TM 9-2320-206-34

D Mqababe ace TM 9-2320-206-3. a Ie TECHNICAL MANUAL DIRECT AND GENERAL SUPPORT \w,, MAINTENANCE MANUAL TRUCK TRACTOR, 10-TON, 6x6 M123 (2320-395-1875), M123C (2320-294-9552) M123A1C (2320-2 26-6081), M123E2 (2320-879-6177) Ivers AND TRUCK CARGO, 10-TON, 6x6 . M125 (2320-219-7340) ec HEADQUARTERS, DEPARTMENT OF (THEA RM eeWARNING CARBON MONOXIDE POISONING CAN BE DEADLY. Carbon monoxide is a colorless, odorless, deadly poisonous gas, which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air contaminated with carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result from severe exposure. It occurs in the exhaust fumes of fuel-burning heaters and internal-combustion engines and becomes dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to insure the safety of personnel whenever the personnel heater, main, or auxiliary engine of any vehicle is operated for maintenance purposes or tactical use. 1. DO NOT operate heater or engine of vehicle in an enclosed area unless it is adequately ventilated. 2. DO NOT idle engine for long periods without maintai tilation in personnel compartmer 3. DO NOT drive any vehicle with inspection plates, cover plates or engine compartment doors removed unless necessary for maintenance purposes. 4.BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If either is present, immediately ventilate personnel com- partments, If symptoms persist, remove affected personnel from vehicle and treat as Expose to fresh air; keep warm; DO NOT permit physical exercise; if , administer artificial respiration. THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS ADEQUATE VENTILATION. Particles blown by compressed air are hazardous. Make certain the air st directed away from the user and other personnel in the area. Before starting disassembly, secure axle assembly in suitable stand. Do not mount on jacks or suspend from hoist. Carbon monoxide poisoning. Do not operate the -65° heater with the vehicle in a completely enclosed area unless adequate means have been provided for extracting exhaust fumes from the area. The -65°heater is equipped with an exhaust diverter to heat the engine oil pan with exhaust gases. Do not operate this diverter in an enclosed or poorly ventilated area. jing adequate ven- The methyl-ethyl-ketone used to activate the thermal barrier cement creates toxic haled. Provide rubber gloves for personnel handling methyl-ethyl- Do not permit smoking, sparks or open flame within 50 feet of the work area during any operation involving removal of fuel lines, fuel draining, or fuel filtering. Dripping fuel is extremely explosive. Do not permit smoking, sparks, nor open flame within 50 feet of work area during heater fuel control valve tests. Be extremely careful that all electrical connections are tight. Use the approved switch for starting and stopping the solenoids; DO NOT operate the solenoids by connecting and disconnecting the test clips.TM 9-2320-206-34 cl Change, HEADQUARTERS, | DEPARTMENT OF THE ARM} No. 1 Washington, D.C., 8 November 197: Direct and General Support Maintenance Manual TRUCK, TRACTOR, 10 TON, 6x6 M123 (2320-395-1875) M123C (2320-294-9552) M123A1C (2320-226-6081) M123E2 (2320-879-6177) AND TRUCK, CARGO, 10 TON, 6x6 M125 (2320-219-7340) ‘TM 9-2820-206-84, 26 April 1972, is changed as follows: Page 8-1. Immediately following the paragraph title add the following note: NOTE An unserviceable reparable engine returned to an overhaul depot must include the accessories listed in table 8-1 prior to issuance of a serviceable replacement. The requisitioner must furnish specific justi- fication or authorization to support other than a one-for-one exchange. Refer to TM 9-2320-206-84P for requisitioning information and data. eo Tables. Newor Rebuilt Bagine W /Accesvres Engine w/container 2815-910-8218, #5709466, Consisting of: Ament reat soxeior- soon ENGINE DIESEL lemusea iver CONTAINER SHIPPING rez (150) COMPRESSOR AIR oes 207 ALTERNATOR Bu oo101 15a) BELTS ALTERNATOR DRIVE Tiawe (180 FAN ASSEMBLY BM 96103 (15434) FAN BELTS Ba Te683 (18480) FLYWHEEL Bat oor (5400 PUMP ASSEMBLY WATER terewsao MANIFOLD EXHAUST LEFT eae 15090) MANIFOLD EXHAUST RIGHT ree 15430) OIL COOLER HOUSING raga) OIL PAN MS 2450126006) OIL SENDING UNIT rsa 5130 olLbiP stick seas 827) THERMOSTAT MS 2457-1 (6008) TRANSMITTER WATER TEMP ‘Tae rte mest rome =e aan whe tania er aBy Order of the Secretary of the Army: ” CREIGHTON W. ABRAMS . General, United States Army Official: Chief of Staff VERNE L. BOWERS Major General, United States Army The Adjutant General ution: ‘To be distributed in accordance with DA Form 12-98, organizational maintenance requirements for Truck Cargo 10-Toa MISS, Tractor ‘M123, MIZ3A1C, M129C, MIS3E2,* TM 9-2320-206-34 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY a No. 9-2320-206-34 WASHINGTON, D. C., 26 April 1972 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL TRUCK TRACTOR, 10-TON, 6x6 M123 (2320-395-1875), M123C (2320-294-9552) M123A1C (2320-226-6081), M123E2 (2320-879-6177) AND . TRUCK, CARGO, 10-TON, 6x6 M125 (2320-219-7340) Paragraph Page Cuaprer 1. INTRODUCTION Section 1. General 4 1d Il. Description and Data. 14 Ll Cuarren 2, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS. Section _I. Repair Parts, Special Tools, and Equipment 2 21 11. Troubleshooting. SO 28. Di IIT. General maintenance as 219 IV. Removal or Installation of Major Components 212 22h Cuarren 3, REPAIR OF POWERPLANT Section _I. Engine Assembly 34 31 HI. Clutch Assembly 5 36 31 IIL. Transmission Oil Pump. : feces BIZ B16 IV. Power Take-off B17 3:19 V. Transfer. e 3233.25 VI. Upper Shifter Cover me 329 3-41 VII. Shift Shaft Carrier Cover. 1335 BM VIII. Transmission 341 348 Swaprern 4, REPAIR OF FRONT AXLE I. Axle End Assemblies oe 41 41 I. Axle Shaft 5 peed (7 439 III. Differential Carrier : 41 440 IV. Axle Housing. a 417 458 V. Adjustments and Tests 5423 459 Cuapren 5. REPAIR OF REAR AXLES Section _I. Rear Axle Assembly Sl II. Axle Shaft 54 IIT. Differential and Carrier 55 IV. Rear Axle Housing. 5-48 *This manual supersedes TM 9-2320-206-34, 29 September 1966, including all changes; and ‘TB 9.2320.206-10/1, 11 March 1958.Carrer 6, REPAIR OF BRAKES Section _I. Service Brakeshoes and Drums. poets 1 61 II. Hand Brakeshoes and Drums a oo 6S 61 HII. Handbrake Lever 69 63 CwaPreR 7. REPAIR OF STEERING SYSTEM. Section ‘Angle Drive Assembly . ta mW Steering Gear Assembly 1 13 CwwrreR REPAIR OF FRAME AND ASSOCIATED PARTS. Section Fifth Wheel and Approach Plates. coe . 8 a1 |. Radiator Guard and Bumper : sneered 8:7) 83 Frame ce + B10 Bs Cuapren 9. REPAIR OF SPRING SUSPENSION. Section I. on 94 I. 9-8 93 IIT, Rear Spring Torque Rod ce Sosieeetet eterna 9-15 95, IV. Rear Spring Trunnions and Spindle senereeeneeneeeh 922) 9-6 Cuapten 10. REPAIR OF BODY, CAB, ND HOOD. Section I. Hood and Fenders . seve MOL 101 Il. Door Assemblies . . 5 107 103 IIT, Windshield Assembly : DS loas 105 "Seat Assemblies : 10-19 106 Cab Assembly 5 , fecceceeees 1085 109 1030 10-10 CuarteR 11. Section I. coveeeeees Mad Il, Brake Band So 166 IIT. Gear Box. ge 18 IV. Fairlead Assembly. : Siectetceceees HB 1112 Y. Trolley Assembly. 5 M29 113 ‘VI. Cable Tensioner Assembly a 1134 11-15 Chapren 12, SPECIAL PURPOSE EQUIPMENT (KITS). Section TI. Introduction. 5 Wt 2d IL. Electric Brake Q 124 12d IIL. Repair of Electric Brake Controller... en 129 12-7 IV. Personnel Hot Water Heater Kit se 1g 129 'V. Winterization Kit (Dual Purpose Arctic Kit)—M123, M123C, and M125... 21247 1221 VI. Fuel Burning Personnel Heater Kit—M123A1C, and M123E2 1221 12-41 VIT. Powerplant Coolant Heater Kit—M123A1C and M123E2 ci 1224 1256 VII. ‘Thermal Beri Ki 5 a 12.29 12-72 IX. Hardtop Closure fet 1231 12-72 X. Troubleshooting the Winterization KitMI23A1C and Mi23E2 - cs 1236 12-74 XI. Repair Instructions for Personnel Heater Kit—M123A1C and MI23E2. ......... 