing the generator. Tap pipe into place, using
a soft hammer or wood block. Use care to avoid damage to
upper end of pipe. Install the control valve hose connecting the

AGO 10167B 121

filler pipe to the air cleaner control valve assembly. Tighten hose
clamp screws securing the hose. Install and tighten y/l6 x 5/s
flat washer screw securing the oil filler pipe support bracket to
the mounting bracket (on engine). Install the oil level gage with
cap assembly on filler pipe. Run engine until normal operating
temperature (160”-180” F.) is reached and check oil filler pipe
at lower end for leaks.

113. External lines and Fittings

a. External lines consist of flexible and solid types.
b. Fittings, as termed, consist of elbows, nipples, tees, and
a shutoff valve.
c. The lines and fittings for various systems are covered
in (1) through (6) below.
(1) paragraph 245.
(2) paragraph 135.
(3) Oil paragraph 110.
(4) paragraphs 135 and
143.
(5) cleaner
paragraph 107.
(6) paragraphs 143 and 265.

Section VI. ENGINE REMOVAL AND INSTALLATION

114. General
For ease of maintenance, the engine, clutch, transmission, trans-
fer, and radiator are removed as a unit, referred to as the power
plant (figs. 31 and 32). The power plant must be removed be-
fore the engine can be separated from the other units.

115. Coordination With Ordnance Maintenance Unit

Refer to paragraph 2 for information on coordination with an
ordnance maintenance unit.

116. Power Plant Removal

Remove the hood (par. 261). Disconnect battery-
to-battery ground cable (fig. 68) from battery “A” located in the
engine compartment.
Note. It is not necessary to drain the radiator, crankcase, transmission,
or transfer before removing the power plant unless vehicle is equipped
with winch and power-take-off.
Close the fuel shutoff valve (P, fig. 34).

AGO 10167B
as
 lt_A 18%530

Figure 32. Left front view of power plant as removed.

 Remove radiator--guard (par. 263).
(2) Remove the two nuts and flat washers from the radiator
hold-down studs (fig. 41) securing the radiator to the
vehicle frame and remove the radiator cushions.
c.
The key letters noted in parenthesis are in figure 33, except where
otherwise indicated.
(1) Pull windshield wiper hose (A) off windshield wiper vent
line (B) and unscrew vent line nut from tee (E)
(2) Unscrew nut on master cylinder vent line (F) and re-
move line from the connector in tee (E)

AGO 10167B 125

 (3) Unscrew nut on fuel tank vent line (H) , and remove Ime
from connector (G).
(4) Loosen hose clamps (J) securing the air cleaner-to-air
intake pipe flexible hose (L) in position and remove
hose.
(5) Loosen the two wing screws securing the air cleaner as-
sembly (D) to the left support bracket assembly. Remove
the two wing screws and lockwashers securing air cleaner
assembly to the right support bracket assembly (C) and
remove air cleaner assembly.
(6) Disconnect cable No. 33 (fig. 85) from the water tem-
perature sending unit (M) by turning cable plug counter-
clockwise and withdrawing from receptacle.
(7) Loosen the set screw securing air cleaner control valve
control wire (N) to swivel and withdraw wire from
swivel.
(8) Disconnect cable No. 12 from the wiring harness filter
receptacle assembly by unscrewing nut (T) from hous-
ing.
(9) Unscrew the connectors securing the generator-to-gen-
erator regulator cable (R) from generator (S) and gen-
erator regulator (V) and remove cable.
(10) Remove the nut and lockwasher securing the battery-to-
starter cable and generator regulator cable (fig. 63) to
starter switch (U) and remove cables from switch.
(11) Remove the self-locking nut, flat washer, and bolt secur-
ing the engine front plate-to-frame ground strap (Q).
Remove the self-locking nut, flat washers, and bolt secur-
ing the front mounting support cushion (P) to vehicle
frame.
d. Operations at Left Side of Vehicle.
The key letters noted in parentheses are in figure 34, except where
otherwise indicated.
(1) Loosen the nuts securing the brace rod (A) to radiator,
and remove the nut and lockwasher securing rod to ve-
hicle cowl. Remove rod and install washer and nut to pre-
vent loss.
(2) Unscrew the nut securing the fuel line to the flexible
fuel line (S) and separate the lines.
(3) Remove the nuts from the stud and bolt securing the ex-
haust pipe (V) to the exhaust manifold (B) and remove
the bolt. Press on flange of exhaust pipe to free it from
the stud in the exhaust manifold and remove exhaust
pipe flange gasket.

AGO 10167B
 Figure 34. Disconnect points at left side of vehicle.

(4) Loosen the setscrew securing the crankcase control valve

control wire (U) to the crankcase control valve control
wire swivel (Q) and withdraw wire from swivel. Re-
move the nut and bolt from the clip securing the conduit
for the control wire (fig. 27) to the support strap located
at carburetor front mounting stud and tie control wire
to vehicle cowl. Replace the nut and bolt on clip to prevent
loss.
(5) Loosen the set screw securing the stop to the throttle
control wire (C) and withdraw wire from shaft (W).
Loosen set screw securing the choke control wire (D) to
the swivel on the choke valve shaft and withdraw wire
from shaft. Remove plain nut and bolt securing the choke
control conduit (G) and clamp to the throttle control
conduit bracket (E) and remove the choke control con-
duit. Spread the opening in the throttle control conduit
bracket and pull the throttle control conduit free. Tie the
conduits to the cowl to prevent damage.

AGO 10167B 127

 (6) Unhook the accelerator pedal return spring (J) from
the accelerator control rod (H) . Remove the cotter pin
and flat washer securing control rod to accelerator cross
shaft (K) . Secure cotter pin and washer to control rod
to prevent loss.
(7) Disconnect cable No. 36 (fig. 85) from oil pressure gage
sending unit (L) by turning cable plug counterclockwise
and withdrawing it from receptacle.
(8) Pull windshield wiper hose (N) from windshield wiper
line (M).
(9) Remove the two self-locking nuts, four flat washers, and
two bolts securing the front mounting support cushion
(R) to vehicle frame.
(10) Loosen the bolt in the upper end of the brake pedal as-
sembly, pull the pad assembly from the pedal assembly
and remove the draft pad and draft pad spring from be-
neath the upper front floor pan cover.
e.
The key letters noted in parentheses are in figure 35, except where
otherwise indicated.
(1) Remove the gearshift lever knob from gearshift lever
(A) and the gearshift lever knobs (B) from the high and
low range gearshift lever (J) and front wheel drive gear-
shift lever (P) .
(2) Loosen the hose clamps (Q and S) and slide transmission
gearshift lever boot (R) off gearshift lever (A). Unscrew
gearshift lever housing cap and withdraw lever from
transmission. Stuff a clean rag in transmission case open-
ing to prevent foreign material from entering.
(3) Remove the sheet metal screws securing the shift Iever
housing cover boot ring (L) and slide ring and transfer
gearshift levers-to-floor board boot (K) off shift levers.
(4) Loosen the two lockwasher bolts securing the transfer
case bolt access plate (M) to lower front floor pan cover
(N) and swing plate to the rear. Reach through access
plate opening, unscrew the pivot pin and remove pin and
lock washer. Remove the high and low range and front
wheel drive gearshift levers (J and P) and gearshift
lever springs from transfer.
(5) Remove the lockwasher bolts securing the steering gear
jacket access plate (E) and steering gear jacket access
plate seal (D) in position. Separate and remove the ac-
cess plate, and slide the seal up on the steering gear
jacket.

AGO 10167B
 JKKE‘I ACCESS

R-

(6) Remove the lockwasher bolts securing the brake master

cylinder inspection cover (T) to the lower front floor
pan cover (N) and remove inspection cover.
(7) Remove the remaining lockwasher bolts securing the up-
per front floor pan cover (H) in position and remove
cover with starter pedal attached.
(8) Remove the lockwasher bolts and accelerator foot rest
(F) securing the transmission cover (G) in position and
remove cover.
(9) Remove the remaining lockwasher bolts securing the low-
er front floor pan cover (N) in position and remove cover.
(10) Disconnect universal joint at rear of front propeller
shaft (par. 209). Push joint forward on shaft, swing to-
ward right side of vehicle, and tie up out of the way.

AGO 129
 (11) Remove plain nut, bolt, flat washer, and plain washer
securing the case support insulator, case support insula-
tor snubber (C, fig. 36)) and case support insulator re-
taining cup in position and remove insulator, snubber,
and cup.
(12) Remove the cotter pin and clevis pin from the clutch con-
trol lever tube cable adjustable yoke (fig. 32) and dis-
connect yoke from the control lever tube.
(13) Unhook and remove the brake pedal retracting spring
(Q, fig. 36).
(14) For vehicles equipped with winch and power-take-off,
unscrew the knob from the power-take-off gearshift con-
trol lever (HH, fig. ‘7). Unscrew the four screws from
the grommet retaining plate (NN, fig. 7) and slide the
plate and the grommets (LL and MM, fig. 7) up off the
gearshift lever. Remove the four screws from the power-
take-off shift lever plate and lift the plate with gearshift
lever out of the power-take-off.
f.
Note. The key letters noted in parentheses are in figure 36, except where
othewise indicated.
(1) Remove the plain nuts, plain washers, lockwashers and
carriage bolts securing the skid plate to engine rear sup-
port cross member (F) and remove skid plate.
(2) Loosen the adjusting nut securing the engine stay cable
(H) and lift cable end out of bracket (G) .
(3) Remove the two self-locking nuts from the studs on the
rear mounting support cushion (L) to loosen cushion
from the engine rear support cross member (F) .
(4) Remove the four plain nuts, flat washers, and lockwash-
ers from bolts (D) securing the engine rear support cross
member (F) to the vehicle frame and remove the cross
member.
(5) Unhook and remove the cable retracting spring (R) .
(6) Remove the plain nut and bolt securing the cable hous-
ing clamp (J) to the rear mounting bracket (K) .
(7) Remove the cotter pin and clevis pin securing the hand
brake rod end yoke (N) to the operating lever (M).
Spread open the clip securing the hand brake cable to bell
housing and slide cable out of clip.
(8) Disconnect speedometer cable (E) from the speedometer
driven gear sleeve (fig. 90).
(9) Remove the four nuts and lockwashers securing the uni-
versal joint (A), located at the front of the rear propeller

130 AGO 10167B

 Figure 36. Disconnect points

shaft, to the hand brake drum (B) . Slide the universal

joint back and tie propeller shaft to vehicle frame to pre-
vent damage.
(10) For vehicles equipped with winch and power-take-off,
perform operations (a) through (d) below.
(G Drain the transmission, transfer, and the power-take-
Off.
(b) Remove the winch hanger bearing assembly (par.
171a).
(c) Loosen the setscrew (Q, fig. 82) securing the universal
joint assembly (M, fig. 82) to the power-take-off out-
put shaft (N, fig. 82) and remove the short drive shaft
(L, fig. 82) with universal joints.
(4 Remove the five bolts and lock washers holding the
power-take-off to the transfer and pull the unit toward
the rear of the vehicle to clear the transfer and remove
the power-take-off from the vehicle.

AGO 10167B
131
 (1) Use a pry bar to move rear of power plant to the right to
disconnect the clutch control lever (P, fig. 36) from the
ball stud located on transfer case.
(2) Connect a suitable lifting device in the rear lifting hook
(fig. 37)) and carefully lift power plant until engine front
mounting support cushions clear vehicle frame. Continue
to lift power plant and, at the same time, roll vehicle back.
Place power plant on a suitable stand.

117. Engine Removal From Power Planf

CL. Drain transmission and
transfer. Unscrew the nut securing the transfer case vent line
(fig. 31) to the elbow located on transfer case. Remove the four
bolts (fig. 31), lockwashers, and flat washers securing the trans-
mission to the clutch bell housing, and remove transmission and
transfer. Discard gasket.
Drain the cooling system (par. 121). Re-
move radiator hose (par. 125). Lift the radiator off the radiator
left and right support rods (figs. 31 and 32).
c. If inspection of pulley shows that inside
flanges are separating at the hub, apply corrective procedure .de-
scribed in (1) through (4) below.

132 AGO
 (1) Remove pulley from engine.
(2) Lay out three holes in the pulley on a 23/4inch diameter
circle, 30” from centerline of key slot (fig. 38).
Caution: Absolute accuracy of spacing is essential to
prevent an unbalanced pulley.
(3) Drill three x-inch holes in pulley.
(4) Install three x x 7/ls flat-head steel rivets 118055 and
rivet securely in place.

118. Engine Installation in Power Plant

a. Position radiator on radiator left and right
support rods. Install radiator hose (par. 125).
b. Using a new gasket be-
tween the transmission and clutch bell housing, install transmis-
sion on the bell housing, guiding spline of the transmission main
gear shaft into the splines of the clutch assembly. Secure the
transmission to the bell housing with four 15/3,-inch flat washers,
X6-inch lockwashers, and 7/la x 1% bolts (fig. 31).

119. Power Plant Installation

(1) Connect a suitable lifting device to the rear lifting hook

(fig. 37) and raise power plant until it clears front of
vehicle.
(2) Lower power plant into engine compartment, tilting
down transfer end of power plant.
(3) Use a pry bar to move power plant to left side of vehicle,
and enter clutch control lever (P, fig. 36) on ball stud
located on transfer case. Install radiator cushions (fig.
41) on radiator hold-down studs. Aline studs with holes
in cross member and aline studs on front mounting sup-
port cushions with holes in vehicle frame. Lower front
of power plant into position in engine compartment.

The key letters noted in parentheses are in figure 36, except where
otherwise indicated.
(1) Untie rear propeller shaft from vehicle frame and
position universal joint (A) on handbrake drum (B) .
Secure in position with four a/s-inch lockwashers and
nuts.
(2) Screw speedometer cable (E) to the speedometer driven
gear sleeve.

AGO 10167B
133
 RIVETS, FL-HD, l/4

RAPD 359101
Figure 38. of rivets in pulley.
 (3) Untie handbrake cable from the vehicle frame and posi-
tion handbrake rod end yoke (N) on operating lever
(M). Screw in position with a K 6 x 1 clevis pin and
yS2 x 1 cotter pin.
(4) Position the cable housing clamp (J) on the rear mount-
ing bracket (K) and secure in position with a 5/16 x ‘/s
bolt and %,-inch plain nut inserting bolt through rear
mounting bracket (K) .
(5) Position the handbrake cable in the clip mounted on
the clutch bell housing and close clip with a pair of pliers.
(6) Hook the cable retracting spring (R) to the extension
located on the operating lever (M) and to the hook
secured to the bracket welded to floor panel.
(7) Install the engine rear support cross member (F) and
secure in position with four a/s x 7/a bolts, lyY/,,-inch flat
washers, a/a-inch lockwashers, and a/s-inch plain nuts.
(8) Install two s-inch self-locking nuts on the studs on rear
mounting support cushion (L) securing the cushion to
the engine rear support cross member (F).
(9) Insert the ball end of the engine stay cable (H) in the
bracket (G) located on the engine rear support cross
member (F).
(10) Position skid plate on engine rear support cross mem-
ber (F) and secure with four 3h x 7/ carriage bolts,
13/32-inch plain washers, $,&inch lockwashers, and 3/8-
inch plain nuts.
(11) For vehicles equipped with winch and power-take-off,
perform operations (a) through (d) below.
(a) Use a new gasket between the power-take-off and the
transfer and position the power-take-off on the rear
of the transfer. Place a/s-inch lockwashers over the
s/s x 1 bolts and push the bolts through the case of the
power-take-off and screw into the transfer.
(b) Install the short drive shaft (L, fig. 82) with uni-
versal joints (par. 169b (4) ) .
(c) Install the hanger bearing assembly (par. 169b (1))
(2), and (3)).
(d) Tighten the setscrew (Q, fig. 82) securing the univer-
sal joint assembly (M, fig. 82) to the power-take-off
output shaft (N, fig. 82).
(12) For vehicles equipped with winch and power-take-off,
perform operations (a), (b) , and (c) below.

135
 (a) Install the power-take-off gearshift control lever (HH,
fig. ‘7) with the shift lever plate in the power-take-off
and install four No. 10 x s/s screws in the plate.
(b) Slide the grommet (LL, fig. 7) over the gearshift
control lever. Slide the grommet (MM, fig. 7) over
the control lever and the grommet (LL, fig. 7). Slide
the grommet retaining plate (NN, fig. 7) over the
control lever and screw the four No. 10 x 5/g screws
through the plate and into the floor pan. Screw the
knob onto the control lever.
(c) Fill the power-take-off with correct grade of lubricant
(par. 66).
c.
Note. The key letters noted in parentheses are in figure 35, except where
otherwise indicated.
(1) Hook the brake pedal retracting spring (Q, fig. 36) at
bracket welded to engine rear support cross member
and at brake pedal shank.
(2) Position the control lever tube cable adjustable yoke
(fig. 32) on control lever tube and secure in position
with 5/16 x 27h2 clevis pin and aA2x 1 cotter pin.
(3) Position the case support insulator retaining cup and
case support insulator snubber (C, fig. 36) between
the transfer and engine rear support cross member.
Position the case support insulator underneath the en-
gine rear support cross member and install a 21/,,-inch
plain washer and l/s x 3 bolt. Secure the snubber in po-
sition with l/s-inch flat washer and plain nut.
(4) Untie the front propeller shaft from vehicle and connect
the universal joint at rear of propeller shaft (par. 209).
(5) Install the upper and lower front floor pan covers (H
and N) and secure in position with twenty-four jh x r/IL
lockwasher bolts. Install the draft pad and the draft
pad spring beneath the upper front floor pan cover.
Push the brake pad assembly through the draft pad and
the spring into the brake pedal assembly, and tighten
the bolt.
(6) Position the ‘brake master cylinder inspection cover (T)
on the lower front floor pan cover (N) and secure in
position with four rh x l/2 lockwasher bolts.
(7) Slide the steering gear jacket access plate seal (D)
down the steering gear jacket and into position on the
upper front floor pan cover (H) . Install the steering
gear jacket access plate (E) over the seal and secure
in position with four 1h x l/g lockwasher bolts.
AGO 10167B
136
 (8) Position the high and low range gearshift lever (J) in
transfer output shaft front bearing cap, being sure
lower end of lever is in the slot of the shifter shaft.
Position the front wheel drive gearshift lever (P) in
the cap, being sure the lower end of the lever is in the
slot of the shifter shaft. Install a s/s-inch lockwasher
on the gearshift lever pivot pin and reach through the
opening of the transfer case bolt access plate (M) and
insert the pin through the right side of the cap and
both shift levers and screw pin loosely into cap. Install
one gearshift lever spring on the left side of the transfer
high and low range gearshift lever (J), with the tangs
of the spring facing to the right of the vehicle, and seat
spring on gearshift lever pivot pin. Install the second
gearshift lever spring between the high and low range
gearshift lever and the front wheel drive gearshift lever
(P),with the tangs of the spring facing to the right of
the vehicle, and seat spring on gearshift lever pivot pin.
Tighten the pivot pin.
(9) Install the transfer case bolt access plate (M) on the
lower front floor pan cover (N) and secure in position
with two l/4 x l/s lockwasher bolts.
(10) Position the gearshift lever (A) in the transmission and
secure with gearshift lever housing cap. Slide the trans-
mission gearshift lever boot (R) down into position and
tighten the two hose clamps (Q and Slide the trans-
mission cover (G) over the shift lever and secure in
position with seven lockwasher bolts. Install the ac-
celerator foot rest (F) in the upper left corner of the
transmission cover (G) . Install the three gearshift lever
knobs.
(11) Slide the transfer gearshift levers-to-floor board boot
(K) down into position. Slide the shift lever housing
cover boot ring (L) over the shift levers and secure in
position with four No. 10 x $42sheet metal screws.
If the clearance between the front wheel drive high and
low range shift lever (fig. 35) and floor board is insufficient and
noise is caused by vibration of lever against the board, proceed
as described in (12) below.
(12) Engage the lever in the high range position (rearward).
Mark or scribe cover boot ring (fig. 35) and floor board
at location of contact. Remove the ring and rubber grom-
met and using a file or cutting torch, cut circular notch
(approx l/s in.) in the ring and floor board.

137
 cl. Operations At Left Side of Vehicle.
Note. key letters noted in parentheses are in figure 34, except where
The
otherwise indicated.
(1) Install the two ISa-inch flat washers, 5/ls x 1 bolts,
11/a,,-inch flat washers, and 5/116-inchself-locking nuts
securing the front mounting support cushion (R) to the
vehicle frame.
(2) Insert the windshield wiper hose (N) over the wind-
shield wiper line (M) .
(3) Connect cable No. 36 (fig. 85) to the oil pressure gage
sending unit (L) by inserting cable plug in receptacle
and turning plug clockwise.
(4) Install the accelerator control rod (H) on the accelerator
cross shaft (K) and secure in position with a No. 8
flat washer and l/is x l/s cotter pin.
(5) Untie the throttle control conduit (F) and choke con-
trol conduit (G) from the cowl. Make certain that the
throttle and choke controls are pushed in on instrument
panel and insert the throttle control wire (C) into
throttle valve shaft (W) and stop. Tighten set screw
in the stop.
Note. Throttle must be fully closed and stop against throttle
valve shaft (W) when screw is tightened.
Insert choke control wire (D) in swivel on choke valve
shaft and tighten set screw. Position the throttle con-
trol conduit in throttle control conduit bracket (E) .
Position choke control conduit clamp, with the conduit,
on throttle control conduit bracket, and secure with a
No. 10 x sh bolt and No. 10 plain nut.
(6) Untie the crankcase control valve control wire (U)
from the cowl. Make certain control button is pushed in
on instrument panel and insert wire into the crankcase
control valve control wire swivel (Q) and tighten set-
screw. Insert the conduit for the control wire into the
clip securing the conduit to the support strap, located
at the carburetor front mounting stud, and secure con-
duit in position with a No. 10 x 1/2 bolt and No. 10
plain nut.
(7) Position the exhaust pipe flange gasket on the exhaust
pipe. Position exhaust pipe (V) on stud in exhaust
manifold (B) and secure pipe to manifold with a s/s-inch
nut. Install a 3/3 x 11/g bolt and a/s-inch nut on other
end of flange. Tighten nuts evenly to prevent distortion
of the gasket.

AGO 10167B
 (8) Screw the nut on the fuel line into the fitting on flexible
fuel line (S) and tighten the nut.
(9) Position brace rod (A) in the bracket welded to radiator
and in hole in vehicle cowl. Secure cowl end of rod with
ylG-inch lockwasher and nut. Position one ylG-inch
nut and flat washer on engine side of brace rod bracket
and one 5k6-inch flat washer, lockwasher, and nut on
radiator side of bracket. Tighten nut on radiator side
until radiator is rigid in vehicle. Tighten the nut on the
engine side of brace rod bracket.

Note. The key letters noted in parentheses are in figure 33, except where
otherwise indicated.
(1) Install the two 17/32-inch flat washers, Xs x 1 bolts, one
1I/! -inch flat washer, and y16-inch self-locking nut
secjiring front mounting support cushion (P) to the
vehicle frame. Install the engine front plate-to-frame
ground strap (Q) on the remaining support cushion
bolt and secure in position with an 1y!2-inch flat washer
and 5/116-inch self-locking nut.
(2) Install the battery-to-starter cable (fig. 63) and gen-
erator regulator cable on the starter switch (U) and se-
cure in position with a a/s-inch lockwasher and nut.
Position the generator-to-generator regulator cable (R)
at generator (S) and generator regulator (V) and
tighten cable connectors.
Connect cable No. 12 to the wiring harness filter re-
ceptacle assembly by inserting cable plug in receptacle
and installing nut (T).
Insert air cleaner control valve control wire (N) into
swivel and tighten setscrew.
Connect cable No. 33 (fig. 85) to receptacle on water
temperature sending unit (M) by inserting cable plug
into receptacle and turning plug clockwise.
Position the air cleaner assembly (D) in the right sup-
port bracket assembly (C) and install two n/3a-inch lock-
washers and r/4 x sj4 wing screws. Position air cleaner
assembly in left support bracket assembly and tighten
the two wing screws.
Install the air cleaner-to-air intake pipe flexible hose
(L) and tighten hose clamps (J) .
Screw the nut on fuel tank vent line (H) into connector
(C).

AGO 10167B 139

 (10) Screw the nut on the master cylinder vent line (F) into
tee (E).
(11) Screw the nut on the windshield wiper vent line (B)
into tee (E) and slide windshield wiper hose (A) over
vent line.
(12) Connect battery-to-battery ground cable to battery “A”
located in the engine compartment.
f.
(1) Secure radiator to vehicle frame cross member by in-
stalling two ll/,z-inch flat washers and yli/,,-inch nuts on
radiator holddown studs (fig. 41).
(2) Install radiator guard (par. 263).

(1) Open fuel shutoff valve (P, fig. 34) by turning valve
handle counterclockwise.
(2) Tighten engine stay cable (H, fig. 36) adjusting nut,
located at engine side of bell housing, until cable is taut.
(3) Fill cooling system (par. 121).
(4) Install hood (par. 261).
(5) Fill crankcase with correct grade of lubricant (par. 68).
(6) Fill transmission and transfer tith correct grade of
lubricant (par. 68).
(7) Start engine and check for fuel, oil, or water leaks.
(8) Make a record of replacement on DA Form 478.

(1) The cooling system (fig. 39) is fully sealed

and pressurized. The system consists of a water pump,
water pump bypass, fan, drive belts, radiator, thermo-
stat, and connecting hose. Water is drawn down through
the radiator to the bottom thence through the water
outlet hose to the water pump which forces it through
the cylinder block, cylinder head, and the water inlet
hose to the top of the radiator. Air, for cooling the water,
is drawn through the radiator by the fan. Correct op-
erating temperature is maintained by the thermostat.
(2) and 32). The radiator is the cellular-
type, with upper and lower tanks. The filler cap has a
spring-loaded seal to maintain a pressure of approxi-
mately 4112 psi when the engine is running. The cap seal
acts as a safety valve by lifting off its seat to relieve
excessive pressure.
AGO
140
 Figure $9. Cooling system.

(3) The thermostat is a bellows-type construct-

ed to maintain an operating temperature of 160” to
180” F. It is located on top of the cylinder head in the
thermostat housing (T, fig. 24).
(4) The water pump assembly (fig.
39) is the centrifugal-type, located at the front of the
cylinder block.
(5) The fan has four blades and is mounted on the
fan and water pump pulley. The water pump and fan
are driven by a matched pair of V-belts.

AGO 141
Radiator:
Manufacturer _______________________~~ Blackstone Mfg CO
Type __~_ ~~_~_____________~~~__.. Cellular
Capacity ~. 11% qt
Filler cap ~~ 4% psi pressure-type
Water pump and fan:
Water pump type__~~_________-____- Centrifugal
Fan _~_ _. ~~~~~~~~_______~_____~____ Four blade, 15-in diam
Drive ________~___________________~-~ Double belt
Location ____________________---~~-~~~ Front of cylinder block
Drive belts :
Type ________________________-----_-- “V”, matched pair
Width _~___________________---__--_~ %-in.
Length ________________________--_~~~ 457/s-in. outside circumference
Thermostat:
Location ____________________---_---- Thermostat housing
Range (opening) ~~_______~~~~~ ~__ ~~ 148” to 155” F.

Caution: The cooling system is pressurized. Use care when

removing radiator cap.
a.
(1) To drain the cooling system, open the hood
and remove the radiator cap slowly to relieve any pres-
sure within the system. If the coolant is to be saved,
place a suitable container under the drain cocks (fig.
40) of the radiator and cylinder block. One drain cock
is located on the right side of the cylinder block just
forward of the starter, and the other is located at the
bottom of the radiator on the left side of the water
outlet hose fitting. Open both drain cocks, allow cooling
system to drain completely, and close drain cocks.
(2) Be sure that both drain cocks (fig. 40) are closed.
Fill the cooling system with water, or antifreeze solu-
tion, of sufficient strength to protect the system against
the lowest anticipated temperature, to a level approxi-
mately 1 inch below the bottom of the filler neck. Run
the engine to circulate the coolant and expel air from the
system, and recheck the coolant level.
Caution: When adding coolant to the system, be sure
that the engine water temperature is below 200” F.
before removing the radiator cap.
For directions for cleaning and flush-
ing, refer to TM 9-2858.

AGO 10167B
 Figure 40. Cooling system drain cocks.

(1) Drain the cooling system (par. 121).

(2) Remove the radiator guard (par. 263).
Loosen the nut on the rear end of the brace rod (fig.
39). Loosen the nut on the front end of the brace rod,
securing the rod to the bracket, sufficiently to permit
the rod to be pulled up out of the bracket. Lift the rod
out of the bracket and swing it toward the rear of the
vehicle to clear the radiator assembly.
Loosen the two hose clamp screws on the water inlet
hose (fig. 39) and remove hose. Loosen the two hose
clamp screws on the water outlet hose (fig. 39) and
remove the hose.
Remove nuts and flat washers from two radiator hold-
down studs (fig. 41) holding radiator assembly to frame
front cross member.
Lift radiator assembly straight up, being careful not
to rub it against fan. When studs (fig. 41) are clear
of frame front cross member, tip radiator forward at
the top and remove from vehicle. Remove radiator cush-
ions from studs (fig. 41).

143
 Figure 41. Radiator hold-down studs.

(1) Place radiator cushions on radiator hold-down studs

(fig. 41). Carefully lower radiator assembly into place,
positioning holes in brackets (fig. 32) on radiator over
radiator left and right support rods.
(2) Install two ii/3a-inch flat washers and x6-inch nuts
(fig. 41) on studs securing the radiator to the frame front
cross member and tighten evenly.
Install water inlet hose (fig. 39) and tighten both hose
clamp screws. Install water outlet hose (fig. 39) and
tighten both hose clamp screws.
Swing the brace rod (fig. 39) toward the front of the
vehicle and aline rod with slot in bracket on the radiator
assembly. Position flat washer against the rear nut at
the front end of the rod, position lockwasher and flat
washer against the front nut at the front end of the rod.
Slide the rod down into the slot. Make sure that one
flat washer is at the rear of the bracket and one flat
washer at the front. Adjust the rear nut so that the
washer is snug against the rear of the bracket. Tighten
the nut at the front end of the rod. Fill the cooling
system (par. 121) and check for leaks. Install the radia-
tor cap. Start the engine and run until normal operating
temperature is reached. Recheck the coolant level.

123. Fan and Generator Drive Belts

a. Loosen the lockwasher screw holding the belt
tension adjustment brace to the drive end head of the generator.

AGO 10167B
144
Move generator toward or away from the engine, as required,
until a firm push on belts will deflect them 1 inch as shown in
figure 42. When adjustment is correct, tighten screw holding brace
to top of generator. If inspection of pulley shows inside flanges
being separated at hub, rivet the pulley as described in para-
graph 117.

Figure 42. Adjusting drive belts.

Loosen lockwasher screw holding belt tension ad-

justment brace to drive end head of the generator and push
generator toward engine as far as possible. Remove forward drive
belt by working it over forward edge of generator drive pulley,
off fan and generator drive pulley, over fan blade, and off fan
and water pump pulley. Remove rear drive belt by first working
it into forward groove in generator drive pulley, fan and gener-
ator drive pulley, and fan and water pump pulley. When belt is in
forward groove of each pulley, follow procedure used to remove
forward belt.

AGO 10167B
145
 c. Installation. Place belt over fan, into forward groove of fan
and water pump pulley, into forward groove of fan and generator
drive pulley, and into forward groove of generator drive pulley.
Start at generator drive pulley and work belt into rear groove of
each pulley. Install the second belt in the forward grooves. When
the belts are in place, adjust as directed in a above.

124. Water Pump Assembly, Fan Blade, and Fan and Water
Pump Pulley
a.
(1) Drain the cooling system (par. 121).
(2) Remove the fan and generator drive belts (par. 123b).
(3) Remove the water outlet hose (par. 122a (4) ) .
(4) Loosen the hose clamp screws securing the water pump
bypass hose (fig. 39) to the water pump assembly and
cylinder head and remove the hose.
(5) Remove four lockwasher bolts (fig. 42) securing the fan
blade to the fan and water pump pulley and remove the
fan blade.
(6) Remove four bolts and lockwashers securing the water
pump (fig. 39) to the cylinder block and remove the
pump and gasket.
(7) Clamp the water pump in a vise with soft jaws. Install
a water pump pulley puller 41-P-2908-240 (fig. 43) on
water pump pulley. Hold puller with wrench and turn
puller screw to remove pulley.

(1) Place fan and water pump

pulley (fig. 42) on end of water pump shaft and press
onto shaft until front face of pulley hub is flush with
end of shaft.
(2)
Make sure that gasket surfaces are clean. Place a new
gasket on water pump body, with bolt holes in gasket
alined with bolt holes in water pump body.
Position pump in opening in front of cylinder block,
at the same time, sliding water pump bypass hose
(fig. 39), with clamps in place, over connections on
water pump and cylinder head.
(c) Insert one 5/16 x 21.~5bolt, with lockwasher, through
hole in water pump body, adjacent to pump inlet.
Start threads, but do not tighten. Insert three 5/ls x 7/8
bolts and lockwashers through holes in pump. Start
all threads, and tighten all bolts evenly.

146 AGO lC167B

 Figure 43. Removing fan and water pump pulley.

