T.O. 36A12-1B-1092-1-3

TM 9-2320-209-20-3-1T.O. 36A12-1B-1092-1-3

T E C H N I C A L M A N U A L

V O L U M E 3 O F 3

P A R T 1 O F 4

M A I N T E N A N C E

O R G A N I Z A T I O N A L L E V E L

2 ½-TON, 6X6, M44A1 AND M44A2 SERIES TRUCKS

( M U L T I F U E L )

T R U C K , C A R G O : M 3 5 A 1 ,

M35A2 , M35A2C, M36A2 ; TRUCK,

T A N K , F U E L : M 4 9 A 1 C , M 4 9 A 2 C ; T R U C K , T A N K ,

W A T E R : M 5 0 A 1 , M 5 0 A 2 , M 5 0 A 3 ; T R U C K , V A N ,

SHOP : M109A2 , M109A3 ; TRUCK, REPA IR SHOP :

M185A2 , M185A3 ; TRUCK , TRACTOR : M275A1 ,

M 2 7 5 A 2 ; T R U C K , D U M P : M 3 4 2 A 2 ; T R U C K ,

M A I N T E N A N C E , P I P E L I N E C O N S T R U C T I O N :

M 7 5 6 A 2 ; T R U C K , M A I N T E N A N C E ,

E A R T H B O R I N G A N D P O L E S E T T I N G : M 7 6 4

D E P A R T M E N T S O F T H E A R M Y A N D T H E A I R F O R C E

M A Y 1 9 8 1

TECHNICAL MANUALNO. 9-2320 -209-20-3-1

TM 9-2320-209-20-3-1

C1TECHNICAL ORDERNO. 36A12-1B-1092-1-3

CHANGE

No. 1

HEADQUATERS DEPARTMENT OF THE ARMYWASHINGTON D.C., 16 April 1990

T E C H N I C A L M A N U A L V O L U M E 3 O F 3 P A R T 1 O F 4 M A I N T E N A N C E O R G A N I Z A T I O N A L L E V E L 2-½ TON, 6X6, M44A1 AND M44A2 SERIES TRUCKS ( M U L T I F U E L )

TRUCK, CARGO: M35A1 M35A2, M35A2C, M36A2C; TRUCK, M35A2, M35A2C, M36A2C; TRUCK, TANK, FUEL: M49A1C; TRUCK, TANK, WATER, M50A1, M5012, M50A3; TRUCK, VAN, SHOP: M109A2, M109A3; TRUCK, REPAIR, SHOP: M185A2, M185A3; TRUCK, TRACTOR: M275A1, M275A2; TRUCK, DUMP: M342A2; TRUCK, MAINTENANCE, PIPLINE CONSTRUCTION: M 7 5 6 A 2 ; T R U C K , M A I N T E N A N C E , EARTH BORING AND POLSETTING: M764

TM 9-2320-209-20-3-1, 27 May 1981, is changed as follows:

1. Remove old pages and insert new pages as indicated below.2. New or changed information is indicated by a vertical bar in the margin of the page.

Remove Page Insert Page

i i i a n d i v N o n e

iii and iv 4-50.1 through 4-50.6

3. File this changed sheet in front of this publication for reference purposes.

By Order of the Secretary of the Army:

CARL E. VUONOGeneral , United States Army

Offical: Chief of Staff

WILLIAM J. MEEHAN IIBrigadier General, United States Army

The Adjutant General

By Order of the Secretary of the Air Force:

LARRY D. WELCHGeneral, United States Air Force

Chief of Staff

CHARLES C. McDONALDGeneral , United States Air Force

Commander, Air Force Logistics Command

DISTRIBUTION:To be distributed in accordance with DA form 12-38 (Block Nos. 0201,

0202), Operator and Unit maintenance requirements for Truck, Multifuel,2½ -ton, 6x6, M44A1 ans M44A2 series.

TMT O● ●

9-2320-209-20-3-136A12-1B-1092-1-3

TECHNICAL MANUAL DEPARTMENTS OF THE ARMYNO. 9-2320 -209-20-3-1 ANDTECHNICAL ORDER THE AIR FORCENO. 36A12-lB-1092-1-3 Washington, D. C., 27 May 1981

TECHNICAL MANUAL

VOLUME 3 OF 3

PART 1 OF 4

MAINTENANCEORGANIZATIONAL LEVEL

2½-TON,6X6, M44A1 AND M4A2 SERIES TRUCKS

(MULTIFUEL)

Model

Truck, Cargo

Truck, Tank, Fuel

Truck, Tank, Water

Truck, Van, Shop

Truck, Repair Shop

Truck, Tractor

Truck, Dump

Truck, Maintenance, PipelineConstruction

Truck, Maintenance, EarthBoring and Polesetting

M35A1M35A2M35A2CM36A2

M49A1CM49A2C

M50A1M50A2M50A3

M109A2M109A3

M185A2M185A3

M275A1M275A2

M342A2

M756A2

M764

NSN without Winch

2320-00-542-56332320-00-077-16162320-00-926-08732320-00-077-1618

2320-00-440-33492320-00-077-1631

2320-00-440-83072320-00-077-16332320-00-937-4036

2320-00-440-83132320-00-077-1636

4940-00-987-87994940-00-077-1638

2320-00-446-24792320-00-077-1640

2320-00-077-1643

NSN with Winch

2320-00-542-56342320-00-077-16172320-00-926-08752320-00-077-1619

2320-00-440-33462320-00-077-1632

2320-00-440-83052320-00-077-16342320-00-937-5264

2320-00-440-83082320-00-077-1637

4940-00-077-1639

2320-00-077-1641

2320-00-077-1644

2320-00-904-3277

2320-00-937-5980

*This manual, together with TM 9-2320-209-20-l, 27 May 1981; TM 9-2320-20-2-l, 27 May 1981; TM 9-2320-209-20-2-2, 27 May 1981; TM 9-2320-209-20-3-2, 27 May 1981; TM 9-2320-209-20-3-3, 27 May 1981; and TM 9-2320-209-20-3-4, 27 May 1981, supersedes TM 9-2320-209-20-1, 31 August 1978.