1238 12-74 XII. Repair Instructions for Coolant Heater Kit—M123A1C and M123E2. 1244 12-82 Appenvix A. REFERENCES. cere AL INDEX : cove Index 1LIST OF ILLUSTRATIONS ‘Te cated bushing type bearing removers and replacers andl el replaces Fabricated bearing nut wrenches. . ‘i . Fabricated differential bearing preload tool ‘Transmission lifting sling bracket—M123A1C, and M123E2...... Febricated Tranamision liting sling bracket —M125A1C, and M123%2 Fuel tank removed Fuel tank a Lower chain pillow block—dual winch Single winch M123C, MI23A1C Spare tire davi Removing dual winch assembly Installing dual winch assembly M125 with bumper removed. Front mounted winch drum shaft and upper pillow block Removing front mounted winch Hood hood side panels, and front and rear fenders. guard disconnect pointe—M123 Front bumper disconnect points—M 125. Removal of running board Steering angle drive Side panel removed under operator's door. Removal of steering gear with control valve. ints of disconnect. Headlight panel bracket assembly removed Winch disconnect points—right side Floor tunnel disconnect points ‘Transmission control lever and handbrake linkage disconnect points. . Carburetor controls disconnect points Disconnect points on right side of engine. Engine compartment from rear. Engine compartment, with air cleaners and ai ‘Tachometer cable disconnect point. Headlight wiring disconnect points—right side Oil filter disconnect points Starter cable disconnect points Hydraulic pump pressure hose disconnect points, Hydraulic pump feed hove disconnect points Compressor hose to reservoir tank disconnect points Front propeller shaft disconnect points. Clutch linkage assembly. Crossmember disconnect points Winch drive shaft disconnect points Rear propeller shaft disconnect points Engine rear support disconnect points Powerplant position on universal transporter Powerplant removed—left front view Powerplant—right rear view Adjusting end motion at powerplant rear mount Engine compartment—exhaust pipes and air induction pipes removed Engine Compartment—Front View—M123A1C, and M123E2. Engine comoartment—right front view—M123A1C, and M123E2 ‘xnaust pipe disconnect—M123A1C, and M123E2. Engine compartment—left front view—M123A1C, and M123E2 Engine compartment—Ieft side view—M123A1C, and M123E2. Powerplant—right front view—M123A1C and M123E2. Powerplant—right rear view—M123A1C, and M123E2 Powerplant—left front view—M123A1C, and M123E2iv Tue Disconnecting thock absorbers. Front brake chamber—installed Front axle drag link. Front axle-to-spring attaching parts Rear suspension (bogiel—top view suspension connection points, Frame aicmbly mounted of Removing prewure plate and backing assembly from fywheel Removing pilot bearing with puller Clutch release bearing and yoke. Clutch and clutch linkage Removing clutch release shaft ‘ing plate assembly on clutch rebuilder. Checking flywheel contact surfaces. Cheeking driving lug alinement Intermediate pressure plate installed Checking pressure plate for warp. Checking release lever for warp, using ball Pressure springs installed on pressure plate Mounting backing plate on pressure plate. Pressure plate with backing plate assembled Checking thrust washer for parallelism, using indicator Installing pressure plate with backing plate assembly Clutch release mechaniam—exploded view ‘Transmission oil pump and clutch release mechanism installed Plate for testing transmission oil pump Oil pump assembly: Transfer case with cover removed Removing and installing power take-off shifter and shifter shaft Main shaft, gears, and clutches in locked position Power takeoff—exploded view Installing oil seal ‘Transfer case end plate installed ‘Transfer ease end plate, covers and drive flange—exploded view ‘Transfer case end plate removed Removing main shaft rear bearing locknut Removing power take-olf drive shaft clutch ‘Transfer case—exploded view. ‘Transfer case separated from transmission. Front drive shifter fork and shalt installed in transfer case. Removing front drive shaft Transfer case. and shafte—exploded view Checking front drive shaft bearing preload Installing oil seal Checking main drive shaft end-play Checking countershaft end-play Upper shifter cover with levers and bracket atsembly—exploded view Removing shift shaft carrier cover: pinion—exploded view Main shaft and related parts—exploded view Removing fourth-speed gear thrust washer key Posit fourth-peed gear thrust washer for removal shaft toward rear. Reverse gear shaft, countershatt Removing reverse gear shaft nd related parts—exploded view . Removing countershaft gears Check end-play of main shaft in center bearing joving center bearing from main shaft spigot bearing from main drive pinion pinion Installing countershaft rear bearing cone433. 434, 435, 436. 437, 438. 439. 440. +41. 442, 443. +44. 445. 446. 447, 448. 4-49. 450. 451. 452. 453. 454. 455. 456. 457. 458. 51. ling spigot bearing in main drive pinion Main drive pinion installed Tightening main driving pinion bearing nut Installing oil pump vane and main driving pinion bearing cover. Transmission oil flow diagram Front axle assembly, right-hand wheel, and brake drum removed Axle end assembly—right elevation view—left-hand end. Front axle drive end—exploded view . Removing steering arm and cross-steering lever, left hand lever. Front drive axle end assembly, mounted on holding fixture adapter. Adjusting nut, installed. : Removing adjusting nut using wrench Removing front wheel hub 2 ‘Third reduction bevel removal. Bevel gear second reduction, bevel pinion, third reduction, pivot shal, and related peeled view Removing second reduction bevel gear beering retainer and bevel gear Removing nut from second reduction bevel gear. Removing oil scraper and oil scraper spring. Pivot shaft bearing retainer removal Removing nut from pivot shaft. Removing second reduction bevel pinion Second reduction bevel pinion bearing nut removal Installing remover and replacer in steering kouckle trunnion Removing steering knuckle trunnion Separating housings at steering knuckle ‘Steering knuckle assembly and third reduction bevel gear hous Installing bushing type bearing Reaming bushing type bearing Alining steering knuckle and third reduction bevel gear housing Joining steering knuckle and axle end housing. Inserting alining guide into steering knuckle positior Installing steering kouckle trunnion Checking third reduction bevel pinton beating preload Installing second reduction bevel gear on bearing retainer ‘Testing second reduction bevel gear bearing preload. Staking nut on second reduction bevel gear Checking second reduction bevel pinion bearing preload. Checking backlash of third reduction bevel gear set Checking backlash of second reduction bevel gear set Improvised seal protection clamps installed ‘Applying load o third reduction bevel gear and pi Installing cross-ateering lever and steering arm Front asle—partilly exploded view Removing bevel gear shoe bevel gear, and bevel pinion—partially exploded view. . Marking caps and housing pedestals ‘Marking differential casings Differential, casings, gears, and pinions—exploded view Removing bevel pinion assembly drive flange aut Differential pinion with related parte—exploded view Pressing pinion out of bearings Peening shaft of pinion over bearing Installing bearing cone and roller. using replacer. Testing bearing preload. pinion setting Imprint indication proper gear tooth contact, Installing outer oil seal Checking front axle camber, caster, and steering knuckle trunnion inclination Rear axe assembliee—M123, M123C, and M125. 367 3-68 3-69 3-70 3-71 BIZ 373 374 3-16 41 42 43 es 46 at +n 412 413 a4 415 416 417 417 418 418 419 4-20 C422 423 424 1 426 427 4-28 429 2 430 431 432 434 435 436 : 437 438 2 440 441 442 443 444 445 446 “at +49 450 451 452 454 455 456 + 457 458 458 459 51we Page Rear axle assemblies—MI23A1C, and M1Z3E2 52 Quick release valve. 