(4 Tighten hose clamps securing the water pump bypass

hose (fig. 39) to the water pump and the cylinder
head.
(4 Install the water outlet hose (fig. 39)) with hose
clamps, on the radiator outlet and the water pump
connections, and tighten the hose clamp screws se-
curing the hose.
(f) Put the fan in place on the front of the fan and water
pump pulley with concave side of blades toward the
engine and secure in place with four l/s x 5/g lock-
washer bolts (fig. 42).
(9) Install and adjust fan and generator drive belts (par.
123).
(h) Fill cooling system (par. 121). Check all hose con-
nections for water leaks.

125. Radiator and Water Pump Bypass Hose

(fig. 39)
a. Water Outlet Hose.
(1) Removal. Drain cooling system (par. 121). Loosen hose
clamp screws securing the water outlet hose to radiator
and water pump assembly and remove hose. Remove
hose clamps if necessary.

AGO
147
 (2) Installation. Make sure that connections are clean and
free from rust or scale. Place hose clamps over ends of
hose. Make sure that reinforcement is in place inside
the hose. Place lower end of water outlet hose over con-
nection on radiator. Place upper end of hose over con-
nection on water pump. Tighten hose clamp screws
securing the hose to the connections. Fill cooling system
(par. 121) and check all connections for leaks.
b. Water Inlet Hose.
(1) Removal. Drain cooling system (par. 121). Loosen hose
clamp screws securing the water inlet hose to radiator
connection and thermostat housing, and remove hose
by pulling from radiator and thermostat housing. Re-
move hose clamps if necessary.
(2) Installation. Make sure that connections at radiator and
thermostat housing are clean and free from rust or scale.
Place hose clamps over ends of hose. Place hose over
connections on thermostat housing and radiator. Tighten
hose clamp screws securing the hose to the connections.
Fill cooling system (par. 121) and check all connections
for leaks.
c. Water Pump Bypass Hose.
(1) Removal. Drain cooling system (par. 121). Loosen hose
clamp screws at both ends of the water pump bypass
hose. Remove end of hose from cylinder head, and re-
move other end from water pump. Remove hose clamps
if necessary.
(2) Installation. Make sure connections are clean and free
from rust or scale. Place hose clamps over ends of hose.
Place hose on water pump and cylinder head connec-
tions and tighten hose clamp screws securing hose to
connection. Fill cooling system (par. 121) and check all
connections for leaks.

126. Thermostat
a. Removal. Drain cooling system (par. 121). Remove three
screws and lockwashers holding thermostat housing (fig. 39)
to cylinder head. Loosen hose clamp screw on radiator end of
water inlet hose (fig. 39). Lift thermostat housing from cylinder
head, being careful not to damage thermostat, and pull inlet hose
from radiator. Use pliers to remove thermostat retainer from
housing and remove thermostat. Discard gasket.
b. Installation. Be sure that gasket surfaces on cylinder head
and thermostat housing are clean. Be sure that connection on

148 AGO 10167B

radiator is clean, and free from rust or scale. Place thermostat
in housing and install the retainer holding thermostat in place.
If retainer extends beyond the surface of the thermostat housing,
remove the retainer and grind until flush with the housing mount-
ing surface to prevent loss of engine coolant. Place a new thermo-
stat housing gasket on cylinder head with screw holes alined.
Position hose clamp on radiator end of water inlet hose. Slide
hose onto radiator. Carefully insert the projecting end of thermo-
stat into cylinder head and aline the screw holes in the thermostat
housing with screw holes in cylinder head being careful not to
disturb gasket. Install three a/s x 1’,s screws and lockwashers
to secure thermostat housing to cylinder head. Tighten screws
evenly. Tighten hose clamp screw securing the water inlet hose
to radiator. Fill cooling system (par. 121) and check all connec-
tions for leaks. Start engine and run until normal operating
temperature (par. 120~ (3) ) is reached. Check operation of ther-
mostat by removing radiator cap and watching water in radiator.
Water should start to flow when 160” F. is reached. Check for
leaks with engine running.

Section VIII. FUEL AND AIR INTAKE SYSTEM

127. Description and Data

CL.Des&p tion.
(1) General. Components of the fuel and air intake system
include the carburetor assembly, fuel and vacuum pump,
air cleaner assembly, accelerator, throttle and choke
controls, fuel filter assembly, fuel tank, fuel gage, fuel
tank level sending unit assembly, and fuel lines and
fittings.
(2) Air cleaner assembly (D, fig. 33). The air cleaner as-
sembly, an oil bath-type with a removable element, is
fully sealed for underwater operation. The assembly is
mounted at the right rear of the engine compartment
and is connected to the carburetor by a hose pipe with
vent valve. Air is drawn through the air precleaner with
rain deflector assembly and against the oil in the oil
cup where most of the dust is deposited. The air then
passes through the element and through the connecting
pipe to the carburetor.
(3) Carburetor assembly (fig. 32). The carburetor assem-
bly is a waterproof, single-venturi, downdraft balanced-

AGO 10167B
149
 type, sealed at all control and adjustment points. The
float chamber is also fully sealed. The carburetor as-
sembly is mounted over the center of the intake manifold.
(4) The fuel and vacuum
pump is the diaphragm-type, providing constant of
fuel to the carburetor when the engine is running. The
vacuum pump is incorporated to assist the windshield
wiper motor action. The pump used in early model
vehicles was equipped with a hand priming lever for
manually pumping fuel to the carburetor.
(5) (P, fig. The fuel shutoff valve
is located at the left of the steering gear assembly. This
valve shuts off the fuel supply from the fuel tank to the
fuel pump.
(6) The fuel tank is located on
the left side of the vehicle, under the driver’s seat. The
filler cap is located in a recess in the left side of the
body panel. The fuel tank level sending unit assembly
is located on top of the fuel tank. The fuel filter assem-
bly is located in the top of the fuel tank. The fuel tank
is equipped with a relief pressure valve which will
permit pressure to build up in the tank to a maximum
of 4 psi. The cap (fig. 5) is a solid-type pressure cap de-
signed for only with this vehicle and should not
be interchanged with the vented-type pressure cap, used
with s/h-ton trucks, which open and release excess pres-
sure. The solid-type cap used with truck M38 (fig. 5)
has a cup about 31/2 inches in diameter, inside of the
shell, with a rivet in the center of the cup and a safety
chain about 1 inch off center. The vented-type
filler cap used on the $&-ton trucks is of a spoke-like
design, has a 31/2-inch diameter cup inside the cap with
a vent hole approximately r/!-inch in diameter in the
center, and a fastener out to which a chain clip
is attached. The cap used on the truck M38 is marked
either embossed letters or decalcomania with the word
pressurized and instructions to open slowly while the
vented-type cap is stamped with the words PRESSURE
CAP.
(7) Fittings and solid and flex-
ible lines connect the various parts of the system. Vent
lines from the fuel tank and carburetor are connected
directly to the air cleaner assembly.

AGO 10167B
 A fuel filter assembly
installed in the top of the fuel tank. The assembly is
removable for cleaning or replacement of the fuel filter
element.

Carburetor assembly:
Manufacturer _~________ Carter Carburetor Corp
Model __~~______________ YS637S
Type ____~____~________ Downdraft
Venturi ________________ Single
Adjustments _________.___ Mixture and speed
Fuel and vacuum pump:
Manufacturer __________ AC Spark Plug Div, GMC
Model___~____________~_ 1539585
Type __________________ Diaphragm
Drive _~________________ Camshaft
Pressure _______________ 4 to 5% psi at 1,800 rpm
Vacuum _~~~_~~_________ 10 in. at 200 rpm, 12 in. at 1,500 rpm
Air cleaner assembly :
Manufacturer ~_~_______ Houdaille-Hershey Corp, Oakes Products Div
Model___~_~____________ OKS-X-615980
Type ___~___~~_________ Oil bath
Capacity (oil) __________ 1% pt
Fuel tank:
Capacity _______________ 13 gal
Type __________________ Pressurized
Filler cap location----.--- Left side

Adjustment of the idle mixture and idle speed, or replacement

of the carburetor assembly, are organizational maintenance op-
erations. Repair or overhaul of the carburetor assembly is per-
formed by the supporting ordnance maintenance unit.

Note. The key letters noted in parentheses are in figure 44, except where
otherwise indicated.
Adjustment screws are provided to adjust the
idle air-fuel mixture and the idle speed. Make both adjustments
with the engine running at normal operating temperature (160”
to 180” F.), and an idle speed of approximately 600 rpm. Adjust
the air-fuel mixture by turning the idle adjusting screw (F)
clockwise or counterclockwise until the engine idles smoothly and
evenly.
Note. Do not jam the idle adjusting screw against the seat in the car-
buretor assembly as the seat and the idle adjusting screw threads are easily
damaged. If damage to screw occurs, replace screw before making adjust-
ment. If the seat is damaged, replace the carburetor assembly.

151
 Figure 44: Carburetor removal or installation-front view.

To adjust the idle speed, turn the throttle lever adjusting screw
(G) clockwise to increase the speed and counterclockwise to de-
crease the speed of the engine.
b.
(1) Loosen the setscrew (K) securing the ,throttle control
wire (L) to the stop (J) and remove the stop from the
throttle control wire.
(2) Loosen the setscrew (Q) securing the choke control
wire (N) to the swivel (P).
Remove the cotter pin and flat washer from the accel-
erator control rod (M) and slide the rod out of the hole
in the throttle lever (H) .

AGO 10167B
 (4) Disconnect the vent line (A) from the elbow (B) on
the carburetor and unscrew the elbow from the car-
buretor.
(5) Disconnect the fuel line (D) from the elbow (C) on the
carburetor and unscrew the elbow from the carburetor.
(6) Remove the nut securing the support strap (E) and the
carburetor assembly to the intake manifold and remove
the strap from the manifold stud.
(7) Loosen the hose clamp screw (fig. 45) securing the
moulded hose to the carburetor.

Figure 45. Carburetor removal or installation-left side.

(8) Remove the plain nut and bolt securing the choke .con-
trol conduit (fig. 45) and clamp to the throttle control
conduit bracket and slide the choke control wire (N)
out of the swivel (P) .
(9) Spread the opening in the throttle control conduit bracket
(fig. 45) sufficiently to pull the throttle control conduit
out of the bracket and the throttle control wire (L) out
of the swivel of the throttle lever.
(10) Unhook the accelerator pedal return spring from the
accelerator pedal return spring clip (fig. 45).

AGO 10167B 153

 (11) Remove the nut securing the accelerator pedal return
spring clip and the carburetor to the manifold stud and
remove the clip from the stud. Lift the carburetor off the
studs and remove from the vehicle. Remove the old
throttle valve body-to-insulator gasket and the throttle
valve body-to-manifold insulator (fig. 45) from the mani-
fold studs.
c. Installation.
(1) Place a new throttle valve body-to-manifold insulator
(fig. 45) and a new throttle valve body-to-insulator
gasket over the studs in the manifold. Place the car-
buretor over the studs and into the moulded hose.
(2) Place the support strap (E) over the front manifold
stud and screw nut onto stud fingertight. Place the ac-
celerator pedal return spring clip (fig. 45) over the
intake manifold stud and screw the nut on the stud
fingertight. Tighten the front and rear nuts on the mani-
fold studs evenly. Hook the accelerator pedal return
spring into the clip.
(3) Slide the throttle control wire (L) through the throttle
control conduit bracket (fig. 45) and through the swivel
on the throttle lever (H) . Make sure that the throttle
control (BB, fig. 7) is pushed all the way into the in-
strument panel. Place the stop (J) over the end of the
throttle control wire (L) and push it up to the swivel on
the throttle lever Tighten the setscrew
(4) Slide the choke control wire (N) through the swivel
(P). Make sure that the choke control (CC, fig. 7) is
pushed all the way into the instrument panel. Push the
choke lever (R) toward the front of the vehicle as far
as it will go and tighten the setscrew (Q). Position the
choke control conduit clamp (fig. 45) on the throttle
control conduit bracket. Put the No. 10 x ah bolt through
the throttle control conduit bracket and the choke control
conduit clamp. Screw No. 10 plain nut on the bolt and
tighten with a screwdriver.
(5) Tighten the hose clamp screw (fig. 45) securing the
moulded hose to the carburetor.
(6) Push the end of the accelerator control rod (M) through
the hole in the throttle lever Place a flat washer
over the end of the rod and install a cotter pin.
(7) Screw the elbow (C) into the carburetor and connect
the fuel line (D) to the elbow. Screw the elbow (B) into
the carburetor and vent line (A) into the elbow.

AGO 1016'7B
 (8) Start the engine and warm up to operating temperature.
Check the controls for proper operation. Check for
smooth, even operation of the engine or air leaks around
the throttle valve flange insulator.

(1)
Disconnect the fuel line (D), between the fuel and
vacuum pump and the carburetor, by unscrewing the
nut at the carburetor end of the line. Disconnect the
vent line (A), between the air intake pipe and the
carburetor, by unscrewing the nut at the carburetor
end of the line.
(b)
Unhook the accelerator pedal return spring from the
accelerator pedal return spring clip. Remove the nut
and accelerator pedal return spring clip (fig. 45)
from the manifold stud at the rear of the carburetor.
Remove the nut and support strap (E) from the
manifold stud at the front of the carburetor.
(c) Loosen the hose clamp screw (fig. 45) securing the
moulded hose to the carburetor and slide the hose
from the carburetor. Raise the carburetor until it
clears the studs in the intake manifold. Remove and
discard the throttle valve body-to-manifold insulator
and throttle valve body-to-insulator gasket and clean
the contact surfaces on the intake manifold and the
throttle valve flange.
(2)
Install new throttle valve body-to-manifold insulator
and throttle valve body-to-insulator gasket over the
intake manifold studs and place the carburetor over
the studs.
(b) Place the support strap (E) over the front stud and
screw a nut on the stud fingertight. Place the ac-
celerator pedal return spring clip over the rear stud
and screw a nut on the stud fingertight. Tighten the
front and rear stud nuts evenly securing the clip,
support strap, and carburetor to the intake manifold.
Hook the accelerator pedal return spring into the clip.
(c) Connect the vent line (A) to the carburetor by screw-
ing the nut at the carburetor end of the line into the
fitting on the carburetor. Connect the fuel line (D)
to the carburetor by screwing the nut at the carburetor

AGO 10167B
155
 end of the line into the fitting on the carburetor. Slide
the moulded hose onto the carburetor and tighten the
hose clamp screw securing the hose to the carburetor.

130. Accelerator, Choke, and Throttle Controls

Note. The key letters noted in parentheses are in figure 46, except where
otherwise indicated.
a.
(1) The accelerator pedal ad-
justment is made through the threaded accelerator con-
trol rod adjusting block (M) of the threaded accelerator
control rod with block and spring clip assembly (P).
(a) Unhook the accelerator pedal return spring (R) from
the accelerator pedal return spring clip
Remove the cotter pin and flat washer from the ac-
celerator control rod adjusting block (M) and separate
the block from the accelerator cross shaft with lever
and bracket assembly (T).
(c) Loosen the nut on the accelerator control rod and screw
the adjusting block forward or backward on the rod
until the desired position is attained. When the block
is properly adjusted, and the accelerator pedal (FF)
is depressed all the way, the top end of the throttle
valve shaft lever (Q) is as far back as it will travel
toward the rear of the vehicle. When the block is
properly adjusted, tighten the locknut (N) on the ac-
celerator control rod. Connect the accelerator control
rod adjusting block (M) to the accelerator cross shaft,
install a No. 8 flat washer on the adjusting block, insert
y16 x 1h cotter pin, and spread the pin.
(2)
Pull the accelerator pedal assembly (FF) out of the
accelerator link boot (X) and the cross shaft lever-to-
accelerator pedal link connector (Y).
Remove the cotter pin from the accelerator pedal hinge
pin (DD) and remove the pin, accelerator pedal hinge
spring, and pedal from the accelerator pedal-to-floor
board hinge (EE) .
(3)
Position the accelerator pedal assembly (FF) in the
accelerator pedal-to-floor board hinge (EE).Position
the accelerator pedal hinge spring between the pedal
and the hinge. Push the accelerator hinge pin (DD)
through the hinge, over the top of the spring, through

156
Figure 46. Aceelemto~, choke, nnrl throttle controls.
 the hinge, over the top of the spring, through the pedal,
and install a l/1fi x I/ cotter pin in the hinge pin.
(b) Push the link (W) of the pedal through the accelerator
link boot (X) and into the cross shaft lever-to-acceler-
ator pedal link connector (Y) .
b.
(1)
Remove the accelerator pedal assembly above).
(b) Unscrew the two bolts (BB) from the nuts (CC) and
remove the accelerator pedal-to-floor board hinge
(EE).
(2)
Position the accelerator pedal-to-floor board hinge
(EE) on the floor board. Install two No. 10 x 1/2
bolts (BB) through the hinge and the floor board and
install the No. 10 nuts (CC) on the bolts.
(b) Install the accelerator pedal assembly (a (3) above).
c.
(1) Remove the accelerator pedal assembly (a(2)
above) and remove the spring.
(2) Install the spring and the accelerator pedal
assembly above).

(1)
Remove the upper front floor plan cover, (H, fig. 35)
(par. 116e(5)-(‘7) ).
(b) Unhook the accelerator pedal return spring (R) from
the accelerator pedal return spring clip
(c) Pull the link (W) of the accelerator pedal assembly
(FF) out of the cross shaft lever-to-accelerator pedal
link connector (Y) .
Remove the cotter pin and flat washer from the accel-
erator control rod adjusting block (M) and remove
the block from the accelerator cross shaft with lever
and bracket assembly (T).
(e) Unscrew the two bolts (V) from the bracket of the
cross shaft and remove the bolt and lock washers (U) .
Remove the cross shaft from the vehicle.
(2)
Position the bracket of the accelerator cross shaft with
lever and bracket assembly (T.) on the rear of the
engine. Place a l/,-inch lockwasher on the two % x y1’/16
bolts, push the bolts through the bracket, and screw
into the engine.

AGO 10167B
 (b)
Position the accelerator control rod adjusting block
(M) in the cross shaft with lever and bracket assem-
bly (T) and install a No. 8 flat washer and a 1/16 x $4
cotter pin. Hook the accelerator pedal return spring
(R) into the accelerator pedal return spring clip
(c) Install the upper front floor pan cover (H, fig. 35)
par. 119c(5), (6), and (7) ).
e. Accelerator Control Rod With Block and Spring Clip As-
sembly.
(1) Removal.
(a) Unhook the accelerator pedal return spring (d (1)
above).
Disconnect the accelerator control rod adjusting block
(d(1) (c) above).
(c) Remove the cotter pin and flat washer from the rod of
the accelerator control rod with block and spring clip
assembly (P) and remove the rod from the throttle
shaft lever (Q).
(2) Installation.
(a) Install the rod of the accelerator control rod with
block and spring clip assembly (P) into the throttle
valve shaft lever (Q) and install a No. 8 flat washer
and a l/is x 1/2 cotter pin in the rod.
(b) Install the accelerator control rod adjusting block
(d(2) (b) above).
f. Accelerator Control Rod Adjusting

Remove the block from the accelerator cross shaft with

lever and bracket asembly (d (1) (a) and (c) above).
(b) Loosen the lock nut (N) and unscrew the block (M)
from the rod.
(2) Installation. Screw the accelerator control rod adjusting
block (M) on the control rod.
(3) Adjustment. Adjust the block (a(3) above).
g. Cross Shaft Lever-To-Accelerator Pedal Link Connector.
(1)
Pull the link of the accelerator pedal assembly (FF)
out of the cross shaft lever-to-accelerator pedal link
connector (Y) .
(6) Unscrew the nut (Z) and remove the lockwasher
(AA). Remove the connector (Y) from the lever of
the cross shaft with lever and bracket assembly (T).
(2) Installation. Push the stud of the cross shaft lever-to-
accelerator pedal link connector (Y) through the hole in

AGO 10167B 159

 the lever of the cross shaft with lever and bracket assem-
bly (T) from the top. Place a No. 10 lockwasher over the
stud and install a No. 10 nut.
h. Throttle Control Assembly.
(1) Adjustment. Push the throttle control (BB, fig. 7) all the
way into the instrument panel. Loosen the bolt (A) in the
hand throttle control wire stop with bolt assembly
Slide the stop up to the pivot on the throttle valve shaft
lever (Q), slide the stop away from the lever slightly,
and tighten the bolt.
(2) Removal.
(a) Loosen the bolt (A) in the hand throttle control wire
stop with bolt assembly (B) and slide the stop off the
wire. Loosen the bolt and nut in the choke control con-
duit clamp (F)
(b) Unscrew the lockwasher nut (J) from the throttle con-
trol assembly on the reverse side of the instrument
panel.
(c) Pull the throttle control assembly out of the pivot of
the throttle valve shaft lever, the clamp (F) , the grom-
met (G) in the dash, the lockwasher nut (J) , and the
instrument panel.
(3) Installation.
(a) Push the end of the throttle control assembly (H)
through the hole in the instrument panel part way and
slide the y&inch lockwasher nut (J) over the end of
the control.
(b) Push the end of the control through the grommet (G) ,
the choke control conduit clamp (F) , and the pivot on
the throttle valve shaft lever (Q).
(c) Screw the 3/X-inch lockwasher nut (J) onto the throttle
control assembly on the reverse side of the instrument
panel. Leave a little slack in the throttle control assem-
bly between the instrument panel and the choke control
conduit clamp (F) and tighten the bolt and nut in the
clamp.
(d) Slide the hand throttle control wire stop with bolt (B)
over the end of the control wire and adjust ( (1)
above).
i. Choke Control Assembly.
(1) Adjustment. Loosen the screw (D) in the pivot (C) on
the choke valve shaft lever (E‘)
, Push the choke control
assembly (CC, fig. 7) all the way into the instrument
panel. Push the lever (E) of the choke valve shaft to-

AGO 10167B
160
 ward the front of the vehicle as far as it will go. Tighten
the screw (D) in the pivot.
(2)
Loosen ‘the screw (D) in the pivot (C) . Loosen the
bolt and nut in the choke control conduit clamp (F).
(b) Unscrew the lockwasher nut (K) from the choke con-
trol assembly on the reverse side of the instrument
panel.
(c) Pull the choke control assembly (L) out of the pivot
(C), clamp (F) , grommet (G) , lockwasher nut (K),
and instrument panel.
(3)
Push the end of the choke control assembly (L)
through the hole in the instrument panel part way and
slide the y&inch lockwasher nut (K) over the end of
the assembly.
(b) Push the end of the choke control assembly (L)
through the grommet (‘G), the choke control conduit
clamp ‘(F) , and the pivot (C) .
(c) Screw the Sk-inch lockwasher nut (K) onto the choke
control assembly on the reverse side of the instrument
panel. Leave a little slack in the assembly between the
instrument panel and the choke control conduit clamp
(F) and tighten the bolt and nut in the choke control
conduit clamp.
(d) Adjust the choke control assembly ( (1) above).

131. Fuel and Vacuum Pump

(fig.

the shutoff valve (N, fig. 52).

(2) Disconnect the fuel line to carburetor at the fuel and
vacuum pump by unscrewing the nut on the line from the
elbow in the pump. Unscrew the elbow from the pump
only if necessary. Disconnect the two vacuum lines from
the pump by unscrewing the nuts on the lines from the
connectors in the pump. Unscrew the two connectors
from the pump only if necessary. Disconnect the vent
line by unscrewing the nut on the line from the connector
in the elbow. Disconnect the flexible fuel line by unscrew-
ing the nut on the line from the fitting on the flexible
line. Unscrew the flexible line from the pump only if
necessary.

AGO 10167B
161
 Figure 47. Fuel and vacuum ~mp-installed.

(3) Remove the two screws securing the fuel and vacuum
pump, rocker arm link spacer, and gaskets to the crank-
case and remove the parts.
b. Modification of Fuel Pump (fig. 48). To minimize premature
failures of fuel pumps caused by excessive pressures within the
fuel pump and the trapped oil in the lower section of the upper
body, modify the pump as described in (1) through (8) below.
(1) Remove machine scre& and lockwashers which secure
the flanges of the upper and lower section bodies.
Note. Scribe marks on outer edge of flanges for alinement dur-
ing assembly.
(2) Remove upper fuel section body, diaphragm with pull
rod, spring retainer, and diaphragm spring.
(3) Using a hook-shaped tool, remove oil seal retainer and
oil seal. Exercise care during this operation to prevent
damage to oil seal retainer.
Note. If oil seal retainer is staked in place, remove the staking
with a small chisel, round file, or grinding wheel before pulling
the retainer and oil seal from the pump.

162 AGO 10167B

 Discard the oil seal but retain the oil seal retainer if fuel
pump repair kit G740-73’75384 is used. Discard the oil
seal and retainer if fuel pump repair kit G758-8329981
is used.
(4) Drill a l/s-inch hole in deck of body (fig. 48) to act as an
oi1 return and pressure relief hole. Metal clips resulting
from the drilling should be blown from the fuel pump
with compressed air.
(5) Install new oil seal and original retainer when using fuel
pump repair kit G740-7375384; if fuel pump repair kit
G758-8329981 is used, install oil seal retainer G758-
8329706.
(6) Install diaphragm spring and spring retainer.
(7) Install new diaphragm with pull rod after soaking it in
clean kerosene. While holding the diaphragm flange in
the upward position, insert the pull rod through the
spring retainer, spring, and oil seal retainer in the lower
fuel section body. The flat of the pull rod must be at
right angles to the fuel link. Hook the pull rod to the
short (outer) fuel link.
(8) Aline the upper fuel section body on the lower fuel sec-
tion body in accordance with marks scribed in (1) above.
Push on rocker arm until diaphragm is flat across body
flange. Install original screws and lockwashers until
screws just engage lockwashers. Push rocker arm in
a full stroke and tighten screws securely.
Note. Diaphragm must be in fixed (down) position while tight-
ening cover screws, or pump will deliver too much pressure.

(1) Insert the two 5/16 x 1Th screws in the fuel and vacuum
pump from the outside. Place a gasket over the screws.
Place the rocker arm link spacer over the screws. Place
a second gasket over the screws. Position the pump with
spacer and gaskets on the engine. Be sure the rocker arm
link is over the top of the cam on the camshaft. Start the
screws into the engine and tighten evenly.
(2) Screw the flexible fuel line into the pump, if removed,
and connect the fuel line to the flexible fuel line by screw-
ing the nut on the end of the fuel line into the flexible
fuel line. Screw the elbow and connector into the pump,
if removed, and connect the vent line to the connector
by screwing the nut on the vent line into the connector.
Screw the two connectors into the pump, if removed, and
connect the two vacuum lines to the pump by screwing

163
 the nuts on the ends of the lines into the connectors on
the pump. Screw the elbow into the pump, if removed,
and connect the fuel line to carburetor to the elbow by
screwing the nut on the line into the elbow.
(3) Carburetor to fuel pump line being too close to exhaust
manifold has caused vapor lock. To avoid this condition,
the line should be reversed in position, thus increasing
distance between the line and manifold.
(4) Open the shutoff valve (N, fig. 52).
(5) Start the engine and check the fuel lines for leaks. Open
the windshield wiper motor air regulating valve (A, fig.
7) and check for proper operation of windshield wiper
motors. If sluggish or slow, check for vacuum line leaks.

132. Air Cleaner Assembly

(fig. 43)
a. Servicing. Refer to paragraph 66.
b. Removal.
(1) Loosen hose clamp screw securing air intake pipe flexible
hose to air cleaner.
FUEL SIDE OIL SEAL REMOVED

DIAPHRAGM W/PULL ROD-

UPPER FUEL SECTION B

LOWER FUEL SECTI

ARM SPRING

RETURN HOLE

ROCKER ARM RA PD 358879A

Figure .48. Sectional view of lower fuel section body of fuel pump showing
oil return hole.

(2) Disconnect the fuel tank vent line from the air cleaner.
Disconnect the master cylinder vent line by unscrewing
the nut on the line from the connector in the tee on the
air cleaner. Pull the windshield wiper hose from the
windshield wiper vent line.
(3) Loosen the two wing screws securing the air cleaner
extension bracket to the left support bracket assembly.

164 AGO 10167B

 Figure 49. Air cleaner assembly.

Remove the two wing screws and lockwashers securing

the extension bracket to the right support bracket as-
sembly.
(4) Remove the air cleaner and extension bracket by sliding
to the right, off the wing screws, and out of the flexible
hose.
c.
(1) Position the air cleaner assembly in the vehicle with the
air outlet inserted inside the air intake pipe flexible hose.
Position slotted openings in the extension bracket on the
wing screws in the left support bracket assembly and
slide the air cleaner toward engine. Aline the holes in
the bracket on the air cleaner with the holes in the right
support bracket assembly and install the two ya2-inch
lockwashers and 1/4 x 3/4 wing screws. Tighten all four
wing screws.
(2) Slide the windshield wiper hose onto the windshield
wiper vent line. Connect the master cylinder vent line to
the connector in the tee on the air cleaner. Connect the
fuel tank vent line to the air cleaner.
Tighten the hose clamp screw securing the air intake
pipe flexible hose to the air cleaner.

133. Fuel Filter Assembly

(1) Remove the driver’s seat (par.

AGO
 (2) Disconnect the fuel line by unscrewing the nut on the
end of the line from the fuel filter assembly. Disconnect
the vent line by unscrewing the nut on the end of the line
from the connector in the fuel filter assembly. Unscrew
the connector from the filter only if necessary.

Figure 50. Fuel tank, fuel filter and fuel tank level sending unit-
seat removed.

(3) Remove the 12 bolts and soft copper sealing washers se-
curing the fuel filter to the fuel tank and remove the filter
and the neoprene cover gasket from the tank. Discard
gasket.
b. Installation.
(1) Place a new neoprene gasket on the fuel tank at the
opening for the fuel filter assembly. Insert the filter in
the tank and aline the holes in the gasket, filter, and tank
and install the 12 soft copper sealing washers and No. 8
x 7/ls bolts, tightening bolts evenly.
(2) Put the end of the fuel line in place in the filter assembly
and screw the nut into the fitting. Screw the connector
(if removed) into the filter. Put the end of the vent line
into the connector and screw the nut into the fitting.
(3) Install the driver’s seat (par. 268).

AGO 10167B
134. Fuel Filter Element
(fig. 51)

(1) Remove the fuel filter assembly (par. 133a).

Figure 51. Removing fuel filter element.

Unscrew the nut on the upper end plate with line, from
the cover plate with vent assembly.
Loosen the screw clamp and slide the fuel filter element
out of the clamp.
Remove the nut and lockwasher from the screw in the
element. Pull the screw out of the element, and remove
the end plates from the element.
After removing the element, wash thoroughly in volatile
mineral spirits or dry-cleaning solvent. To dry the ele-
ment, apply compressed air from inside the element to
the outside.

(1) Slide the end plate over the No. 10 x 6 screw. Slide the
fuel filter element over the screw and position on the end
plate. Slide the end plate with line over the screw and
position on the element. Install a No. 10 lockwasher and
nut on the screw.
(2) Slide the element into the clamp. Screw the nut on the
end of the line into the cover plate. Tighten the screw in
the clamp.
(3) Install the fuel filter assembly (par. 133b).

AGO 10167B 167

 Note. The key letters noted in parentheses are in figure 52, except where
otherwise indicated.

(1) Unscrew the nut (U) on the fuel line (T) from
the fitting on the flexible fuel line (AA). Unscrew the
flexible fuel line (AA) from the elbow (BB) on the fuel
and vacuum pump (V)
(2) Screw the flexible fuel line (AA) into the
elbow (BB) on the fuel and vacuum pump (V). Screw
the nut (U) , on the end of the fuel line (T),into the fit-
ting on the end of the flexible fuel line (AA).

(1) Unscrew the nut (U), on the end of the fuel

line from the fitting on the flexible fuel line (AA).
Unscrew the nut (R) from the connector (Q) in the pipe
tee (P) . Remove the bolt, nut, and lockwasher securing
the fuel line-to-fender splasher clip (S) and remove the
line.
(2) Screw the nut (R) into the connector (Q)
in the pipe tee (P).Screw the nut (U) , on the end of the
fuel line (T), into the fitting on the flexible fuel line
(AA). Position the fuel line-to-fender splasher clip
over the hole in the fender splasher, insert bolt through
clip and splasher, and install lockwasher and nut on bolt.
c.
(1) Unscrew the nut on the rear end of the fuel
line (J) from the elbow (D). Unscrew the nut (L) on the
front end of the fuel line (J) from the connector
Remove the nut and bolt securing the fuel line-to-dash
bracket clip (K) . Remove the screws securing the two
fuel line-to-floor pan clips (F and H) to the underside of
the floor pan and remove the line.
(2) Position the fuel line (J) in the vehicle.
Screw the nut (L) on the front end of the line into the
connector (M) on the shutoff valve (N).Screw the nut
on the rear end of the fuel line (J) onto the elbow (D).
Position the fuel line-to-dash bracket clip (K) on the
dash bracket, insert bolt through the clip and the bracket,
and install the nut on the bolt. Working underneath the
vehicle, position the two fuel line-to-floor pan clips (F
and H) on the floor pan and install the screws through
the clips and into floor pan.