i

TM 9-2320-209-20-3-1

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistake or if you knowof a way to improve the procedure, please let us know. Mail your letter,DA Form 2028 (Recommended Changes to Publication and Blank Forms) , orDA Form 2028-2 located in the back of this manual direct to: Commander,U.S. Army Tank Automotive Materiel Readiness Command, ATTN: DRSTA-MB , Warren, Michigan 48090. A reply will be furnished to you.

TABLE OF CONTENTS

CHAPTER 1. GENERAL MAINTENANCE INFORMATIONScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air System Leakage Test.... . . . . . . . . . . . . . . . . . . . . .Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . .Common Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Inspection and Testing of Lifting Device . . .Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Improvement Report andMaintenance Digest (EIR MD) andEquipment Improvement Report andMaintenance Summary (EIR MS) . . . . . . . . . . . . . . . . .

Reporting Improvement Recommendations . . . . . . . . .Metric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Destruction to Prevent Enemy Use . . . . . . . . . . . . . . .Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Upon. Receipt of Materiel . . . . . . . . . . . . . . . . .Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . .General Lubrication Instructions . . . . . . . . . . . . . . . . .Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2. ENGINE SYSTEM GROUP MAINTENANCESection I . Scope

Equipment Items Covered . . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . . . . . .

Section II . Engine AssemblyFront Engine Mounts Removal and Replacement . . .

Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . . . . .Identification of Engine Mounts . . . . . . . . . . . . . . . . .Removal (Basic Type) . . . . . . . . . . . . . . . . . . . . . . . . .Replacement (Basic Type) . . . . . . . . . . . . . . . . . . . . .Removal (Revised Type) . . . . . . . . . . . . . . . . . . . . .Replacement (Revised Type) . . . . . . . . . . . . . . . . . . .

Paragraph Page

1-11-21-31-41-51-61-71-81-91-10

1-111-121-131-141-151-161-171-181-191-201-21

2-12-2

2-32-3a2-3b2-3C2-3d2-3e2-3f

1-11-11-11-21-21-21-21-21-21-2

1-21-51-51-51-51-51-101-111-111-111-11

2-12-12-12-12-12-12-22-32-52-62-8

ii

TM 9-2320-209-20-3-1

TABLE OF CONTENTS-CONT

Section III.

CHAPTER 3.Section 1.

Section II.

CHAPTER 4.Section 1.

Section 11.

Section III.

Rear Engine Mounts Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication System . . . . . . . . . . . . . . . . . . . .Oil Filter Element Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . .. . . . . . . . . . .

Crankcase Breather Tube Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH SYSTEM GROUP MAINTENANCEScope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Covered . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . .

Clutch Linkage Assembly . . . . . . . . . . . . . . . . . . . .Clutch Control and Linkage Removal,Repair, Replacement, and Adjustment . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM GROUP MAINTENANCEScope . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . .Equipment Items Covered . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered. . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intake Air Cleaner Removal, Repair,and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner Indicator Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tanks and Fuel Lines . . . . . . . . . . . . . . . . . .Fuel Lines and Fittings Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

2-42-4a2-4b2-4C

2-52-5a2-5b2-5C

2-62-6a2-6b2-6C

3-13-2

3-33-3a3-3b3-3C3-3d3-3e

4-14-2

4-34-3a4-3b4-3C4-3d

4-44-4a4-4b

4-54-5a4-5b

Page

2-102-102-102-122-13

2-132-132-132-16

2-192-192-192-24

3-13-13-13-1

3-13-13-23-73-73-15

4-14-14-14-1

4-14-14-24-44-4

4-64-64-74-8

4-84-94-19

i i i

TM 9-2320-209-20-3-1


Section IV.

Section V.

Fuel Tank Removal and Replacement (AllTrucks Except Trucks M275A1 andM275A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Removal and Replacement(Trucks M275A1 and M275A2) . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump (In-Tank) Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump (In-Tank) Bracket and Pump AssembliesPreliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump (In-Tank) Fuse Removaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Filter Assemblies Removal,Replacement, and Air Bleeding . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal of Primary Fuel Filter Assembly . . .Removal of Secondary and Final Fuel FilterAssemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement of Primary Fuel Filter . . . . . . . . .Replacement of Secondary and Final FuelFilter Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .Air Bleeding of Low Pressure Fuel System . .