53 Removing rear axle propeller shalt : 53 Rear axle amembly—exploded view : : 55 ifferenti : 56 ( 51 Interazle drive shaft, bevel pinion, bearings, retainer, and drive flange—exploded view 58 Removing nut, using socket wrench 59 ing interaxle beating ret 5-10 bevel pinion and interaxle shaft 511 5.12 5.13, Pressing interaxle drive shaft out of bevel pinion pee ss ferential assembly—exploded view—M123, M123C, and M125 woe 515 Removing spur pinion shaft bearing adjusting nut... eee eeannananen 516 Removing bevel gear nut : BOT sat Removing spur pinion salt bearing retain vee ieetncecreeeneres SelB |. forward-rear—exploded view—M123A1C, and M123E2 : 5-20 housing and retainers, forward-rear—exploded view—MI23A1C, and Mi23E2..... |... 5-22 Differential, rear-rear—exploded view—M123A1C, and M123E2. Eoreoteeed 5-25 Differential housing and retainers, rear-rear—exploded view—MI123A1C, and M123E2 Stl 586 Installing interaxle drive shaft bearing cup : westerns enemas 27 Installing bevel pinion bearing cup Seteseuetscsevsenseccreneses SoBB Installing bevel pinion bearing cone fe, $629 Installing spur pinion bearing cup. coe ce : + 5-80 Installing oil seal in bevel pinion bearing retainer cover. poeseeneneeneeeeremeneneniennenng 515] Pressing interaxle drive shaft into bevel pinion. aoe Sol 82 Checking bevel pinion bearing preload. : eaeenenne Pe 5:83 Setting gage plug and tube installed 2 5:34 Checking bevel pinion setting, using tube, arm, and plug. = ve 5.35 Checking spur pinion bearing adjustment a Fis 56 Installing outer bearing cone. : 537 Proper gear tooth contact 538 Positioning bearing cup lock... : veces peeeente ll! $89 Checking differential bearing preloed : ; 2 5-40 Adjusting differential bearings SN USI Sal ( Handbrake—exploded view a Ditieeeecesess 62 Handbrake lever assembly—partilly exploded view. nee BEI 68 Steering angle drive—exploded view wo ; pecans 7-3 Steering gear essembly—exploded view. : ao 1 Steering cam lever shaft assembly—exploded view aeeeenaeieereeree 18 Power steering cylinder—exploded view... vee see 16 Valve unit steering control with end shaft housing—exploded view a Installing lever shaft bushing type bearing, using remover and replacer. ncmnemnennns 75) Burnishing lever shaft bushing type bearing, using burnisher....... apenas.) Installing lever shaft oil seal, using replacer.... : sees 710 Installing cam bushing type bearing, using remover and replacer Tu Line burnishing cam bearings, using burnisher. m2 Installing oil seal in adapter. using handle with replacer 113 Insualing oll sealin housing upper cover, using handle with replace. Ts Installing housing upper cover, using guide. Installing cam lever shaft, using guide. Fifth wheel assembly—exploded view Frame assembly Frame alinement diagram Front spring suspension—exploded view Removing spring inner-eye bearing. Rear spring assembly—exploded view Rear torque rod—partially expioaed view Rear spring and trunnion—partially exploded view 9-7 Hood, fenders, and side panels vite cvenensnoe 2 1o2 Cab amembly—partially exploded view - pe 108 Cab door—exploded 5 S104 Windshield assembly. conn enn 2S 106 Operator's seat base assembly—exploded view. eI 10-7 Operator's seat assembly—exploded view. Seeeenerennnet 16-8 Companion seat assembly—partially exploded view. : pox ws Cargo body. feet 100 viDual winch assembly—M123, and M123E2 Single winch—M123C, and M123A1C. Front single winch—M125, Trolley assembly Cable tensioner installed Fairlead assembly installed Basic winch Safety brake with band—M123, M123C, M123A1C. and M125—exploded view ale brake with band —M123E2—exploded view x aseembly—exploded view Faveed asemblyetpoded view Trolley assembly with track—exploded view Cable tensioner—exploded view. Cable socket attachment Controller. installed Rheostat installed on flange Rheostat installed on steering column rember drilling details ing details gram for M125 (one-receptacle) Wiring diagram for M123,M123C, M123A1C, and M123E2 (ewo-eeepacel racks Wiring diagram for tests Resistor mounting details. ‘Thermostat right and left bypass housing Installation at left manifold Heater mounting brackets scoop hood and heater support brackets. inlet adapter and hose assembly stor assembly Air outlet adapter and hose amembly ‘Adapter to diverter hose assembly Diverter defroster hove assembly Control bracket and air and defroster cable installation Switch and circuit breaker assembly Y¥ connector assembly and heater clip location Wiring diagram Loop locations Winterization side panel covers ssembly. Primer tubing installed Manifold deflectors installed Heater Hose. Clamps, shield, connector, and receptable (electrical) installed Plate. gasket, and fuel tank tube assembly installed. nd plug installed Switch box and control bracket installed Master switch, shutoff cock, primer pump, and controls installed Control cables installed at diverter Y connector and cables installed Alcohol evaporator installed Shielding under right fender Shielding under left front fender. Brush quard loop locations: Brush guard cover installed. Hood. side panel, and brush guard covers Brush guard cover springs and hooks installed Installation of electric fuel pump.‘Number viii ‘Te Installation of fuel pump to filter Location of personnel heater mount Installation of personnel heater Installation of exhaust tube. Installation of heat duct elbow. Installation of diverter assembly. Installation of defroster deflectors Installation of air and defroster controls Installation of personnel heater control box. Installation of hamess and wiring holes. Installation of evaporator Installation of wiring diagram and instruction plates Installation of side panel assembly Installation of hood right side panel cover: Alinement of U channel, mounting plate, and splash shield Positioning of splash shield Locating heater shroud and battery box mounting holes. Heater and circulating pump alinement. Installation of heater and circulating pump brackets Installation of oil pan shroud. installation of exhaust tube and coolant hose. Exhaust tube mounting brackets Installation of battery box insulation Installation of 102-inch coolant hoses Direction of flow of coolant Coolant heater fuel line Installation of heater shroud. Roaf panel modification Tnntlotion of upper end lower stip seis Securing roof panel 19 windshield header Installation of retainer clips Disassembly of personnel hester—exploded Disassembly of fuel control valve—exploded vi Test wiring set up for heater teste Fuel control valve test set up Heater mounting positions Coolant heater disassembly—exploded view 12-43 12-43 12-44 12-45 12-46 12-47 1248, 1249 + 1250 1251 1252 1252 1253 1254 1255 1257 1257 12.58 12.59 12-60 12-61 12462 12-63 2 1264 1265, 2 1266 1267 12-6 12-69 12-70 12-71 12-72 12-73 12-73 2 123 12-74 12-76 cz 12-79 12.80 1281 mereyyLIST OF TABLES ‘nue Standard Torque wrench requirements. Repair and Replacement standards Time schedule. Special tools, test and support equipment Fabricated tools ‘Troubleshooting Fuel flow Page 16 Lat Ll 27 Pat 215 12.82CHAPTER) INTRODUCTION Section |. GENERAL 1-1, Scope a. This manual contains direct and general support maintenance instructions, including special tool lists and special purpose kits, for the 10-Ton, 6x6 Truck Tractor M123 and M123C (dual and single rear mounted winch, gasoline engine vehicles), M123E2, M123A1C (dual and single rear mounted winch, diesel engine vehicle) and the 10-Ton, 6x6 Cargo Truck M125 (single front mounted winch, gasoline vehicle). These instructions provide information on the maintenance of the equipment which is beyond the scope of the personnel, tools, equipment, and supplies normally available to the using organization. b. Appendix A of this manual contains a list of all publications referenced in the text. 1-2. Forms and Records 4. General. Responsibility for the proper execution of forms, records, and reports rests upon the officers of all units maintaining this equipment. However, the value of accurate records must be fully appreciated by all persons responsible for their compilation, maintenance, and use. Records, reports, and authorized forms are normally utilized Section II. 1-4, Description CAUTION These vehicles exceed the dimension limitations permitted under AR 700-105. ‘Advance planning will be required in the selection of routes because of bridge capacities and underpass and road clearances involved. A general description of the Truck Tractor, M123, M123C, M123A1C, and M123E2, and the Cargo Truck, M125, and information pertaining to identification plates are contained in TM 9-2320- 206-10. A more detailed description of specific components is provided in the applicable maintenance paragraphs of this manual. 