AGO 1016TB
168
Figure 52. Fuel and air intake system.
 (1) Unscrew the nut on the rear of the fuel line
(B) from the elbow (D) . Unscrew the nut on the front
end of the fuel line (fig. 50) from the fuel filter assem-
bly. Bend the clip (fig. 50) securing the fuel line to the
tank and remove the line by pulling it through the floor
pan from the top.
(2) Position the fuel line (fig. 50) in the vehicle
by inserting through the floor pan from the top. Screw
the nut on the front end of the line into the fuel filter
assembly, and bend the clip on the top of the tank down
over the fuel line. Screw the nut on the rear end of the
fuel line (B) onto the elbow (D) . On early production
vehicles, install fuel and vent lines as described in (a)
through (c) below, to prevent chafing by the driver’s
seat frame support gusset.
(a) Bend fuel and vent lines upward, at fuel tank, so that
vent line will locate above the fuel line (fig. 48).
(b) Bend fuel and vent lines away from seat frame support
gusset and against fuel tank after the lines are con-
nected to the fuel tank.
\c) Secure lines together with friction tape at point of
contact with fuel tank to prevent chafing.
e.
(1) Unscrew the nuts (W and Y) on the ends of
of the fuel line (X), from the elbow on the pump, and
the elbow on the carburetor assembly, and remove the
line.
(2) Position the fuel line (X) between the fuel
and vacuum pump and the carburetor assembly. Screw
the nuts (W and Y) on the ends of the line into the el-
bow on the carburetor and the elbow on the fuel and
vacuum pump respectively.
f.
(1) Unscrew the nut (L) on the front end of the
fuel line (J) from the connector and unscrew the
connector from the shutoff valve (N).Unscrew the shut-
off valve from the pipe tee (P) .
(2) Screw the shutoff valve (N) into the pipe
tee (P) with shutoff valve handle at the top. Screw the
connector (M) into the shutoff valve. Position the fuel
line (J) in the connector (M) and screw the nut (L)
into the connector.
 g. Pipe Tee.
(1) Removal. Unscrew the nut (R) from the connector (Q).
Unscrew the connector from the pipe tee (P) . If primer
line is connected to the pipe tee, disconnect the line from
the pipe tee. Unscrew the pipe tee from the shut-off valve
(N).
(2) InstaZZation. Screw the pipe tee (P) onto the shutoff
valve (N). Screw the connector (Q) into the pipe tee.
Screw the nut (R) into the connector (Q). If primer
pump is installed in vehicle, connect the line to the pipe
tee.

136. Fuel Tank Replacement

(fig. 50)
a. Removal.
(1) Remove the drain plug (E, fig. 52) from the bottom of
the tank and drain the fuel into a suitable container.
(2) Remove the driver’s seat (par. 268).
(3) Remove the fuel tank level sending unit assembly (par.
189).
(4) Remove the fuel filter assembly (par. 133~~).
(5) Bend up the clip on the vent line and swing the line up
and out toward the left side of the vehicle.
(6) Bend up the clip on the fuel line. Loosen the nut con-
necting the line to the elbow (D, fig. 52). Swing the line
at the top of the tank toward the right rear of the vehicle
to clear the top of the tank.
(7) Remove the fuel tank filler cap with chain assembly by
turning the cap counterclockwise and unhooking the
chain from inside the fuel tank filler neck.
(8) Remove the bolt, lockwasher, and hold-down clamps at
the rear of the tank. Remove the bolt and nut from the
end clamp and the hold-down strap with antisqueak and
swing the strap up toward the right side of the vehicle.
(9) Slide the tank to the right until the filler neck has cleared
the grommet in the filler neck opening in the side of the
body and remove the tank. Remove the five fuel tank
antisqueaks and one end clamp antisqueak. These will
stick on the tank, the vehicle body, or the end clamp.
b. Installation.
(1) Before installing the new tank, make sure that the four
fuel tank antisqueaks and one end clamp antisqueak are
in place as indicated by marks on the tank which was
removed. Position the tank in the vehicle and carefully

171
 slide the filler neck through the grommet in the opening
in the side of the body.
(2) Install the hold-down clamp at the rear of the tank, and
secure in place with 9$,-M x 7,s bolt and lockwasher.
Place the hold-down strap in position on the top of the
tank over the antisqueak, install the bolt through the end
clamp and the hold-down strap, and screw the nut onto
the bolt.
(3) Install the fuel tank level sending unit assembly (par.
189).
(4) Install a new fuel filter element (par. 134) and the fuel
filter assembly (par. 133).
(5) Connect the vent line to the fuel filter by screwing the
nut on the end of the line into the fitting on the filter.
Bend the clip on the tank over the line. Connect the fuel
line to the fuel filter by screwing the nut on the end of
the line into the filter. Bend the clip on the tank over the
line. Connect the fuel line to the elbow (D, fig. 52) by
tightening the nut on the end of the line.
(6) Install the drain plug (s-in. pipe plug) (E, fig. 52) in
the bottom of the tank. Install the fuel tank filler cap
with chain assembly by hooking the chain into the loop
inside the filler neck. Fill the tank with fuel and install
filler cap on fuel tank turning clockwise to lock cap on
tank.
(7) Start the engine and make sure there are no leaks at
fuel line connections. Check the fuel gage for proper
operation of the fuel tank level sending unit.
(8) Install the driver’s seat (par. 268).

Section IX. EXHAUST SYSTEM

137. Description
The exhaust system (fig. 53) consists of the exhaust pipe, ex-
haust pipe extension, muffler, exhaust pipe extension support
bracket, and muffler support clamp bracket. The tail pipe is part
of the muffler and has a flange at the rear end for attaching the
fording kit extension.

138. Exhaust Pipe and Extension

(fig. 53)
a.
Remove the nut from the stud in the flange of
the exhaust manifold. Remove the nut and bolt holding
the flange of the exhaust pipe to the exhaust manifold.
AGO 10167B
172
 Figure 53. Exhaust system.

Remove the three nuts and bolts holding the flange of

exhaust pipe to the flange of the exhaust pipe extension.
Separate these flanges, drop the exhaust pipe straight
down, and remove. Remove and discard the two gaskets.
Installation. Clean the gasket surfaces of the flanges.
Place a new gasket on the front flange of the exhaust
pipe. Position the exhaust pipe over the stud in the ex-
haust manifold and start the g-inch nut on the stud but
do not tighten. Insert yh x 1 1’/2 bolt through the flanges
and.gasket, entering the bolt from the top. Start y&inch
nut on the bolt. Place a new gasket on the flange on the
rear of the exhaust pipe, position against the exhaust pipe
extension flange, insert three y8 x 1% bolts through the
flanges and gasket, and start the three 3/,-inch nuts onto
the bolts. Tighten both nuts securing the exhaust pipe
to the exhaust manifold. Tighten the three nuts and bolts
securing the exhaust pipe extension to the exhaust pipe.
b. Exhaust Pipe Extension.
(1) Removal. Remove the three nuts and bolts securing the
exhaust pipe extension to the exhaust pipe. Remove the
three nuts and bolts securing the exhaust pipe extension
to the muffler. Remove the nut, bolt, and spacer securing
the exaust pipe extension support bracket to the frame
cross member. Loosen the bolt securing the muffler sup-
port clamp bracket to the frame rear cross member and
slide the muffler back about one inch. Separate flanges at
both ends of the exhaust pipe extension and remove the
pipe and bracket. Discard gaskets.

173
 (2) Installation. Clean the gasket surfaces of flanges. Place
exhaust pipe extension in approximate position under
the vehicle, with the offset end toward the muffler. In-
sert the 4( F x 1 bolt through the hole in the frame cross
member, from the top, and place the spacer over the bolt.
Raise the exhaust pipe extension into place, insert the
bolt through the exhaust pipe extension support bracket
and start the 5/,,-inch nut onto the bolt. Place a new
gasket on the front flange of the exhaust pipe extension
and insert three yq x I’/, bolts through the exhaust pipe
flange, gasket, and exhaust pipe extension front flange.
Start the $/,-inch nuts onto the bolts but do not tighten.
Place a new gasket on the muffler front flange. Insert
three $(j x 1% bolts through the muffler flange, gasket,
and exhaust pipe extension rear flange. Slide the muffler
forward until flanges are together. Start the %-inch nuts
on the bolts but do not tighten. Tighten bolts and nuts
securing the exhaust pipe extension to the exhaust pipe.
Tighten bolts and nuts securing the muffler to the exhaust
pipe extension. Tighten the bolt and nut securing the
exhaust pipe extension support bracket to the frame
cross member. Tighten the clamp bolt and nut in the ex-
haust pipe extension support. Tighten the bolt securing
the muffler support clamp bracket to the frame rear cross
member. Start engine and check all exhaust connections
for leaks.

139. Muffler and Bracket

(fig. 53)
a. Removal. Remove three nuts and bolts securing the muffler
to the exhaust pipe extension. Remove the bolt and Iockwasher
securing the muffler support clamp bracket to the frame rear cross
member and remove the muffler.
b. Installation. Insert three s x 1% bolts through the muffler
flange and place a new gasket over the bolts. Raise the mufller into
position and insert the bolts through the exhaust pipe extension
flange. Start the s-inch nuts onto the bolts but do not tighten.
Insert the 5/16 x 1% bolt with lockwasher through the muffler sup-
port clamp bracket and start the threads into the hole in the frame
rear cross member. Tighten the three bolts securing the muffler
to the exhaust pipe extension. Tighten the bolt securing the muf-
fler support clamp bracket to the frame rear cross member. Start
the engine and check all exhaust connections for leaks.

AGO
174
 Section X. IGNITION SYSTEM

140. Description and Data

a.
(1) The ignition system (fig. 54) consists of the
batteries, ignition switch, distributor with coil assem-
bly, spark plugs, and primary and secondary circuit
cables. The distributor with coil assembly supplies high
voltage current to the spark plugs at timed intervals.
The entire system is shielded for radio interference sup-
pression and is completely waterproofed.
Note. The batteries are necessarily a part of each of the various
electrical systems. The operations on batteries are in paragraphs
154 through 164.
(2) The distribu-
tor, capacitor, and ignition coil comprise a single unit
with automatic spark advance built-in to vary the igni-
tion timing for most efficient operation. The assembly
is located on the right side of the engine and is driven
from the camshaft.
(3) The 14-mm spark plugs are shielded and
waterproof, with built-in resistors for radio interference
suppression.
(4) The spark plug
cable assemblies are fully shielded and waterproof, with
threaded connectors on each end.
(5) 54). There are two distinct circuits in the
ignition system, the primary circuit and the secondary
circuit. The primary, or low voltage circuit, consists of
the batteries, ignition switch, distributor points, capaci-
tor, and the primary winding of the ignition coil. The
secondary, or high voltage circuit, consists of the sec-
ondary winding of the ignition coil, distributor rotor,
distributor cover assembly, distributor cap assembly,
spark plug cable assemblies, and spark plugs.

Distributor with coil assembly:

Manufacturer ~~__~~~. ~~~~~~___~____~~______~_ Electric Auto-Lite Co
Model ____________~~________-_-------------~- IAU-4006UT
Rotation ___________~~_______~~~~~~_~_~_~--~ Counterclockwise
Type advance __.__~~~~~~.~~~~________________. _ Centrifugal
Breaker point opening------ __~~_______________ 0.020 in.
Breaker arm spring tension_~~~____________--__ 1’7 to 20 oz
Firing order __~~~~-....____~~~~______________~~ l-3-4-2
Voltage _______~_____________-___------------ 24
Cam angle _____________~__~_____------------ 38 deg

175
Ignition coil:
Manufacturer ______________________-__--_-__- Electric Auto-Lit@ Co
Model ____~~________________---_--__--___--_- CT-4002
Voltage _~_____~_______________----__---__-- 24
Spark plugs :
Ordnance number ~_~_~______~~______~_~__. _.~ 7524258
Thread size ___~ ~~~. _~~___~_____________~~__14-mm
Electrode gap ~~~~ ~~~~~__~~~~__________~~__0.030 in.

Periodic inspection and lubrication of the ignition system is

the responsibility of the using organization. See lubrication order
(par. 66) for detailed instructions. Information and data for ig-
nition system maintenance are given in paragraphs 142 through
146. Operations not described are the responsibility of ordnance
maintenance units. However, in an emergency, using organizations
may perform ordnance maintenance unit operations, provided
permission is obtained from the ordnance maintenance unit.

The ignition is timed by adjusting the distributor so the

distributor points open at the correct firing intervals. Since the
distributor with coil assembly is sealed, a special adapter (fig.
59) is required to connect the timing light.
b. Mark the position of No. 1 spark plug cable assembly (fig.
55) on the side of the distributor with coil assembly, to aid in
determining the position of the distributor rotor after the dis-
tributor cover and cap assemblies are removed.
c. Remove six lockwasher screws securing the distributor cover
and cap assemblies (fig. 55) and remove the assemblies. Turn the
crankshaft until the distributor points are open, with the breaker
lever (fig. 56) on one of the four high points of the cam. Loosen
the screw securing the stationary contact bracket to the breaker
plate. Adjust the point gap by turning the adjusting eccentric
(fig. 57) until a 0.020-inch feeler gage will enter between the
points with a slight drag on the gage. Tighten the screw securing
the stationary contact bracket to the breaker plate and again
check the point gap.
On early production vehicles, turn the crankshaft with a
crank, or suitable socket wrench, until the distributor rotor points
to the mark (b above) and the timing mark “5 BTC” on the
flywheel is alined with the pointer in the timing hole in the fly-
wheel housing. On late production vehicles, aline the hole in the
back of the fan and generator drive pulley (fig. 57) with the
“5” mark on the timing gear cover (fig. 57).

AGO 10167B
 T- 0
0
0

_&

8 +
%

‘L’

I I

Figure 54. circuit.

 removed.

AGO 10167B
178
 57.

marks on timing
gear cover.

AGO 10167B
 e. Loosen the mounting clamp screw located under the dis-
tributor with coil assembly toward the rear of the distributor
mounting bracket. Turn the distributor counterclockwise until
the distributor points are closed, and the distributor rotor is
pointed to the No. 1 position (11 above). Turn the distributor
clockwise slowly until the points start to open. Tighten the mount-
ing clamp screw. The ignition timing is now roughly adjusted.
f. Be sure that the rubber gasket (fig. 56) is seated in its
groove. Position the distributor cover and cap assemblies over
the gasket and secure with six No. 10 x ll/lG lockwasher screws
(fig. 55).
g. Unscrew the terminal nut securing the spark plug cable
assembly to No. 1 spark plug (fig. 59). Push the timing light
adapter (fig. 59) over the spark plug and connect the No. 1 cable
to the adapter. Connect one terminal of the timing light to the
adapter and the other terminal to ground at any convenient place
on the engine.

Timing

h. Start the engine and run it at idle speed. Direct the beam
from the timing light toward the timing marks (fig. 58). Loosen
the mounting clamp screw under the distributor with coil as-
sembly and turn the distributor until the timing marks appear
together. When the timing marks appear together, tighten the
mounting clamp screw.

AGO 10167B
 i. Stop the engine and remove the timing light. Pull the timing
light adapter (fig. 59) from the spark plug and unscrew the
terminal nut from the adapter. Install No. 1 spark plug cable
assembly by screwing the terminal nut onto the spark plug.

143. Distributor
a. Distributor Cap A.sww~~/~J(fig. 60).
(1) Removal. Remove the six lockwasher screws (fig. 55)
securing the distributor cover and cap assemblies and
remove the assemblies. Remove the three screws and
lockwashers holding the distributor cap assembly to the
distributor cover assembly and remove the cap. Do not
lose the four cap sealing washers between the cover and
cap assemblies.

Figure 60. Distributor cover and cap assemblies.

(2) Installation. Install the four cap sealing washers on the

four projections on the top of the cap assembly. Position
cap assembly inside the cover assembly and secure in
place with three No. 8-32 x 1 screws and internal-teeth
lockwashers. Install the distributor cover and cap as-
semblies on the distributor (par. 142f).

AGO 1016i'B 181

(1) Remove six Iockwasher screws (fig. 55) se-
curing the distributor cover and cap assemblies and
remove the assemblies. Loosen the screw securing the
breaker lever spring clip and slide the breaker lever
spring up and out of the clip. Lift the breaker lever up
and off the pin. Remove the screw securing the sta-
tionary contact bracket and remove the bracket.
(2) Place the stationary contact bracket over
the pin in the breaker plate, and over the adjusting ec-
centric. Install the No. 8 x 3/116screw securing the
bracket to the plate, but do not tighten. Place the breaker
lever onto the pin on the breaker plate and position the
slot in the breaker lever spring over the screw, inside
the breaker lever spring clip. Push the breaker lever
onto the pin as far as it will go and tighten the screw
securing the clip, making sure that the spring and
terminals are alined.
Test the distributor breaker lever spring
tension with a contact spring gage as shown in figure
61. The points should start to open with a pull of 17
to 21 ounces. Adjust the tension by bending the breaker
lever spring if necessary. Always have gage at right
angle to the points, as shown in figure 61. Check the
point adjustment (par. 142~). Install the distributor
cover and cap assemblies (par. 142f).

AGO 10167B
 (1) Removal. Remove the six lockwasher screws (fig. 55))
and remove the distributor cover and cap assemblies.
Loosen the screw securing the breaker lever spring clip,
and lift the capacitor cable terminal from the screw.
Remove the screw securing the capacitor to the breaker
plate and remove the capacitor.
(2) Position the capacitor on the breaker plate
and secure it with one No. 6 x 3//ls screw. Place the
capacitor cable terminal on the screw securing the
breaker lever spring clip and tighten the screw. Install
the distributor cover and cap assemblies (par. 142f).
cl. 56).
(1) Remove the six lockwasher screws (fig. 55))
and remove the distributor cover and cap assemblies.
Lift the rotor up and off the cam.
Note. If the rotor is tight, use care in removing as it is easily
broken.
Place the rotor on top of the cam, with
the flat spot in the bore of the rotor alined with the flat
spot on the cam. Press the rotor into place by hand. Do
not hammer on top of the rotor. Install the distributor
cover and cap assemblies (par. 142f).

The ignition filter assembly is a separate unit mounted in the en-

gine compartment in vehicles before serial No. 20601. Beginning with vehicle
serial No. 20601, the filter is installed in the wiring harness filter receptacle
assembly on the distributor body.
(1) In vehicles before serial No. 20601, unscrew
the nuts securing the cables to the connectors on both
ends of the ignition filter assembly. Remove four screws
and lockwashers securing the filter assembly and remove
the assembly.
(2) Place the ignition filter assembly in position
(on the fire wall below the air cleaner assembly), and
secure with four screws and lockwashers. Screw the
cables onto the connectors on the filter assembly.
f.
(1) In vehicles after serial No. 20601, unscrew and
remove the six lockwasher screws (fig. 53) securing the
distributor cover assembly to the distributor housing
and remove the assembly. Loosen the nut (fig. 56) on
the positive terminal of the ignition coil and remove nut,
washer, and terminal of ignition coil primary cable.

AGO 10167B
183
 Loosen the coil bracket mounting bolt securing the cable
clip, for the primary cable, to the coil mounting bracket
and remove bolt, lockwasher, and clip. Unscrew the nut
(T, fig. 33) securing the primary cable to the wiring
harness filter receptacle, and pull the cable from the
receptacle. Remove the four lockwasher screws secur-
ing the wiring harness filter receptacle (fig. 55) to the
distributor housing. Pull the receptacle assembly from
the distributor housing, and separate the capacitor
from the receptacle.
(2) Insert the wiring harness filter into the
wiring harness filter receptacle, contact end first, until
the flange of the filter rests against the flange of the
receptacle. Insert the terminal end of the ignition coil
primary cable in the distributor housing. Pull the cable
through sufficiently to place the cable terminal over the
positive terminal of the ignition coil and secure with
No. 10 washer and No. lo-32 nut. Secure the receptacle
to the distributor housing with four No. 6-32 x 11/3a
lockwasher screws. Position and secure the ignition coil
primary cable into the distributor housing. Pull the cable
clip, No. 10 lockwasher, and a No. lo-32 x 7/ls fillister-
head bolt. Insert the primary cable plug into the re-
ceptacle, and install the nut. Position the distributor
cover assembly on the top of the distributor housing and
secure with six No. 10-11/116 fillister-head, internal-teeth
lockwasher screws.

a. Remove the six lockwasher screws (fig. 55) and

remove the cover and cap assemblies. Remove the two coil termi-
nal stud nuts, and lift the terminals from the%tuds. Remove the
coil bracket mounting bolts and two cable clips. Lift the coil
straight out and remove.
b. Slide the coil into position, with terminals
spaced as shown in figure 56. Place the cable terminals on the coil
terminal studs. Arrange the cables as shown in figure 56 and
secure each terminal with a No. 10 coil terminal stud nut and
lockwasher. Place the cable clips in position to hold cables. Install
one No. 10 x Ws coil bracket mounting bolt, through each cable
clip and hole in the coil bracket and into the hole in the distributor
base. Install the distributor cover and cap assemblies (par. 142f).

184 AGO 10167B

 (1) Unscrew the terminal nuts securing the spark
plug cable assemblies to the spark plugs. Remove all dirt
from the recesses in the cylinder head around the spark
plugs. Loosen the spark plugs with a deep socket wrench
and remove the plugs. Discard the spark plug gaskets.
(2) Measure the electrode gap with a wire
feeler gage, and adjust to 0.030 inch. Place new gaskets
over the spark plug threads. Install the plugs and tighten
to torque of 25-30 pound-feet. Screw the terminal nuts
of the spark plug cable assemblies onto the spark plugs.

(1) Mark the spark plug cable assemblies for

identification. Unscrew the terminal nuts (fig. 55) and
disconnect the cables from the distributor cover assem-
bly. Unscrew the terminal nuts and disconnect the cables
from the spark plugs, and remove the cables.
(2) Place the spark plug cable assemblies in
position, with the long cable for No. 1 cylinder. Start
the terminal nuts onto the threads on the spark plugs,
but do not tighten until the cables are alined. Start the
terminal nuts onto the threads on the distributor cover
assembly (fig. 55), making certain that the correct firing
order is maintained. Aline the cables at the distributor
cover and spark plugs, to avoid kinks or sharp bends.
Tighten the terminal nuts on both ends of the cables.

Mark the spark plug cable assemblies for identification

at installation.
(2) Unscrew the terminal nuts securing the spark plug
cable assemblies to the distributor cover assembly, and
disconnect the cable assemblies.
(3) Unscrew the nut securing the distributor-to-carburetor
air intake pipe vent line assembly to the connector on
the distributor, and pull the line from the connector.
Unscrew the connector. Unscrew the nut securing the
distributor-to-windshield wiper fitting vent line assem-
bly to the elbow and pull the line from the elbow. Un-
screw the elbow.

AGO 10167B
 (4) Unscrew the nut securing cable No. 12 (fig. 54) to the
wiring harness filter receptacle assembly, and disconnect
the cable.
(5) Remove the mounting clamp screw and flat washer se-
curing the distributor with coil assembly to the spark
advance control arm, located under the distributor. Re-
move the distributor by lifting up and toward the right
side of the vehicle. Do not lose the spark advance control
arm thrust washer located between the distributor and
the spark advance control arm.
b. Installation.
(1) Make sure that the distributor drive shaft friction
spring is in place on the lower end of the distributor
drive shaft assembly. Place the spark advance control
arm thrust washer onto the bottom of the distributor.
Insert the drive shaft into the bore in the side of the
cylinder block, and lower the distributor with coil as-
sembly into position. Make sure that the offset tang on
the end of the drive shaft enters the slot in the oil pump
drive gear. When the tang is seated properly, the dis-
tributor will rest on the spark advance control arm.
(2) Put the flat washer onto the G x $$ mounting clamp
screw and start the screw through the spark advance
control arm into the bottom of the distributor with coil
assembly. Do not tighten this screw until the ignition
has been timed.
(3) Insert the No. 12 cable terminal plug into the wiring
harness filter receptacle assembly. Start the terminal nut
onto the receptacle and tighten with a wrench.
(4) Screw the elbow into the side of the assembly. Install
the distributor-to-windshield wiper fitting vent line as-
sembly in the elbow and screw the nut into the elbow.
Screw the connector into the side of the assembly. Install
the distributor-to-carburetor air intake pipe vent line
assembly in the connector and screw the nut into the
connector.
Note. If the other end of the vent line is retained by a mount-
ing clip held under the cylinder stud nut, remove the nut and lift
off the vent line clip. Install the nut and tighten to 65 to 75 pound-
feet with torque wrench. Install vent line mounting clip over stud
and secure on stud with a 7he-20NF jamnut 107824. Installation
of the clip on top of stud nut will eliminate bending and twisting
of the vent line when nut is tightened.

186
 (5) Connect the spark plug cable assemblies to the distribu-
tor cover assembly by screwing the terminal nuts onto
the cover assembly. Be sure that the cables are installed
in correct firing order.
(6) Set the ignition timing (par. 142).

The starting system (fig. 62) consists of the

starter, the starter switch, and starter pedal assemblies; the
batteries, connecting linkage and electrical cables, and in some
cases an auxiliary power receptacle for cold-weather starting.
The batteries are necessarily a part of each of the various electrical
systems. The operations on batteries are in paragraphs 154 through 164.
The auxiliary power cable receptacle with connecting cables is
considered a part of the starting system as it is the connection
for the application of any outside power source such as a booster
battery or a charging and starting power unit. The starter pedal
assembly engages the starter drive pinion with the flywheel ring
gears, and also operates the starter switch assembly. The starter
assembly (fig. 64) is a fully sealed, waterproof unit, mounted on
the front of the flywheel housing, at the right side. The starter
switch assembly (fig. 64) is a separate unit, mounted on top of
the starter assembly. The drive incorporates an over-running
clutch, which automatically disengages when the engine starts.
The starter bearings are lubricated at assembly and require no
further lubrication.

Figure 62.

187
 b. Data for Starter Assembly.
Manufacturer ~~~___~__~~~__~~_____________---_____Electric Auto-Lite Co
Model _~__~~~_______~___________-------~~---~-_~_~MCI-40OlUT
Voltage __~~~~_____~_____________________---_------24
Cranking speed ____~__.._~_~___________-~-~--__----185 rpm
Drive _______~__~~___~~~ _~ _________~_~~_~_~~_Overruning clutch
Switch ____~__~_____~~~__~ ___~~_~~_~_~~~~ Mounted on starter

a. Removal. Loosen the lead-coated nut securing the battery-

to-starter cable No. 82 terminal to the positive terminal of bat-
tery “B” (fig. 62)) and remove the cable from the terminal stud.
Full the cable out of the battery box to avoid accidental contact
with the battery terminal. Remove the terminal nut, lockwasher,
battery-to-starter cable, generator regulator cable, and auxiliary
power receptacle cable (if vehicle is equipped with an auxiliary
power receptacle) from the starter switch terminal (fig. 63).
Remove the bolt and lockwasher securing the starter assembly
to the starter support (fig. 64). Remove the nut and copper washer
(fig. 64) from bolt, and remove the bolt and copper washer from
the starter clutch and pinion housing assembly and the flywheel
housing. Remove the screw and lockwasher in the upper hole of
the clutch and pinion housing assembly securing the starter as-

Figure 63. Starter switch terminal-cable No.

AGO lOlG7B
188
 Figure 64. Starter installed on engine.

sembly to the flywheel housing. Remove the starter assembly by

pulling straight toward the front of the vehicle until the drive
pinion is clear of the flywheel housing.
Insert the drive pinion end of the starter as-
sembly into the flywheel housing, and position the starter. Place
a $&inch copper washer on the l/rL x 3ih~ bolt and insert the bolt
through the flywheel housing, through the starter clutch and
pinion housing assembly, and install a l/L-inch copper washer
and j/&inch nut on the bolt. Install the i/(L x 11, screw and lock
washer through the upper hole in the clutch and pinion housing
assembly and screw into the flywheel housing. Secure the front
of the starter to the starter support (fig. 64) with a/a x 7/8 bolt
and lockwasher. Place the battery-to-starter cable, generator
regulator cable, and the auxiliary power receptacle cable, if used,
on the starter switch terminal (fig. 63) and install the TAG-inch
lock washer and terminal nut. Coat the starter switch terminal
and cable terminals with ignition insulation compound. Insert the
battery-to-starter cable through the rubber grommet in the bat-
tery box, place the cable terminal onto the stud on the battery
“B” positive terminal (fig. 62)) and install the %,-inch lead-
coated nut. Coat the battery terminal with artillery and auto-
motive grease (GAA) .

AGO 1016’7B
 149. Starter Switch Assembijr
a. Loosen the nut securing the battery-to-starter cable
, No. 82 terminal to the positive terminal of battery “B” (fig. 62)
and remove the cable, from the terminal stud. Remove the termi-
nal nut and lockwasher securing the battery-to-starter cable
(fig. 63), generator regulator cable, and auxiliary power re-
ceptacle cable, if used, to the starter switch terminal, and remove
the cables. Remove the nut and lockwasher from the terminal
stud (fig. 63) on the starter assembly. Remove the nut and lock-
washer from the terminal stud (fig. 63) on the starter switch
assembly, and remove the switch-to-terminal stud connector (fig.
63). Remove four bolts and lockwashers securing the starter
switch assembly to the starter assembly and remove the starter
switch assembly.
b. Place the starter switch assembly on the starter
assembly and install four No. 10 x s/s bolts and lockwashers
holding switch to starter. Place the switch-to-terminal stud con-
nector (fig. 63) over the terminal studs on the starter and starter
switch. Install the 7/;fi-inch nuts and lockwashers securing the
connector to the terminal studs. Place the battery-to-starter cable,
generator regulator cable, and the auxiliary power receptacle
cable, if used, on the starter switch terminal. Install ylG-inch
lockwasher and terminal nut. Insert the battery-to-starter cable
t.hrough the grommet in the battery box and place the terminal
over the positive terminal stud on battery “B” (fig. 62). Install
the s ,-inch lead-coated nut securing the battery-to-starter cable
to the terminal, Coat terminal with artillery and automotive
grease (GAA) and check the operation of the starter switch
assembly. If the switch does not make contact so that starter
operates, adjust (c below).
c. Loosen the jamnut (fig. 63) on the setbolt in
the drive pinion shifting yoke shifting lever. Depress the starter
pedal as far as possible. Adjust the setbolt in or out until the
starter switch makes a good contact, and tighten the jamnut.
Release the starter pedal, wait a few seconds, and try the pedal
again. If adjustment is correct, the starter will operate properly.

150. Auxiliary Power Receptacle _,and Cable Assembly

(1) Unscrew the lockwasher bolt in the starter support from

the support and the commutator end head assembly and
remove the bolt, two internal- and external-teeth lock-

AGO 10167B
190
 washers, and the ground cable. (If the auxiliary power
receptacle is not to be installed, insert the a/s-inch lock-
washer bolt through the support and screw into the
commutator end head.)
(2) Unscrew the nut from the starter terminal. Remove the
lockwasher and cable from the terminal. (If the auxilary
power receptacle is not to be installed, place the 5/,,-inch
lockwasher over the terminal and screw on the 5/,,-inch
nut.)
(3) Remove the screw, nut, lockwasher, and the two clips
used to secure the two cables to the fender splash apron.
(4) Remove the four lockwasher screws holding the auxiliary
power receptacle to the mounting bracket and remove
the receptacle.
(5) Remove the four lockwasher screws and nuts holding
the bracket to the fender and remove the bracket.
b. Ins tallation.
(1) Position the auxiliary power receptacle mounting bracket
on the top of the right front fender and aline the holes
in the bracket with the four holes in the fender. Push
the four No. 12 x v~ lockwasher screws through the holes
in the bracket and the fender and screw a No. 12 nut
on each bolt.
(2) Push the two cables of the auxiliary power receptacle
through the hole in the mounting bracket from the out-
side. Position the receptacle on the bracket, aline the
holes in the receptacle with the holes in the bracket,
and install the four No. 12 x 5/a lockwasher screws.
(3) (If the auxiliary power receptacle was not removed from
the vehicle, remove the lockwasher bolt from the starter
support and commutator end head assembly, and the
nut from the starter terminal.) Install a s/s-inch internal-
and external-teeth lockwasher, and ground cable, and
a second a/a-inch internal- and external-teeth lockwasher
over the 3/3 x 7/3 lockwasher bolt, and install the bolt
through the support and into the commutator end head.
Install the auxiliary power receptacle cable on the starter
terminal and install the 5,/,6-inch lockwasher and nut.
(4) Install a No. 10 x J$ screw through the hole in the two
s/s-inch clips. Position the clips over the two cables,
push the screw through the hole in the splash apron,
and install a No. 10 lockwasher and nut on the screw.

AGO 1016’7B 191

151.

The generating system (fig. 65) consists of

the generator assembly, generator regulator assembly,
batteries, and connecting cables. The system is sealed
and waterproof. It is a 24-volt, single-wire system, de-
signed to automatically increase or decrease the charging
rate to keep the battery fully charged without over-
charging.
Note. The batteries are necessarily a part of the various elec-
trical systems. The operations on batteries are included in para-
graphs 154 through 164.
(2) The generator assembly (Z, fig.
66) is a 25-ampere, 24-volt, constant-duty-type, sealed,
and waterproof. It is located at the right side of the
engine and is driven from the crankshaft by a matched
pair of V-belts. The mounting support (R, fig. 66) per-
mits adjustment of the drive belts. All external electrical
connections are made by a single waterproof wiring
harness receptacle assembly.
(3) The generator regulator
assembly consists of three units: the voltage regulator,
which controls the generator output voltage to prevent
overcharging the batteries ; the current regulator, which
prevents overloading the generator; and the circuit
breaker, which opens to prevent discharging the bat-
teries when the generator output falls below the level
required to charge the batteries. The regulator assembly
is a waterproof unit.