Fuel Filters Repair . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Disassembly of Primary Fuel Filter . . . . . . . . .Disassembly of Secondary and FinalFuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . .Assembly of Primary Fuel Filter . . . . . . . . . . .Assembly of Secondary and Final FuelFilters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold Heater (Top-Mounted, Uncovered)Nozzle and Valve Assembly, Removal andReplacement (Trucks with EnginesLDS 427-2 and LDS 465-1) . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

4-64-6a4-6b4-6c

4-74-7a4-7b4-7c

4-84-8a4-8b4-8c4-8.14-8.la4-8.lb4-8.lc

4-94-9a4-9b

4-104-10a4-10b

4-10c4-10d

4-10e4-10f4-114-11a4-11b

4-11c4-11d4-11e

4-11f

4-124-12a4-12b4-12c

Page

4-294-294-294-31

4-334-334-334-39

4-464-464-464-484-50.14-50.14-50.34-50.5

4-514-514-534-55

4-554-554-55

4-574-58

4-604-614-634-634-63

4-654-674-67

4-694-71

4-714-714-714-72

i v Change 1

TM 9-2320 -209-20-3-1

TABLE OF CONTENTS-CONTParagraph Page

Manifold Heater (Top-Mounted, Uncovered)Ignition Unit Removal and Replacement . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Top-Mounted, Uncovered)Spark Plug Removal and Replacement(Trucks with Engines LDS 427-2 andLDS 465-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Side-Mounted) FuelFilter Removal and Replacement . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Side-Mounted) Spark Plugand Nozzle Removal and Replacement . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . .

Engine Manifold Heater Removal andReplacement (Trucks with EnginesLDS 427-2and LDS 465-1). . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater Fuel Pump Removal andReplacement (Trucks with EnginesLDS 427-2 and LDS 465-1) . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . .Replacement. . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater Electric Fuel Supply Pumpand Fuel Filter Removal and Replacement . . . . .Preliminary Procedures . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement. . . . . . . . . . . . . . . . . . . .

Engine Manifold Heater Pump Lines andFittings Removal and Replacement (Truckswith Engines LDS 427-2 and LDS 465-1) . . . . . .Preliminary Procedures . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . .

Manifold Heater Nozzle and Valve AssemblyRemoval and Replacement . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . .

4-134-13a4-13b4-13c

4-144-14a4-14b4-14c

4-154-15a4-15b4-15c

4-164-16a4-16b4-16c

4-174-17a4-17b4-17c

4-184-18a4-18b4-18c

4-194-19a4-19b4-19c

4-204-20a4-20b4-20c

4-214-21a4-21b4-21c

4-734-734-734-74

4-754-754-754-76

4-774-774-784-82

4-864-864-864-87

4-884-884-894-91

4-944-944-944-96

4-984-984-984-100

4-1024-1024-1024-111

4-1214-1214-1214-122

v

TM 9-2320-209-20-3-1


Manifold Heater Ignition UnitRemoval and Replacement (Truckswith Engines LDS 427-2 and LDS 465-1) . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Top-Mounted, Covered)Spark Plug Removal and Replacement . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Top-Mounted, Covered)Fuel Filter Removal and Replacement . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake Manifold (Top-Mounted, Covered)Flame Heater and Elbow Removal andReplacement (Trucks with EnginesLD 465-1, LD 465-lC, and LDT 465-lC) . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Flame Heater (Top-Mounted,Covered) Fuel Pump and Ignition UnitRemoval and Replacement (Trucks withEngines LD 465-1, LD 465-lC and LDT 465-lC) .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater (Top-Mounted, Covered)Ignition Coil and Fuel Pump Removal andReplacement (Trucks with EngineLD 65-lC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section VI. Accelerator, Throttle, and Engine Stop ControlsThrottle Control and Linkage Removal,Repair, Replacement and Adjustment. . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator Controls and Linkages, Removal,Repair, Replacement, and Adjustment. . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-224-22a4-22b4-22C

4-234-23a4-23b4-23C

4-244-24a4-24b4-24c

4-254-25a4-25b4-25C

4-264-26a4-26b4-26c

4-274-27a4-27b4-27C

4-284-28a4-28b4-28c4-28d4-28e

4-294-29a4-29b

4-1234-1234-1234-125

4-1274-1274-1274-128

4-1294-1294-1294-130

4-1314-1314-1324-138

4-1434-1434-1444-147

4-1504-1504-1514-1544-157

4-1574-1574-1574-1604-1604-163

4-1664-1664-166

vi

TM 9-2320-209-20-3-1


Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Stop Controls and LinkagesRemoval, Repair, Replacement, andAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5. EXHAUST SYSTEM GROUP MAINTENANCESection I. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Items Covered . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . . .

Section II. Exhaust Pipes and Mufflers . . . . . . . . . . . . . . . . . . . . .Exhaust System (Horizontal) Removal andReplacement (Trucks with Engine LD 465). . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System (Horizontal) Removal andReplacement (Trucks M50A1, M50A2,and M50A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System (Horizontal) Removal andReplacement (Trucks with Engine LD 427)Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System (Vertical Stack) Removaland Replacement (Trucks with EnginesLD 465-1, LD 465-lC , and LDT 465-ICExcept Truck M50A2 and M50A3) . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System (Clean Air) Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6. COOLING SYSTEM GROUP MAINTENANCESection I. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Paragraph

4-29C4-29d4-29e

4-304-30a4-30b4-30C4-30d4-30e

5-15-2

5-35-3a5-3b5-3C

5-45-4a5-4b5-4C

5-55-5a5-5b5-5C

5-65-6a5-6b5-6C

5-75-7a5-7b5-7C

6-16-2

Page

4-1694-1694-174

4-1754-1754-1754-1774-1774-179

5-15-15-15-1

5-15-15-25-10

5-175-175-185-30

5-455-455-455-50

5-555-555-555-64

5-765-765-765-83

6-16-16-1

v i i

TM 9-2320-209-20-3-1


Section II.