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 depots; etc. The forms, records, and reports establish the work required, the progress of the work within the shops. status of the materiel upon completion o 6, Maintenance Forms and Records. tenance forms, records, and reports which are to be used by maintenance personnel at all maintenance levels are listed in and prescribed by TM 38-750. 1-3, Reporting of Equipment Publication Improvements The reporting of errors, omissions, and recom- mendations for improving this publication by the individual user is encouraged. Reports should be sub: ed on DA Form 2028. (Recommended ‘Changes to DA Publications) and forwarded direct to: Commanding General, US Army Tank- Automotive Command, ATTN: AMSTA-M, Warren, Mi. 48090. DESCRIPTION AND DATA 1-5. Difference Between Models. Major differences between the M123, M123C, M123A IC, and M123E2, Truck Tractors, and the M125 Cargo Truck are listed in TM 9-2320-206- 10. Differences in assemblies used on the vehicles will be noted in the maintenance procedures of this manual. 16. Tabulated Data. 4. Identification. Refer to the operator's manual (TM 9-2320-206-10) and organizational maintenance manual (TM 9-2320-206-20) for identification plates and additional data.b. Tabulated Data. (1) Clutch. ‘M123, M123C, and M125 MI23AIC and M123E2 Manufacturer. Mack Mack Model . Lo CL50 Type. Dual dry-disk Dual dry-disk Disk and friction facings: Outside diameter Inside diameter of facing Total area of facings Facing thickness Pressure plate springs: Inner: ‘Number 18 Color Yellow Free length 3:3/32 in, Outside diameter i Lin. Pressure at 2% in. length: 41.0 to 45.0 Ib, 41.0 to 45.0 bb. Outer: ‘Number : 18 18 Free length 3627/32 in. 327/32 in Out 1 i 114 in Pressure at 24 88.5 to 97.5 Ib. 88.5 to 97.5 b. Bearings: Clutch pilot: ‘Type. cee Shielded, ball Shielded, ball Radial clearance 0.0020 in. 0.0020 in, (2) Transmission and transfer. Manufacturer Mack Mack Model ‘TRDXT-72 TRDXT-12 Ordnance No....- : 8332883, 8332883 Type. Selective constant mesh. Selective constant mesh. ‘Transmission gear ration (high / low): First. : Second Third Fourth Fifth (direct) Reverse Transfer ratios Lubricant capacit ‘Transmission section Transfer section Speedometer gear ratio: Drive Driven’ (3) Spring Suspension. (a) Front suspension. (M123, M123C, M125 MI23A1C, M123E2 Manufacturer 5 5 Mock Mack Spring type. 5 ‘Multileaf semieliptic. ‘Multileat semielliptic. Number of leaves. Length (under load) 50 in, Width 3 in, Leaf rebound clips... ~~ 4 (b) Rear suspension. ‘M123, M123C, M125 ‘MI23A1C, M123E2 Manufacturer. . Mack Mack Spring type. . Multileat semielliptic. Multilea! semiellipti. Number of leaves ; Le As 3 Length 60 in. 60 ia. Width Sin, Sin, Leaf rebound clips 2 2 (4) Cab Assembly. ‘M123, M123C, M125 MI23A1C, M123E2 Manufacturer Budd Universal (M51). Budd Universal (MS1). Type Open, 3-man capacity with Open, 3-man capacity with half-doors, collapsible canvas half-doors, collapsible canvi top, and canvas-covered top, and canves-covered meats, meats, 12Mounting. (5) Cargo Body. Inside width, Outside width. Overall width Height (floor to under Overal inside (6) Winch. (1) Front Axle. Manufacturer Model Type Final ratio Spindle diameter: Taner bearing Outer bearing ‘Axle shafts: Type. Material Spline diameter Number of splines Differential carrier: Type Ratio End assemblies: Type. Ratio. (8) Rear Axles. Manufacturer Model Type. Ratio. Type of drive (9) Brake System. (10) Steering System. (a) Angle drive. Manufacturer Ross identification number (b) Steering get Manufacturer Ross identification number Type. Gear ratios: Center of cam. Ends of cam. Lever shaft torque (hydraulic) Hydraulic pump. (11) Frame. Sie Inside channel reinforcement. Crommember material Frame width Number of crosmembers . Triple-reduetion, ‘M123, M123C, M125 ‘Three point. Solid type on si rails at right-hand and left- hand front, Biscuit type at rear center. M125 96 in. 108 in. M4 in 60 in, 180 in. 156 23 in. 20 in. high MI23AIC, M123E2 ‘Three point. Solid type on side rails at right-hand and left- hand front. Biscuit type at rear center. Refer to TM 9-2320-206-20 for tabulated data. Miz3,Mi23c, M12s FA491 Il gear drive. 9.02:1 3 1-7/8 in Full-floating ‘Chrome-nickel-steel. 25% 7 Single reduction 3.92:1 Doublereduction, wheel drive bevel gears. 2.38:1 ‘M123, M123C, M125 9.02:1.00 Straight through Refer to TM 9-2320-206-20 ‘M123, M123C, M125 Rou Gear and Tool Co. K-23644 ‘M123, M123C, M125 Row Gear and Tool Co. GB-61001 Hydr 22: 11 3,600 ft-lb. at 1000 psi ‘oylinder pressure. Gear driven . M123. M123, M125 Mack Pressed channel Chrome-manganese steel, heat-treated. 10% x 3% x 5/16 inches 10 x 2-7/8 x 1/4 inches Carbon steel 34 inches 6 MI23A1C, M123E2 Mack FAG91 Triplereduction all gear drive. 1oM:1 Chromernickebsteel. 25 in, 7 Single reduction 44021 Doublereduction, wheel drive bevel gears. 2.38:1 }123A1C, M123E2 Mack swo7t Spiral, spar pinion and gear, ‘dual reduction with interaxle power divider on forward rear axle, 10.1 Straight through for tabulated data. MI123A1C, M123E2 Rous Gear and Tool Co. K.23644 ‘M1234 IC, M123E2 Ro Gear and Tool Co. HP-81006 Hydraulic 22:1 al 3,600 ft-lb, at 1000 pai ‘oylinder pressure. Belt driven MI23A1C, M123E2 Mack Pressed channel Chrome-manganese steel, heat-treated. 10% x 34 x 5/16 inches 10 x 2-7/8 x \4 inches Carbon steel 34 inches 6Location of crossmembers. Wheelbase: Frame overall length (12) Fifth Wheel. Manufacturer (13) Fuel burning personnel heater kit. (a) Heater. Manufacturer Model No. Weight Dimensions: Width Length Height Heat output: High heat Low heat Fuel consumption: High heat Low heat. Fuel pressure required Operating voltage Current consumption: Starting. Low heat. High heat cove (b) Blower motor. Manufacturer Current consumption. (c) Fuel filter. Manufacturer . (14) Powerplant Coolant Heater Kit. (a) Heater. Manufacturer Weight Dimensions: Ww Heat output (coolant): igh heat Low heat. Heat output (exhaust): heat Low heat, Fuel consum High heat Low heat, Fuel pressure required Operating voltage Current consumpti Starting. : Low heat. High heat (b) Blower motor. Manuf Model No. Ordnance part no. Operating voltage rent consumption (c) Fuel filter. Manufacturer 14 M123, M123C, M125 (1) Engine support; (1) front toring rear" bracketa; (1) Brermediate) (1) ahead of rear bogie; (1) rear bogie; (1) rear. 169% Tnches 267%4 inches Mi23, Mizsc Fruehauf, 36 in M123, M123C, M125 (no data available) ‘M123, M123C, M125 M123, M123C, (no data available) ‘M123, M123C, M125 (no data available) M123, M123C, M125 (no data available) W123, M1236, M125 (vo data available MI23A1C, M12362 (1) Engine support; (1) front spring ring brackets; (1) intermediate; (1) ahead of rear bogie; (1) rear