Generator assembly:
Manufacturer ___~_________________--__-________- Electric Auto-Lite Co
Voltage ____________________-__--_---___--_--_~-_ 24
Polarity __________~_~__~__~_____________________ negative ground
Controlled output __~__~___~____..__________--___- 25 amp

Generator regulator assembly:

Manufacturer ______~___~__~__________----_--_--_ Electric Auto-Lite Co
Voltage ___________~_.~~_~_~_____---~--~----__~--_ 24
Polarity _____________________--_---___-_-_----_- negative ground
Amperes ____________________-___-___--____---__- 25

192 AGO 10167B

 /
t

II 3
 Remove the wiring harness (A) by unscrewing
the nut on the connector (B) securing the wiring harness to the
wiring harness receptacle assembly (C) with a spanner wrench.
Remove the lockwasher screw (D) and flat washer (E) securing
the belt tension brace (G) to the drive end head (H) of the
generator assembly. Swing the generator assembly (Z) toward
the engine as far as it will go and remove both drive belts (F)
from the generator pulley.
Note. Flat washers (L, P, T, and V) may drop when bolts (Q and S)
are removed. Recover or remove the flat washers after removing the gen-
erator assembly.
Remove nut (J) , lockwashers bolt (Q),and flat washer (P)
securing the drive end head (H) of the generator assembly to the
engine front mounting support assembly (N) . Remove the nut
(X) , lockwasher bolt (S), and flat washer (T) securing
the commutator end head (Y) of the generator assembly to the
mounting support (R) . Remove the generator assembly (2)
by lifting straight up until it clears the brace insulators (M and
U) and lifting the commutator end up and out between the bat-
tery box and the air cleaner assembly. Examine both brace in-
sulators in the mounting support (R). Do not remove unless
damaged or deteriorated.
Lower the generator assembly (Z), drive end
first, between the battery box and the air cleaner assembly, and
work generator forward into position over the mounting support
(R). Aided by a helper working underneath the vehicle, start
the X6 x 21/a bolt (S) and lT&-inch ID flat washer (T) through
the brace insulator (U) . Place the 15/3a-inch ID flat washer (V)
between the brace insulator and the commutator end head (Y)
of the generator and push the bolt (S) through the flat washer
(V) and the commutator end head (Y) . Place 7/,e-inch lock-
washer (W) over ‘the end of the bolt (S) and install the The-inch
nut (X) but do not tighten. Have the helper start the x B x
21&.bolt (Q) and 17/&-inch ID flat washer (P) through the brace
insulator Place the 1X2-inch ID flat washer (L) between
the brace insulator (M) and the drive end head (H) of the gen-
erator and push the bolt through the flat washer and drive end
head. Place the 7/,,-inch lockwasher (K) over end of the bolt and
install the 7/,,-inch nut (J) but do not tighten. Position the drive
belts (F) over the drive pulley and pull the generator away from
the engine until the drive belts are snug in place in all pulleys.
Place ah-inch flat washer (E) over the 3/g x 1 lockwasher screw

194 AGO 10167B

 __4.“=._...

66.

(D) and insert through the belt tension brace (G) and into the
drive end head (H) of the generator assembly. Start bolt into
threads but do not tighten. Adjust belt tension (par. 123). Tighten
nut (J) and bolt (Q) securing the drive end head (H) of the
generator to the engine front mounting support assembly (N).
Tighten the nut (X) and bolt (S) securing the commutator end
head (Y) of the generator to the mounting support (R). Posi-
tion the wiring harness (A) in the wiring harness receptacle
assembly (C) by alining the slot in the connector (B) with the
pin in the receptacle. Push the connector in as far as possible
and screw the nut of the connector onto the receptacle with a
spanner wrench.

195
153. Generator Regulator Assembly
(fig. 67)
Caution: Disconnect battery ground cable (par. 155c(2) ) be-
fore attempting any work on the generator regulator assembly.
See warning on top of regulator cover.
a. Use a spanner wrench to unscrew the two cable
connector coupling nuts, and pull the cables from the receptacles.
Remove four nuts and lockwashers securing the generator regu-
lator assembly to the mounting bracket cushions, and remove
the regulator.

Figure 67. Generator regulator assembly-installed.

Place the generator regulator assembly in posi-

tion over the studs of the mounting bracket cushions, with the
cable receptacles to the rear. Install four 5/1c-inch lockwashers
and nuts securing the regulator. Push the cable connector plugs
into their receptacles, being careful to enter the keys on the plugs
into the slots in the receptacles. Install the cable connector
coupling nuts and tighten with spanner wrench.

Section XIII. BATTERIES AND LIGHTING SYSTEM

154. Description and Data

Lighting system current is furnished by two

12-volt batteries connected in series to supply 24 volts

196 AGO 101676

 to all units. All units and connecting cables are sealed
and waterproof. Cables are connected to the various
units with bayonet-type connectors, joined together by
interlocking sleeves or threaded couplings. All lighting
circuits are controlled by the light switch (E, fig. ‘7)
on the instrument panel. Starting, lighting, and ignition
circuits are protected by the three circuit breakers lo-
cated in the passenger compartment on the rear of the
instrument panel.
(2) One battery is located in the right side of
the cowl (fig. 69) and is accessible through a door on
the top of the cowl. The other battery is located in the
right side of the engine compartment (fig. 68). Termi-
nals are waterproofed by applying a thick coating of
artillery and automotive grease (GAA) after installation.
(3) The headlights are adjustable
sealed lamp-units located on the front of the vehicle and
controlled by switches in the passenger compartment.
(4) The blackout headlight is
an adjustable, sealed lamp-unit located on top of the
left front fender. It is controlled by a switch in the
passenger compartment.
(5) A
blackout marker and service parking light is located
beneath each headlight. These lights are controlled by
the light switch.
(6) The
blackout taillight and stoplight is mounted on the right
rear corner of the body. The assembly includes a blackout
stop lamp in the upper portion, and a blackout taillamp
in the lower portion. The stop lamp is controlled by the
stoplight switch. The taillamp is controlled by the light
switch.
(7) The
service taillight and stoplight is mounted on the left rear
corner of the body. The assembly includes a stop lamp
and a service taillamp in the upper portion, and a black-
out taillamp in the lower portion. The stoplamp is con-
trolled by the stoplight switch. The service taillamp and
the blackout taillamp are controlled by the light switch.
(8)
The trailer coupling connector receptacle assembly is
located on the body rear panel, above the service tail-

AGO 10167B
 supplying current to the trailer lights. Current to the
receptacle is controlled by the light switch (E, fig. 7).
b. Battery Data.
Manufacturer ~________~________~__~ __________ The Electric Auto-Lite Co
Model __________________~_______-_-----~-_~-- 2HH
Voltage _______.._____________-_--_-----_-__-_ 12
Plates per cell ~______~_~____ ~_ _ 11
Type _____~___ .______~_______~_~_____---____ waterproof
Number of batteries used ~_ .~_.._~-..~.~__~.~_~.~. 2
How connected ___~~_.___~__~__~_~_-.~_______~. series for 24 v

155. Batteries
a. General. For purposes of identifying the individual batteries
in the procedures given in this paragraph, the battery located
in the engine compartment is identified as battery “A” (fig. 68)
and the battery located in the cowl is identified as battery “B”
(fig. 69).
b. Battery Maintenance. Refer to TM 9-2857 for specific gravity
test, adding water, and cleaning.
c. Battery “A” Removal (fig. 68).
(1) Lift and release the ring latches securing the insulating
box cover and open the cover.
(2) Remove the terminal nut and disconnect the ground
cable from the clamp-type terminal on the negative post.
(3) Remove the terminal nut and disconnect the battery-to-
battery cable from the clamp-type terminal on the posi-
tive post.
(4) Remove the two wing nuts and flat washers securing
the hold-down frame to the battery, and the wing nuts
and flat washers securing the battery box-to-fender
straps to the battery box and hold-down frame. Remove
the box-to-fender strap bolts and remove the hold-down
frame.
(5) Lift the battery straight up and out of the battery box.
Note. Do not use a lifting strap that fastens to the battery posts
as it m’ay result in damage to the battery.
d. Battery “A” Installation (fig. 68).
(1) Lower the battery into the battery box, with the battery
posts toward the engine side of the box.
Note. Replacement batteries may not be equipped with clamp-
type terminals. If not, remove the terminals from the old bat-
tery and install on the replacement battery. Be sure that battery
posts and terminals are clean.

198 AGO 10167B

 Figure Battery “A” located in compartment.

(2) Install the hold-down frame and install the two y/l6 x
ah bolts through the hold-down frame, the battery box,
and the battery box-to-fender strap. Secure the hold-
down frame and box-to-fender straps with four s8-inch
plain washers and y16-inch wing nuts.
(3) Connect the battery-to-battery cable to the clamp-type
terminal on the positive post, and secure with a s-inch
terminal nut.
(4) Connect the ground cable to the clamp-type terminal
on the negative post, and secure with a a/a-inch terminal
nut.
(5) Check polarity (9 below).
(6) Close the insulating box cover and secure with the ring
latches.
e. Battery “B” Removal (fig. 69).
(1) Open battery “A” insulating box cover (c (1) above).
(2) Disconnect the ground cable from battery “A” (c (2)
above).
(3) Turn the wing nuts securing the battery box door one-
quarter turn and open the door.
(4) Remove the terminal nut and disconnect the battery-to-
battery cable from the clamp-type terminal on the
negative post.
 (5) Remove the terminal nut and disconnect the battery-to-
starter cable from the clamp-type terminal on the posi-
tive post.
(6) Remove two wing nuts securing the hold-down frame
and remove the frame.
(7) Remove the battery (c (5) above).

Figure 69. Battery “B” located in cowl.

f. Battery “B” Installation (fig. 69).

(1) Lower the battery into the cowl (see Note in d (1)
above).
(2) Install the hold-down frame and secure with two 5//ls-
inch wing nuts.
(3) Connect the battery-to-starter cable to the clamp-type
terminal on the positive post and secure with a ye-inch
terminal nut.
(4) Connect the battery-to-battery cable to the clamp-type
terminal on the negative post and secure with a s/a-inch
terminal nut.
(5) Close the battery box door and secure by turning the
wing nuts one-quarter turn.
(6) Connect the ground cable to battery “A” (d (4) above).
(7) Check polarity (9 below).

200
 (8) Close the battery “A” insulating cover and secure with
the ring latches.
g. Check polarity by turning on headlights. If
they light, and the ammeter shows discharge, the polarity is cor-
rect. If headlights do not light and ammeter shows no appreciable
reading, one battery is reversed. If headlights light and ammeter
shows charge, both batteries are reversed. Correct installation
as necessary.

and 69)
a.
(1) Open the insulating box cover (par. 155~ (1) ) .
(2) Disconnect the ground cable (par. 155~ (2) ) .
(3) Remove the nut, bolt, and two lockwashers securing the
other end of the ground cable to the battery box support
and remove the cable.

(1) Install a s-inch internal-external tooth lockwasher over

a a/s x 7/s bolt. Position the ground cable terminal over
the hole in the battery box support and insert the bolt
with lockwasher through the terminal and support.
Secure with a ah-inch lockwasher and nut.
(2) Insert the other end of the cable through the rubber
grommet in the insulating box.
(3) Connect the ground cable to the battery (par. 155d (4) ) .
(4) Close and secure the insulating box cover (par. 155d (6) ) .
c. 68)
(1) Open battery “A” insulating box cover (par. 155~ (1) ) .
(2) Disconnect the ground cable at battery “A” (par.
155c (2) ) .
(3) Disconnect the battery-to-battery cable at battery “A”
(par. 155c(3)).
(4) Open battery “B” box door (par. 155e (3) ) .
(5) Disconnect the battery-to-battery cable at battery “B”
(par. 155e (4) ).
(6) Remove the nut, lockwasher, and bolt securing the bat-
tery-to-battery cable closed clip to the fender splash
shield and remove the cable.

(1) Install the battery-to-battery cable closed clip over the

cable and secure to the fender splash shield with a No. 10
x 5/g bolt, lockwasher, and nut.

201
 (2) Position the battery-to-battery cable through the holes
in the battery boxes, being sure that the rubber grom-
mets are in place.
(3) Connect the cable at battery “A” (par. 155d (3) ).
(4) Connect the cable at battery “B” (par. 155f (4) ) .
(5) Connect the ground cable to battery “A” (par. 155d (4) ) .
(6) Close both battery boxes (par. 155d (6) and f (8) ) .

(1) Open both battery boxes and disconnect the ground cable
at battery “A” (par. 155~ (2) ).
(2) Disconnect the battery-to-starter cable at battery “B”
(par. 155e(5)).
(3) Remove the nut and lockwasher securing the other end
of the cable to its terminal on the starter switch (fig.
64) and remove the cable.
f.
(1) Install one end of the battery-to-starter cable on its
terminal at the starter switch (fig. 62) and secure with
a a/s-inch lockwasher and nut.
(2) Insert the other end of the cable through the rubber
grommets in the cowl and battery “B” box.
(3) Connect the cable at battery “B” (par. 155f(3) ) .
(4) Connect the ground cable at battery “A” (par. 155d (4) ) .
(5) Close both battery boxes (par. 155d(6) and f (8) ).

157. Headlights

(1) Remove two lockwasher screws securing the

headlight guard to the radiator guard. Unscrew three
screws securing the door assembly to the housing assem-
bly and remove the door and door gasket. The screws
are fastened in the door to prevent loss. Loosen the three
screws securing the lamp-unit retaining ring to the
housing assembly, and remove the retaining ring by
turning counterclockwise. Pull the sealed lamp-unit from
the housing. Pull the three cable connectors from the
clips in the housing, and disconnect the cables at the
connectors. Remove the sealed lamp-unit.
(2) Connect cable Nos. 17, 18, and 91 on the
sealed lamp-unit to cable Nos. 17, 18, and 91 at the
connectors in the housing assembly and clip the con-
nectors in the housing. Place the sealed lamp-unit in the
housing with the projections on the edge of the lamp-
unit in the notches in the rim of the housing. Place

AGO 10167B
 Figure 70. Headlight-partially exploded view.

the lamp-unit retaining rim over the lamp-unit and

under the heads of the three screws in the housing.
Turn the ring clockwise and tighten the screws. Be
certain that the door gasket is in place in the door as-
sembly. If gasket was damaged during removal, use a
new gasket. Place the door assembly against the hous-
ing. Start the three screws securing the door assembly
to the housing assembly. Draw the screws up gradually
and evenly until the door assembly is seated against the
housing. Place the headlight guard in position and secure
it with two l/* x s/s lockwasher screws.
Place the vehicle on a level surface
and arrange a wall target as shown in figure ‘71. Remove the
headlight guard and door assembly (a above). Cover head-
light not being adjusted. Turn on the headlights (par. 33) and
be sure that the high beam is on (par. 40). Aim the headlight by
turning the adjustment screws (fig. 72)) as required, until the
headlight beam conforms with the headlight beam pattern (fig.
73). Turn off the headlights. Install the door and guard
above).
c. The removal procedure is the
same for both headlights.
(1) Remove the headlight sealed lamp-unit ((I.(1) above).

AGO 203
I
I

(2) Remove the rubber grommet from the top of the head-
light housing.
Remove the headlight cables from the headlight housing.
Remove eight lockwasher screws securing the headlight
housing to the radiator grille.
Remove headlight housing and mounting pad.
The installation procedure
is the same for both headlights.
(1) Position the mounting pad on the rear of the headlight
housing with the mounting holes in the pad alined with
those in the housing.
(2) Position the housing with mounting pad in the radiator
grille and secure with eight No. 10 x 175 lockwasher
screws (fig. 78).
(3) Slip the rubber grommet over the headlight cables, and
insert cables and grommet in headlight housing.
(4) Install the headlight sealed lamp-unit (2) above).

a.
(1) Unscrew three screws securing the door as-
sembly to the housing assembly, and pull the door and
sealed lamp-unit from the housing assembly. Pull the
cable connectors from the clips in the housing assembly
and disconnect both cables. Remove three retaining
springs securing the sealed lamp-unit in the door as-
sembly and remove the unit.

AGO
 Figwre 7.4. Blackol*t headlight assembly-partially exploded view.

(2) Place the sealed lamp-unit in the door as-

sembly, with the pad on the edge of the lamp-unit in the
notch in the door assembly, and secure with three re-
taining springs. Place the door and lamp-unit in front
of the guard with support, and fasten the connectors
on the lamp-unit cables to the connectors inside the
housing assembly. Place the connectors in the clips in-
side the housing. Position the door and lamp-unit on
the housing assembly and secure the door assembly to
the housing assembly with three No. 8 x 3/s screws,
which are retained in the door.
b.
(1)
Note. Three bolts, lockwashers, and nuts secure the cable clips
and ground terminal to the fender. The bolts are installed from
the top and the nuts are under the fender.
Remove the bolt, nut, and lockwasher securing the horn
and ground cables to the fender splash shield. Remove
two bolts, nuts, and lockwashers securing the cable clips
to the fender. Disconnect cable No. 91 at the connector
adjacent to the ground cable terminal. Remove the nut,
lockwasher, and bearing washer securing the light as-
sembly to the guard with support, and remove the light
assembly.
(2) Place the light assembly on the guard with
support, with the stud on the housing through the hole
in the support, and install the bearing washer (convex

206 AGO
 Figwe 75. Blackout headlight assembly-installed.

side up), lockwasher, and nut. Point the light straight-

ahead and tighten the nut. Insert one No. 10 x $42 bolt
through each cable clip and the holes in the fender.
Install a lockwasher and nut on each bolt from beneath
the fender. Secure the terminal on cable No. 91, together
with the horn ground cable, to the fender splash shield
with one No. 10 x rho bolt, lockwasher, and nut.

Note. Instructions in a and b below apply to both right and left lights.
CL. Remove two screws securing the door with
lens assembly and gasket to the housing assembly and remove.
Push the lamp in, turn counterclockwise, and remove.
Note. Gasket should stay in the door assembly.
Insert the new lamp into the socket and
turn clockwise to lock in place. Examine the gasket in the door
with lens assembly. If damaged, replace. Place the door against
the housing assembly and secure with two No. 8 x 1h screws.
c.
The removal procedure is the same for both blackout
marker and service parking lights.

AGO 10167B 207

 marker and service

(1) Disconnect cable No. 20 from the wiring harness clipped

to the side of the radiator grille.
(2) Remove the lockwasher nut securing the light to the
mounting bracket on the radiator guard and remove the
light and mounting pad.

The installation procedure is the same for both black-

out marker and service parking lights.
(1) Position the mounting pad on the mounting stud of the
assembly.
(2) Insert the stud through the hole in the mounting bracket
on the radiator guard and secure the light assembly with
a 5/i6-inch lockwasher nut.
(3) Connect cable No. 20 to the wiring harness.

160. Taillight, Stop, and Blackout lights

(1) Unscrew the six screws securing the

door with lens and screws assembly to the housing as-
sembly and remove the door and gasket. Push defective
lamp in and turn counterclockwise to remove. Insert the
new lamp and turn clockwise to lock in place. Examine

208 liao 10167B

 the gasket and replace if necessary. Position the door
with lens and screws assembly against the housing as-
sembly and start the six No. 10 x 11/3a screws. Tighten
the screws evenly.

Remove two cables from the clip on the back

of the housing assembly, pull the cables out until the
cable connectors are exposed, and uncouple both con-
nectors. Remove two bolts and lockwashers securing
the blackout taillight and stoplight assembly and remove
the assembly.
(3) Insert the connectors through the hole in
the blackout taillight and stoplight assembly mounting
bracket, position the assembly on the bracket, and se-
cure with two s/s x 5/s bolts and lockwashers. Couple
the connectors in accordance with the cable numbers.

Refer to a (1) above.

(2) Remove two lockwasher screws securing the
taillight and trailer connection guard to the body left
rear panel. These screws are located near the left rear
corner of the body, one screw below the reflector and one
above the reflector. Remove two lockwasher screws se-
curing the guard to the body side panel. These screws
 are located adjacent to the left edge of the rear seat in
the passenger compartment. Remove the guard from
the left rear wheel housing. Disconnect the three tail-
light and stoplight cable connectors (fig. 79). Remove
two bolts and lockwashers securing the service taillight
and stoplight assembly to the service. taillight and stop-
light bracket and remove the assembly.
(3) Place the service taillight and stoplight
assembly in position on the service taillight and stop-
light bracket and secure with two 3/ x 5/8 bolts and
lockwashers. Connect the taillight and stoplight cable
connectors in accordance with the numbers on the cables.
Place the taillight and trailer connection guard in posi-
tion inside the left rear wheel housing. Start the two
l/b x 5/8 lockwasher screws through the body left rear
panel and into the guard. Start the two 1h x 5/s lock-
washer screws through the body side panel and into the
guard. Tighten all four screws.

161. Instrument Panel tights

Refer to paragraph 39 for description and location, and para-
graph 165 for removal and installation of the instrument panel
lights.

210 AGO lli167B

Figure 79. Taillight and trailer connection guard assembly removed to show
trailer coupling, and taillight and service stoplight cable connectors.

162. Trailer Coupling Connector Receptacle Assembly

(fig. 79)
a. Follow instructions in paragraph 160b(2) for re-
moval of the taillight and trailer connection guard. Disconnect
the three trailer coupling cable connectors and the double con-
nector by pushing the halves of the connectors together and
rotating them left hand. Remove the bolt, nut, and lockwasher
securing the ground cable to the body rear panel. Remove four
bolts and lockwashers securing the trailer coupling connector
receptacle assembly to the body rear panel and remove the as-
sembly and polarizing bracket (fig. 9). The receptacle cover and
receptacle connector assemblies will separate after removal. Pull
the cables through the body rear panel, one at a time, to avoid
damaging the connectors.

AGO 10167B 211

 b. Installation.
trouble is experienced with the receptacle cover striking and
damaging reflex reflector when inter-vehicular cable is plugged into recep-
tacle, rotate the entire receptacle and cover as a unit, 90” clockwise before
installing.
Place the receptacle cover assembly on the receptacle connector
assembly. Position the polarizing bracket (fig. 9) behind the
receptacle with the longest prong of the bracket downward and
directly opposite the hinge of the receptacle cover. Insert the
connectors through the hole in the body rear panel and position
the assembly against the panel, with the cover hinge at the top.
Install four $!! x 5/8 bolts and lockwashers securing the assembly
to the panel. Insert a No. 10 x 5/s bolt through the hole below
the assembly, and place the ground cable terminal over the bolt,
securing with a No. 10 lockwasher and nut. Push the two halves
of the double connector together and turn right hand to lock.
Place the two halves of each trailer coupling cable connector to-
gether, as numbered, and turn right hand to lock. Install the tail-
light and trailer connection guard (par. 160b (3) ) .

Table IV lists each circuit number in the electrical system and

traces each circuit from source to end as shown on figure 80.
A point-to-point check for circuit continuity can be made, using
a standard low-voltage circuit tester equipped with long cables.
Multiple contact connectors are used at the light switch, the
voltage regulator and trailer electric receptacle. In these units
the circuits are identified in both the plugs and sockets by letters
mou!ded into the insulating material.

Numbers

Circuit
number I Circuit description

Voltage regulator output A terminal to starter

Battery to ground
Voltage regulator output B terminal to positive ammeter
terminal
9 VoItage reguIator output D termina1 to negative ammeter
terminal
10 Voltage regulator output C terminal to horn switch, ignition
switch, and light switch connector
11 Ignition switch to light switch F terminal
12 Distributor and ignition coil to ignition switch
15 Generator regulator C terminal to light switch F terminal
16 Light switch M terminal to dimmer switch
17 Headlight to dimmer switch and high beam indicator
18 Headlight to dimmer switch

212 AGO 10167B

 Circuit
number Circuit description

19 Light switch D terminal to blackout headlight

20 Light switch E terminal to blackout marker lights
21 Light switch H terminal to trailer coupling connector recep-
tacle E terminal and left taillight
22 Light switch C terminal to trailer coupling connector recep-
tacle B terminal and left taillight
23 Light switch N terminal to trailer coupling connector recep-
tacle F terminal and right taillight
24 Light switch E terminal to trailer coupling connector recep-
tacle A and C terminals and right and left taillights
25 Horn circuit from voltage regulator C terminal to horn
switch, horn, and horn ground
27 Instrument panel to ignition switch
28 Fuel gage to fuel gage sending unit
33 Water temperature gage to water temperature gage sending
unit
36 Oil pressure gage to oil pressure gage sending unit
40 Light switch B terminal to instrument cluster lights
68 Battery “B” positive terminal to battery “A” negative
terminal
75 Light switch A and K terminal to stop light switch
82 Battery “A” to starter
85 Ignition switch to open connector
90 Trailer coupling connector receptacle to ground
91 Blackout driving light and headlights to ground

164. Headlight High Beam Indicator light

Refer to paragraph 40 for description and location, and para-
graph 179 for removal and installation of the headlight high
beam indicator light.

Section XIV. WINCH ASSEMBLY

165. ,Description
a. Description. The horizontal drum-type winch assembly is
mounted between the frame side members at the front of the
vehicle as shown in figure 81. The winch is driven from the power-
take-off (par. 202) on the rear of the transfer through a system
of shafts and universal joints.
b. The operation and data of the winch
and power-take-off are discussed in paragraphs 54 and 55.

166. Coordination With Ordnance Maintenance Unit

Replacement of the winch assembly is normally an ordnance
maintenance unit responsibility, but may be performed in an

AGO 10167B
213
 ii

Figure 80.
 Figure 81. Winch installed.

emergency by the using organization, provided authority for per-

forming this replacement is obtained from the supporting ord-
nance officer. Tools and equipment needed for this operation
which are not carried by the using organization may be obtained
from the supporting ordnance unit.

167.
The using organization is responsible for the lubrication of the
winch assembly as covered in paragraph 66.

Note. The key letters noted in parentheses are in figure 82, except where
otherwise indicated.
a.
(1) Loosen the setscrew (Z) securing the universal joint
to the shaft of worm gear (A). Slide the long drive shaft
(C) with universal joint toward the rear of the vehicle
into the universal slip joint assembly (D) and off the
shaft of worm gear and the key. Lower to floor.
(2) Remove the four bolts (fig. 81) and lockwashers secur-
ing the winch frame to the frame support brackets, and
raise the winch with frame up and out of the vehicle.

Position the winch with the winch frame (fig. 81) on the
frame support brackets and aline the holes in the frame
with the holes in the brackets. Place a l$z-inch lockwasher
over each of the four l/r, x 1 bolts. Insert the bolts with
washers through the holes in the winch frame and screw
into the frame support brackets.

AGO 101670 215

E-
F-

shafts and universal

 (2) Raise the long drive shaft (C) with universal joint and
slide the drive shaft toward the rear of the vehicle and
into the universal slip joint assembly (D) . Aline the
universal joint with the shaft of worm gear (A). Aline
the keyway in the universal joint assembly (B) with the
key in the shaft of worm gear. Slide the universal joint
and drive shaft forward and onto the shaft of worm gear
and the key, and tighten setscrew (Z).
c. Adjustment of Worm Brake. With the winch operating in the
forward direction (drawing in cable), loosen the brake adjusting
screw locknut, and turn the adjusting screw until it begins to
tighten. Tighten the locknut.

169. Drive Shafts

(fig. 82)
a. Remove Long and Short Drive Shafts.
(1) Remove the long drive shaft (C) with universal joint
assemblies by loosening the setscrew (V) securing the
universal slip joint assembly (D) to the front end of
hanger bearing shaft (E) . Loosen the setscrew (Z) se-
curing the universal joint assembly (B) to the shaft of
worm gear (A). Slide the shaft with universal joint to-
ward the rear of the vehicle into the universal slip joint
and off the shaft of worm gear and the key. Pull the
universal slip joint off the front end of hanger bearing
shaft and the key, and remove the drive shaft with uni-
versal joint assemblies from the vehicle.
(2) Remove the universal joint assemblies (par. 170a(2)
and (3) ) if necessary.
(3) To remove the short drive shaft (L) with universal
joint assemblies, loosen the setscrew (T) securing the
universal joint assembly (K) to the rear end of hanger
bearing shaft (E) and loosen the setscrew (Q) securing
the universal joint assembly (M) on the power-takeoff
output shaft (N) .
(4) Unscrew the bolt (J) securing the hanger bearing brace
(H) to the flywheel housing (F) and remove the bolt
and lockwasher. Unscrew the bolt (G) securing the
hanger bearing assembly (U) to the flywheel housing
and remove the bolt and lockwasher. Slide the hanger
bearing assembly with the short drive shaft (L) and
universal joint assemblies toward the front of the ve-
hicle on the splines of the long drive shaft (C) and off
the power-take-off output shaft (N) and key. Pull the
 short drive shaft with universal joint assemblies off the
rear end of hanger bearing shaft (E) and key, and re-
move the shaft with the universal joint assemblies from
the vehicle.
(5) Remove the universal joint assemblies (par. 170b (2) )
if necessary.

(1) Install the universal joint assemblies on the long drive

shaft (par. 17Oc( 1) and (2) ) if removed.
(2) Aline the keyway in the universal slip joint assembly
(D) with the key in the front end of hanger bearing
shaft (E) and slide the universal slip joint onto the shaft
and key. Aline the keyway in the universal joint assem-
bly (B) with the key in the shaft of worm gear (A) and
slide the universal joint onto the shaft and key. Tighten
the setscrew (Z) securing the universal joint assembly
(B) to the shaft of worm gear. Tighten the setscrew (V)
securing the universal slip joint to the front end of
hanger bearing shaft.
(3) Install the universal joint assemblies on the short drive
shaft (par. 170d (1) ) if removed.
(4) Aline the keyway in the universal joint assembly (M)
with the key in the power-take-off output shaft (N) and
slide the universal joint onto the shaft and key.
(5) Slide the hanger bearing assembly (U) and universal
slip joint assembly (D) onto the splines of the long drive
shaft (C) . Aline the keyway in the universal joint as-
sembly (K) with the key in the rear end of hanger bear-
ing shaft (E) . Slide the rear end of hanger bearing shaft
into the universal joint assembly (K) .
(6) Position the hanger bearing assembly (U) on the fly-
wheel housing (F).Place a yI c-inch lockwasher over the
y16 x 11/2 bolt (G) , insert the bolt with washer through
the hole in the hanger bearing and screw the bolt into
the flywheel housing. Place a 7/ls-inch lockwasher over
the 7/ls x 1% bolt (J) , insert the bolt with washer
through the hanger bearing brace (H) , and screw the
bolt into the flywheel housing.
(7) Tighten the setscrew (Q) securing the universal joint
assembly (M) to the power-take-off output shaft (N).
Tighten the setscrew (T) securing the universal joint
assembly (K) to the rear end of hanger bearing shaft
(E).

2ia AGO 10167B

170. Universal Joint Assemblies
(fig. 82)

(1) Remove the long drive shaft with universal joint assem-
blies (par. 169a( 1) ) .
(2) Remove the universal joint assembly (B) by loosening
the setscrew (Y) securing the joint to the shaft and pull
the joint off the shaft and key.
(3) Remove the universal slip joint assembly (D) by remov-
ing the drive shaft seal clamp (W) securing the drive
shaft seal (X) to the joint and pull the joint off the
splines of the shaft and out of the seal.
b.
Remove the short drive shaft with the universal joint
assemblies (par. 169a (3) and (4) ) .
(2) Loosen the setscrews (R and S) securing the universal
joint assemblies (K and M) to the shaft, and pull the
joints off the shaft and keys.
c.
(1) Line up the keyway in the universal joint assembly (B)
with the key in the long drive shaft (C) , and slide the
joint onto the shaft and key.
(2) Slide the splined end of the universal slip joint assembly
(D) into the drive shaft seal (X) and onto the splined
end of the long drive shaft.
(3) Install the shaft with universal joint assemblies (par.
169b(2) ).
(4) Tighten the setscrew (Y) securing the universal joint
assembly (B) to the shaft. Install the drive shaft seal
clamp (W) securing the drive shaft seal (X) to the
universal slip joint.

(1) Line up the keyways in the universal joint assemblies

(K and M) with the keys in the short drive shaft (L),
and slide the universal joints onto the shaft and key.
(2) Install the short drive shaft with universal joints (par.
169b (4)-(7) ).
(3) Tighten the setscrews (R and S) securing the joints to
the shaft.

171. Hanger Bearing Assembly

(fig. 82)

(1) Loosen the setscrew (V) securing the universal slip

inin+ nqsemblv
J..*--’ -..,- _____~(D) on the front end of hanger bearing
AGO 219
 shaft (E).Loosen the setscrew (T) securing the univer-
sal joint assembly (K) on the rear end of hanger bearing
shaft
(2) Unscrew the bolt (J) securing the hanger bearing brace
(H) to the flywheel housing (F), and remove the bolt
and lockwasher. Unscrew the bolt (G) securing the
hanger bearing assembly (U) to the flywheel housing,
and remove the bolt and lockwasher.
(3) Pull the rear end of hanger bearing shaft (E) and key
out from the universal joint assembly (K) . Pull the
front end of hanger bearing shaft (E) and key out from
the universal slip joint assembly (K) and remove from
the vehicle.