Section III.

Section IV.

Section V.

Section VI.

CHAPTER 7.Section I.

Section II.

Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radiator Removal and Replacement . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Stone Shield Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses and Clamps Removal and Replacement . . .Cooling System Hoses and Clamps . . . . . . . . . .Turbocharger System Hoses and Clamps . . . . .

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermostat Removal and Replacement . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Pump Removal and Replacement . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Assembly and Related Parts . . . . . . . . . . . . . . . .Engine Cooling Fan Removal and Replacement . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Drive Belts Removal, Replacement, andAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement and Adjustment . . . . . . . . . . . . . . .

Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . .Cooling System Service . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Neutralization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM GROUP MAINTENANCEScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Covered . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . .

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator and Pulley Removal and Replacement.

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

6-36-3a6-3b6-3C

6-46-4a6-4b6-4C6-56-5a6-5b

6-66-6a6-6b6-6C

6-76-7a6-7b6-7C

6-86-8a6-8b6-8C

6-96-9a6-9b6-9C

6-106-10a6-10b6-10C6-10d6-10e6-10f

7-17-2

7-37-3a7-3b

Page

6-16-16-16-16-8

6-166-166-166-186-206-206-276-316-316-316-316-346-396-396-396-396-406-426-426-426-426-43

6-446-446-446-466-496-496-496-506-516-546-676-73

7-17-17-17-17-17-17-2

viii

TM 9-2320- 209-20-3-1


Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator and Pulley Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Regulator Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section III. Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Pedal and Linkage AssemblyRemoval, Repair, and Replacement . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Starter Switch Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Switch Removal, Replacementand Adjustment (Trucks with PedalStarter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Button Removal and Replacement . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starter Removal and Replacement(Trucks with Floor Pedal Starter Switch) . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . ...” . . . .

Engine Starter Removal and Replacement(Trucks with Pushbutton Starter Switch) . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section IV. Instrument Panel Components . . . . . . . . . . . . . . . . . .Instrument Cluster Removal and Replacement. . .

Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

7-3C7-3d

7-47-4a7-4b7-4C

7-57-5a7-5b7-5C

7-67-6a7-6b7-6C7-6d

7-77-7a7-7b7-7C

7-87-8a7-8b7-8C7-8d7-97-9a7-9b7-9C

7-107-10a7-10b7-10C

7-117- lla7-1lb7-llC

7-127-12a7-12b7-12c

Page

7-67-11

7-147-147-147-20

7-277-277-277-287-29

7-297-297-297-317-31

7-357-357-367-38

7-417-417-417-427-447-467-467-467-47

7-487-487-487-51

7-547-547-547-597-647-647-647-647-69

i x

TM 9-2320-209-20-3-1


Instrument Cluster Components (ExceptSpeedometer and Tachometer) Removaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light Switch Removal and Replacement . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Switch Removal and Replacement . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Breaker Removal and Replacement . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section V. Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Service Headlight AssemblyRemoval and Replacement . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Service Headlight Assembly Repair . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Service Headlight Assembly Adjustment . .Front Service Sealed Beam Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Drive Light Assembly and BracketRemoval and Replacement (Trucks withWinch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Drive Light Assembly and BracketRemoval and Replacement (Trucks WithoutWinch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Drive Light Sealed Beam UnitRemoval and Replacement . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-137-13a7-13b7-13C7-147-14a7-14b7-14C7-157-15a7-15b7-15C7-167-16a7-16b7-16c

7-177-17a7-17b7-17C7-187-18a7-18b7-18C7-18d7-19

7-207-20a7-20b

7-217-21a7-21b7-21c

7-227-22a7-22b7-22C

7-237-23a7-23b

7-747-747-747-767-787-787-787-807-827-827-827-847-867-867-867-877-88

7-887-887-887-897-907-907-907-927-937-95

7-1027-1027-103

7-1047-1047-1047-106

7-1097-1097-1097-111

7-1137-1137-115

x

TM 9-2320-209- 20-3-1


Blackout Drive Light Assembly RepairPreliminary Procedures . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection and Repair . . . . . . . . . . . .

Taillight and Stoplight Assembly (RightSide Only) Removal and Replacement(Early Model Trucks with Turn Signals) . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taillight and Stoplight Assembly (RightSide Only) Repair (Truck M756A2). . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taillight and Stoplight Lamps (Right SideOnly) Removal and Replacement . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taillight and Stoplight Assembly (Left SideOnly) Removal and Replacement . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taillight and Stoplight Lamp (Left SideOnly) Removal and Replacement . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Taillight and Stoplight Assembly (LeftSide Only) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Stoplight Assembly (RightSide Only) Removal and Replacement(Early Model Trucks with Turn Signals) . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Stoplight Lamp (Right Side Only)Removal and Replacement (Early ModelTrucks with Turn Signals) . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Stoplight Assembly (Right Side Only)Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rep air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

7-247-24a7-24b

7-257-25a7-25b7- 25c

7-267-26a7-26b7-26c7-26d

7-277-27a7-27b

7-287-28a7-28b

7-297-29a7-29b

7-307-30a7-30b7-30C7-30d

7-317-31a7-31b

7-327-32a7-32b

7-337-33a7-33b7-33C7-33d

Page

7-1177-1177-118

7-1197-1197-1197-120

7-1217-1217-1217-1227-123

7-1247-1247-124

7-1267-1267-127

7-1287-1287-129

7-1307-1307-1307-1317-132

7-1337-1337-134

7-1357-135”7-136

7-1377-1377-1377-1387-138

x i

TM 9-2320-209-20-3-1


Front Marker Light and Bracket AssemblyRemoval and Replacement. . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Marker Lamps Removal and Replacement..Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Marker Light Repair . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floodlight and Bracket Assembly Removal,Repair, and Replacement (Truck M756A2) . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floodlight Housing Removal, Repair, andReplacement (Truck M756A2) . . . . . . . . . . . . . . . . .

Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection and Repair . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floodlight Sealed B earn Removal, Repair,and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair. . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Composite Light and Bracket AssemblyRemoval and Replacement . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Composite Lamps Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Composite Light Repair . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection and Repair . . . . . . . . . . .

Rear Composite Light and Bracket AssemblyRemoval and Replacement . . . . . . . . . . . . . . . . . . . .

Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Composite Light Repair . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . . .

xii

Paragraph Page

7-347-34a7-34b7-357-35a7-35b7-367-36a7-36b7-36c7-36d

7-377-37a7-37b7-37C

7-387-38a7-38b7-38c7-38d

7-397-39a7-39b7-39C

7-407-40a7-40b

7-417-41a7-41b7-427-42a7-42b

7-437-43a7-43b7-43C7-447-44a7-44b

7-1397-1397-1417-1447-1447-1457-1467-1467-1467-1477-148

7-1497-1497-1507-150

7-1517-1517-1517-1527-153

7-1547-1547-1567-156

7-1587-1587-160

7-1637-1637-1647-1657-1657-166

7-1677-1677-1677-1697-1717-1717-172

TM 9-2320 -209-20-3-1


Rear Composite Lamps Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Blackout Clearance LightsRemoval and Replacement (Truck M756A2) . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Blackout Clearance LampsRemoval and Replacement. . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section VI. Sending Unit Gages and Warning BuzzersWater Temperature Transmitter Removaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Transmitter Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Gage Sending Unit Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Air Pressure Buzzer Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section VII. Horn Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horn Button Removal, Repair, andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures. . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Horn and Solenoid Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures. . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Horn Removal and Replacement . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

7-457-45a7-45b

7-467-46a7-46b

7-477-47a7-47b

7-487-48a7-48b7-48c

7-497-49a7-49b7-49C

7-507-50a7-50b7-50C

7-517-51a7-51b

7-527-52a7-52b7-52c7-52d7-52e

7-537-53a7-53b7-53C7-547-54a7-54b7-54C

Page

7-1737-1737-174

7-1757-1757-177

7-1797-1797-1807-181

7-1817-1817-1817-182

7-1837-1837-1837-184

7-1857-1857-1857-186

7-1887-1887-1897-190

7-1907-1907-1907-1937-1937-193

7-1977-1977-1977-1997-2027-2027-2027-203

x i i i

TM 9-2320-209-20-3-1


Section VIII. Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Batteries . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Specific Gravity Check . . . . . . . . . . . . . . . . . . . . .Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . .

Storage Batteries Removal and Replacement . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ground Straps Removal and Replacement . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Ground Cable . . . . . . . . . . . . . . . . . . . . . . . .Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section IX. Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator-to-Regulator Harness Removal,Repair, and Replacement (Trucks withEngines LDS 427-2, LD 465-1, andLDT 465-lC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer Connector Electrical CableRemoval and Replacement . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer Electrical Coupling ReceptacleRemoval and Replacement . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer Electrical Receptacle Removaland Replacement (Trucks M275A1 and M275A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section X. Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . .Directional Signal and Solid State FlasherRemoval, Repair, and Replacement . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Heater Switch Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..”....Replacement . . . . . . . . . . . . . . . . . . . . ...”... . . . .

7-557-55a7-55b7-55C7-567-56a7-56b7-577-57a7-57b7-587-58a7-58b

7-597-59a7-59b7-59C7-59d

7-607-60a7-60b

7-617-61a7-61b

7-627-62a7-62b

7-637-63a7-63b7-63c7-63d

7-647-64a7-64b7-64c

7-2057-2057-2057-2057-2077-2097-2097-2127-2177-2177-2207-2237-2237-2257-227

7-2277-2277-2277-2287-229

7-2307-2307-231

7-2327-2327-234

7-2367-2367-2397-242

7-2427-2427-2427-2447-246

7-2487-2487-2487-249

xiv

TM 9-2320-209-20-3-1



Section II.

CHAPTER 9.

Section I.

Section II.

Headlight Dimmer Switch Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Floodlight Housing Switch Removal, Repair,and Replacement (Trucks M756A2 andM764). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning, Inspection, and Repair . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Stoplight Switch Removal andReplacement (All Trucks Except ModelsM275A1 and M275A2) . . . . . . . . . . . . . . . . . . . . . . . .Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement of Switch pn 7064588 . . . . . . . . . .Replacement of Switch pn 7760414 withSwitch pn 7064588 . . . . . . . . . . . . . . . . . . . . . . . . .

Air Stoplight Switch Removal and Replacement(Trucks M275A1 and M275A2) . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Air Pressure Buzzer Switch Removaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type A Replacement . . . . . . . . . . . . . . . . . . . . . . . .Type B Replacement . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION SYSTEM GROUP MAINTENANCEScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Covered . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . . . .

Transmission Breather Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission Breather . . . . . . . . . . . . . . . . . . . . . .