bogie: a 169% inches 26744 inches M123A1C, M123E2 Frichaul 36 in. MI23A1C, M123E2 Stewart -Warner Corp. 8420-D24 17 Ib. TH in, L 9% in. 20,000 Btu/ hr 8,000 Btu / hr 0.272 gph 0.122 gph 3 to 15 psi 24v 16.0 to 19.5 amp 3.0 to 7.5 amp 3.0 to 7.5 amp MI23AIC, M123E2 Stewart-Wai 6700139 ay 27 amp MI23AIC, MIZ3E2 Bendix Corp. MI23A1C, MI23E2 Stewart-Warner Corp. 15 Ibe. 6% in, 155/16 in 9% in, 16,000 B.tu. /hr. 5,500 B.tiu. /hr. 8,000 Btu. /hr. 4,500 Btu. /hr. 0.260 gph 0.110 gph 3'wo 15 pai 24v 11 amp 1.0 amp 1.0 amp MIZ341C, 12382 Stewart-Warner Corp. 6700139 18359780 Hy OF amp MI23.416, M123 Bendix Corp.c. Torque Specifications. The following listed items are special torque wrench requirements. Special requirements are used for critical attachment or alinement of vehicle component pat Ore requirements are also listed in their ap- propriate paragraphs throughout the manual. When not specified, bolts, screws, and nuts are to be tightened accordance with standard requirements as listed in table 1-1. ‘Torque valve oot pounds) Clutch housing hand hole cover screw 18-28 265-295, 70.90 ery cover screws 18-28 Oil pump inspection hole cover 18-28 Oil pump to transmission case screw 70.90 Power take-off cover screws 18-28 {t carrier to transmission case screws .... 30-40 gears and shafts: Countershaft rear bearing clamp screw 18-28 70.90 Center bearing retainer inner nut 450-500 Center bearing retainer outer nut Center bearing retainer screws Reverse gear shaft lock plate screw ‘Transfer case, end plate, and cover: Countershaft cover to end plate screw End plate screws and nuts Front drive bellerank pivot pin support assembly ...... 70-90 Mainshalt bearing cover to end plate screw ... 155-185 Speedometer gear sleeve 75-80 ‘Transfer ease to transmission © screws and nuts 115-143 ‘Top cover screw 18.28 ‘Transfer gears and shafts: Front drive bearing cover screw 70.90 Front drive flange nut 800-1200 High-low range gear shifter fork shaft screw . 45-55 M aft front bearing clamp screw . 18-28 Drive flange nut 800-1200 Housing to transfer case end plate screw... 10.90 Shifter fork shaft nut 115-145 Front Axle: ‘Axle end assembly to axle housing bolts... 160-170 Bevel gear shoe to housing nut 350-400 75-60 18-28 145-175, End assembly crosesteering lever nuts 300-350 End assembly steering arm out 600.900 ‘ot shaft bearing housing cover screws ---- 10-16 Second reduction bevel gear bearing nut .... 800-1200 Sec Stee ing arm crossateering lever bolt Steering knuckle housing nuts Steering knuckle outer bearing adj ‘aut Tock screw ‘Third reduction bevel gear housing cover hhub screws ‘Third reduction bevel gear wheel hub bolts ‘Third reduction bevel pinion bearing pivot shaft nut Rear axle—M123, M123C, and M125. Bevel gear compartment side cover screws ing retainer cover screws ‘and carrier assembly axle ute, Differential bearing cap nuts Differential case spur gear nuts Drive flange and/or drive yoke interaxle drive shaft nut Interaxle bearing retainer cover screw Spur pinion shaft bearing adjustment nut clamp bolt nut ion shaft bearing adj inion shaft bearing cover screws Cage bearing retainer cover screws ‘and carrier assembly axle cap bolts Interaxle bearing cover screws Spur gear carrier housing cover serews Spur gear differential Spur gear shaft clamp screws Rear rear axle—MI23A1C and M123E2: Bevel gear cover screws Bevel pinion cover screws Differential and carrier assembly ‘axle housing nuts Differential bearing cap bolts Interaxle cover screws Pinion housing screws Spur gear cover screws Spur gear differential case nuts ‘Spur gear shaft clamp screws Yoke nut Brake system: Lever clamp bolt Spring Suspension: Rear spring assembly U bolt nuts Torque rod stud nuts Trunnion bracket cap nuts ‘Torque value foo pounds) 800-1200 85-95 165-195 20.30 10-16 80-90 ‘800-1200 70.90 30-40 45.55, 170-180 90-100 800-1200, 70-00) 60-70 ing nut screw 20-30 50.00 800-1200 0-90 400-480 00-1200 120-140 125-155, 800-1200 25-30 1600-1700 1150-1250 250-300 15Table 1-1. Standard Torque Wrench Requirements ‘Nominal ‘Torque value Tread thread oo pounds) per Diam Inch Baie "Folerance? ss 9 3 20 28 3/16 18 5 18 24 3/8 32 5 16 24 1/16 50 10 4 20 we 8 10 13 20 116 0 15 12 18 5/8 150 20 n 18 3/4 265 35 10 16 1/8 420 60 9 4 1 640 80 8 4 % 800 100 1 2 m% 1000 120 1 2 1% 1200 150 6 12 % 1500 200 6 12 d. Repair Standards. The repair standards (Table 1-1) give the minimum, maximum, and key clearances of new or repaired parts. They also give wear limits which indicate that point to which a part or parts may be worn before replacement in order to receive maximum service with minimum replacements. Normally, all parts which have not 1-6 been worn beyond the dimensions shown in the wear limits column or damaged from corrosion will be approved for service. An asterisk (*) in the wear, limits column indicates that the part or parts should be replaced when worn beyond the limits given in the sizes and fits of new parts column. All dimensions are in inches unless otherwise specified.Table 1-2. Repair and Replacement Standards sie = — [some | oon | SE SSS TRANSMISSION manne wn | sane | ane soe Clearance between pinion and cover. 0.0060 0.0100 . Fit of bearing on pinion. 0.0004T 0.0015T * oan | ea | om de Bait ie | Bs Soe Clearance of first speed gear bushing to main-| 0.0039 0.0049 0.0080 se ee cncmrnneton)| toe | tan in ct Clearance of fourth-speed gear bushing to 0.0036 0.0046 0.0080 ns ae er tuerne| tome | so on si ak vase | sx se ses ¢ Sr ia | i is ee dt tse | di ite End play of reverse gear cluster. 0.0040 0.0130 0.0190 dee Sa weno] ae | He ie ok Inside diameter of first-speed gear bushing. 3.1294 3.1324 Inside diameter of second: and third-speed gear 3.5048 3.5078 ae Sn sommareone ve va Bs tert eee | ms | say su Outside diameter of reverse gear shaft. 1.4990, 1.4995, 1.4960 Selene yal dsc | 1S “ rT em sameness | coe “et rat | SS “es eT | |S ce ree ‘Case, Gears, and Shafts ming et a ew sone | an yl ee amen | tose | sae se Clearance of high range gear bushing to sleeve. 0.0048 0.0058 0.0100 Clearance of low range gear bushing to sleeve. 0.0058. 0.0068 0.0100 ‘Clearance of high-low range shifter fork in sliding 0.0050 0.0200 0.0400, clutch. Seam uname| toe | cum vo i ac seneenan | tam | ewe vos Inside diameter of high range gear bushing. 3.0043 3.0048 3.0078 Inside diameter of low range gear bushing. 3.0053 3.0058 3.0078 poe deere | ao SS eee amma nwras| vom | cow sos Spline clearance between sliding clutch and main 0.0050 0.0080, ae a neuen ve on High range gear thrust washer thickné 0.3120 * eect ed a Sint eens Clearance between sliding clutch and shaft 0.0030 0.0060 0.0080 = ‘Clearance of shaft in main shaft bushin, 0.0040 0.0060, 0.0080 V7Table 1-2, Repair and Replacement Stendards—Continved Manufactures mensions Copenet codteane ace Daaredcearance Moree Minimum | Maximum | Minim Meximam | erence Power Take-Off—Continued Clearance of shifter fork in sliding clutch. 0.0050 0.0200 0.0040 Free height of shift shaft ball spring. 19/16 |1-9/16in, 1/2 Shift shaft ball spring pressure when compressed | 4 tbs. 50 ba, 35. to 13/16 in, Upper Shifter Cov: Gear shifter hand lever spring-free height. 23/4 23/4 2172 Gear shifter hand lever spring pressure when 6 35 38 Ib. compressed to I 4 in. Hand control lever shaft spring-free height. 3/4 3/4 181b. Hand control lever shaft spring pressure when | 70 1b. 70Ib. 651b. compressed to 4 in. Power take-off lift latch spring-free height. 25/16in, | 25/16in. 23/16in. Power take-off lift latch spring pressure when ‘Ob. 1b. Tbe. compressed to 1 9/16. ‘Shift Shaft Carrier Cover Length of interlock pin 0.6820 0.6780 Length of interlock plungers 3120 1.3080 Selector stop plunger spring free height. 