(1) Line up the front end of hanger bearing shaft (E) with
the universal slip joint assembly (D) , position the key
in the shaft with the keyway in the joint, and slide the
shaft and key into the joint. Line up the rear end of
hanger bearing shaft (E) with the universal joint assem-
bly position the key in the shaft with the keyway
in the joint, and slide the shaft and key into the joint.
(2) Position the hanger bearing assembly (U) on the fly-
wheel housing (F) . Place a y16-inch lockwasher over the
y16 x 11/2 bolt (G) and insert the bolt through the hole
in the hanger bearing and screw the bolt into the fly-
wheel housing. Place a 7/16-inch lockwasher over the 7/16
x 11/2bolt (J) , insert the bolt through the hanger bear-
ing brace (H) , and screw the bolt into the flywheel
housing.
(3) Tighten the setscrews (T and V) securing the universal
slip joint assembly (D) and the universal joint assembly
(K) to the hanger bearing shaft.

The speedometer, ammeter, oil

pressure gage, water temperature gage, fuel gage, two instrument
panel lights, and headlight high beam indicator light are mounted
in the instrument panel mounting plate located in the instrument
panel. This assembly is referred to as the instrument cluster. The
location and function of the various units in the instrument cluster
are described in paragraphs 25, 26, 29, 30, 31, 39, and 40.
 Figure 83. Instrument cluster-front view.

b. Switches. The location and function of the various switches,

except for the stop light switch, are described in paragraphs 32,
33, and 34. The stoplight switch is attached to the front of the
brake master cylinder, and is hydraulically operated by the action
of the brake pedal.
c. Sending Units.
(1) Water tempe+rature sending unit. The water temperature
sending unit is mounted on the right side of the cylinder
head. It electrically transmits the water temperature to
the water temperature gage through cable No. 33.
(2) Oil pressure sending unit. The oil pressure sending unit,
mounted on the lower left rear side of the cylinder block,
electrically transmits the engine oil pressure to the oil
pressure gage through cable No. 36.
(3) Fuel tank level sending unit. The fuel tank level sending
unit, mounted in the top section of the fuel tank, electri-
cally transmits the level of the fuel in the tank to the fuel
gage through cable No. 28.
d. Horn. The horn is of the vibrator-type, electrically operated,
and fully waterproofed. It is mounted underneath the hood and
attached to the left front fender by a mounting bracket. The horn
is connected to the horn button by the two cables No. 25.
e. Cable Numbers. Standard circuit or cable numbers are used
throughout. These cable numbers are stamped on small metal tags
attached near the ends of each cable. These numbers are shown in
the identification diagram (fig. 85).

AGO 221
173. Instrument Cluster
Note. The key letters noted in parentheses are in figure 84.
a. Disconnect the ground cable (par. 155~ (2) ) . Turn
each of the four instrument cluster mounting plate studs (fig. 83)
one-half turn counterclockwise and pull instrument cluster free
from instrument panel. Unscrew the nut securing the speedometer
flexible shaft assembly to the speedometer and pull shaft free
from speedometer. Disconnect cable No. 2’7, at connector (T) ,
from the instrument cluster circuit breaker-to-gages wiring har-
ness (AA). Disconnect cable No. 1’7 at connector (U) . Disconnect
cable No. 40 at double connector (R). Disconnect cable Nos. 8
and 9 from ammeter at terminals (H and L) . Disconnect cable
No. 33 from water temperature gage at terminal Disconnect
cable No. 36 from oil pressure gage at terminal Disconnect

E-

H-TERMINAL

K -NUT

Figure 84. Instrument cluster--rear view.

1016'7B
222
 /
Rv
I
cable No. 28 from fuel gage at terminal (A). Remove instrument
cluster from instrument panel.
Position instrument cluster at instrument panel
so that cables may be connected. Connect cable No. 36 to oil pres-
sure gage at terminal (W) , and cable No. 33 to water temperature
gage at terminal (&!I). Connect cable No. 28 to fuel gage at termi-
nal (A). Connect cable No. 8 to terminal (H) and cable No. 9 to
terminal (L) of ammeter. Connect cable No. 40 to double connector
Connect cable No. 17 to connector (U) . Connect cable No.
27 to connector (T) . Position speedometer flexible shaft assembly
in speedometer and tighten nut securing shaft to speedometer.
Install instrument cluster in instrument panel and secure in posi-
tion by turning the four instrument cluster mounting plate studs
(fig. 83) one-half turn clockwise. Connect the ground cable (par.
155d(4) ).

174.
Note. The key letters noted in parentheses are in figure 84.

Disconnect ground cable (par. 155~ (2) ) . Turn the

four instrument cluster mounting plate studs (fig. 85) one-half
turn counterclockwise and pull instrument cluster free from in-
strument panel. Disconnect cable Nos. 8 and 9 from terminals (H
and L) . Remove the two nuts and lockwashers (K) securing the
ammeter and ammeter mounting bracket (J) to the instrument
panel mounting plate (E) and remove ammeter and bracket.
Position ammeter on the instrument panel
mounting plate (E) and rotate ammeter until it engages the lo-
cating slot in the plate. Position ammeter mounting bracket (J)
over the ammeter and secure ammeter and bracket to plate with
two No. 8 lockwashers and nuts (K) . Connect cable No. 8 to
terminal (H) and cable No. 9 to terminal (L) . Position the instru-
ment cluster on the instrument panel and turn the four instrument
cluster mounting plate studs (fig. 83) one-half turn clockwise.
Connect ground cable (par. 155d (4) ) .

175.

The removal procedure for the fuel gage is the same

as the removal procedure for the ammeter (par. 1’74a) with the
exception of the mounting bracket and the cables. The fuel gage
is mounted on the fuel gage mounting bracket (B). Disconnect
cable Nos. 27 and 28 from fuel gage terminals (D and A).
The installation procedure for the fuel gage is
the same as installation procedure for the ammeter (par. 174b)

AGO
with the exception of mounting bracket and the cables. Connect
cable No. 28 to terminal (A) and cable No. 2’7 to terminal (D)
of the fuel gage mounting bracket.

176. WTEgr l$mperature Gage

.
a. The removal procedure for the water temperature
gage is the same as the removal procedure for the ammeter (par.
174a) with the exception of the mounting bracket and the cables.
Disconnect cable No. 27 from terminal (Q) and cable No. 33 from
terminal (M) on water temperature gage mounting bracket (N) .
The installation procedure for the water tem-
perature gage is the same as installation procedure for the am-
meter (par. 1’74b) with the exception of the mounting bracket
and the cables. Connect cable No. 33 to terminal (M) and cable
No.. 27 to terminal (Q) on water temperature gage mounting
bracket (N) .

177. Oil Pressure Gage

(fig. 34)
a. The removal procedure for the oil pressure gage
is the same as removal procedure for the ammeter (par. 174a)
except for the mounting bracket and the cables. Disconnect cable
No. 27 from terminal (Y) and cable No. 36 from terminal (W)
on oil pressure gage mounting bracket (V) .
Installation of the oil pressure gage is the same
as installation of the ammeter (par. 174b) with the exception of
the mounting bracket and the cables. Connect cable No. 36 to
terminal (W) and cable No. 27 to terminal (Y) on oil pressure
gage mounting bracket (V) .

178. Speedometer
Note. The key letters noted in parentheses are in figure 84.
Turn the four instrument cluster mounting plate
studs (fig. 33) one-half turn counterclockwise and pull the instru-
amentcluster free from instrument panel. Unscrew the nut secur-
ing the speedometer flexible shaft assembly to the speedometer
and pull shaft free from speedometer. Remove the nut (CC), lock-
washer, and plain washer securing the instrument cluster circuit
breaker-to-gages wiring harness (AA) to the wiring harness
mounting stud (BB) and detach harness from the stud. Remove
the plain washer, stud, and lockwasher from the speedometer
mounting stud. Remove the nut and lockwasher (G) from the re-
maining speedometer mounting stud and remove speedometer

AGO 10167B 225

mounting bracket (F) and speedometer from instrument panel
mounting plate
Position the speedometer in the instrument panel
mounting plate (E) and locate speedometer mounting bracket (F)
over speedometer mounting studs. Install a No. 8 lockwasher on
speedometer lower mounting stud, and install the wiring harness
mounting stud (BB) . Install the 0.322-inch ID, 0.582-inch OD
plain washer, instrument cluster circuit breaker-to-gages wiring
harness (AA), 0.203-inch ID, 0.50-inch OD plain washer, No. 8
lockwasher, and No. 8 nut (CC). Install a No. 8 lockwasher and
nut (G) on remaining speedometer mounting stud. Install the
speedometer flexible shaft assembly in speedometer and tighten
nut. Position instrument cluster on instrument panel and turn the
four instrument cluster mounting plate studs (fig. 81) one-half
turn clockwise. When replacing speedometer flexible shaft assem-
bly on vehicles with serial numbers below 44034 use shaft assem-
bly-7522480 which is 54% inches long. When replacing the shaft
assembly in vehicles with serial numbers 44031 use shaft as-
sembly-7389881 which is 56sh inches long.

179. Headlight High Beam Indicator light

Note. The key letters noted in parentheses are in figure 84.
Disconnect the ground cable (par. 155~ (2) ) . Turn
the four instrument cluster mounting plate studs (fig. 83) one-
half turn counterclockwise and pull instrument cluster free from
instrument panel. Disconnect cable No. 17 at connector Re-
move the two screws and lockwashers securing the headlight high
beam indicator light and cover to the instrument panel mounting
plate (E) and remove indicator light (S) .
Position the headlight high beam indicator light
on the instrument panel mounting plate (E) and secure in posi-
tion with two No. 8 x 1/2 screws and lockwashers. Connect cable
No. 17 to connector (T). Position instrument cluster on instru-
ment panel and turn the four instrument cluster mounting plate
studs (fig. Sl) one-half turn clockwise. Connect the ground cable
(par. 155d (4) ).
c. Disconnect the ground cable (par.
155~ (2) ) . Turn the four instrument cluster mounting plate
studs (fig. 83) one-half turn counterclockwise and pull instru-
ment cluster free from instrument panel. Turn the cover of the
headlight high beam indicator light (S) counterclockwise and
pull cover out of light body. Press in and turn lamp counterclock-
wise to disengage it from lamp socket. Install new lamp by press-
ing it into lamp socket and rotating clockwise. Position indicator

AGO 10167-B
light cover on light body, press in and turn cover clockwise to
engage with light body. Position instrument cluster on instru-
ment panel and turn the four instrument cluster mounting plate
studs (fig. 83) one-half turn clockwise. Connect the ground cable
(par. 155d(4) ).

180. Instrument Panel Lights

Note. The key letters noted in parentheses are in figure 84.
a. Disconnect the ground cable (par. 155~ (2) ) . Turn
the four instrument cluster mounting plate studs (fig. 83) one-half
turn counterclockwise, and pull instrument cluster free from in-
strument panel. The two instrument panel lights with cables are
permanently connected together in connector (R) and must be
replaced as one unit. Disconnect cable No. 40 at connector (R) .
Remove the four screws and lockwashers securing the instrument
panel lights to the instrument panel mounting plate (E) and re-
move lights (Z) and light shields (fig. 83).
Position the light shields in the instrument panel
mounting plate (E) . Position the two instrument panel lights on
the plate and secure each with two No. 8 x 5/16 screws and lock-
washers. Connect cable No. 40 to connector (R) . Position instru-
ment cluster on instrument panel and turn the four instrument
cluster mounting plate studs (fig. 83) one-half turn clockwise.
Connect the ground cable (par. 155d (4) ) .
c. Disconnect the ground cable (par.
155~ (2) ) . Turn the four instrument cluster mounting plate studs
(fig. 83) one-half turn counterclockwise and pull instrument
cluster free from instrument panel. Press in on the cover of the
instrument panel light (Z), turn counterclockwise and pull cover
out of light body. Press in and turn lamp counterclockwise to dis-
engage it from lamp socket and remove lamp. Install new lamp
by pressing lamp into socket and turning clockwise. Install in-
strument panel light cover by pressing in and turning clockwise
in lamp body. Position instrument cluster on instrument panel
and turn the four instrument cluster mounting plate studs (fig. 83)
one-half turn clockwise. Connect the ground cable (par.,155d (4) ).

181. Ignition Switch

a. Disconnect ground cable (par. 155c(2) ). Remove
the bolt and lockwasher securing the ignition switch lever to the
ignition switch (G, fig. 7) and remove lever. Remove the plain
nut and lockwasher securing the ignition switch to the instrument
panel and push switch out of instrument panel. Disconnect con-
nectors on cable Nos. 11,12, and 27 (fig. 80). Remove switch from
reverse face of instrument panel.
 Position switch and connect connectors on cable
Nos. l&12, and 2’7 (fig. 80). Cable No. 85 (fig. 80) is an auxiliary
cable and is not connected to any unit. Position ignition switch
in instrument panel and secure with a l/,-inch lockwasher and
plain nut. Position ignition switch lever on the ignition switch and
secure with a No. 8 lockwasher and No. 8 x l/z bolt. Connect ground
cable (par. 155d (4) ) .

182. light Switch

Disconnect ground cable (par. 155~ (2) ) . Remove
the four lockwasher bolts securing the light switch (E, fig. 7) to
the instrument panel. Pull switch out from instrument panel and
disconnect cable plug from the receptacle in the switch.
b. Connect cable plug to receptacle in light switch.
Install light switch through instrument panel and secure in posi-
tion with four No. 10 x l/ILlockwasher bolts. Connect ground cable
(par. 155d (4) ).

86. dimmer

183. Headlight Dimmer Switch

(fig. 86)
Disconnect ground cable (par. 155c(2) ). Discon-
nect connector on cable No. 1’7. Disconnect connectors on cable
Nos. 16 and 18. Remove the two lockwasher screws securing the
switch to the underside of floor pan and remove switch.
b. Position headlight dimmer switch in floor pan
and secure with two I/! x j,LLlockwasher screws. Connect cable

AGO 1016'7B
228
Nos. 16 and 18 to switch. Connect cable No. 1’7 to double con-
nector. Connect ground cable (par. 155d (4) ) .

184. Horn Button and Switch

(1) Pull the horn button cap off the steering wheel
nut. Pull the rod extending from the horn button to the
horn switch out of the steering gear.
(2) Slide the rod extending from the horn but-
ton to the horn switch into the steering gear. Snap the
horn button over the top of and into the groove in the
steering wheel nut.

(1) Disconnect the ground cable (par. 155c(2) ).

Disconnect the connectors on the two cables No. 25 (fig.
80). This disconnects the horn switch from the wiring
harness. Slide the two spring clips to the rear off the
horn switch harness and the left front fender splash
shield. Unscrew switch from bottom of steering gear
housing and remove switch, using care that the rod does
not slide out of the steering gear.
(2) If necessary, push the rod back into the
steering gear and screw horn switch into bottom of steer-
ing gear housing. Position the switch wiring harness
against the inside of the left front fender splash shield
and slide the two clips onto the harness and shield. Con-
nect the connectors in the two cables No. 25 (fig. 80).
Connect ground cable (par. 155d(4) ).

185. Horn
Disconnect the connectors in the two cables No. 25
(fig. 86). Remove the two cap screws and lockwashers securing
the horn to the horn bracket and remove horn.
Position the horn on the horn bracket and secure
with two l/b-inch lockwashers and l/a x s/s cap screws. Connect
the connectors in the two cables No. 25 (fig. 80).

186. Stoplight Switch

U-k. 80)
cc. Disconnect the connectors near the stoplight switch
in the two cables No. 75. Unscrew the stoplight switch from the
front of the brake master cylinder.
Screw the stoplight switch into the front of the
brake master cylinder. Connect the connectors in the two cables
No. 75. Bleed brake system (par. 246),

AGO 10167B
 (1) To replace old-type switch 7760414 with new-type switch
7388813, sever the electric cables from the old-type
switch as close as possible to the switch body and strip
these cable ends to permit the installation of two male
terminals 572929, the waterproof cable connector grom-
met 573005, the grommet adapting bushing 572999, and
the female Y connector waterproof shell 573008. Utiliz-
ing this modified portion of the old-type switch and two
electrical connector terminal sleeves 573000, connect the
new-type switch to the chassis harness.
(2) To replace new-type switch 7388813 with old-type switch
7760414, cut the male waterproof cable connector shell
573010 and the female waterproof cable connector shell
573007 off the old-type switch. Replace with the male
waterproof connector shell 573009, utilizing the termi-
nals, grommets, and bushings of the old-type switch. Con-
nect the chassis harness to the old-type stoplight switch.

187. Water Temperature Sending Unit

(fig. 87)
a. Disconnect cable No. 33 from the water temperature
sending unit. Unscrew sending unit from cylinder head.
b. Screw sending unit into cylinder head. Connect
cable No. 33 to the sending unit.

Figure s?‘.

188. Oil Pressure Sending Unit

(fig.
Disconnect cable No. 36 from oil pressure sending
unit. Remove the nut and bolt from the clip securing the fuel and

AGO 10167B
vacuum pump vent line to the oil pressure sending unit support.
Free vent line and clip from support. Remove the nut and lock-
washer from the bolt securing the support to the engine, and lift
support off sending unit. Unscrew sending unit from elbow.
b. Screw the oil pressure sending unit into the el-
bow. Position the oil pressure sending unit support around the
sending unit and over the mounting bolt and secure support to
engine with a s/s-inch lockwasher and nut. Position the clip secur-
ing fuel and vacuum pump vent line in the sending unit support
and secure in position with a 1h x a/4 bolt and $&-inch plain nut.
Connect cable No. 36 to the sending unit.

189. Fuel Tank level Sending Unit

(fig. 56)
Remove driver’s seat (par. 268). Disconnect cable
No. 28 from the sending unit. Remove the five bolts and sealing
washers securing the sending unit to fuel tank and remove send-
ing unit and gasket. Discard gasket.
b. Position a new sending unit gasket on the fuel
tank and aline the mounting holes in the gasket with those in the
fuel tank. Install the sending unit in the fuel tank and aline the
mounting holes in the unit. Secure the sending unit in position
with five copper sealing washers and No. 8 x 7/ls bolts. Connect
cable No. 28 to the sending unit. Install driver’s seat (par. 268).

Section XVI. RADIO INTERFERENCE SUPPRESSION

190. Purpose
a. Radio interference suppression is the elimination or mini-
mizing of electrical disturbances which interfere with radio re-
ception or disclose the location of the vehicle to sensitive electrical
detectors. It is important that all vehicles, with or without radio
equipment, be suppressed properly to prevent interference with
radio reception of neighboring vehicles.
b. Radio interference suppression is accomplished in this ve-
hicle by use of filters, capacitors, resistors, ground straps, and
metallic sheathing on any cable carrying currents that may cause
interference.

191. Description
Ignition system suppression is achieved by
an ignition filter assembly, spark plug resistors, and shielding the
spark plug cables.

231
 b. Generating System. Generating system suppression is accom-
plished by capacitors, a filter at the generator regulator, shielding
the generator regulator cables, and bond straps at the generator
regulator.

192.
a. The ignition filter assembly is a fully-sealed, waterproof unit.
In vehicles before serial No. 20601, it is located in the engine com-
partment, on the fire wall above the starter assembly. Beginning
with serial No. 20601, the filter is installed in the wiring harness
filter receptacle on the distributor body. The filter is connected in
the ignition primary circuit, to suppress any stray current origi-
nating in the circuit.
b. All spark plugs are equipped with solid type resistors.
c. The spark plug cables are shielded. The shielding is grounded
to the spark plug body at one end and the distributor cover, cap
assembly at the other end.

a. Generator Assembly. The generator assembly is a sealed,

waterproof, shielded unit with a built-in capacitor which may be
replaced, if necessary, by ordnance maintenance units.
b. Generator Regulator Assembly. The generator regulator as-
sembly is a sealed, waterproof, shielded unit, with built-in resis-
tors, one for each unit in the assembly. The cushioned regulator
assembly is grounded to the regulator base. All connecting cables
are shielded and grounded.

a. Fasteners. Cables in the primary and secondary ignition cir-

cuits, and generator assembly-to-generator regulator assembly
circuits are shielded. The shielding is grounded to the various units
by threaded connectors (fasteners). The units are also grounded
to the engine and/or vehicle frame by the mountings and mount-
ing bolts.
b. Ground Straps. Four ground straps (fig. 67) ground the gen-
erator regulator assembly to the mounting support, one strap for
each mounting bolt. The engine is grounded to the vehicle frame
by a ground strap at the right front of the engine. The entire elec-
trical system is grounded through the battery “B” negative ter-
minal and cable No. 7. See figure 80 and table IV.
-- ____--
AtiU 1”1B7D
232
 Section XVII. CLUTCH

195. Description and Data

a. Description. The clutch is located between the engine and
transmission and, on early production vehicles, inclosed in a stand-
ard automotive bell housing. Late production vehicles are equipped
with a pressurized-type bell housing to prevent entrance of water
when fording. The clutch is a single plate-type, composed (in
addition to the engine flywheel) of two major units, the clutch
pressure plate and driven disk assemblies. The clutch serves to
engage or disengage the engine and the power train. The pressure
plate assembly is adjusted when manufactured and requires no
other adjustment.
b. Data.
Pressure plate assembly:
Manufacturer _ ~__~___________________--__--_----_- __ -Auburn Mfg Co
Manufacturer’s No __-___-__-___--_-______--__-__ABF-80501-38
Ordnance No ~--__---__----~-__~~_____--________7372664
Type _~~ ~____________________----_~~~__~----~~_-. __~single dry plate
Size _~_~~~_____._____________-___--____-----_---_--~- 8% in.

Driven disk assembly :

Manufacturer ___~~______________~___..~___--~-~--~~ _ Borg and Beck
Manufacturer’s No --_---_-----___--__--_-----------_-BB-1196
Ordnance No .~~_~__-_~~_-____-~~__--~__-______--_-___737Z66l

196. Clutch linkage Adjustment

The clutch pedal must have at least lx-inch free travel (fig.
88). To adjust clutch pedal free travel, loosen jamnut (fig. 89)

_i-
AWJ 10167B 233
 Figure 89. Clutch pedal linkage adjustment.

on control lever tube cable. Unscrew cable until pedal has a 11/a-
inch free travel. When correct adjustment has been obtained,
tighten jamnut.

31, 32, and 90). The transfer assembly, an

added gear unit attached to the rear of the transmission, provides
either a direct drive, or an additional gear reduction for opera-
tion on unusual terrain. The transfer provides a means of en-
gaging or disengaging the front axle drive. On the rear of the
transfer assembly are mounted the hand brake assembly and, on
some vehicles, a power-take-off assembly. The power-take-off as-
sembly, when supplied, transmits power from the transfer to a
winch (par. 165). The single-speed power-take-off is engaged or
disengaged by the power-take-off gearshift control lever (fig. 12).
b.
Transfer assembly:
Manufacturer ~_~-_____-_---_---___-____-_____-Spicer Mfg Corp
Ratio :
High range ____~__________________-__-____ __l.OO:l
Low range ___-____--__--_---_-___-------_---2.43:1
Lubricant capacity __-___________________-------3 pt
Power-take-off:
Manufacturer ___-_~_-__-__________-...._--.~_.__Ramsey Winch Mfg Co

AGO 10167B
 Refer to paragraph 2 for coordination with an ordnance mainte-
nance unit.

Organizational maintenance of the transfer assembly consists

of lubrication (par. 66)) inspection for looseness or noise, and the
testing of the controls for proper operation (pars. 17 and 18).

Remove the power plant (par. 116).

b. Remove five lockwasher screws securing the transfer rear
cover and remove the cover. (If the vehicle is equipped with a
power-take-off instead of a transfer rear cover, loosen setscrew
(Q, fig. 82) securing universal joint assembly (M, fig. 82) to
power-take-off output shaft (N, fig. 82). Remove five lockwasher
screws securing power-take-off to the transfer assembly. Pull the
power-take-off straight back until the main drive gear is clear of
the transfer assembly and the output shaft is out of the universal
joint.) Discard gasket. Working through the hole in the rear of
the transfer assembly, remove the cotter pin, nut, plain washer,
and transfer input gear from the transmission main shaft. Re-
move five bolts and lockwashers securing the transfer assembly
to the transmission assembly and remove the transfer. Discard
gasket. Make certain that the transmission mainshaft bearing is
in place against the rear face of the transmission.

Position .a new gasket on the rear face of the transmission

assembly. Make certain that the transmission main shaft bearing
is in place. Position the transfer assembly against the rear of the
transmission. Install the 3/ x 1% bolt with lockwasher at the
bottom just over the rear motor mount. Install two vs x 1 bolts
and lockwashers on the left side and one on the right side at the
top through the transfer flange and into the transmission. Install
the s/s x 1 bolt and lockwasher on the right side at the bottom
through the flange of the transmission and into the transfer. Draw
the bolts up evenly.
b. Working through the opening at the rear of the transfer as-
sembly, place the transfer input gear onto the transmission main
shaft and install the plain washer, 7/,,-inch nut, and cotter pin
securing the gear to the main shaft. Place a new gasket around
the opening and position the transfer rear cover on the gasket.

AGO 10167B
235
 Figure go. Transmission and transfer installed on engine.

(If the vehicle is equipped with a power-take-off instead of a

transfer rear cover, aline the key in the power-take-off output
shaft (N, fig. 82) with the keyway in universal joint assembly
(M, fig. 82) and slide the shaft into the joint.) Install five 3/ x 1
lockwasher screws securing the cover on the power-take-off. If
power-take-off was installed, tighten setscrew (Q, fig. 82) secur-
ing the power-take-off output shaft to the universal joint.
c. Install the power plant (par. 119).

202. Power-Take-Off Assembly

Unscrew and remove the knob from the power-
take-off gearshift control lever (fig. 12). Remove the four screws

AGO 10167B
 (fig. 12) securing the grommet retaining plate (NN, fig. 7) to
the floor pan and remove the plate and the two grommets by lift-
ing straight up and off the lever. Remove the four screws from
the power-take-off shift lever plate and lift the plate with the
power-take-off gearshift lever out of the power-take-off. Loosen
setscrew (Q, fig. 82) securing universal joint assembly (M, fig.
80) to the power-take-off output shaft (N, fig. 82). Remove five
bolts and lockwashers securing the power-take-off assembly to
the transfer assembly. Pull the power-take-off straight back until
the main drive gear is clear of the transfer assembly and the
power-take-off output shaft is out of universal joint assembly.
Lower the power-take-off to the floor and remove from under the
vehicle. Discard the power-take-off housing cover gasket and the
gasket between the power-take-off housing and the transfer.
Place a new gasket between the power-take-off
and the transfer and position the power-take-off at the rear of
the transfer. Aline the key in the power-take-off output shaft (N,
fig. 82) with the keyway in the universal joint assembly (M, fig.
82). Push the shaft into the universal joint and position the power-
take-off on the transfer. Place i7/8-inch lockwashers over ah x 1
bolts and push the bolts through the case of the power-take-off
and screw into the transfer. Tighten the setscrew (Q, fig. 82)
securing the universal joint assembly (M, fig. 82) to the power-
take-off output shaft (N, fig. 82). Install the power-take-off gear-
shift control lever (HH, fig. ‘7)) with the shift lever plate, in the
power-take-off and install four No. 10 screws in the plate. Slide
the grommet (LL, fig. 7), the grommet (MM, fig. 7)) and the
grommet retaining plate (NN, fig. 7) over the gearshift lever in
the above order and screw the four No. 10 x $/s screws through
the plate and into the floor pan. Screw the knob onto the gear-
shift control lever. Start the engine and test the power-take-off
assembly for proper shifting or noise.

Section XIX. TRANSMISSION ASSEMBLY

203. Description and Data

and 90). The transmission assembly
is three-speed, selective sliding gear-type, with synchromesh sec-
ond and third speed gears. The gears are shifted (see shifting
instructions plate on dash) by a cane-type ball and socket shifting
lever, located to the right of the driver. The transmission is sealed
for underwater operation.

AGO 10167B
 Data.
Manufacturer -__-___________-_____.--Borg-Warner Corp, Warner Gear Div
Type ________________________-_-___synchromesh
Speeds .___________________---~-~-- -three forward, one reverse
Ratios :
Low ______-_-______________-_--__2.798:1
Intermediate --___________________1.55l:l
High _____________________---_----l.OOO:l
Reverse ______~___________________3.798:1
Lubricant capacity ______--__________2 pt

204. Coordination With Ordnance Maintenance Unit

Refer to paragraph 2 for coordination with an ordance mainte-
nance unit.

205. Organizational Maintenance

Organizational maintenance of the transmission assembly con-
sists of lubrication (par. 66), inspection for looseness or noise,
and proper operation of the controls (par. 19).

206. Removal
a. Remove the power plant (par. 116).
b. Remove the transfer assembly (par. 200b).
c. Remove the two bolts and lockwashers securing the clutch
linkage inspection cover (fig. 31) and remove the cover. Reach
through the inspection hole and disconnect the clutch release
bearing carrier spring from the carrier and the bracket on the
clutch housing and remove the spring. Remove four bolts and
lockwashers (fig. 90) securing the transmission assembly to the
clutch housing and remove the transmission by sliding straight
back until the input shaft is clear of the housing.

207. Installation
a. Insert the transmission input shaft into the clutch housing,
through the clutch release bearing and clutch disk, and into the
clutch pilot bearing. Install four 7/ls x 11/a bolts and lockwashers
(fig. 90) securing the transmission to the clutch housing. Work-
ing through the inspection hole in the top of the housing, install
the clutch release bearing carrier spring by hooking one end to
the bracket on the housing and the other end in the hole in the
carrier. Place the clutch linkage inspection cover (fig. 31) over
the inspection hole and secure with two ‘/a x 1h bolts and lock-
washers.
b. Install the transfer assembly (par. 201).
c. Install the power plant (par. 119).
2 nnnirr.

AGO 10167B
238
 Major Unit Assembly Replacement Record and Organizational
Equipment File.

Section XX. PROPELLER SHAFTS WITH UNIVERSAL JOINT

ASSEMBLIES

208. ,Description and Data

a. Description.The front propeller shaft with universal joint
assemblies (fig. 91) transmits power from the transfer to the
front axle. The rear propeller shaft with universal joint assem-
blies (fig. 92) transmits power from the transfer to the rear
axle. Each assembly includes a propeller shaft, a universal joint
sleeve assembly, and two universal joint assemblies. Correspond-
ing parts of both the front and rear assemblies are the same
except for the length of the shaft and the front universal joint
assembly of the rear propeller shaft. This universal joint assem-
bly includes the propeller shaft flange yoke, and is modified ac-
cordingly. The four universal joint assemblies are roller bearing-
types.
b. Data.
Manufacturer ~~_____--______~-_--_______-______--_-___Spicer Mfg Carp
Type of shaft _______-~________~_______---_-__________tube, welded seam
Type of joints ~_~~~~~____~______~_~~~~....~___________roller bearing

209. Propeller Shafts With Universal Joint Assemblies

a. Remove Front Propeller Shaft with Universal Joint As-
semblies (fig. 91).
(1) Remove the four nuts from the two U-bolts holding the
universal joint assembly to the transfer front axle out-
put shaft yoke. Remove the two U-bolts and separate the
joint from the yoke.

91. universal

AGO
 (2) Remove the four nuts from the two U-bolts holding the
universal joint assembly to the front axle end yoke. Re-
move the two U-bolts and remove the front propeller
shaft with universal joint assemblies from the vehicle,
b.

(1) Remove the four nuts from the two U-bolts holding the
universal joint to the rear axle end yoke. Remove the two
U-bolts and separate the joint from the yoke,

Figure 92. Rear propeller shaft with universal joint assemblies-installed.

Remove the four nuts and lockwashers holding the

(2)
propeller shaft flange yoke to the rear companion flange
and remove the rear propeller shaft with universal joint
assemblies from the vehicle.
G. l&all
91).
(1) Position the universal joint assembly, on the end of the
front propeller shaft, on the front axle end yoke. Install
the two U-bolts over the ends of the universal joint and
through the holes in the yoke, and secure in place with
four 5/16-inch nuts.
(2) Position the universal joint assembly, on the end of the
universal joint sleeve yoke assembly, on the transfer
front axle output shaft yoke. Install the two U-bolts
over the ends of the universal joint and through the
holes in the yoke, and secure in place with four y16-inch
nuts.

240 AGO 1016'7B

 (1) Position the propeller shaft flange yoke on the bolts
projecting from the rear companion flange and secure
in place with four lockwashers and nuts.
(2) Position the universal joint assembly, on the end of
the propeller shaft, on the rear axle end yoke. Install the
two U-bolts over the ends of the universal joint and
through the holes in the yoke, and secure in place with
four x6-inch nuts.

2 10. Universal Joint Assemblies

(fig. 93)
Note. The operations for removing and installing the universal joint as-
semblies from the front end of the front propeller shaft, the rear end of the
rear propeller shaft, and the universal joint sleeve yoke assembly of the front
shaft are exactly the same and will therefore be referred to figure 91 which
shows the rear propeller shaft.