Preliminary Procedure . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION TRANSFER SYSTEM GROUPMAINTENANCEScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Covered . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered. . . . . . . . . . . . . . . . . .

Paragraph

7-657-65a7-65b7-65c

7-667-66a7-66b7-66c7-66d

7-677-67a7-67b

7-67c

7-687-68a7-68b7-68C

7-697-69a7-69b7-69C7-69d

8-18-2

8-38-3a8-3b8-3C

9-19-2

Transmission Transfer Control and Linkage AssemblyTransmission Transfer Controls and LinkageWith Power Takeoff Removal and Replacement(Trucks M49A1C, M49A2C, M50A1, M50A2,M50A3, M756A2, and M764) . . . . . . . . . . . . . . . . . . . 9-3

Page

7-2507-2507-2507-252

7-2547-2547-2547-2557-256

7-2577-2577-260

7-261

7-2637-2637-2647-265

7-2667-2667-2667-2697-270

8-18-18-1

8-18-18-18-28-3

9-19-19-19-1

x v

TM 9-2320-209-20-3-1


Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal of Transmission Transfer ShiftLever and Linkage (Trucks M756A2 andM764) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of Transmission Transfer ShiftLever and Linkage (Trucks M49A1C ,M49A2C, M50A1, M50A2, and M50A3) . . . . . . .Removal of Transmission Transfer ReverseShift Linkage (Transfers Without AirActuated Positive Lockup) . . . . . . . . . . . . . . . . . .Removal of Power Takeoff Shift Controlsand Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of Transmission Transfer PowerTakeoff Shifting Lever Lockout Linkage(Trucks M49A1C, M49A2C, M50A1, M50A2,and M50A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair of Transmission Transfer Controlsand Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement of Transmission Transfer ShiftLever and Linkage (Trucks M49A1C ,M49A2C, M50A1, M50A2, and M50A3) . . . . . . . .Replacement of Transmission Transfer ShiftLever and Linkage (Trucks M756A2 andM764) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement of Transmission TransferPower Takeoff Shift Controls and Linkage . . .Replacement of Transmission TransferPower Takeoff Shifting Lever LockoutLinkage (Trucks M49A1C , M49A2C ,M50A1, M50A2, and M50A3) . . . . . . . . . . . . . . . . .

Transmission Transfer Controls andLinkage (Without Power Takeoff)Removal, Repair, and Replacement . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal of Transmission Transfer ShiftLever and Linkage . . . . . . . . . . . . . . . . . . . . . . . . .Removal of Transmission Transfer ReverseShift Lever and Linkage (TransmissionTransfers Without Air ActuatedPositive Lockup) . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly of Transmission TransferReverse Shift Rod (TransmissionTransfers Without Air ActuatedPositive Lockup ) . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly of Transmission Transfer ReverseShift Rod (Transmission Transfers WithoutAir Actuated Positive Lockup) . . . . . . . . . . . . .Repair of Transmission Transfer Controlsand Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

9-3a

9-3b

9-3C

9-3d

9-3e

9-3f

9-3g

9-3h

9-3i

9-3j

9-3k

9-49-4a

9-4b

9-4C

9-4d

9-4e

9-4f

Page

9-1

9-1

9-2

9-4

9-4

9-5

9-8

9-14

9-16

9-249-24

9-25

9-27

9-33

9-35

x v i

TM 9-2320-209-20-3-1

TABLE OF CONTENTS-CONTParagraph

Replacement of Transmission TransferShift Lever and Linkage . . . . . . . . . . . . . . . . . . .Replacement of Transmission TransferReverse Shift Levers and Linkage(Transmission Transfers WithoutAir Actuated Positive Lockup) . . . . . . . . . . . . .

Transmission Transfer Reverse ShiftLinkage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Transmission Transfer Reverse ShiftLinkage Check . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Transfer Reverse ShiftLinkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Adjustment (Forward Speed) . . . . . . . . . . . . . . . .Adjustment (Reverse Speed) . . . . . . . . . . . . . . .

Transmission Transfer Output Cover Sealand Air Vent Removal and Replacement . . . . . . .Preliminary Procedure . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 10. PROPELLER SHAFTS GROUP MAINTENANCESection I. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Section II. Propeller Shaft Assemblies . . . . . . . . . . . . . . . . . . . . .Propeller Shaft and Universal Joint(Intermediate Propeller Shaft) Removaland Replacement (Truck 36A2) . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propeller Shaft and Universal JointsRemoval and Replacement (All ExceptIntermediate Propeller Shaft OnTruck M36A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Universal Joint (Snapring, C-Ring, andBearing Cap Type) Repair . . . . . . . . . . . . . . . . . . .Disassembly (Snapring and C-Ring Type). . . .Disassembly (Bearing Cap Type) . . . . . . . . . . . .Cleaning (All Types) . . . . . . . . . . . . . . . . . . . . . .Inspection and Repair (All Types) . . . . . . . . . . .Assembly (Snapring and C-Ring Type) . . . . .Assembly (Bearing Cap Type) . . . . . . . . . . . . .

CHAPTER 11. FRONT AXLE GROUP MAINTENANCESection I. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Items Covered . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . .

9-4g

9-4h

9-59-5a

9-5b

9-69-6a9-6b9-6C

9-79-7a9-7b9-7C

10-110-2

10-310-3a10-3b

10-410-4a10-4b

10-510-5a10-5b10-5C10-5d10-5el0-5f

11-111-2

Page

9-35

9-41

9-459-45

9-45

9-469-469-469-49

9-519-519-519-52

10-110-110-110-1

10-110-210-5

10-910-910-10

10-1210-1210-1510-2010-2010-2110-24

11-111-111-1

xvii

TM 9-2320-209-20-3-1


Section II. Front Axle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jacking and Supporting Axle Housing . . . . . . . . . . .