117 2in, 13/8in. Selector stop plunger spring pressure when | 201b. 18. compressed to 5% in. Selector stop plunger ball and shift rail springs} 40 1b. 351. pressure when compressed to 13/16 in. Selector stop plunger ball and shift rail spring-ee | 1.916 | 1-9/16 1iy2 height. Oil Pump and Relief Valve Clearance between geai 0.0075 Oil pump pressure 15 Ib. Outside diameter of dt 0.5610 Outsi 0.5610 Radial clearance of gears in hou 0.0060 Relief valve compression spring free height. * Relief valve compression spring pressure when . compressed to 115/16 in. FRONT AXLE Differential Backlash of bevel gear set 0.0030 0.0060 * Radial runout of bevel gear, maximum. 0.0060 . ferential pinion thrust washer thicknes 0.0450 0.0470 * Side gear thrust washer thickn 0.0390 0.0620 . Clearance between spider and pinion. 0.0030 0.0060 0.0160 End Assembli Inside ream diameter of brake cam bushings type| 1.5010 1.5030 1.5050 bearings. Clearance of camshaft in bushings. 0.0040 0.007 0.0080 Backlash in gear and pinion sets 0.0030 0.0060 * Outside diameter of cam 1.4960 1.4970 . Oil scraper apring-free height 4/2 1/2 . Oil scraper spring pressure when compressed to Vib. 11/21b, 1olb. 7/16 in. Second reduction gear spacer thickness. 0.1870 0.1890 . 0.3340 0.3380 . Second reduction gear shim thickness, 0.0020 0.0050 0.0150 0.0200 Second reduction pinion shim thickness. 0.0020 0.0050 0.0150 0.0200 0.0300Table 1. . Repair and Replacement Standards—Continsed ——<= — ee ee Minimum | Maximum | — Minimum ‘asim | cere ae ane ‘Third reduction thickness. mace Clearance of splines, pinion to shalt. 0.0000 0.0030 i * Clearance of stud in bushing 0.0040, 0.0060, | 0.0100 Radial runout of bevel gear, maximum. 0.0060 | os Backlash of spur gear to pinion 0.0000 0.0120 . beret passe |Pasee : vor on | etter | Radial runout of bevel gear, maximum. 0.0060 * Beutel eaesl eases f Pe reais ood oa : Eee ecend ere foee faa : 0.6830Table 1-2. Repair and Replacement Standards—Continved Manufacturer's dimensions Maximum Component ad oerances in inches Desired clearance stoic Minimum | Maximum [Minimum ‘Maximum | clearance M123AC, M123E2—Continued ‘Thickness of spur pinion bearing shims available. 0.0200 . 0.0220 0.0250 0.0810 ‘Thickness of bevel pinion bearing shims available. 0.0200 . 0.0220 0.0250 0.0310 BRAKE: Service Brake jameter of brake shoe bushing type 2500 1.2520 1.2550 i. 1.5020 1.5030 1.5060 71/16 71/16 * lob. 18h 13. tended to 7% in. Inside diameter of brake drum 17.250 17.375 Hand Brake Diameter of cross-shaft 0.9985 0.9995 . Inside diameter of cross-shaft bracket bushing. | 1.0000 1.0020 1.0700 Clearance of cross-shaft in bushings. 0.0025 0.0100 Hand brake lever poppet ball spring-free height. 15/32 * Hand brake lever poppet ball spring pressure el / 2b. 1b. when compressed to in. Diameter of cam operating shaft 0.8730 . Retracting spring (actuating end) free height. NL / 32 . Retracting spring (actuating end) pressure when 53. 40b. extended to 1.9/1 Retracting spring (adju 3/8 35/8 . Retracting spring adjusting end) tension when 36 Ib. 4b. 301b. extended to 3.15/16. Inside diameter of camshaft bracket bushing. 8750 0.8770 0.0105 Clearance of cam operating shaft in bushings. 0.0020 0.0050 0.0050 End play of cam operating shaft after assembly of | 0.0050 0.0150 * lever. Runout of drum 0.0100 0.0100 . STEERING SYSTEM Steering Gear Assembly Inside diameter of worm bushing type bearing | 1.7485 1.7500 1.1570 Inside diameter of levershaft bushing type bearing | 2.0010 2.0020 2.0060 \burnish) Outside diameter of levershaft 1.9980 1,990 . Clearance of levershaft in bushi 0.0020 0.0040 0.0070 Diameter of worm 1.7460 1.7470 * Clearance of worm in bearings 0.0015 0.0040 0.0100 yatrol Valve Assembly Inside diameter of bushing type bearing. 1.7510 1.7510 . Cleat 1006 0.0013 0.0018 Aree height 15/32 N53 / 32 * pressure when compressed t0 1o0 lb. 110tb. 80 bb. etree height Lays Lays . spring pressure when compressed to % in. Ub. Lb. 374 Ib. ‘Thrust washer thickness 0.3700 Jo.3750 . Power Cylinder Assembly ID of hole in piston rod jo.oiss OD of piston rod. adapter end 1.1230 Clearance of piston rod in adapter. jo.oo13 Clearance of adapter in housing .0030 Clearance of piston in housi 0115 1-10Table 1-2. Repair and Replacement Standards—Comineed | ues wenrand clearance Angle Drive Assembly Backlash of ge 0.0090 Jacket tube spring-tree height, maximum. 15/16 * Jacket tube spring presmure when compresed to 30 Ib. 2b. Horn contact spring-free height 7/16 * Horn contact spring pressure when compressed to 1b. Tb. 5/16 in. SPRING SUSPENSION Front Suspension Diameter of front spring front 2.1230 2.1170 Diameter of front spring rear pi 1.7480 1.7420 Diameter of front spring front bushings. 2.1280 2.1340 Diameter of front spring rear bushings. 7530 1.7590 rance of front spring front pin in bushin 0.0060 0.0100 Clearance of front spring rear pin in bushing. 0.0060 0.0100 Clearance of pin in shackle 0.0060 0.0100 REAR SUSPENSION sam diameter of trunnion bu 4.0010 4.0200 lerance of trunnion spindle in bushing type 0.0250 0.0350 saring, maximum. End play of trunnion None . ‘Thickness of inner thrust wi 5/16 . Thickness of outer thrust washer 1/4 . CLUTCH PEDAL AND LINKAGE a. Clutch Pedal lutch pedal lever shalt bushings 0.8750 WINCH osteo Gear Box Clearance between sleeve bushing and input shaft. 0.0050 0.0120 Backlash in driven clutch gear, reverse idler gear, 0.0070 0.0200 and output shaft gear. Shift shaft springs-free height 21/8 * e. Time Schedule—M123. The date listed in Table 1-3 has been compiled to serve as a guide for personnel who direct and supervise the operation of a direct and general support maintenance facility. Table 1-2 lists the number of man-hours required, under normal conditions, to perform the indicated maintenance and repair for the M123 Truck ‘Tractor. Under ideal conditions, with highly skilled mechanics, most of the operations can be accomplished in less time. Table 1-3. Time Schedule Man-hours ‘Axles, transmission, or wheel end assembly: Drain, flush, and refill with new oil (each unit) 03 Wheel bearing rear 5.0 Universal joints: Lubricate (all). 0.3 Chassis: Lubricate in accordance with LO 9-2320-206-12. 1s, Service vehicle: (a) Daily D. 10 (b) Weekly W. 10 (e) 1,000 Miles... 3.0 (a) Semiannually (6 months) S. 1.0 16.0 fe) Annually (12 months)Table 1-3. Time Schedule—Continued Maintenance operation Group 01—Engine 0100—Powerplant: Engine, with accessories and clutch assembly— remove and install (includes removi and installing powerplant, transferring air cleaners, radiator, front engine support. piping. and minor tune-up) Powerplant semove end inal includes removing and installing powerplant) ‘Transmission—remove and replace (includes removing and 0100—Engine Assembly: Engine, with accessories and clutch assembly (removed from Powerplant). Disassemble into subassemblies and assemble from subassemblies— (includes removal and installation of accessories Insulator, support, front—remove and replace all Insulator, support, front—remove and replace: ‘One side Both sides. ‘Test cylinder compression and vacuum Tune up, major—includes torquing cylinder head stud nut i nuts to specifications; checking jer compression; cleaning, adjusting, and testing spark plugs; cleaning and inspecting battery cables and batteries; checking distributor ailing powerplant) ‘checking engine vacuum; checking fuel pump pressure: cl fuel bowi and adjusting float level; rem: cleaners; adjusting valve tappets; adjusting engine high- idle speed (no-load) and idling speed; testing generator output and voltage regulator (no parts replacement) Tuneup, minor—includes checking and adjusting tappets; checking valve pecting distributor breaker points and checking ignition engine idle speed (no parts replacement) Cylinder Sleeves, and Cylinder Heads: Gasket, cylinder head—remove and replace (one) (includes removing carbon and adjusting tappets, one bank) Head, cylinder, with valves, assembly—remove and replace (includes ‘adjusting tappets): ‘One. Both Sleeve, crankease cylinder—remove and replace (see Piston and Rings 0104). 