(1) Remove rear propeller shaft with universal joint assem-

blies from vehicle (par.
Remove the two journal bearing snap rings (A) from
the propeller shaft flange yoke (Y) by squeezing the
open ends together with a pair of pliers. Place a brass
drift against the end of one of the bearings (B) and
drive it into the propeller shaft flange yoke (Y) until
the bearing on the other end of the journal (F) is driven
out of the yoke. Pull the bearing (B), journal bearing
oil seal (C) , and journal bearing oil seal retainer (D)
from the journal, being careful not to lose the rollers.
Using the brass drift against the end of the journal from
which the bearing has just been removed, drive the
journal back until the second bearing (B) has been
driven* out of the yoke. Pull the second bearing (B),
journal bearing oil seal (C), and journal bearing oil
seal retainer (D) from the journal, being careful not
to lose the rollers. Slide the yoke to one side of the journal
and work the journal out of the yoke.
(3) Remove the two journal bearing snap rings (A), bear-
ings (B), journal bearing oil seals (C), and journal
bearing oil seal retainers (D) , holding the journal (F)
to the universal joint sleeve yoke (G), following the
procedures given in (2) above.
 view.
s
s
“m
 b. Remove Universal Joint Assembly From Rear PropelleT Shaft.
(1) Remove rear propeller shaft with universal joint assem-
blies from the vehicle (par. 209b).
(2) Remove the two journal bearing snap rings (M) from
the propeller shaft (L) by squeezing the open ends to-
gether with a pair of pliers. Place a brass drift against
the end of one of the bearings (N) and drive it into the
propeller shaft yoke until the bearing on the other end
of the journal (S) is driven out of the propeller shaft.
Pull the latter bearing (N), journal bearing oil seal
(P), and journal bearing oil seal retainer (Q) from the
journal being careful not to lose the rollers. Using
the brass drift against the end of the journal from which
the bearing has just been removed, drive the journal
back until the second bearing (N) has been driven out
of the propeller shaft yoke. Pull the second bearing (N) ,
journal bearing oil seal (P), and journal bearing oil
seal retainer (Q) from the journal, being careful not
to lose the rollers. Slide the yoke to one side of the journal
and work the journal out of the yoke.
c. Remove Universal Joint Assembly From Front Unive+rsal
Joint Sleeve Yoke Assembly.
(1) Remove front propeller shaft with universal joint as-
semblies from the vehicle (par. 209a).
(2) Remove the universal joint assembly (fig. 91) from the
front universal joint sleeve yoke assembly following
the procedure given in b (2) above.
d. Remove Universal Joint Assembly From Front Propeller
Shaft.
(1) Remove front propeller shaft with universal joint as-
semblies from the vehicle (par. 209a).
(2) Remove universal joint assembly (fig. 91) from the
front propeller shaft following the procedures given in
b (2) above.
e. Install Universal Joint Assembly in Front Propeller Shaft.
Push a journal bearing oil seal retainer (Q) onto each of the two
trunnions of the journal (S) , convex side first. Push a journal
bearing oil seal (P) onto each trunnion of the journal and into
the concave side of the retainer. Insert the journal (S) into the
propeller shaft (L) so that the trunnions will be inside the holes
in the yoked end of the shaft, and the universal joint tie bar (T)
will face away from the shaft. Apply grease to the rollers in the
two bearings (N) so that the rollers will not fall out. Carefully
_L.._L
sLa1 b LL,^
Lne c--.,.
LW” L,..-...:W..-.-
uealIl,g;o IhT\
\L1, onl,v4, +h,,
c11.Z+r,~~n:,-.~o n-.=4 I1Ib”
bI UIIII1”IIUC&IIU :nCr\ +hn
LZllG II”IGiY

AGO 10167B 243

in the yoked end of the propeller shaft (L).Using a brass drift,
carefully tap the bearings in until their outer ends are just inside
the snap ring grooves in the holes. Install the two journal bear-
ing snap rings to hold the bearings in place by squeezing the
ends together with a pair of pliers.

Install the universal joint assembly (fig.

91) in the front universal joint sleeve yoke assembly following
the procedures given in e above.
g.
Install the universal joint assembly in the propeller shaft (L)
following the procedures given in e above.

(1) Install the universal joint assembly in the universal

joint sleeve yoke (G) following the procedures given in
e above.
(2) Install the propeller shaft flange yoke (Y) on the two
remaining bearings (B) of the universal joint assembly
installed in (1) above. Follow procedures given in e
above.

211. Universal Joint Sleeve Yoke Assemblies

(fig. 93)
The universal joint sleeve yoke assemblies (figs. 91
and 92) used on the front and rear propeller shafts are practically
identical and removal and installation procedures will be refer-
enced to the rear sleeve yoke illustrated in figure 91.

(1) Disconnect the universal joint from the transfer front

axIe output shaft yoke (fig. 89) (par. 209a (1) ), and
lower the rear end of the shaft assembly to the ground.
(2) Unscrew the universal joint sleeve yoke dust cap (K)
from the universal joint sleeve yoke and slide the yoke
off the splined shaft. Remove the universal joint sleeve
yoke dust cap (cork) packing washer (H) and the uni-
versal joint sleeve yoke dust cap split washer (J)
from the universal joint sleeve yoke dust cap (K).
Work the two washers and cap off the shaft over the
splines.
(3) If necessary, remove the universal joint assembly from
the universal joint sleeve yoke (G) following the pro-
cedures given in paragraph 210~ (2).

AGO 10167B
 Remove the four nuts and lockwashers holding the pro-
peller shaft flange yoke to the rear companion flange and
lower the rear end of the shaft assembly to the ground.
(2) Unscrew the universal joint sleeve yoke dust cap (K)
from the universal joint sleeve yoke (G) and slide the
yoke with universal joint assembly and flange yoke off
the splined shaft. Remove the universal joint sleeve yoke
dust cap (cork) packing washer (H) and the universal
joint sleeve yoke dust cap split washer (J) from
the universal joint sleeve yoke dust cap (K) . Work the
two washers and cap off the splines.
(3) If necessary, remove the universal joint assembly with
propeller shaft flange yoke (Y) following the procedures
given in paragraph (3).

If rear universal joint assembly and propeller shaft

flange yoke (Y) were removed, assemble them with the
universal joint sleeve yoke (G) following procedures
given in paragraph 210h (1).
(2) Slide universal joint sleeve yoke dust cap over splines
on end of propeller shaft (L) convex side first. Slide
universal joint sleeve yoke dust cap split washer (J)
over splines and install in dust cap (K).Slide universal
joint sleeve yoke dust cap (cork) packing washer (H)
over splines and install in dust cap. Slide the universal
joint sleeve yoke (G) onto the splined end of the pro-
peller shaft in such a position that the yoke is parallel
with the yoke on the propeller shaft (L). Screw the
universal joint sleeve yoke dust cap (K) , with the two
washers inclosed, onto the end of the yoke.
(3) Lift the front end of the shaft, position the propeller
shaft flange yoke (Y) on four bolts protruding from the
rear companion flange, and install four lockwashers
and nuts holding the yoke to the flange.
e.
(1) If the universal joint assembly was removed from the
front universal joint sleeve yoke, install by following
procedures given in paragraph 210f.
(2) Install front universal joint sleeve yoke assembly on
front propeller shaft following procedures given in (2)
above.
(3) Lift the rear end of the shaft, position the universal
joint assembly on the transfer front axle output shaft

245
 yoke (fig. 91), put the two U-bolts over the bearings and
through the holes in the shaft yoke, and install the four
5/I,6-inchnuts.

Section XXI. REAR AXLE

212. Description and Data

a. The rear axle is of the semifloating-type and
transmits power from the propeller shaft to the rear wheels. The
axle with suspension supports the rear-end load on the wheels.
The axle consists of a housing which extends the width of the
vehicle tread and contains two rear axle shafts, one for each wheel,
a set of drive gears, a differential gear train, and brake mech-
anisms. The differential housing is offset to the right to permit
a straight line of drive from the transfer to the differential.

Manufacturer -__-___-___-_____-___-_____--_--_--_---_-Spicer Mfg Corp

Model __-___-_____________-_----------___-----_----.---~~-Z
Drive gear ratio ______________________--------_--_-_---5.38:l
Drive ____________________--_--_---______-_-_-_---~--_Hotchkiss
Type ___~_~________________-_-____-__-_-~-___----__...- semifloating
Differential type __~___~_______~_____~__~..~ .______-_-_-two pinion

213. Coordination With Ordnance Maintenance Unit

Refer to paragraph 2 for information regarding coordination
with an ordnance maintenance unit.

2 14. Organizational Maintenance

The using organization is responsible for the correction of
lubricant leakage, provided complete disassembly of the rear
axle is not necessary. Keep the mounting bolts tight and replace
any damaged axle shafts, wheel hubs, or brake drums. Lubricate
differential and wheel bearings as prescribed on lubrication order
(par. 66). Report any unusual noise to ordnance maintenance unit.

215. Rear Axle Shafts

(1) The removal procedure is the same for the left or right
rear axle shafts.
(2) Place a jack under the rear axle and raise the vehicle
until the wheels are clear of the ground. Place safety
stands under both ends of the axle outside the spring
U-bolts or block axle with solid blocking.
Remove wheel (par. 256).
Pry off hub cap, and remove cotter pin, axle shaft nut,
and axle shaft washer (fig. 94).
Ai33 iOiG?B
 axle removed.

(5)Install a wheel puller on three hub studs of the hub

and drum assembly (fig. 94) and remove hub and drum
assembly and the key.
(6) Remove the six plain nuts, lockwashers (fig. 95)) and
bolts securing the brake grease protector, brake grease

Rear axle

AGO 10167B
247
 protector gaskets, and axle shaft grease retainer assem-
bly to the service brake backing plate and remove the
grease protector, gaskets, and grease retainer assembly.
(7) Unscrew the nut securing the brake line (fig. 95) to
service brake backing plate and pull line free. Pull the
backing plate with attached brake parts off the axle.
(8) Remove the bearing retainer and bearing shims from
the axle housing flange (fig. 96).

Figure 96. Rear axle shaft, bearing shims, and bearing retainer.

(9) Withdraw the axle shaft and bearing cup and cone from
the axle housing. Pry the inner oil seal out of its seat
in the housing.
(10) Pull the bearing cup off the bearing cone and pull the
cone off the axle shaft.
Clean bearing cones with dry-cleaning
solvent or volatile mineral spirits. Pack bearing cones (par. 67).
c.
(1) Position a new inner oil seal, with the lip facing inward,
in the axle housing and carefully tap into place as shown
in figure 98. Be sure that the seal is seated on the flange
in the housing.

AGO 10167B
 Figure 97. Removing rear uxle shaft with bearing cup and cone.

Figure 98. Installing inner oil seal in axle housing.

(2) Insert the axle shaft into the axle housing and rotate
shaft until the spline enters the differential side gear.
(3) Position the bearing cone on the axle shaft with the
small end of the bearing taper facing out. Position the
bearing cup over the cone and tap the cup and cone on
the axle shaft until the cone seats.

AGO 10167B 249

 Position the bearing shims and bearing retainer over
the axle shaft, alining the drain holes in the retainer
and shims with the drain hole in the axle housing flange
(fig. 96). Insert two of the six 3/8 x 1% bolts through
the axle housing flange from the inner side and through
the shims and retainer to maintain the alinement.
Position the service brake backing plate and attached
brake parts on the axle housing flange and aline the
drain hole with the drain hole (fig. 95) in the flange.
Position one brake grease protector gasket, axle shaft
grease retainer assembly, second brake grease protector
gasket, and the brake grease protector (fig. 95) the
two 3/ x ll/a bolts protruding through the backing plate,
alining the drain holes in the gaskets and protector and
the drain passage in the retainer with the drain hole in
the backing plate.
Install the four remaining s/8 x ll$& bolts through the
axle housing flange, and install six s/s-inch lockwashers
and s/-inch plain nuts (fig. 95).
Position the hub and drum assembly (fig. 94) on the
axle shaft and aline the keyway in the hub with the
keyway in the axle shaft. Insert the key into the key-
ways and tap key and hub and drum assembly into po-
sition on the axle shaft.
Install the axle shaft washer and axle shaft nut (fig.
94) on the axle shaft. Tighten the nut and secure in
position with a 1/ x 11/2 cotter pin. Position the hub cap
(fig. 94) over the axle shaft and tap cap into position
on the hub.
Position the brake line (fig. 95) in its opening in the
service brake backing plate and tighten the nut securing
the line to the plate.
Install the wheel (par. 256).
Remove the safety stands or blocking and lower the
wheels to the ground.
Bleed the brake system (par. 246).

216. Rear Axle Shaft Bearings

Place a jack under the axle and raise vehicle
until wheels are clear of ground. Test axle shaft end play by
grasping wheel and moving in and out. If the bearings are cor-
rectly adjusted, end play will be just perceptible. If end play is
not correct proceed as shown in (1) through (13) below.

AGO 10167B
250
 (1) Unscrew the five nuts and remove the wheel.
(2) Pry off the hub cap (fig. 94).
(3) Remove the cotter pin from the axle shaft nut, unscrew
the nut, and remove the axle shaft washer (fig. 94).
(4) Install a puller on three of the hub studs and pull the
hub and drum assembly from the axle. Remove the key.
(5) Unscrew the nut on the end of the brake line from the
wheel cylinder. Remove six nuts and lockwashers from
the bolts and remove brake grease protector, brake
grease protector gasket, axle shaft grease retainer as-
sembly, brake grease protector gasket, and service brake
backing plate (fig. 95).
(6) Pull the bearing retainer (fig. 96) off the bolts and re-
move or install shims to adjust the axle bearing to pro-
vide 0.003- to 0.007-inch end play of the axle shaft.
(7) Install the bearing retainer (fig. 96) over the shims
making sure the drain hole is at the bottom.
(8) Install the service brake backing plate, brake grease
protector gasket, axle shaft grease retainer assembly,
brake grease protector gasket, and brake grease pro-
tector (fig. 95) in the order named and with drain holes
at the bottom and install the six lockwashers and nuts
on the bolts.
(9) Install the key in the axle shaft, and put the hub and
drum assembly onto the shaft. Install the axle shaft
washer, screw on the axle shaft nut, and install the
cotter pin (fig. 94).
(10) Push the hub cap into place.
(11) Position the wheel on the hub studs and secure with
five nuts.
(12) Position the brake line in the wheel cylinder and tighten
the nut.
(13) Bleed the brake system (par. 246).
b. Remove the bearings (par. 215~~). Clean and pack
bearings (par. 215b).
c. Install the bearings (par. 215~).

217. Inner Oil Seals

a. Remove inner oil seal (par. 215a( 1) through (9) ).
b. Install inner oil seal (par. 215~).

218. Rear Hubs

a. Place a jack under axle and raise vehicle until
tire is off the ground. Place safety stand under axle at outside

AGO 10167B
spring U-bolts or block axle with solid blocking. Remove the
wheel (par. 256). Pry off the hub cap and remove the cotter pin,
axle shaft nut, and axle shaft washer (fig. 94). Install a wheel
puller on three hub studs and remove the hub and drum assembly.
Remove the key. Remove the three bolts (fig. 94) securing the
brake drum to the hub and pull the drum off the hub. If it is
necessary to replace any hub studs (fig. 94), drive them out of
the hub.
b. Installation. If any hub studs have been removed, drive new
studs into hub.
Note. Use studs with left-hand threads in hubs on left side of vehicle,
studs with right-hand threads on right side of vehicle.
Position the brake drum on the hub, alining the mounting holes
in the drum with those in the hub. Secure the drum to the hub
with three l/b x s/s flat-head bolts (fig. 94). Position the hub and
drum assembly on the axle shaft, alining the keyway in the hub
with the keyway in the axle shaft. Insert the key into the key-
ways and tap the hub and drum assembly and key into position.
Install the axle shaft washer and axle shaft nut. Tighten nut and
secure in position with a l/a x 11/s cotter pin (fig. 94). Position
hub cap (fig. 94) over axle shaft and tap onto hub. Install the
wheel (par. 256). Remove safety stands or blocking and lower
vehicle to ground.

219. Rear Brake Drums

a. Removal. Remove wheel (par. 256). Pry off the hub cap and
remove the cotter pin, axle shaft nut, and axle shaft washer (fig.
94). Remove the three bolts (fig. 94) securing the brake drum
to the hub and pull the drum off the hub.
b. Installation. Position the brake drum on the hub, alining the
mounting holes in the drum with those in the hub. Secure the
drum to the hub with three r,!$ x s/s flat-head bolts (fig. 94).
Position the axle shaft washer on the axle shaft, install the axle
shaft nut and secure nut in position with a l/s x 11/s cotter pin
(fig. 94). Position the hub cap (fig. 94) over the axle shaft and
tap cap onto hub. Install wheel (par. 256). Lower vehicle to
ground and remove jack.

220. Rear Axle Assembly

a. Removal.
(1) Place a jack under the rear axle and lift the vehicle.
Install suitable blocking under frame side rails in front
of the rear springs. Leave the jack in position to support
the axle during removal.

252 AGO 10167B

 (2) Remove both rear whe.els (par. 256).
(3) Unscrew the nut that secures the flexible line (W, fig.
117) to the rear axle tee. Remove the clip that secures
the end of the flexible line to the bracket on the frame
cross member.
(4) Disconnect the universal joint from the rear axle (par.
209b).
(5) Loosen the four U-bolt nuts on the two U-bolts securing
the U-bolt plate to the axle housing. Remove nuts, lock-
washers, and U-bolts. Swing the lower end of the shock
absorber, with U-bolt plate, toward the front of the ve-
hicle. Repeat procedure on other side of vehicle.
(6) Remove spring shackles from both spring assemblies
(par. 250)) and lower ends of springs to the ground.
(7) Remove axle from rear of vehicle.
(8) If required, remove all brake lines, connections, and
fittings from the axle assembly (par. 245).
b. Installation. Any parts not supplied with the new axle should
be removed from old axle.
(1) If necessary, install all brake lines, connections, and
fittings on the axle assembly (par. 245).
(2) Position the axle assembly between the rear springs
and frame.
(3) Raise the ends of the springs, making certain that each
spring center bolt enters the recess in the spring saddle.
Install spring shackles (par. 250).
(4) Swing the lower end of one shock absorber, with U-bolt
plate, toward the rear and under the axle. Install two
U-bolts over housing and through plate and secure with
four xc-inch lockwashers and se-inch U-bolt nuts. Re-
peat on other side of vehicle.
(5) Connect the universal joint at the rear axle (par. 209d).
(6) Insert the end of the flexible line (W, fig. 117) through
the bracket on the frame cross member. Push the spring
clip into the groove on the end of the flexible line. In-
sert the end of the flexible line into the rear axle tee
and tighten the nut.
(7) Install the wheels (par. 256).
(8) Remove blocking and lower vehicle.
(9) Bleed and refill the brake system (par. 246).
(10) Make a record of replacement on DA Form 478.

AGO 10167B
253
 Section XXII. FRONT AXLE

221. Description and Data

a. The front axle is a full-floating, Hotchkiss drive-
type, with single-reduction hypoid gears transmitting the power
from the transfer through constant velocity universal joints to
the front wheels. The front axle differential housing is offset to
the right to permit a straight line of drive from the transfer to
the differential.

Manufacturer ______________________--__--__----_-___--Spicer Mfg Corp

Model __.-_________________--______--____--____------~-25
Drive gear ratio ____________________--------__--___ .__5.38:1
Drive type ___~~__________________-__------_---_------Hotchkiss
Axle type ~___~__________~_______---------------~-~----full-floating
Differential type ________________________--------------2 pinion
Differential drive gear-type ________________________hypoid
Turning angle ______________________--_____-_-------_-22% to 25 deg
Lubricant capacity ~~~~____~~~_____~_~___~~___~__~~~__11/4 qt

222. Coordination With Ordnance Maintenance Unit

Refer to paragraph 2 for information on coordination with an
ordnance maintenance unit.

223. Organizational Maintenance

The using organization is responsible for the maintenance
and/or replacement of filler or drain plugs, steering knuckle flange
oil seals, vent valves, axle shaft assemblies, correct lubrication
at proper intervals (par. 66), and tightening of mounting bolts.
Any unusual noise should be reported to the ordnance mainte-
nance unit.

224. Front Axle Shafts

(1) The removal procedures contained in this paragraph

apply to either left or right axle shaft assemblies.
(2) Place the front wheels in the straight ahead position.
(3) Place a jack under the front axle and raise the vehicle
until the tires clear the ground. Place safety stands or
suitable blocking under the axle to support the weight of
the vehicle.
(4) Pry off the hub cap and remove the six screws and lock-
washers securing the shaft drive flange to the hub
(fig. 99).

254 AGO 10167'B

Figure 99. Front axle assembly-partially exploded view.
(5) Install a suitable puller over the lip of the shaft drive
flange and pull the flange off the axle shaft assembly.
Separate the shaft drive flange gasket from the shaft
drive flange (fig. 99).
(6) Remove the wheel (par. 228).
(7) Remove the brake drum (par. 228).
(8) Straighten the lip of the hub bearing nut lockwasher
(fig. 99) to clear the hub bearing jamnut (fig. 99).
Position wheel bearing nut wrench 41-W-3825-200 (fig.
100) on the jamnut and unscrew the nut from the spindle
assembly (fig. 99). Slide the bearing nut lockwasher
(fig. 99) off the spindle assembly.

Figure 100. Removing front hub bearing jamnut.

(9) Position the wheel bearing nut wrench 4I-W-3825-200

(fig. 100) on the hub bearing adjusting nut and unscrew
the nut from the spindle assembly. Slide the hub bearing
washer off the spindle assembly (fig. 99).

AGO 10167B
(10) Pull the hub from the spindle assembly. Lift the hub
outer bearing cone out of the hub (fig. 99). The hub
outer bearing cup will remain in the hub.
Note. It is not necessary to remove the hub inner bearing or
hub bearing oil seal to replace the axle shaft assembly.
(11) Unscrew the nut of the front wheel cylinder line (fig.
101) from the wheel cylinder assembly.
(12) Remove the six bolts and lockwashers securing the brake
assembly and spindle assembly to the steering knuckle
flange with arm assembly (fig. 101) and pull the brake
off the spindle.
(13) Pull spindle (fig. 101) from steering knuckle.
(14) Pull the shaft with universal joint assembly out of the
axle housing.

(1) Insert the shaft with universal joint assembly through

the steering knuckle flange with arm assembly (fig. 101)
and into the axle housing. Rotate the shaft until the
splines on the shaft enter the differential side gear.
With a soft mallet, tap axle shaft into axle housing
until it seats.
(2) Position the spindle assembly (fig. 101) on the shaft,
aline the spindle mounting holes with the mounting
holes in the steering knuckle flange and tap the spindle
into position against the flange.
(3) Position the brake assembly on the shaft, aline the
mounting holes in the brake with the mounting holes in
the spindle and press brake against the spindle. Secure
the brake and spindle to the steering knuckle flange with
six s/s-inch lockwashers and 3/s x 33h bolts (fig. 101).
(4) Position the hub (fig. 99) on the spindle. Insert the
hub outer bearing cone (fig. 99) into the hub, with the
small end of the bearing taper facing toward the vehicle.
Slide the hub and bearing on the spindle until hub ‘seats
against the spindle shoulder. Work the hub up and down
on spindle and, at the same time, press bearing cone
into position in hub.
(5) Position the brake drum on the hub with the bolt holes
in the drum and hub alined. Install the three l/b x 5/s
bolts (fig. 99).
(6) Position hub bearing washer on the spindle shaft, alin-
ing the tang on the washer with the slot in the shaft,
and slide washer onto shaft. Screw hub bearing adjusting
nut (fig. 99) onto the spindle shaft fingertight.
brake
 (7) Position the hub bearing nut wrench 41-W-3825-200
(fig. 98) over the hub bearing adjusting nut and tighten
nut. Rotate wheel in alternate directions while taking
up on adjusting nut until a bind is noted in wheel rota-
tion. Back off adjusting nut % to $!%turn or sufficiently
to allow free rotation. Lock adjustment in this position.
Caution: Insure that brakes are completely released
and that-shoes are not rubbing on brake drum.
(8) Position the hub bearing nut lockwasher on the spindle
shaft, alining the tang on the washer with the slot in
the shaft, and slide washer onto shaft. Screw hub bear-
ing jamnut (fig. 97) on the spindle shaft and tighten
with wheel bearing nut wrench 41-W-3825-200 (fig.
100). Bend lip of lockwasher over wheel bearing housing
adjusting and jamnuts.
(9) Apply a little grease to the gasket surface of the shaft
drive flange. Position a new shaft drive flange gasket
(fig. 99) on the drive flange, alining the mounting holes
in the gasket with the mounting holes in the flange.
(10) Position the shaft drive flange and gasket on the shaft
assembly, alining the splines in the flange with the
splines in the shaft. With a soft mallet, tap flange and
gasket part way onto the shaft. Rotate the hub and drum
until the mounting holes in the drive flange aline with
the mounting holes in the hub. Tap drive flange com-
pletely onto shaft and secure to hub with six ah-inch
lockwashers and s/8 x 2l/r2screws (fig. 99).
(11) Screw the nut of the front wheel cylinder line (fig. 101)
into the wheel cylinder assembly.
(12) Position the hub cap over the shaft drive flange and tap
into position.
(13) Install wheel (par. 228).
(14) Remove the safety stands or blocking and lower vehicle
to ground.
(15) Bleed brakes (par. 246).

225. Front Hub Bea.rings

a. Adjust front hub bearings by following direc-
tions given in paragraphs 224a and b.

Perform the operations outlined in paragraph

(2) Lift the hub outer bearing cone (fig. 99) out of the hub.
(3) Remove the hub inner bearing cone and drive the hub
bearing oil seal (fig. 99) out of the hub.

AGO 10167B 259

 Position remover and replacer 41-R-2374-845 and screw
41-S-1047-330 (fig. 102) in the hub and drive out hub
inner bearing cup. Reverse the hub, position remover and
replacer 41-R-2374-845 and screw 41-S-1047-330 in
hub and drive out hub outer bearing cup.

Figure 10%. Removing front hub bearing cup with remower and replacer
41-R-2374-845 and screw 41-s-1047-330.

c. Cleaning and Packing. Clean all lubricant from front hub

inner and outer bearing cups and cones with dry-cleaning solvent
or volatile mineral spirits. Pack bearing cones (par. 67).
Installation.
(1) Position the hub outer bearing cup (fig. 99) in the brake
drum side of the hub. Install the remover and replacer
41-R-2374-845 and screw 41-S-1047-330 (fig. 102) in
the hub and drive cup into position.
(2) Position the hub inner bearing cup (fig. 99) in the brake
assembly side of the hub. Install the remover and replacer
41-R-2374-845 and screw 41-S-1047-330 (fig. 102) in
the hub and drive cup into position.
(3) Position the hub inner bearing cone (fig. 99) in the hub
with the small end of the bearing cone taper facing
toward the brake drum.

AGO 10167B
 (4) Place a new hub bearing oil seal (fig. 99) in the brake
assembly side of the hub (fig. 99) with the lip of the seal
facing the hub inner bearing cone. With a soft mallet,
tap the seal into the hub until it is flush with the hub.
(5) Perform operations as outlined in paragraph 2243.

226. Front Hubs

(1) Follow the procedures given in paragraph 224a(2)

through (10).
(2) Remove the hub inner and outer bearings (par. 2253 (2)-
(4) ) . Clean and pack bearings (par. 225~).
Install the hub inner and outer bearings (par.
225d(l)-(4) ). Install the hub as outlined in paragraph

227. front Hub Bearing Oil Seal

a. Remove the hub as outlined in paragraph 224a,
Drive the oil seal out of the inside end of the hub.
Drive the oil seal into the inside end of the hub
with the lip of the seal facing the bearing cone. Install the hub
as outlined in paragraph

228. Brake Drums

Jack up the vehicle until the tire clears the ground.
Remove the five hub nuts (nuts on left wheels are threaded left
hand and those on right wheels are threaded right hand). Pull the
wheel off the hub and studs. Unscrew the three bolts (fig. 99)
and pull the drum from the hub.
Position the brake drum on the hub with the
bolt holes in the drum and hub alined. Install the three 1$ x 5/s
bolts. Put the wheel in place over the hub and studs and install
five x-inch nuts (nuts on left wheels are threaded left hand
and nuts on right wheels are threaded right hand).

229. Steering Knuckle Flange Oil Seal Assembly

Place a jack under the front axle and
raise vehicle until the tire clears the ground. Remove the eight
screws and lockwashers securing the two halves of the steering
knuckle flange oil seal assembly to the steering knuckle assembly.
Pull the two halves of the oil seal, with the front axle shaft
assembly identification plate (fig. 5) and steering knuckle flange
oil seal gasket off the steering knuckle flange,

261
 Apply a little grease to the gasket
surface of the steering knuckle flange assembly. Position a new
steering knuckle flange oil seal gasket on the steering knuckle
flange and aline the mounting holes in the gasket with those
in the flange. Position the two halves of the steering knuckle
flange oil seal on the flange and secure in position with eight
5/16-inch lockwashers and !A6 x t/8 screws, positioning the front
axle shaft assembly identification plate (fig. 5) on the upper
section. Lower vehicle to ground and remove jack.

230. Steering Knuckle Flange Cap Bearings

(1) Remove the front axle shaft assembly (par. 224~).

(2) Withdraw the cotter pin and unscrew the nut securing
the steering tie rod end (fig. 104) to the steering knuckle
arm.
(3) Unscrew the nut securing the line between the front
tee and the front brake flexible line (fig. 104) to the
flexible line.
(4) Remove the two bolts and lockwashers securing the
front brake flexible line guard to the flange cap and
remove guard and front brake flexible line (fig. 104).

262 AGO 10167B

 Figure 104.Steerin.g knuckle flange with arm assembly.

(5) Remove the two remaining bolts and lockwashers se-

curing the steering knuckle flange cap in position and
pry the cap and shims (fig. 105) out of the steering
knuckle flange.
(6) Remove the four bolts and lockwashers securing the
(lower) steering knuckle flange cap in position and
pry the cap out of the steering knuckle flange (fig. 105).
(7) Remove the steering knuckle flange oil seal assembly
(par. 229a).
(3) Pull the steering knuckle flange off the front axle
housing and steering tie rod end.
(9) Lift one steering knuckle flange cap bearing cone out
of the steering knuckle flange and the other cone out
of the front axle housing.
(10) Position the remover and replacer 41-R-2374-750 and
screw 41-S-1047-300 (fig. 106) in the front axle hous-
ing and drive the steering knuckle flange cap bearing
cup out of the housing. Remove the lower steering knuckle
flange cap bearing cup in the same manner.

AGO 10167B 263

 Clean the steering knuckle flange
cap bearing cups and cones with dry-cleaning solvent or volatile
mineral spirits. Pack bearing cones with the grease prescribed
on lubrication order (par. 66). If a bearing packer is not avail-
able, work grease into cones by hand. Keep cones and grease
clean.
c.
(1) Position a steering knuckle flange cap bearing cup
in upper section of the front axle housing with the small
end of the bearing taper facing down. Place the re-
mover and replacer 41-R-2374-750 (fig. 106) in the
bearing cup. Install the screw 41-S-1047-300 (fig. 106)
in the remover and replacer and drive the bearing cup
into the housing until upper edge of cup is flush with
housing.
(2) Position a steering knuckle flange cap bearing cup in
the lower section of front axle housing with small end
of bearing taper facing up. Place the remover and re-
placer 41-R-2374-750 (fig. 106) in the cup. Install the
screw 41-S-1047-300 (fig. 106) in the remover and re-
placer and drive the cup into the housing until the
upper edge of the cup is flush with the housing.
(3) Position a steering knuckle flange cap bearing cone
in its cup in the upper section of the housing. Position
the steering knuckle flange arm (fig. 104) on the stud
of the tie rod end and swing the flange into position
on the housing. Tilt the flange up and slide the second
steering knuckle flange cap bearing cone in from the
rear of the flange and between the flange and housing.
Seat the bearing cones in their cups by working the
flange up and down.
(4) Insert one steering knuckle flange cap up through the
lower section of the steering knuckle flange (fig. 105).
Secure the cap to the flange with four v&inch lockwash-
ers and 3/3 x 11/s bolts.
(5) Insert a steering knuckle flange cap and shims (fig.
105) into the upper section of the steering knuckle
flange. Secure the cap to the flange with two ?&inch
lockwashers and 3/s x i5/s bolts, in the two outside holes.
The thickness of shims must be adjusted until vertical
movement of the flange is eliminated and there is
only slight drag when the flange is turned.

AGO 10167B 265

 (6) Position the front brake flexible line guard (fig. 104)
on the steering knuckle flange cap and secure in posi-
tion with two y&inch lockwashers and s$ x II/r2 bolts.
(7) Screw the nut on the line between the front tee and
the front brake flexible line into the fitting of the front
brake flexible line (fig. 104).
(8) Screw the S&inch nut (fig. 104) onto the stud of the
steering tie rod end and insert a yaa x 7/8 cotter pin
through slots in nut and hole in the stud.
(9) Install the steering knuckle flange oil seal (par. 229b).
(10) Install front axle shaft assembly (par. 224b).

231. Front Axle Assembly

a.
(1) Place a jack under the front axle and raise vehicle
until tires clear the ground. Place safety stands or suit-
able blocking under vehicle frame side rails. Leave the
jack in position to support weight of axle during re-
moval procedures.
(2) Remove front wheels (par. 228).
(3) Withdraw the cotter pin and unscrew steering tie rod
end nut (fig. 104). Tap the stud of the tie rod end out
of the steering knuckle arm (fig. 104). Repeat the pro-
cedure at the other side of the vehicle.
(4) Disconnect the two front shock absorbers at the
lower end only (par. 253).
(5) Unscrew the nut on the end of the master cylinder
front line assembly (HH, fig. 117) from the front tee-
to-master cylinder front line (T, fig. 117). Remove the
clip, securing the line to the bracket (S, fig. 117) on
the vehicle frame, from the groove in the end of the
flexible line.
(6) Disconnect the lower end of each shock absorber (par.