Jacking and Supporting Front AxleHousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of Front Axle Housing Supports. . . . . . .Jacking and Supporting RearAxle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of Rear Axle Housing Supports . . . . . . .

Jacking and Supporting Truck Chassis . . . . . . . . . .Raising Front Chassis . . . . . . . . . . . . . . . . . . . . . . . .Lowering Front Chassis . . . . . . . . . . . . . . . . . . . . . . .Raising Rear of Chassis (One Side). . . . . . . . . . . .Lowering Rear of Chassis (One Side) . . . . . . . . . .Raising Rear of Chassis (Both Sides) . . . . . . . . . .Lowering Rear of Chassis (Both Sides). . . . . . . . .

Front Axle Shaft Assembly Removaland Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section III. Steering Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Knuckle Boot Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 12. REAR AXLE GROUP MAINTENANCESection I. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Items Covered . . . . . . . . . . . . . . . . . . . . . . .Equipment Items Not Covered . . . . . . . . . . . . . . . . . . .

Section II. Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Shaft Removal and Replacement. . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Axle Breather Valve Removal andReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3

11-3a11-3b

11-3C11-3d11-411-4a11-4b11-4C11-4d11-4e11-4f

11-511-5a11-5b11-5C

11-611-6a11-6b

12-112-2

12-312-3a12-3b

12-412-4a12-4b

11-211-3

11-411-511-611-611-711-811-911-1011-11

11-1211-1211-1211-14

11-22

12-112-112-112-112-112-112-3

12-412-412-5

xviii

TM 9-2320-209-20-3-1


Section II.Section III.Section IV.Section V.Section VI.Section VII.Section VIII.CHAPTER 14.

Section I.Section II.Section III.Section IV.

CHAPTER 15.Section I.Section II.

CHAPTER 16.


CHAPTER 17.


CHAPTER 18.

Section I.Section II.Section III.Section IV.Section V.Section VI.

Section VII.Section VIII.

TABLE OF CONTENTS-CONTPART 2 OF 4 Paragraph

( TM 9-2320 -209-20-3-2 )

BRAKE SYSTEM GROUP MAINTENANCE . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Handbrake Assembly and Related Parts . . . . . . . . . . .Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Brake System . . . . . . . . . . . . . . . . . . . . . . . .Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . .Trailer Brake Connections . . . . . . . . . . . . . . . . . . . . . . .WHEEL GROUP MAINTENANCE. . . . . . . . . . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STEERING SYSTEM GROUP MAINTENANCE . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Steering Gear Assembly . . . . . . . . . . . . . . .FRAME AND TOWING ATTACHMENTS GROUPMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pintle and Towing Attachments . . . . . . . . . . . . . . . . . .Spare Wheel Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fifth Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPRINGS AND SHOCK ABSORBERS GROUPMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART 3 OF 4( TM 9-2320 -209-20-3-3 )

BODY , CAB , HOOD, AND HULL GROUPMAINTENANCEScopeCab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brackets and Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cargo Body Components . . . . . . . . . . . . . . . . . . . . . . . .Tank Body Components . . . . . . . . . . . . . . . . . . . . . . . . .Special Purpose Bodies . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

13-113-113-113-4913-7313-13413-14813-23713-26714-114-114-114-4614-7815-115-115-1

16-116-116-116-1716-48

17-117-117-117-1117-12

18-118-118-118-1418-1818-4618-4818-6718-359

xix

TM 9-2320-209-20-3-1


CHAPTER 19.

Section I.Section II.Section III.

CHAPTER 20.Section I.Section II.

CHAPTER 21.


CHAPTER 22.

Section I.Section II.

CHAPTER 23.


APPENDIX A.INDEX

PART 4 OF 4( TM 9-2320-209-20-3-4)

WINCH AND HOIST ASSEMBLIES AND POWERTAKEOFF CONTROLS AND LINKAGE GROUPMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Winch and Hoist Assemblies.. . . . . . . . . . . . . . . . . . . . .Power Takeoff Controls and Linkage . . . . . . . . . . . .BUMPER GUARDS GROUP MAINTENANCE . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bumper Brackets, Guards, and ProtectiveDevices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BODY ACCESSORY ITEMS GROUPMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Canvas Accessory Items . . . . . . . . . . . . . . . . . . . . . . . .Cab Accessory Items . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NONELECTRICAL GAGES GROUPMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ScopeNonelectrical Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE OF MATERIAL USED INCONJUNCTION WITH MAJOR ITEMS . . . . . . . . . . . .Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Winterization Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deep Water Fording Kit . . . . . . . . . . . . . . . . . . . . . . . . .Special Purpose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . .REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph Page

19-119-119-119-12920-120-1

20-1

21-121-121-121-421-24

22-122-122-1

23-123-123-123-10323-120A-1Index 1

xx

TM 9-2320- 209-20-3-1

CHAPTER 1

GENERAL MAINTENANCE INFORMATION

1-1. SCOPE . This manual contains the organizational maintenance instructions forthe trucks listed below. This manual includes procedures for disassembly, cleaning,inspection, repair, test and adjustment as authorized by the maintenance allocationchart.