0102—Crankshaft, Bearings, Damper, and Pulley: Crankshaft and main bearings—remove and replace from di front and rear oil seals) sembled Pulley. crankshaft—remove and replace 0103—Flywheel, Ring Gear, and Housing: Flywheel, assembly—remove and repla Includes removing and installing powerplant. In combination with group 0200 Clutch Assembly—remove and replace: Gear, ring, flywheel ‘and replace Includes removing and installing powerplant. flywheel—remove and replace: stalling powerplant. sn with Flywheel Assembly—remove and replace Pins, and Connec iston—remove and replace with 0.005 oversize (one! ues fitting pin in piston and rod) inus—remove and replace (one) (includes pin in connecting rod, and replace cylinder sleeved Man hours 19.2 12.0 135 64 25 35 42 65 16.0 120 0.8 0.6Table 1-3. Time Schedule—Continued Maintenance operation Group 01—Engine—Continued 0104—Pistons, Rings. Pins and Connecting Rode—Continued Rings and pins, piston—remove and replace (includes rods, replacing connecting rod bearing set and piston pin bushings. 0105—Valves, Springs, Guides, and Inserts: Guide, valve—remove, replace, and ream (one) (head removed): Iycludes removing and replacing valve and refacing valve seat. Each additional, add All in same head Insert, valve seat—remove and replace (head removed) (one): Includes remove and replace valve. Each additional, add Valve—remove and replace (one) (head removed) (includes refacing valve seat) Valvee—grind all, cylinder head removed (includes removing carbon, cleani One Two heads. 0105—Pushrods, Rocker Arms, and Tappets: ‘Arm, rocker—remove and replace (one valve) (inciudes adjusting of tappeta): One bank : Each additional, within same bank, add : Gaskets, rocker arm cover—remove and replace (one) Rod. push—remove and replace, engine in ch Does not include removing rocker arm assembly (one) Each additional, within same bank, add Shalt, rocker arm—remove and replace, engine in ch Includes adjusting valve tappets: One. Both Teppets—adjust all (includes cold adjust, stud nuts and manifold screws, 0.5 hour en time, removing and replacing cover gaskets) 0105—Camshaft (all operations on disassembled engi ‘Bearing, bushing type, camshaft—remove and replace (includes line boring bearis 0106—Oil Pump and Relief Valve (all operations on disassembled engine): Pump, oil, assembly—remove and replace Pump, oil, assembly—rebuild Strainer, scavenger, oil, assembly—remove, clean, and install Strainer, floto-creen, oil, assembly—remove, clean, and install 0106—Oil Filter: Element, oil filter—remove and replace (both) Filter, oil, assembly—remove and replace tion, Breather and Filler: Regulator, ventilation, assembly—remove and replace. Breather, vent, flywheel housing—remove and replace 0106—Oi1 Pan Pan, oil, lower, assembly—remove and replace 0108—Intake and Exhaust Manifolds: Gaskets, manifold—remove and replace Manifolds—remove and replace. .... 0109—Accessory drive and Idler Gear Assembly: ‘Accessory drive—remove and replace {rom ‘linement with timing gear cover, reami Group 02—Clutch 0200—Clutch Assembly Housing: Clutch assembly—remove and replace (includes removing and replacing powerplant and transmission) Housing, clutch: Remove and replace In combination with 0700 Transm driven with hubs and facings-rel removed) Plate, intermediate-ebuild (plate removed) Plate, pressure, with springs and levers—rel yuing cylinder head ‘normalizing jembled engine (includes ete.) ‘Assembly-remove and replace. one! (disk ld (plate removed) 25 02 02 WsTable 1-3. Time Schedule—Continued Maintenance operation Group 02—Clutch—Continued 0202—Clutch Release Mechanism. Bearing, release: Remove and replace In combination with 0700 Transmission Assembly—Remove and replace Controls and Controls and linkage—repair. Pedal, clutch—remove and replace Shalt, release—remove and replace (includes installing bushings), In ‘combination with 0700 Transmission Assembly—remove and replace. Yoke, clutch—remove and replace. In combination with 0700 ‘Transmission Assembly remove and replace Group 03—Fuel System 0301—Carburet Carburetor assembly—adjust.. Carburetor, assembly—rebuild (carburetor removed) Carburetor, assembly—remove and replace Gasket. carburetor to manifold—remove and replace 0302—Puel Pump (Electrical): Remove and replace 0304—Air Cleaner: Cleaner, sir, asembly—clean and refill (both) Cleaner, air, assembly—remove and replace (one) Tank, fuel—el One : In combination with Tank, Fuel—remove and replace. Tank, fuel—remove and replace (one) . 0306—Fuel Lines and Fitings. Hone, filler, vent tube—remove and replace Lines and fittings—remove and replace (all) 0308—Engine Speed Governor: Governor—adjust (includes installing seala). Governor, mechanovae, assembly—remove and replace. 0312—Accelerator, Throttle or Choke Controls: ‘Controls and linkage, throttle, assembly—remove and replace Control, choke, assembly—remove and replace. Controls, throtle and choke—repair and adjust Pedal, accelerator—remove and replace. Group 04—Exhaust System: (0401—Muffler and Exhaust and Tailpipes. Bracket, muffler support—remove and replace (one) Gasket, extension and tail pepe—remove and replace (one). Gasket, exhaust pipe to manifold—remove and replace (one) Gasket, tail pipe to muffler—remove and replace (one). Mulfler—remove and replace (one) Muffler, exhaust pipe, and tail pipe assembly—remove and replace (one) Pipe, tail, muffler—remove and replace (one) Group 05—Cooiing System 0501—Rediat Cock, drain—remove and replace. Radiator, assembly—remove and replace (includes removing and installing upper beush guard)... Shroud, fan—remove and repair (includes removing fend tovaling radiator! 0503—Lines, Fittings, Hoses, Thermostat: Howe, radiator—remove and replace (all). Hose, radiator, water inlet—remove and replace (one). . Howe, radiator, water outlet—remove and replace. Housing—thermostat—remove and replace. Thermostat—remove, test, and install... 0504—Water Pump. (All operations iachide removing and replacing radiator, fan, and fan drive): Body, water pump—remove and replace. Impeller, water pump—remove and replace. 14 Man dours os 07 06 os 0.3 1s. 0s 10Table 1-3. Time Schedule—Continued Maintenance operation an-hours Group 05—Cooling System—Continued 0304—Water Pump—Continued Seal. oil. water pump drive shaft: Remove and replace In combination with water pump body, remove and replace. 0505—Fan, Fan Belts, Fan Pulley Belt, fan—remove and replace (alll Fan blade, assembly—remove and replace Group 06—Electrical System 0601—Generator ‘Armature, assembly—remove and replace (includes removing and replacing generator) 10 Brush, generator—remove and replace (all) 10 Generator assembly—remove and replace 04 0602—Generator Regulator: Regulator, generator —adjust 05 Regulator, generator—remove and replace. 