(7)
Remove the spring pivot bolts (par. 251). Lower front
springs to ground.
(8) Disconnect the front propeller shaft at the front axle
(par. 209a).
(9) Lower the jack supporting the axle and remove axle
from under vehicle.
(10) If required, remove all brake lines, connections, and
fittings (par. 245).
b. Any parts not supplied with a new axle as-
sembly should be removed from the old axle.

266 AGO
 (I) If necessary, install all brake lines, connections, and
fittings (par. 245).
(2) Position the axle on a jack and slide jack and axle
into position under front of vehicle. Raise the jack until
the front propeller shaft can be connected to front
axle. Connect propeller shaft (par. 209c).
(3) Raise the two front springs into position and install
spring pivot bolts (par. 251). ,
(4) Place a U-bolt over the axle on each side of the spring.
Note. The two U-bolts for the right front spring are of different
sizes. Place the wider U-bolt over the differential housing.
Place the spring and shock absorber mounting seat
(fig. 105) over the ends of the U-bolts with the free
end of the shaft of the mounting seat forward and
pointing outward. Secure with four 7/:,-inch lockwashers
and U-bolt nuts. Repeat the procedure on the other side
of the vehicle.
(5) Push the front tee-to-master cylinder front line (T,
fig. 117) through the hole in the bracket (S, fig. 117))
on the frame, and insert the clip in the groove on the
end of the flexible line securing the line to the bracket.
Screw the nut on the end of the master cylinder front
line assembly (HH, fig. 117) into the flexible line.
(6) Connect the lower end of the front shock absorbers to
the spring and shock absorber mounting seats following
the applicable instructions contained in paragraph 253.
(7) Tap the stud of the tie rod end up into the steering
knuckle arm (fig. 104) and secure in position with a
?&inch nut and K2 x 7/s cotter pin. Repeat the proce-
d&-e on other side of vehicle.
(8) Install front wheels (par. 228).
(9) Remove safety stands and blocking, lower vehicle to
the ground and remove jack.
(10) Lubricate axle as directed on lubrication order (par.
66).
(11) Bleed the brake system (par. 246).
(12) Make a record of replacement on DA Form 478.

Section XXIII. STEERING SYSTEM

232. Description and Data

a. Description. The steering system (fig. 107) comprises the
steering gear assembly, pitman arm, steering drag link assem-
bly, steering bellcrank assembly, and two steering tie rod with

267
end assemblies. These units are interconnected, and serve to
turn the front wheels as the steering wheel is turned. The
steering gear assembly is the cam and twin-pin lever-type, and
carries a conventional pitman arm. The drag link is the conven-
tional ball and socket-type, with spring-loaded adjustment. The
bellcrank assembly has needle bearings between the bellcrank and
bellcrank shaft. The right tie rod assembly connects the bell-
crank assembly to the right steering knuckle arm. The left tie
rod assembly is fastened to the left tie rod end of the right
tie rod assembly, and the left steering knuckle arm.

Figure 107. Steering system linkage.

b. Data.
Manufacturer .___________________-_-----__-_-- _--Ross Gear and Tool Co,
Model _-___..~~_-______-______-__-___--___--..-----TA 13077
Type _- _____ _ ________ ____-----___________--_-_--cam and twin-pin lever
Ratio ___..___ .~_ .___--____-----_________----_----variable high point-type
Steering geometry :
King pin inclination _-____----___-_-____-_______7~ deg
Wheel camber ---~~--_______--__--______-___-..__l~ deg
Wheel caster -~__---_______--____-_____--__----3 deg
Wheel toe-in __-___________________--__----_---_Nz to KG in

Organizational maintenance consists of lubrication (par. 66))

periodic inspection (pars. ‘73-76), and toe-in adjustment (par.
234) as required. Any operation involving correction of steer-
ing factors (except toe-in) is the responsibility of the ordnance
maintenance unit.

268 AGO
234. Toe-In Adjustment
(figs. 10’7, 108, and 109)
Loose wheel bearings, worn bushings in steering knuckle sup-
ports, damaged wheels and bent steering knuckles, a bent axle
housing, or a bent or improperly adjusted tie rod will effect
toe-in. Inspect and correct any damaged units found.
a. Inflate tires to correct pressure (par. 254)) and check
for proper wheel bearing adjustment. With the vehicle on a
smooth, level surface, turn the steering wheel until the steering
bellcrank is at right angles with the front axle. Place straight-
edge or line against outside of left wheels ; check to see if left
front wheel is in line with or straightahead of the left rear
wheel. If left front wheel is not straightahead, loosen the two
nuts and screws securing the left tie rod and clamp (fig. llO),
and turn tie rod to obtain straightahead position.
Note. Tie rod end on right side of vehicle has left-hand threads; the one
on the left side has right-hand threads.
Repeat same operation to check right front wheel; use right tie
rod to adjust right front wheel.
After both wheels are at straightahead position, place
toe-in adjustment gage (fig. 108) between the wheels ahead of the
axle, with the ends of the gage bearing against the tire side
walls and with both pendant chains just touching the ground.
Set gage so that pointer registers zero. Move the vehicle for-
ward until gage is brought into position in back of the axle
(fig. log), with both pendant chains just touching the ground.
The pointer will indicate the amount of toe-in or toe-out. Cor-
rect toe-in is 3/& to 3/ls inch.

Figure 108. Toe-in gage in place ahead of axle.

AGO
269
 Figure 109. Toe-in gage in plucc behind rtrcle.

c. If toe-in is not correct, loosen the nut and screw securing

the right tie rod end clamp (fig. 110) and turn tie rod to obtain
correct adjustment. Make sure that clamp nuts and screws are
tightened after adjustment has been made.

110)

(1) Place the vehicle on a hard level surface and apply

the hand brake.
(2) Remove the cotter pin and nut securing the right end
of the left tie rod with ends assembly to the left of the
right tie rod with ends assembly.
(3) Using a suitable puller, separate the two tie rod ends.
Note. Do not hammer on the tie rod ends to separate them.
(4) Remove the cotter pin and nut securing the left tie
rod with ends assembly to the left steering knuckle arm.
(5) With a suitable puller, separate the tie rod end from
the arm and remove the left tie rod with ends assembly.
(6) Remove the cotter pin and nut securing the right tie
rod with ends assembly to the bellcrank.
(7) Using a suitable puller, separate the right tie rod end
from the bellcrank.
(3) Remove the cotter pin and nut securing the right tie
rod with ends assembly to the right steering knuckle arm.
(9) Using a suitable puller, separate the tie rod end from
the arm and remove the right tie rod with ends assembly.

270 AGO
Figure Steering tie rod with ends assemblies and bellcrank with bearing and oil seal assembly installed.
 Section I. SHIPMENT OF MATERIEL

277. Shipping Instructions

a. shipping the IL-ton 4x4 utility trucks M38,
the officer in charge of preparing the shipment will
for furnishing the vehicles to carriers for transport in a service-
condition, adequately protected against corrosion, deteriora-
tion, and damage during shipment from the supply source to the
tirst receiving activity for immediate use (Level C Packaging and
Packing of AR 740-15)) as prescribed in SB 9-4 (type I process-
ing) and in paragraphs 279 and 280 (loading and blocking).
Note. Type I processing of SB 9-4 is considered as meeting the require-
ments of Level C of AR 740-15.

Personnel withdrawing vehicles from storage for shipment

remove other than to insure that the ve-
hicles are complete and serviceable. If it has been determined that
preservatives have been removed, they must be restored to the
prescribed level prior to shipment. Removal of preservatives is
the responsibility of depots, ports, and field installations (posts,
camps, and stations) receiving shipments.
c. It will be the respon-
sibility of the officer in charge of the organization performing
arctic lubrication to insure that the equipment is marked as pre-
scribed in SR 746-30-10. It will be the responsibility of the officer
in charge of the organization shipping arctic-lubricated equip-
ment to insure that each item is so marked. Commanders of using
organizations will insure that such markings are not obliterated
while the equipment is arctic-lubricated. When the equipment is
deprocessed of the special lubrication, such marking will be im-
mediately and thoroughly obliterated.
Prepare all Army shipping docu-
ments accompanying the vehicles in accordance with TM 38-705.
e. If deep-water fording is anticipated dur-
ing shipment, prepare vehicles in accordance with TM 9-2853.

AGO x?:GB
278. Receiving Instruments
a. If vehicles are received in a damaged condition or improperly
processed, notify the transportation officer and prepare a DD
Form 6 in accordance with SR 745-45-5.
Prior to use, deprocess the vehicles as prescribed in SB 94
and service the vehicles as prescribed in paragraphs

279. loading the %-TON 4x4 Utility Truck M38 on Railroad

Flatcars

When vehicles are shipped by rail, every precaution must

be taken to see that they are properly loaded and securely
fastened and blocked to floor of flatcar.
(2) On-vehicle materiel (OVM) will be thoroughly cleaned,
preserved, packed (boxed or crated), and securely stowed
in or on the vehicle as prescribed in SB 94. Publications
will be packed in heavy duty, type 1 heat sealable, grade
A, waterproof, class b bags (Method lC-3) and packed
in the OVM container. Publications provided by separate
technical services will be packed in the same OVM con-
tainer as the material to which they are applicable.
(3) Load vehicle on flatcars so they will not form an un-
balanced load.
(4) After a vehicle has been finally spotted on flatcar, apply
parking brakes.
(5) Increase tire pressure slightly higher than normal, ex-
cept when vehicles are exposed to extremely hot-weather
conditions.

For method of loading and general loading rules pertaining to

rail shipment of ordnance vehicles, see TM 9-1005 and TB 9-
OSSC-G.
Warning: The height and width of vehicles, when prepared for
rail transportation, must not exceed the limitations indicated by
the loading table in AR 700-105 (see II). Whenever possible, local
transportation officers must be consulted about the limitations of
the particular railroad lines to be used for the movement in order
to avoid delays, dangerous conditions, or damage to equipment.

280. Blocking the %-TON 4x4 Utility Truck M38 for Rail
Shipment
All blocking instructions specified herein are mini-
mum and are in accordance with “Pamphlet No MD-7, Rules Gov-
erning the Loading of Defense Materiel on Open Top Cars” of the

AGO 10167B
Association of American Railroads. Additional blocking may be
added, as required, at the discretion of the officer in charge. Double-
headed nails may be used, except in the lower piece of two piece
cleats. All reference letters in h through (? below refer to details
and locations in figures 136 and 137. The number of vehicles to
be loaded will depend upon the length of flatcar.
Note. Any other loading instructions, regardless of source, which are in
conflict with this publication or existing loading rules of the carriers, must be
submitted for approval to the Chief of Ordnance, Washington 26, D. C.
b. Brake Wheel Clearance “A.” Load vehicles on flatcars, with a
minimum clearance of at least 4 inches below and 6 inches above,
behind, and to each side of the brake wheel. Increase clearance
provided it is consistent with proper location of load.
Note. Three methods of blocking are given herein; the method to be used
will depend on dimensions of flatcars and availability of required blocking
materials. The instructions herein are for vehicles, double-loaded, as shown
in figure 136. Vehicles may be single-loaded, double-deck loaded, or incline-
loaded (with the front wheels of the second vehicle positioned in the rear body
of the first vehicle and the front wheels of the third vehicle positioned in the
rear body of the second vehicle, etc).
c. Method I.
(1) Chock blocks “B” (6 x 9 x 12, six rqr per truck, con-
structed as shown in detail 1, fig. 2). Locate the 53” sur-
face of blocks against the front and rear of each outside
wheel, against the front of each inside front wheel, and
against the rear of each inside rear wheel. Nail heel of
each block to car floor with three fortypenny nails and
toenail both sides of blocks to car floor with one forty-
penny nail each.
Note. Alternate type B-l or B-2 chock blocks may be constructed
as shown in details 2 and 3, figure 131, and located against tires as
shown in details 1 and 2, figure 136. Single-loaded vehicles require
chock blocks at the front and rear of all four wheels.
(2) Inside wheel blocks “c” (6 x 9 x 12, four rqr per truck
constructed as shown in detail 1, fig. 137). Locate the
6 x 9 surface of block flush against the inside of each
wheel, as shown in figure 136. Nail heel of each block to
car floor with four fortypenny nails and toenail each
side to floor with one fortypenny nail.
Note. Alternate type inside wheel blocks C-l, may be constructed
as shown in detail 4, figure 137, and located against tires as shown
in detail 2, figure 136. When inside wheel blocks C-l are used,
cushioning material “D” (wtrprf paper or burlap) will be placed
between blocks C-l and inside of tire. The material should extend
2 inches beyond block on car floor and 2 inches above block against
side of tire;

AGO 10167B
325
Figure 136.
Figure ld7. Methods of blocking the x-ton 4x4 utility trucks M38 on flatcars (details).
Methods of blocking the %-ton .4x.4utility trucks M38 on flatcars (details)-Continued.
 (3) Vehicle strapping “E” (1 in. No. 14 BW ga, hot-rolled
steel, lgh to suit, two rqr per truck). Locate strapping
“E” over front bumper of vehicle and through rear pull-
ing hook of vehicle, as shown in figure 136. Pass strap-
ping through two anchor plates (detail 5, fig. 137) and
nail anchor plates to car floor with eight twentypenny
nails. Substitute, if desired, four strands of No. 8 gage,
black annealed wire, E-l, twist-tie to form cables. Pass
the cable over the bumper or through the pulling hook
underneath and around ramdom 2 x 4 cleat “F” (detail
6, fig. 137). Nail cleat lengthwise to car floor and twist-
tighten cables to remove all slack.
(4) Vehicle ties “G” (6 strands, 3 wrappings, No. 8 ga, black
anld wire, lgh to suit). Pass cables around frame (bump-
ers, hooks, brackets, etc.) at front and rear of every
two side-by-side vehicles as shown in figure 136. Twist-
tighten cables to remove all slack.
d. Method II.
(1) Wheel cleats “N” (4 in. wd, 6 in. high, 8 in. longer than
width of car, four rqr per truck). Locate a cleat “N”
across the front and rear of front and rear wheels as
shown in detail 3, figure 136, and toenail each to car
floor with four thirtypenny nails.
(2) Wheel supports “Q” (2 x 4, 2 in. longer than distance
between ouside faces of cleats “N”, four rqr per truck).
Locate the two-inch side of support “Q” against each
side of car floor. Secure each end to cleats “N” with
l$$-inch diameter bolt, nut, and washer, as shown in de-
tail 3, figure 136.
(3) Wheel cleats “J” (2 x 4, 2 in. longer than distance be-
tween outside faces of cleats “N”, four v*qr per truck).
Locate cleat “J” across top cleats “N” with sides of
d&s “J” flush against inside of tires as shown in
detail 3, figure 136. Nail end of each cleat “J” to cleats
“N” with three twentypenny nails.
(4) Support cleats “P” (2 x 4 x 18, eight rqr per truck).
Locate four cleats “P” equidistant across car floor, with
ends flush against cleats “N”, as shown in detail 3, fig-
ure 136. Nail cleat to car floor with four thirtypenny
nails. Locate one cleat on top of each lower cleat and
nail with four thirtypenny nails.
e. Method III.
(1) Wheel cleats “H” (2 x 4, lgh to suit, eight rqr for every
two side-by-side vehicles). Locate a cleat “H” across
flatcar, close to front and rear of front and rear wheels,
AGO
329
 and nail to car floor with ten thirtypenny nails ; locate
a cleat on each lower cleat and nail with ten thirtypenny
nails as shown in detail 4, figure 136.
(2) 4, 4 in. longer

Locate a cleat “J” against inside or outside of

wheels as shown in detail 4, figure 136, and nail each
end to cleats “H” with three twentypenny nails.
(3)
Locate a cleat “K” on top of cleats “H,” with end flush
against cleat “J,” and nail to cleats “H” with two twenty-
penny nails as shown in detail 4, figure 136.
Note. If flatcar is too narrow, cleats “J” will be placed on the
inside of wheels and cleats “K” will be placed on the outside of
cleats “J”. If flatcars are wide enough, cleats “J” will be placed
on the outside of wheels and cleats “K” will be on the inside of
cleats “J”

Locate a cleat “L” across cleats “J” and nail

to cleats “J” and “K” with three twentypenny nails at
each end as shown in detail 4, figure 136.
(5) Locate a
cleat “M” on car floor at each end of load, with end flush
against cleat “H,” near each side of car, and secure with
four thirtypenny nails. Locate one cleat “M” on top of
each lower cleat and secure with four thirtypenny nails
as shown in detail 4, figure 136.

a. Identification marking will be stamped on metal tags after

which tags will be dipped in ordnance yellow paint, and securely
attached with soft wire on the front and rear of each vehicle.
Marking will consist of nomenclature, stock number, gross weight,
cubage, and shipping dimensions.
Processing directive (identifying number), symbol of in-
stallation performing processing, and date processed, will be
stenciled with gasoline-soluble white or yellow paint on the inside
surface of the windshield, opposite to the driver.
c. The complete coded oversea address (where applicable) will
be stenciled in an unobstructed location (front and rear) with
gasoline-soluble paint (white or yellow on OD surfaces). The
stenciling will be in letters not more than 11/s inches nor less than
3/a inch high. An equilateral triangle (ordnance yellow) not more
than 3 inches nor less than 11/2 inches high will be stenciled on
each vehicle adjacent to the oversea address.
Marking of boxed items will be in accordance with TM g-1005.

330 AGO 10167B

 Destruction of the utility truck M38, when subject to capture
or abandonment in the combat zone, will be undertaken by the
using arm only when, in the judgment of the unit commander
concerned, such action is necessary in accordance with orders of,
or policy established by, the army commander. When in the pos-
session of ordnance maintenance personnel, destruction will be in
accordance with FM 9-5 and the information below as applicable.
b. The information which follows is for guidance only. Certain
of the procedures outlined require the use of explosives and in-
cendiary grenades which normally may not be authorized items
for the trailer. The issue of these and related materials, and the
conditions under which destruction will be effected, are command
decisions in each case, according to the tactical situation. Of the
several means of destruction, those most generally applicable are-
Mechanical -Requires axe, pick mattock, sledge, crowbar,
or similar implement.
Burning -Requires gasoline, oil, incendiary grenades, or
other flammables.
Demolition -Requires suitable explosives or ammunition.
Gunfire -Includes artillery, machineguns, rifles using
rifle grenades, and launchers using antitank
rockets. Under some circumstances hand
grenades may be used.
In general, destruction of essential parts, followed by burning
will usually be sufficient to render the material useless. However,
selection of the particular method of destruction requires imagi-
nation and resourcefulness in the utilization of the facilities at
hand under the existing conditions. Time is usually critical.
c. If destruction to prevent enemy use is resorted to, the ma-
teriel must be so badly damaged that it cannot be restored to a
usable condition in the combat zone either by repair or cannibali-
zation. Adequate destruction requires that all parts essential to
the operation of the materiel, including essential spare parts, be
destroyed or damaged beyond repair. However, when lack of time
and personnel prevents destruction of all parts, priority is given
to the destruction of those parts most difficult to replace. Equally
important, the same essential parts must be destroyed on all like
materiel so that the enemy cannot construct one complete unit
from several damaged ones.
If destruction is directed, due consideration should be given
to :

331
 (1) Selection of a point of destruction that will cause greatest
obstruction to enemy movement and also prevent hazard
to friendly troops from fragments or ricocheting projec-
tiles which may occur incidental to the destruction.
(2) Observance of appropriate safety precautions.

283. Method No. l-Destruction by Burning

a. Remove and empty portable fire extinguishers.
b. Using an axe, pick mattock, sledge, or other heavy implement,
smash all vital elements such as distributor, carburetor, gen-
erator, ignition coil, fuel pump, spark plugs, air cleaner, lights,
instruments, and controls. If time permits, and a sufficiently heavy
implement is available, smash the engine cylinder block and head,
crankcase, and transmission.
c. Slash tires. If tires are inflated, exercise care to prevent
injury should the tire blow out while being slashed. Whenever
practicable, it is usually preferable to deflate tires before slashing.
d. Remove the drain plug from the fuel tank or puncture the
tank as near the bottom as possible, collecting gasoline for use
as outlined in f below.
e. Explosive ammunition, if available nearby, should be removed
from packing or other protective material. Place ammunition on
and about the entire utility truck so that it will be fully exposed to
the fire and in such locations that the greatest damage will result
from its detonation. Remove any safety devices from the am-
munition.
f. Pour gasoline or oil in and over the entire utility truck. Ig-
nite by means of an incendiary grenade fired from a safe distance,
by a burst from a flame thrower, a combustible train of suitable
length, or other appropriate means. Take cover immediately.
Caution: Cover must be taken without delay since an early
explosion of the explosive ammunition, if present, may be caused
by the fire. Due consideration should be given to the highly flam-
mable nature of gasoline and its vapor. Carelessness in its use
may result in painful burns.
If explosive ammunition is present, the danger zone is approxi-
mately 250 yards. Elapsed time: about 6 minutes.

284. Method No. 2-Destruction by Demolition

a. Remove and empty portable fire extinguishers.
b. Smash all vital elements as outlined in paragraph 283b.

332 AGO
 c. Prepare two 2-pound charges of EXPLOSIVE, TNT (using
two l-lb blocks or equivalent together with the necessary detonat-
ing cord to make up each charge). Place the charges as follows:
(1) Set the first charge on top of the clutch housing.
(2) Set the second charge as low on the left side of the en-
gine as possible.
d. Connect the two charges for simultaneous detonation with
detonating cord.
e. Provide for dual priming to minimize the possibility of a
misfire. For priming, either a nonelectric blasting cap crimped
to at least 5 feet of safety fuse (safety fuse burns at the rate of
1 ft in approx 40 set; test before using) or an electric blasting
cap and firing wire may be used. Safety fuse, which contains
black powder, and nonelectric blasting caps must be protected
from moisture at all times. The safety fuse may be ignited by a
fuse lighter or a match; the electric blasting cap requires a
blasting machine or equivalent source of electricity.
Caution: Keep the blasting caps, detonating cord, and safety
fuse separated from the charges until required for use.
Note. For the successful execution of methods of destruction involving the
use of demolition materials, all personnel concerned will be thoroughly familiar
with the pertinent provisions of FM 5-25. Training and careful planning are
essential.
f. Destroy the tires by placing an incendiary grenade under
each tire. The detonation of the explosive charges should be de-
layed until the incendiary fires are well started. This will prevent
the fires from being extinguished by the blast when the charges
are detonated.
g. Detonate the charges. If primed with nonelectric blasting cap
and safety fuse, ignite and take cover. If primed with electric
blasting cap, take cover before firing. The danger zone is ap-
proximately 250 yards. Elapsed time: about 6 minutes.

285. Method No. 3-Destruction by Gunfire

a. Remove and empty portable fire extinguishers.
b. Ordinarily destruction of the tires is effected incidental to
and in conjunction with the destruction of the utility truck by
gunfire. However, if such destruction is not practicable, destroy
the tires as outlined in paragraph 283~ or 284f.
c. Drain or puncture the fuel tank, unless incendiary grenades
are to be used to destroy the tires.
 d. Destroy the utility truck by gunfire using artillery, machine
guns, rifles using rifle grenades, or launchers using antitank
rockets. Fire on the utility truck aiming at the engine, axles, and
wheels. Although one well-placed direct hit may render the utility
truck temporarily useless, several hits are usually required for
complete destruction unless an intense fire is started, in which case
the materiel may be considered destroyed.
Caution: Firing artillery at ranges of 500 yards or less should
be from cover. Firing rifle grenades or antitank rockets should
be from cover. Elapsed time: about 4 minutes.

334 AGO 10167B

 Indexes
DA pamphlets of the 310-series and DA Pam 108-l should be
consulted frequently for latest changes or revisions of references
given in this appendix and for new publications relating to ma-
teriel covered in this manual.

2.
The following manuals of the Department of the Army Supply
manual pertain to this materiel:

Explosives and Demolitions. . . . . . . . . . FM 5-25

Land Mines and Components; Demoli- ORD 3 SNL R-7
tion Explosives and Related Items ;
and Ammunition for Simulated Ar-
tillery, Booby Trap, Hand Grenade,
and Land Mine Fire.
Regulations for Firing Ammunition for SR 385-310-l
Training, Target Practice, and Com- AFR 50-13
bat.
Report of Malfunctions and Accidents SR 700-45-6
Involving Ammunition and Explo-
sives (During Training and Combat).
Safety : Accident Reporting. ......... SR 385-10-40

Index of Supply Manuals-Ordnance DA Pam 310-29

Corps. ORD 1
Introduction .......................

c.
Cleaners, Preservatives, Lubricants, Re- ORD 3 SNL K-l
coil Fluids, Special Oils, and Related
Maintenance Materiels.
Items of Soldering, Metallizing, Braz- ORD 3 SNL K-2
ing and Welding Materiels: Gases
and Related Items.

335
Lubricating Equipment, Accessories, ORD (*) SNL K-3
and Related Dispensers.
Lubricating Fittings, Oil Filters, and ORD 5 SNL H-16
Oil Filter Elements.
d.
Truck, I$$-Ton, 4 x 4 Utility, M38. . . . . . ORD 7, 8, 9, SNL G-740
Winterization Equipment . . . . . . . . . . , . ORD 9, SNL G-249 Sec. 9

3. Forms
The following forms pertain to this materiel :
Standard Form 91, Operator’s Report of Motor Vehicle Accident
Standard Form 94, Statement of Witness
DA Form 9-3, Processing Record for Shipment and Storage of
Vehicles and Boxed Engines
DA Form 9-4, Vehicular Storage and Servicing Record
DA Form 9-68, Spot Check Inspection Report for Wheeled and
Half-Track Vehicles
DA Form 9-75, Daily Dispatching Record of Motor Vehicles
DA Form 348, Driver Qualification Record
DA Form 452-1, Placard-Documents Covering Shipment Are on
Other Side of Car
DA Form 452-2, Placard-Documents Covering Shipment Are on
This Side of Car
DA Form 460, Preventive Maintenance Roster
DA Form 461, Preventive Maintenance Service and Inspection
for Wheeled and Half-Track Vehicles
DA Form 461-5, Limited Technical Inspection
DA Form 468, Unsatisfactory Equipment Report
DA Form 478, Organizational Equipment File
DA Form 811 and 811-1, Work Request and Job Order and Receipt
DA Form 1208, Report of Claims Officer (cut sheet)
DD Form 6, Report of Damaged or Improper Shipment
DD Form 313, U. S. Government Operator’s Permit
DD Form 317, Preventive Maintenance Service

4. Other Publications
The following explanatory publications contain information
pertinent to this materiel and associated equipment:

Camouflage, Basic Principles. . . . . . . . . . . . . . . . . . . FM 5-20

Camouflage of Vehicles. . . . . . . . . . . . . . . . . . . . . . . . FM 5-20B

(*) See DA Pam 31049, Index of Supply Manuals-Ordnance Corps, for published types of
manuals of the Ordnance section of the Department of the Army supply manual.

336 AGO 1016’7B

 b. Decontamination.
Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-220
Defense Against Chemical Attack. . . . . . . . . . . . . . . FM 21-40

c. Destruction to Prevent Enemy Use.

Explosives and Demolitions. . . . . . . . . . . . . . . . . . . . FM 5-25

d. General.
Artillery Materiel and Associated Equipment. . . . . TM 9-2300
Association of American Railroad Rules Governing No. MD-7
the Loading of Department of Defense Materiel
on Open Top Cars.l-Pamphlet
Chassis Coating Compound (Underbody Corn- TB ORD 401
pound), Description, Method of Application, and
Equipment Used.
Cooling Systems: Vehicles and Powered Ground TM 9-2858
Equipment.
Driver’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 21-305
Driver Selection, Training and Supervision. . . . . . TM 21-300
Fuel-Burning Heaters for Winterization Equipment TM 9-8662
Inspection of Ordnance Materiel in the Hands of TM 9-1100
Troops.
Instruction Guide : Operation and Maintenance of TM 9-2855
Ordnance Materiel in Extreme Cold (0” to -65”
F.).
Military Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2800
Motor Transportation, Operations.
Motor Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 25-10
Mountain Operations . . . . . . . . . . . . . . . . . . . . . . . . . FM 70-10
Operations in the Arctic. . . . . . . . . . . . . . . . . . . . . . . FM 31-71
Precautions in Handling Gasoline. . . . . . . . . . . . . . . AR 850-20
Preparation of Ordnance Materiel for Deep-Water TM 9-2853
Fording.
Principles of Automotive Vehicles. ............. TM 9-8000-l
(TM g-2700)
Prevention of Motor Vehicle Accidents. .......... AR 385-55
Reports of Accident Experience. ............... SR 385-10-40
Sparkplugs.. ............................... TB ORD 313
Storage Batteries, Lead-Acid Type. ............. TM 9-2857
Motor Vehicles .............................. AR 700-105
Unsatisfactory Equipment Report. ............. AR 700-38

1 Copies may be obtained from Aberdeen Proving Ground, Aberdeen, Md.

AGO 10167B 337

Abrasive, Cleaning, Preserving, Sealing, Adhesive, TM 9-850
and Related Materiels Issued for Ordnance Ma-
teriel.
Cleaning Lead-Acid Type Storage Batteries. . . . . . TB ORD 557
Hand, Measuring, and Power Tools. . . . . . . . . . . . TM 10-590
Instruction Guide: Care and Maintenance of Ball TM 37-265
and Roller Bearings.
Lubrication ..,.......,...................... TM 9-2835
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-8012
Maintenance and Care of Hand Tools. . . . . . . . . . . . TM 9-867
Maintenance and Care of Pneumatic Tires and TM 31-200
Rubber Treads.
Inspection and Reports Ordnance Corp Materiel. . AR 750-925
Maintenance Responsibilities and Shop Operation. . AR 750-5
Painting Instructions for Field Use. . . . . . . . . . . . . TM 9-2851
Preparation of Ordnance Materiel for Deep Water TM 9-2853
Fording.
Tactical Motor Vehicle Inspection and Preventive TM 9-2810
Maintenance Services.
Wheeled and Half-Track Vehicles, Trailers, and TB 9-2835-12
Towed Artillery : Lubrication of Wheel Bearings.
Note. For a complete listing of cleaning, preservation, packaging, and pack-
ing specifications, consult the Operational List of Packaging Specifications
and Instructions (General Supply). Copies may be obtained from Command-
ing Officer, Rossford Ordnance Depot, Toledo 1, Ohio, Attention: ORDWD-P.

f.
Army Shipping Document. . . . . . . . . . . . . . . . . . . . . TM 38-705
Instruction Guide : Ordnance Packaging and Ship- TM 9-1005
ping (Posts, Camps, and Stations).
Marking and Packing of Supplies and Equipment: SR 746-30-10
Marking of Arctic-Lubricated Materiel and
Equipment.
Marking and Packing of Supplies and Equipment: SR 746-30-6
Shipment and Digit Marking.
Marking and Packing of Supplies and Equipment: SR 746-30-5
-Marking of Oversea Supply.
Marking for Shipment and Storage. . . . . . . . . . .MIL STD 129A’
Ordnance Storage and Shipment Chart-Group G . TB 9-OSSC-G
Preparation of Supplies and Equipment : Process- AR 747-30
ing of Unboxed and Uncrated Equipment for
Oversea Shipment.

1 Copies may be obtained from Philadelphia Quartermaster Depot, 2800 S. 20th St. Philadel-
phia, Pa.

AGO 10167B
338
Preservation, Packaging, and Packing of Military TM 38-230
Supplies and Equipment.
Processing of Motor Vehicles and Related Unboxed SB 9-4
Materiel for Shipment and Storage.
Protection of Ordnance General Supplies in Open TB ORD 379
Storage.
Reusable Shipping Containers for Tank and Auto- SB 9-69
motive Assemblies: Proper Use and Care.
Shed and Open Storage of Supplies. . . . . . . . . . . . . . SR 743-5-10
Report of Damaged or Improper Shipment. . . . . . . SR 745-45-5
Standards for Oversea Shipment and Domestic TB ORD 385
Issue of Ordnance Materiel Other than Ammuni-
tion and Army Aircraft.
Station Supply Procedure. . . . . . . . . . . . . . . . . . . . . . TM 38-403
Storage in the Zone of Interior. . . . . . . . . . . . . . . . . TM 38-402
Loading Rules, Test Loadings, and Test Shipments SR 55-155-1

AGO 10167B
339
 Paragraph Page.