Truck, Cargo: 2 1/2 ton, 6x6, M35A1, M35A2, M35A2C, and M36A2Truck, Dump: 2 1/2 ton, 6x6, M342A2Truck, Tractor: 2 1/2 ton, 6x6, M275A1 and M275A2Truck, Tank, Fuel: 2 1/2 ton, 6x6, M49A1C and M49A2CTruck, Tank, Water: 2 1/2 ton, 6x6, M50A1, M50A2, and M50A3Truck, Repair Shop: 2 1/2 ton, 6x6, M185A2 and M185A3Truck, Van, Shop: 2 1/2 ton, 6x6, M109A2 and M109A3Truck, Maintenance, Earth Boring and Polesetter: 2 1/2 ton, 6x6, M764Truck, Maintenance, Pipeline Construction: 2 1/2 ton, 6x6, M756A2

Information is provided on maintenance of trucks which is beyond the scope of tools,equipment, personnel, or supplies normally available to the operator or using organization.1-2. GENERAL MAINTENANCE . The general maintenance and repair covered byother manuals and called out in this manual are as follows:

TM 9-214 Inspection, Care and Maintenance of Antifriction Bearings.TM 9-237 Operator’s Manual: Welding Theory and Application (TO 34W4-1-5).FM 43-3 General Repair for Canvas and Webbing.TM 9-247 Materials Used for Cleaning, Preserving, Abrading and Cementing

Ordnance Materiel and Related Materials Including Chemicals.FM 43-2 Metal Body Repair and Related Operations.TB 750-254TB 43-0212

TM 43-0139TB 43-0209

TB 43-0213

Cooling Systems: Tactical Vehicles Changes 1, 2.Purging, Cleaning and Coating Interior Ferrous and TerneSheet Vehicle Fuel TanksPainting Instructions for Field Use.Color, Marking and Camouflage Painting of Military Vehicles,Construction Equipment, and Materials Handling Equipment.

(Rustproofing)TM 9-2300-422-20 Security-of Tactical Wheeled Vehicles.

1-3. CLEANING . All parts must be cleaned before inspection and assembly andafter repair.

WARNING

Dry cleaning solvent is flammable. Do not usenear an open flame. Keep a fire extinguishernearby when solvent is used. Use only in well-ventilated places. Failure to do this may resultin injury to personnel and damage to equipment.

Clean inner and outer surfaces of metallic parts and all areas subject to oil or greasewith dry cleaning solvent, type II (SD-2), Fed. Spec P-D-680. Clean out sludge andgum with a stiff brush. Use steam cleaning to take off accumulated grease and dirtafter dry cleaning solvent has been applied. Dry with clean rags. To clean bearings,

1-1

TM 9-2320- 209-20-3-1

refer to TM 9-214. The general cleaning covered by other manuals and referencescalled out in this manual are as follows:

TM 9-247 Materials Used for Cleaning, Preserving, Abrading and CementingOrdnance Materiel and Related Materials Including Chemicals.

TM 9-214 Inspection, Care and Maintenance of Antifriction Bearings.

1-4. PAINTING. Instructions for the preparation of the material for painting, howto paint, and material to be used are in TM 43-0139. Instructions for camouflagepainting are contained in TB 43-0209. Stenciling and marking must be done periodicallydue to weathering or repainting. Instructions for marking military trucks is called outin TB 43-0209.

1-5. AIR SYSTEM LEAKAGE TEST . The following procedures give instructions forchecking the compressed air system for leaks. These instructions are of a generalnature and are given here so that they do not have to be repeated throughoutchapter 12.

a. With compressed air system filled, brush each air line and fitting with soapywater.

b. If air bubbles appear, line or fitting is leaking.

c. Tighten fitting just enough to stop leak and do steps a and b again.

d. If you still have a leak, remove and replace line or fitting.

1-6. TORQUE VALUES . Critical torque values for a particular component are givenin the maintenance procedures. When torque values are not given, bolts, screws,and nuts are to be tightened as given in table 1– 1.

1-7. SPECIAL TOOLS AND EQUIPMENT . Special tools and equipment are providedto make it easier to do particular maintenance tasks and to keep the truck in good re-pair. Table 1-2 lists the special tools and equipment and gives a reference to themaintenance paragraph where they are used and what they are used for.

1-8. COMMON TOOLS. In the maintenance procedures covered in this manual,specific wrench sizes have been given, However, due to modifications made to equip-ment in the field or in production at the factory, you may need different wrench sizes.

1-9. SAFETY INSPECTION AND TESTING OF LIFTING DEVICES. Refer toTB 43-0142 for safety inspection and testing of lifting devices used in this manual.

1-10. FORMS AND RECORDS . Maintenance forms, records, and reports which are tobe used by maintenance personnel at all levels are listed in and prescribed byTM 38-750.

1-11. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)AND EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE SUMMARY (EIR MS).The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39series, contains valuable field information on the equipment covered in this manual.The information in the TB 43-0001-39 series is compiled from some of the EquipmentImprovement Reports that you prepared on the vehicles covered in this manual. Manyof these articles result from comments, suggestions, and improvement recommendationsthat you submitted to the EIR program. The TB 43-0001-39 series contains informa-tion on equipment improvements, minor alterations, proposed Modification Work Orders(MWO’ s) , warranties (if applicable) , actions taken on some of your DA Form 2028’s(Recommended Changes to Publications) , and advance information on proposed changes

1-2

Documents

T.O. 36A12-1B-1092-1-3