Accelerator control __~~~ ___~_______~_~________~_-_~- 130 156

Accelerator pedal _____~___~_~___~__~______--_--_~_.~_ 15 22
Air cleaner ______~.________~~____~_-..~~-~~-~--. ~~_~_ 127,132 149,164
Air intake system. (See Fuel and air intake system.)
Air intake, troubleshooting _.___~~_~_.~~_~-~.~~_._~_~__~ 79 78
Ammeter ________________~___~.-________~ 30,174 25,224
Auxiliary power receptacle _~.._ ~~~._~_~~_~~~~_~__ .___ 150 190
Axle, front:
Coordination with ordnance maintenance unit ~____ 222 254
Data ____________________--~_---~_-~-_~---_-_-- 221 254
Description _______________.____-.----~-~-------_~ 4,221 6,254
Organization maintenance _~_______~_~____.._____~ 223 254
Shafts _~_____~.________~______---~~--------__--- 224 254
Troubleshooting _______~_____________------__._-- 93 96
Axle, rear:
Assembly ______________________---_----_-----~- 220,231 252,266
Bearings, hub ____________________-_. ___________ 225 259
Bearings, knuckle flange cap __________________.__.- 230 262
Bearings, shaft _~.._____~_____________---__--.---- 216 250
Brakedrum ~_~_____________________________~--__- 219,228 252,261
Coordination with ordnance maintenance unit __~___ 213 246
Data _____________.___________________________ 212 246
Description _____~_____~~___~________---_-----~~ 4,212 6,246
Drum, brake ____________________-~--~_---~__--- 219,228 252,261
Flange seal ____~__________~_____~__--____-__-._ 229 261
Hub ____________~___~_~~_~___-~-__----_---___-~ 218,226 251,261
Oil seals, inner ___~~__~~~__~..___~___~_~______-~- 217 251
Organizational maintenance ~____~~~_.-_~_____~___ 214 246
Seal, hub bearing ~_~_~~___~__~_~~_~______~____ 227 261
Seal, knuckle flange __~___~_____~___~_~~______-- 229 261
Seal, oil, inner _____~.___~__~______~__~___------_ 217 251
Shaft ______________________-___---~---__---_-- 215 246
Troubleshooting ____________________---~.-----_-- 94 97

Battery:
Cables ____________________--_-----------_--__-- 156 201
Data ____________________------~~_----__--___-- 154 196
Description ____________~_~____~_______________ 154 196
Installation ____~__~____~__~~_____~__~_-_---___- 155 198
Removal ________~___.___~___~~___----___---__-__ 155 198
Troubleshooting _____.________~____~___--__------ 84 85
Belt, fan, and generator drive ____~___~___~___________ 123 144
Blackout headlight _______~__________~___-----__---- 158 205
Blackout light _____________.-______--__---__-_--_--- 160 208
Blackout marker light _____~~_~~..__ ______~__________ 159 207
Blocking for rail shipment ____...____~~~___________-__ 280 324

AGO 10167B
340
 Paragraph Page
Body and frame :
Bumper _~______~______________-____--_~--~__~- 269 317
Data ___~~~___-.___~___~________--~_----~_-----_ 258 302
Description 258 302
Fenders ____________~_~___~~~~__~~__---~~_---~~ 262 305
Hood _______~_. _~~~~_~_______~~~~___~~~~_.-__~__ 261 304
Mirror __________..____~__ -~~.~~_____-.~____~~~~_ 271 318
Organizational maintenance ~~~~ ._ ~___~_ __~~___~ 259 303
Pintle ___________~__ _~ ~~~~~~~..~__~~____________ 267 312
Radiator guard ~__~__~__~~~~~___~______ .~~.._______ 263 307
Reflectors __.~_____~_________~______~________ 270 318
Seats and cushions _________ __..__~~~__~~ ~________ 268 314
Shackles ____________________-~~~----~~-.-----__- 267 312
Top, doors, and side curtains ~__~~~~~__~~.-________ 264 307
Windshield .~________________~~_~__-~-------~_- 260 303
Windshield wiper _____~~~~__~~~______,___.-____~~~ 265,266 311,312
Brake, hand. (See Brake system.)
Brake system:
Bleed _______________~~__~~___------_----------~ 246 290
Cylinder, master ____________________~~~--~~_~~~. 244 283
Cylinder, wheel _____________~___~____---___~ 243 283
Data _______.-_____________-___________---__---~_- 240 277
Description _____________~______~_-_._..-----_---.~ 240 277
Fittings _________~~___ _ _~___~_____~_~__________ 245 285
Handbrake __~____~~_____~.___~__~~~__--___--___~ 247 291
Handbrake handle ~~~ ~~__~____~~~_____~_~_____ 20 23
Lines and fittings .~__~_~.~~~_~~_
~~~___ ~~_.__~_.__~___ 245 285
Master cylinder _~_. _~~ ~_~ __~____~___~~__~_~_~ 244 283
Organizational maintenance ~________~__________ 241 278
Service brakes ~~~~~~.~~~ ~.___~~~.~__~~___~___~.._. 242 278
Troubleshooting _~_~~._~~~~_~~...~~~~~.. ~~.~.~~~__~ 95, 96 98, 99
Wheel cylinder ___~~__ ~_ _ .~~~~~~~~~ _.~.._~~~ 243 283
Bumpers _______~_______~____~_____~~~___--___-____- 269 317
Button, horn __~~__~_~~_____________._~ _~______~__~~ _ 184 229

Cables, battery __~__ _____ ____~_~_________~_~_____..-. 156 201

Carburetor __________~_________~~__~~~ ~_____-._____~ 127,129 149,151
Caution plates ________________~___ __~_____~____~~__ 5 10
Choke control __. __.__. ~__.____________~_______--__~~- 22,130 23,156
Cleaning _____-~.___~_~____~._~___-.--~~~-~..~~~~..-~~ ~__ 74 60
Clutch :
Data _~___~_~__~~~~~~_______~__~~_~~_.._-~_~_-___ 195 233
Description _~__~~_.-~_~~~___~~____~~_______-~~-- 195 233
Linkage adjustment ~_~~~~__~_~~~~~_________~___ 196 233
Pedal __________~____~______---_--___---------_ 14 22
Troubleshooting _~_~_____~__~~~~~~~~_~-.~~___~_~_ 89 93
Coil, ignition __________~_____~_____-~~---~~---_~~~-.. 144,146 184,185
Cold weather _______~___~__~_~_~~______--~_---~~---_ 272,273 318,319
Common tools and equipment____________________----_ 64 49
Controls and instruments :
Accelerator pedal ~~~~____~_~ ~~~~~._~___~________ 15 22
Ammeter __~~___~~___~~____~~__ ~_~.___~_______ 30 25

341
 Paragraph Page
Controls and Instruments-Continued
Brake pedal ~_~_~______~~__~~__~________--_--_-_ 13 20
Choke control __~ _~_.~____. ______________________ 22 23
Clutch pedal _~_~~~ _~_~_~____~ __ ~_~~~~_~___~_____~ 14 22
Dimmer switch ..~__________..___~_~___~__---_---- 34 26
Fuel filter ______________~_~_~________________ 28 25
Fuel gage ____________________-_---_-~_--_-__-_- 26 24
Fuel tank level sending unit__--__ ~_~_~___~__~___ 27 25
General ________________~__~ ~_________________ 11 20
Handbrake handle __~__~_~~_ ~-~.~~__~~.____~_~__ 20 23
Headlight dimmer switch-__-- .~______~____ ._____ 34 26
Headlight indicator light______..__________--_---- 40 27
Hornbutton __________________________________ 35 27
Ignition switch ___________~_ ~____~____~_____ ____ 32 26
Instrument panel lights__ __~_______~~_________~__ 39 27
Lights, instrument panel-__---. ~__~____~____~____ 39 27
Light switch ___~_______ ~~._~__.~~~________~___ 33 26
Map compartment lock-_ .~ ~.~~__~______~__~______ 41 28
Oil pressure gage--..-~_~~ _.~~._____~_________~~____ 25 24
Speedometer ~__~~_~_____.~~______.-____----_---_- 31 25
Starter pedal______-_____~~__--__-___---------_-- 16 22
Steering wheel ____ ~~_~___~__~~_~_~_~_______~__ 12 20
Temperature gage _______~__~_________~__------- 29 25
Throttle control ________~_~_~_~~__~___~_~~______ 21 23
Transfer front wheel drive gearshift lever-- .~_~__ 17 22
Transfer high and low range gearshift lever_______ 18 22
Transmission gearshift lever____.~-~____~__~_~____ 19 23
Valve, vent ~ontrol~_______~___~_._~ ~~_~__~___~___ 23 24
Vent control’valve _______~ ____..__~_~____________ 23 24
Water temperature gage--_--_---_------ _~~______ 29 25
Winch controls _____________~__~_____-_--__--.._- 24 24
Windshield lock ~___~_ __~_.____~_ .~ ~__~~_________ 38 27
Windshield wiper manual controll ~_~~__~_________ 37 27
Windshield wiper regulating valve--~ ~__~_~_______ 36 27
Cooling system :
Belts, fan and generator drive _~ ~~__~_ 123 144
Data ___________~~~~__~.-.~~_~_~~~__~_--_---~--_-- 120 140
Description ______~__~_____~~_ ~~____________~___ 120 140
Fan ____________~~~_~ __~___________~~____~____ 124 146
Hose ________~__~~_~~_~__~___~___~-~~-__~-_~-__ 125 147
Organizational maintenance _~ ~~_~~__~~__~_____~ 121 142
Radiator ________~~~___~_~~_~_~~__~~_~___-_--__- 122 143
Thermostat ____________~ ~_~___________________ 126 148
Troubleshooting ________~~__~~_~_________~~~__~__ 85 86
Water pump ___________~__~_______---_----__--_ 124 146

Data :
Axle, front _____~__~_~____~_~_____~_. ~~_~..______ 221 254
Axle, rear ______________________-__--_~-__-__-- 212 246
Battery ________~____________-------__-________ 154 196
Body and frame.~._~______-~___~.._____--_~~__~___ 258 302
Brake system __~_~ ~~~~~__~ ~~~~__~_..~~_~___~___ 5 10
Clutch _~____~_____ -._ __~_ ._____~_____________ 195 233

AGO 10167B
342
 Paragraph
Data-Continued
Cooling system _____________________---__------_ 120 140
Engine ..__ ____________________-----___-~~--___- 101 105
Fuel and air intake system______~____-____------_ 127 149
Generating system ________~~______________-----_ 151 192
Ignition system _________~_~~___________________ 140 175
Lighting system ______~_~~____________~_------_- 154 196
Power-take-off _______~~___~____~~~___~___----___~ 197 234
Propeller shafts and universal joints ~~________~~__ 208 239
Springs and shock absorbers .___~_~~~ ~_~_________._ 248 293
Starting system _~~~__~_____~_~___~_~_______--~_ 147 187
Steering system ____________________------__--_- 232 267
Transfer ____________________________________ 197 234
Transmission __~~________________~_~~_-----__-_ 203 237
Winch ____________________-___----------------_ 54 37
Data plates ________~___~___~______---------~-----_- 5 10
Data, tabulated __________________________-_________ 6 16
Decalcomanias ______________~_______------____-___ 5 10
Deficiencies, correction ___________~__________________ 10 20
Description _____________~____~____-----~~~-____---_ 4 6
Destruction :
Burning ________________~___~~~_~.-_______ 283 332
Demolition __________~__~~~~~~________---_~-----_ 284 332
General_______-__-__________.~--_--_- 282 331
Gunfire _____~~_~~_______~~_______-------__----_ 285 333
Distributor____~__________~_-~---__----------___~~~__ 143 181
Distributor with coil___~~_~_______~~_____-----___ 146 185
Drive shaft, winch~_________--_____-----__------~--_ 169 217
Driving vehicle ___~______~_______________-~-__~~ ~~__ 44,45,46, 29,30,
48, 49, 50, 51 32,33

Electrical system, description____--__-___-----_---_--_ 4 6

Engine :
Air cleaner control valve- ~__~_ ~~_~~_________~~___ 107 114
Crankcase control valve____--__-___ __~___~_______ 107 114
Cylinder head __~__________.-~_~___. _______~_~___ 104 111
Data ___~_______________~__--~-~-~~----__~__~-_ 101 105
Description ________~~~____..~~__~~~~_~~____----_ 4,101 6,105
Fittings __.____~________~~~~_-.___~_~_~_~______ .__ 113 122
Gasket, cylinder head_~__~_~~~...____~~~_~_____---_ 103 106
Installation _~______~______~_~_____~_----------~ 118,119 133
Lines ____~_~____~__~~____~__~~_~_--~~-___--~~-~ 113 122
Manifold gasket replacement______~___---_------- 109 118
Manifold replacement _~_~ _~~_____~_______~_~~~~~ 108 115
Metering valves ~_______~~____~_~_~~__~_~____-~_ 107 114
Oil filter replacement _~~__~~~_~___~~__~_~~. ___ 110,111 118, 120
Operations performed while in vehicle----------__- 102 105
Removal ____________________-~---~~~~---~~~ 114,116,117 122,123
Serial number ____________________--~-__-______- 5 10
Starting _______________~_____----------~-----_- 43 28
Stopping __________~__________-__------__----_- 51 33
Troubleshooting ____________________-___--_____- 78 73
Valve adjustment ____________________--_----___- 105,106 111,113

343
 130 156
132 164
129 151
130 156
127 149
127 149
131 161
28, 133, 25,165,
134 167
135 168
136 171
130 156
79 78
131 161
175 224

Gage. (See Item for which used.)

(See Instrument cluster.)
Gages, troubleshooting ~~___~_____-.___~__~_-._~___---~. 87 88
Gasket, cylinder head_-___-----~._~ ______~~ __~____~___ 103 106
Gasket, manifold replacement-___. ~~____~__~~~_~_~___ 109 118
Generating system:
Data ~~______~~~__~~~___~~__~~~ ____~~~~_~~_____~_ 151 192
Description ~~~__ _~~~___~~____~_~~___~~~_____~~~ 151 192
Generator .__~~ ~~~..~~___~~~ ~_~_____.._~____~ 152 194
Radio interference suppression___--____--_-_____-- 183 228
Regulator _~~~~~_~~__~~____~_..~~_~~~___________--. 153 196
Troubleshooting _ ____-___________________------_ 83 84
Generator ________________________---_____---____-_- 152 194
Ground straps ___----___-_______________--.--_-----__ 194 232

Head, cylinder, replacement~_.~~~~..-~__--_____---_____ 104 111

Headlight ~___~~__~_~~.___~_________~~~~_---___-----_ 157 202
Hood __~~~____~~____~~~~_~~~~~_~_~_~~_____-_-~---__ 261 304
Horn. (See also Instrument cluster.) 86,185 88,229
Hose .~_~__~~~~__~________~~___ _~~__~__._________ 125 146

AGO 1016'7B
344
 Paragmph Page
Ignition system:
Cables ____________________-----__----~-- 145 185
Capacitor ~~~~~~________._.._~~~_______--------._ 143 181
Coil ~~~~~_~~~~~~~~~~_~_____~~~. ~_~~~~~~_____ 144,146 184,185
Data _..~~__ .~____~_~~~~~~~ .~_ ..-._ 140 175
Description ~~~~_____~ ~~~~ 140 175
Distributor _~~..~~__~__~~_~ _.~-~._.._~~____~___~___ 143 181
Distributor with coil ~~~~~~ _ ~~ ___-._~~~~~ ~~__ 146 185
Organizational maintenance _~ 141 176
Plugs ___- ---- ______~~_. .~~ 145 185
Radio interference suppression ~~~~~~_________ 192 232
Timing .~__~__~_~~__~~~~~_~___~ ~~~~~~~____~~~____-._ 142 176
Troubleshooting ~~~~ ___~ ~~~~_~_~_~_~~. ___~~_____ 81 82
Indicator light, headlight ~~_~~...__~~~~~~_~~~~~.._~~__~._ 179 226
Instruction plates ~~ 5 10
Instrument cluster, instruments, gages, switches, sending
units, and horn:
174 224
184 229
175 224
172 220
185 229
179 226
173 222
161,180 210,227
177 225
189 231
87 88
187 230
178 225
183 228
184 229
181 227
182 228
87 88
Water temperature gage 176 225

Light. (See also Lighting system.)

Light, beam indicator ~~~~~~___. _ _.._____________~~~_ 40 27
Lighting system :
Blackout headlight _~~_~~~_~~_~~~_____________~ 158 205
Blackout light ~_~~~_____ ~~~__~___~~___~~~_~_.~ 160 208
Blackout marker light .~_~ 159 207
Cables ~_~.~___~_~~~~ ._~ ~~~~~_______-~.-.__~_~_~~~~ 163 212
Circuits __~~~~~~~~__~_~~ __~~__~~__~~__ ~~~_ ~~ 163 212
Data ~~~____~~~~~~_______.________-~-- ~___~_~__~~ 154 196
Description ___~~~~~~_ ~_____~__~~~_~_ 154 196
Headlight __._~~~~~~~_~ 157 202
Headlight beam indicator light 164 213
Instrument panel light--- ~~~ ~~ ._~_ 161 210
Service parking lights-_- ~.._~ _..__________ 159 207
Stop light ____________~~~_. 160 208
Taillight ____~______~_~~~~~~ _ ._ ._____~_~ ~~~____ _ 160 208
Trailer coupling connector receptacle~~___-_______ 162 211

AGO 1016i'B 345

Lights, instrument panel_______-____-__--__--_-----_- 39 27
Lights, troubleshooting ______ _____________________-_- 84 85
Lines, fuel ___~_________________-------------____-__ 135 168
Loading for rail shipment____________________________ 279 324
Lock, map compartmental_________---_---_-----_-_--- 41 28
Lock, windshield _____________________--__--___---_-- 38 27
Lubrication :
After dusty or sandy conditions __________________ 71 59
After fording _________________~___-_____-_-_-__ 70 57
Below 0" F._______~___~____________-_------____- 69 57
Order ___________~__________---_---_--__---__-- 66 50
Instructions _____________________---__-------_- 67 50
Unusual conditions ___~___..______________---__-- 68 51

Maintenance under unusual conditions :

Extreme-cold weather _________~___________--_-- 272,273 318,319
Fording ____________~__~_____~~_---_-~~-___--_~ 275 320
Operation on unusual terrain ~__.______~___________ 276 322
Manifold replacement __~_~ __~~~_~__~___~___________~ 108 115
Mirror __________~___~~_________________________ 271 318
Muffler __________~___________------------_---__--__ 139 174

Nameplates _~___________________--__---_---_----_-- 5 10

Oilpressuregage..________~__________~---_----_----__ 177 225

Operation :
Cold weather ~____~____~_______~_____--__---__-- 57, 58 41, 42
Fording ~_____________________--_--~-_---___-__ 61 46
General________-___-_______-_------_--_-____-__ 42 28
Hot weather __~__________________--_--------_-- 59 44
Unusual conditions ___~~____~________..____---_-- 56 40
Unusual terrain _~___~____~___~___~__ .~_________ 276 322
Operations performed with engine in vehicle .~_______ 102 105
Organizational maintenance :
Allocation __~__________~________-_-------__-_-- 2 4
Body ____________________-_----_---_--------__- 259 303
Brakes _______~____~_______~____-----_---_--__- 241 278
Cooling system __~______~____________--------_-- 121 142
Frame _______~___~__~_____~_..--__ ~____________ 259 303
Front axle ~___________~__~_______---__---_---_- 223 254
Fuel and air intake system~___~___~________-__-_ 128 151
General__~___~_____-___-____---_---_----_-____- 233 268
Ignition system ________________~__~~___---___-- 141 1’76
Power-take-off __________________~__----------_-- 199 235
Rear axle __________________~________________--__-- 214 246
Springs and shock absorbers ~~_~_~___~__________ _ 249 294
Tires ____________________-~_-----------_------_ 254 299
Transfer ___~_________________--__---_---__---- 199 235
Transmission ____________________---_-_--__--__- 205 238
Wheels _____________________-___--__-__-_-___-- 255 299
Winch ____________________-______--_----_---_-_ 167 215

Painting ____________________---_--__--__--___------ 72 59
Parts _________~___________-~----__-_--------_----__ 62 48

346
 Parapraph Pane

Pintle ______________________--__----__----_________ 267 312

Plates, name, caution, data, and instruction____________ 5 10
Plugs, spark. (See Spark plug.)
Power plant installation ~__ ~~~~_~~ 119 133
Power plant removals____ ___~~___~_~~~~ 114,116 122
Power-take-off:
Coordination with ordnance maintenance unit__ ._.._ 198 235
Data ________~~_____~_~~~~~~~~~____~~__..-~~___~~ 197 234
Description ~~~~~~~~~~~~~~~___~___~____~__~_______ 24,197 24,234
Installation ______~~~_..-.__~_______~_----~_~ ~____ 202 236
Organizational maintenance __~_____~____________ 199 235
Removal ________~~ _~~____~_________~~______--- 202 236
Preventive maintenance service :
Cleaning __________~~~~_..~~~~~____~____------___ 74 60
Daily “A” and biweekly “B”__.._____________---- 75 61
General ______~_______ _. ..__ .__~_~~____________ 73 59
Mileage “C” and semiannual-mileage “D”______-_ 76 63
Propeller shafts and universal joints:
Data ____~_~___________~~~. ~~___~~~~______ 208 239
Description ___~_~_____~~ ~~~~~~_~~.._____________ 208 239
Installation _____~_____~_~__~~~~~~_____~__--____ 209 239
Removal ___~.~_________~~~~__~~_~__~~__--__~_--- 209 239
Sleeve yokes ____~__________~~_~~~~~____~_-_---~ 211 244
Troubleshooting __~~~~_____~~~. _~~~~~~-._~_~~____ 92 96
Universal joints ~~_~___.-______~~~_________~-~--- 210 241
Pump, fuel, and vacuum .._~~~~__~~~_. ~_..~~~_~_~~__~~ 127,131 149,161
Pump, water ____________________--~------~~----~~-- 124 146

Radiator ____________~~~_~~~~~~____~~___-~~----~~_~ 122 143

Radiator guard ~__~_~_~~_~~__~___..___~ __~~_________ 263 307
Radio interference suppression :
Description ~~~~~~~_~_~~~~~_______~~_..~~____~_~_ 88,191 91,231
Fasteners _________~~~__~___~~~~~______-------~_ 194 232
Generating system ~_____~_~~____~~-..__~___~____ 193 232
Ground straps ~____~_____________~~__~~_--~-~~~ 194 232
Ignition system ____________~ ~___~~~_~~~__~____~~~ 192 232
Purpose _______~________~~_~~____-~~-------~-~ 190 231
Rail shipment ____~__~__~~____~_____~___--------.. _~~ 279,280 324
Rear axle. (See Axle, rear.)
Receptacle, trailer coupling __ ~__~~____~___~~_~____~~ 162 211
Records ____~____________~~____--______________--__-- 3 5
Reflectors _~_____~~~~____~______________________ 270 318
Regulator,generator _~_~__________________-_-----~-- 153 196
Reports _~___~~_~_____~___________________________ 3 5

Seats and cushions______________-- ~. ~_~~~_~________ 268 314

Sending unit. (See Item for which used.)
(See Instrument cluster.)
Serial number plate-____________- 5 10
Service parking light~___________~ .._. ~. __~~_________ 159 207
Service upon receipt of material:
Break-in _______~________~~_____----------_----- 9 19
Correction of deficiencies ___..~________________-- 10 20

347
 Paragraph Page
Service upon receipt of material-Continued
Preliminary ~~__.~~~~~~~~~~~_~ ~_________ 8 18
Purpose ________________~ ~~. .~ ~~ ~- 7 18
Shackles _.._~~~~~~~~~__~~~._. 267 312
Shifting gears ___~_~___~ ~~~~~~ 46, 47,48 30, 31,32
Shipping instructions, domestic 277 323
Shock absorbers :
Troubleshooting ________________~_______------__ 98 100
Spark plug ____~~~________~______.._~--______ 145 185
Special tools and equipment________-----_-__--_--_---- 65 49
Speedometer __~~_._~~~~~~~~~~__~~~~_~~____~~~_~_~~~~ 31,178 25,225
Springs and shock absorbers :
Data ________~~__~~.~.._..__ ~_~~~_~~~~~~~__~____~~ 248 293
Description __~___~_~~_~__~~~~..~~________~~~_~~.._ 248 293
Organizational maintenance ~~__~___~___~______ 249 294
Pivot bolts _~~~~~~~_~~~~~~~~._~ _~~~~_____________ 251 296
Shackles ___~~~_~______~~~___~~_~~~~______~~~__~__ 250 294
Shock absorbers _~__.._______-.__~~_~~______---___ 253 298
Springs ______~~__~_____~~___________----_--_-_ 252 297
Troubleshooting ~~_~_____~._____________--___-_ 98 100

Starting system :
Auxiliary power receptacle~~_~~__~~~__--~-----___ 150 190
Data _________~~_~~_~ _~~_~~___~_______________~_- 147 187
Description _~_____~__~~ .___~__-._~__.~~_~________ 147 187
Pedal ______..______________----___-_-------_-__ 16 22
Switch ______~_~~___~~~_~~_~~ ~~~~~_~.._._._~__~____ 149 190
Starter __~~~~~______~_~~_~________~~__--------_ 148 182
Troubleshooting ______~~____~_.~~~_~~_______~__-_ 82 83
Steering system :
Adjustment, toe-in ~~__~__~~_~~__~_____~__~~______ 234 269
Bellcrank __~-...._~_____~__..__~~~~__--------_~___ 238 273
Data _.-~_~~__________~~____~~~.-_____________~ 232 267
Description ~_________~_~_______~~_~__-----~_~ __ 232 267
Drag link ~~~~_~__~~~..~~~~_~~~__~_~~_________~__ 237 272
Ends, tie rod ~_~_~__~~~~~~~_~__~_______~_____~.. 236 272
Organizational maintenance ~_~_~~____.._~___~___~ 233 268
Steering gear ___~~_~~~~_.._~______~_______----~~_ 239 274
Tie rod __~________~__________--~~~~~~~---~~__-- 235 270
Tie rod ends__________-------___------_------___ 236 272
Toe-in adjustment _____________-.~~__~~____--_--.- 234 269
Troubleshooting ______~_______________~_________ 99 101
Stoplight _____~~....___~_~ ~~~~..___ .__~_______________ 160 208
Storage instructions ~_~__ ~~ ~_ -_--- 278 324
Switch. (See also Instrument cluster.)
Switch :
Dimmer ____________~___. ~~_~_~ ~~_~__.._______~ 33,183 26,228
Horn ______________~______~~____-----_--_-_-- _ 184 229
Ignition __________.._~___~_____~~..-~~ __~_____~~ 32,181 26,227
Light ______________________---------_---_----- 33,52,182 26,33,228
Starter ____~__~________________----_____---____ 149 190
Stoplight ____________________--____-------_---- 186 229
Troubleshooting ______________________________-- 87 88

348 AGO
 ParaQmph Page
Tables :
I. Special Tools and Equipment for Organizational 65 49
Maintenance.
II. Driver’s or Operator’s Preventive Maintenance 75 61
Services.
III. Organizational Mechanic or Maintenance Crew ‘76 63
“C” and “D” Preventive Maintenance Services.
IV. Circuit Numbers and Descriptions ~_~ _~ ..-_~- 163 212
Taillight _____~________~~~~_~-.___~ ~~..~_~ .~~~~....~ _~__ 160 208
Tank, fuel ______________~~_________________ 127,136 149,171
Tank sending unit ~~~~~_~~~~_~__~~__~_~_~ _~__~____~__ 27 25
Thermostat __~~~~__~~..__~_____~____~__ _~___________ 126 148
Throttle control ____~___~_~_____~~__~~_~~~~_~____--- 130 156
Timing ignition ~______________~__~_________________ 142 176
Tires :
Data ____________~________________~--______ 254 299
Description _____________~._~_______---_------__- 254 299
Instructions regarding ~_________~_______~~~~__~~ 257 302
Organizational maintenance ~~_~~~__~____________ 255 299
Troubleshooting __________________________---___ 97 99
Top, doors, and side curtains-~-~~~~~~~~..__~_______--- 264 307
Towing vehicle __~~._~~~_~____~_~~~~____. ____________ 53 34
Transfer:
Coordination with ordnance maintenance unit______ 198,204 235,238
Data ________~~____~~~~_~~~~~~~~~__~~~~~~~ _____ 197 234
Description _______________~__~_~~_____________ 197 234
Gearshift lever _~_____~_~__~~~~___~________-__~_- 17,18 22
Installation __~_~__~~___~__~~_________________~ 118,119, 133,235,
201,207 238
Organizational maintenance __~ ~~~___~~ ~~__~__ 199,205 235,238
Removal ~~___~________ ____~_____ _______________ 114,116, 122, 132,
117,200,206 235,238
Shifting gears _~.._________~_________--______ 47 31
Troubleshooting _~~_~~___________________~_-~-_-_ 91 95
Transmission:
Data __________________~__~--_____---~------___ 203 237
Description ____~_________~_~~_____-.-----..~~-_~- 4,203 6,237
Gearshift lever __________________~______________ 19 23
Installation ___________~____~~~_____~~~___~__--- 118,119 133
Removal ____~___~_____________----___------ 114,116,117 122,132
Shifting gears __________________.~__-__----_-_--- 46, 50 30, 33
Troubleshooting ____________________-_-----_-___ 90 94
Troubleshooting :
Air intake and fuel system_-________--.-.------_--- 79 78
Battery ______________________-----____-----_-__ 84 85
Brake,hand ~_~_______~______~~________________ 96 99
Brake, service _____~_______________~_~_____ 95 98
Clutch ____________________________----------___ 89 93
Cooling system ____________________------------- 85 86
Engine _____________..______-------_------______ 77 72
Exhaust system ___~~~ __~__________________-____ 80 81
Front axle ~~__~__~_~..___~__________~__----_____ 93 96
Fuel and air intake system_-------__-___-___..____ 79 78

AGO 349
 Paraayraph Page
Troubleshooting-Continued
Gages ______~~___~______________-___________--- 87 88
Generating system ~____~____________ ____________ 83 84
Horn _____~_~~_~~~~~~~~~~__~_~_~~~ _.~_________ 86 88
Ignition system __~___~_~___~______~_____-___---- 81 82
Instruments ___~~_~~.._~___~_ ~~~__~_____~__~.._____ 87 88
Lighting ____________~________~~-___--.-__----- 84 85
Propeller shafts ~_~_~~____~_~~_________________.. 92 96
Rear axle ________.-___________---_--------_----- 94 97
Scope ________~_________~_____~---____________--_- 77 72
Sending units _______________~_____-.__---____--- 87 88
Springs and shock absorbers-_------__-----------. 98 100
Starting system ______~ __..___~______________--_ 32 83
Steering ____________________----_.------____---- 99 101
Switches _______~_____________-_---_-----_----__ 87 88
Tires _______________________----_--_-_--_____-- 97 99
Transfer ________________~_~___-__----_-_-_---- 91 95
Transmission _~_________~______~~~_~~___~___~__- 90 94
Universal joints ___~~_________________--_..-_--- 92 96
Wheels ______~__ ~_~ ___~___~_______~._________ 97 99
Windshield wipers _~~~~___~________________------ 100 104

Universal joint, winch ..~____________________---_-- 170 219

Vacuum pump ___________________---_-_--___----_-_ 131 161

Valve :
Adjustment _____.___. ~____________________--_ _ ._ 105,106 111,113
Control _______~_._ ~_ .___________________----- 107 114
Fuel shutoff __~_~ ~~_~ __~~~ _ _.._ ~~~..~ .._. __~_~.._~ 127 149
Metering ___~___~~____~~_~~~~~_ __..____________ 107 114
Windshield wiper motor _~~ _ ~_~__ _-.~___ 36 27

Water pump _________~~~__~_________----_---_-----_ 124 146

Water temperature gage~_____~---__-_----___-----__ 29,176 25,225
Wheels :
Data _________~____________----___------_------ 254 29s
Description ____________________---- ____________ 254 299
Installation _________~_____________------______- 256 300
Organizational maintenance _____________________ 255 299
Removal ____________________-----______-_______ 256 300
Troubleshooting ___~___________________--_______ 97 99
Winch :
Adjustment ____~__~________________----________ 168 215
Controls _________~___________---_-___-_-_______ 24 24
Coordination with ordnance maintenance unit----_- 166 213
Data ______________~___________________------____- 54 37
Description _~__~~~_______~~~___________________ 54,165 37,213
Drive shaft ____________________-..-__-----__---- 169 217
Hanger bearing _~~_____________________-______- 171 219
Installation ____________________-__----_-_------ 168 215
Operation ____________________----______________ 55 38
Removal ____________________---_-_-_----_____-_ 168 215
____________________-_--_---__--- 170 219
Windshield_---_------_---------_--__--------___---_ 260 303

AGO 10167B
Windshield wipers ____________________--___-__------ 100,266, 104,311,
266 312
Wiring circuits and cables___--_-__-_-__________-_-__ 163 212

[AG 451.2 (2 Sep 56)]

BY ORDER THE SECRETARIES OF THE ARMY
AND THE AIR FORCE:

MAXWELL D. TAYLOR,

OFFICIAL :
JOHN A. KLEIN,

F. TWINING,
OFFICIAL:
E. E. TORO,

Active Army:
CNGB (1) 229R, 9-347R, 9-3673, 9-387R (1).
Tee Svc, DA (1) except Ft & Cp (2)
COFOBD (25). Gen & Br Svc Sch (2) except Ord
Ord Bd (2) Sch (SO).
Hq, CONARC (3) PMST Ord ROTC Units (1)
Army AA Comd (2) Gen Depots (2) except Atlanta Gen
OS Maj Comd (2) Depot (None).
OS Base Comd (2) Ord Set, Gen Depots (5)
Log Comd (3) Ord Depot (10) except Rossford Ord
MDW (1) Depot (12)) Anniston Ord Depot
Armies (3) (16).
Corps (2) POE (2)
Div (2) OS Sup Agencies (1)
Brig (2) Ord PG (10)
Regt Gp (1) except Ord Ord Arsenal (5) except Raritan Ar-
GP (2). senal (100)) Benicia Arsenal (20).
Bn (1) except Ord Bn (2) Mil Dist (1)
except TOE: D-45R (1). Ord Proc Diet (10)
Ord Co (2) except TOE Q- MAAG (1)
12R, 9-17R, 9-46R, B- Mil Men (1)
47R, 9-49R, 9-57R, 9-
ZVt3: State AG (6): units-same as Active Army except allowance is
one eopy to each unit.
USA R : None.
For explanation of abbreviations used, see SR 326-50-l.

* U. S. Cov*mment Printing O&e: 1966-8677tO

AGO