03 0603—Starter, Starter Switch Pedal: Brush set, starter—remove and replace (includes removing and replacing Starter assembly) 18 Pedal, assembly—remove and replace 06 Starter, assembly—remove and replace 08 Switch, starter magnetic—remove and replace 03 (0605—Diatributor Cap. assembly—remove and replace 03 Gapacitor—remove and replace 03 Geil. ignition—remove and replace 04 butor, assembly—adjust lincludes points and ignition timing) 08 ributor, assembly—remove and replace lincludes reset timing) LI Lever, breaker, with point assembly and bracket with stationary ssembly—re:nove, nd adjust 0.5 Cable set, spark plug—remove and replace Plug. spatk—remove, clean, adjust, and install (all) Plug, spark—remove and replace 0607—Instrument Panel, Instruments, Switches, Lights, Lamps, Gage Breaker, circuit, assembly-—remove and replace (onel. Buzzer, warning, low air pressure—remove and replace. pressure—remove and replace. fuel (indicator—remove and replace. Pressure—remove and replace Indicator, battery and generator—remove and replace Light, instrument panel—remove and replace Switch, dimmer—remove and replace Switch, floodlight, assembly~remove and replace Switch, fuel gage. assembly—remove and replace Switch, fuel pump, assembly-—remove and replace Switch, ignition, assembly—remove and replace. Switch. light, atsembly—remove and replace Switch, stoplight—remove and replace 0609—Head. Tail. and Marker Lights: Lamp unit, auxiliary light, assembly—remove and replace (one) Lamp unit, blackout drive, assembly—remove and replace (one! Lamp unit, blackout marker, assembly—remove and replace (one) Lamp unit, blackout stop. assembly—remove and replace (one! Lamp unit, blackout tail, assembly—cemove and replace (one) Lamp unit, headlight, assembly~-remove and replace (one) Lamp unit, park, assemb.y—remove and replace (one) Lamp unit fand stop. assembly—remove and replace Light, blackout drive, assembly (without cable)—remove and replace Light. blackout marker. and service park, assembly—remove and replace Light, blackout tail and stop. assembly—remove and replace 1-15,Table 1-3. Time Schedule—Continued Maintenance operation Group 06—Elee-rical System— 0609 —Heat, Tail and Marker Tights—Continued Light, sersice tail and stop, and blackout tail, assembly remove and replace Light, head. service, with bracket, assembly—remove and replace fone} 0600—Auxiliary Lights, Lamps: Lamp, flood light, assembly—remove and replace Light, flocd, assembly—remove and replace. 0610—Sending Units. . sending. engine oll pressure gage, exvembly—remove and replace Unit, sending, engine water temperature gage assembly—remove and replace . sending, fuel gage. remove and replace (one) jorn and Horn Button: ble, horn button, assembly: Remove and replace from removed angle drive 14012 In combination with angle steering—remove, rebuild, and install Horn, assembly—remove and replace , rorn—remove and replace Cable, battery interconnector, assembly—remove and replace Cable, battery to ground, assembly—remove and replace. Cable, battery to magnetic switch, assembly—remove and replace Cable, magnetic switch to starter--remove and replace Keceptacle, Trailer, assembly—remove and replace 0615—Radio Suppressor Bond, geounding—remove and replace (one) Heceptacle, radio—remove and replace fer fer Assembly. ‘Transmission and transfer, assembly—remove and replace, see 0100 ywerplant.. ‘Transmission and transfer, assembly (removed)—rebi 0704-Top Cow. Gear Shift Levers, Shafts, and Forks (one 0721—Transmission and Transfer Assembly Oil Filter: Screen, oil 0721—Transmission and Transfer Assembly Oil Pump (Removed transmission): Pump, oil-—remove and replace Pump, oil-—rebuild Group 09—Propeller Shaft and Uni 0900—Propeller Shat Joint, universal—remove and install journal and bearing kit toned Shaft, propeller, transfer to front axle, assembly (with universal jointe) remove and replace. Shaft, propeller, transfer to forward rear—axle, ‘assembly (with universal joints}—remove and replace Shalt, propeller, forward-rear axle to rear-rear axle, Assembly ‘with universal joints)—remove and replace Mandours 3.5 0.2 02 0.2 28.5 25 3.0 27 0.3 04 08 08Group 09—Propeller Shafts and Univers (0900—Propeller ble 1-3. Time Schedule—Continued tenance operation ts—Continued jints—Continued Shafts and Universal Shaft, propeller, power take-off to winch, assembly (with universal joints!—remove and replace Shaft, propeller, steer assembly (with 1 angle to hydraulic power unit, zeal joints)—remove and replace. Group 10—Front Axle 1000—Front Axle Assembly Axle, front wit and replace th hubs and drums, assembly remove Axle, assembly—rebuild (removed and includes drive end assemblies. 1000—Housing Housing, front axle, assembly—remove and replace 1000—Axle Shafts and Flanges: Shaft, ie Carrier, with differential, assembly. 1004—Front Ax e—remove and replace (one broken) (includes le Drive End Assembly: ‘Arm, steering—remove and replace (includes adjust toe-in) End, drive, End, drive, Pin, ‘tee Group 11 ‘assembly—remove and replace (one) ‘assembly—rebuild (removed) 1g knuckle—remove and replace (one) Rear Axle. 1100—-Rear Axle Assembly: Ale, forward-rear or rearrear with brakes, drums, and hubs, assembly—remove and replace Axle, forward-rear or rearrear with brakes, drama, and hubs, ‘assembly—rebuild (removed) 1100—Rear Axle Shaft: Shaft, drive, (includes removing a right or left—remove and replace (one broken} replacing differential to inspect housing for any pieces remaining 1101—Rear Axle Housing: 1102—Di Carrier, axle, rea ential and Carrier, Ca ith differential, remove and replace (one) Gears, and Pinions: (removed, er includes complete disassembly, replacing necessary adjusting) (one) ith differential, assembly—remove and replace (one) Flange, com panion, drive, pinion—remove and replace al, oil, dri Group 12—Brakes ive pinion bearing—remove and replace 1201—Hand Brake: Band, hand Brake, hand. brake—Remove, reline, install, and adjust idjust lining to drum clearance Drum—remove and replace Lever. assembly—remove and replace 1202—Service Brakes: ‘Shoe—remove, reline and is I (all wheels) ‘includes drums true up, and resetting slack adjuster Shoe, with Sp ssembly—remove and replace (all wheels) mn, brake shoe return—remove and replace (front wheel) (one) Spring. ten replace (r brake shoe return—remove and sar wheel) (one 1s 12 42 33.0 13.0 10.0 8.0 40 175, 30.0 20.0 Lo a0Table 1-3. Time Schedule—Continued Maintenance operation Group 12—Brakes—Continued 1206—Mechanical Controls—Continued Pedal and linkage—remove and replace 1208—Brake Chambers, Diaphragms, and Valves: Chamber, brake, assembly—remove and replace (one) (front wheel) Cylinder, brake, assembly—remove and replace tone) (rear wheel! hragm—remove and replace (one) (front only) Valve, application—remove and replace Control, differential brake—remove and replace Valve, control trailer—remove and replace Valve, double check—remove and replace ick rel 1d replace Valve, tire inflation—remove and replace 1208—Air Reservoir and Fit Reservoir, air—remove and replace (one) Reservoir. air—remove, clean, test, and install (two) 1209—Air Compressor and Air Governor: Belt—remove and replace Cleaner, air service ir assembly—remove and replace |—remove and replace Governor, air assembly—remove and replace Valve, unloader, assembly—adjust Courtney hal and service (one) Coupling, hall, sir brake and/or air hose—remove and replace one) Group 13—Wheels, Hubs. and Drums 1300—Wheel Alignment: Check toe Adjust toe-in Check camber and ca Adjust easter twith spring shims) 1311—Wheel Assembly. Bearings, Seals, Hubs, Drums, Studs.and Nuts: Bearing. wheel, rear—adjust and repack (one) ing, wheel, rear inner and / oF outer—remove ‘and replace Drum. brake, front—remove and replace (one) Drum, brake, rear—remove and replace (one) Hub, assembly, rear—remove and replace (one) 1311—Wheel Assembly. Bearings, Seals, Hubs, Drums, Studs, and Nuts: Seal, oil, wheel bearing assembly, rear—remove ‘and replace (one! Wheel, with tire assembly—remove and replace (includes removing spare tire from carrier and stowing and replacing wheel and tire assembly: brake and/or sir hose—adju ‘One Inner dual rear ‘Tires, Tubes, and Bead Locks: ire—remove and replace (one) Tube—remove and replace (one) Group 14—Controls 1401—Swering Drag Link: Link, drag. assembly —adjust one end (removed!—rebuild ‘using repair kit) Link, drag. assembly—remove and replace 1401—Angle Drive: steering, ussembly—remove and replace . assembly—remove, rebuild, Man ours 20 12Table 1-3. Time Schedule—Continued Maotenance operation Group 14—Controln—Continued 1401—Angle Drive—Continued Wheel steering—remove and replace .. 1401—Tie Rods End. tie rod—remove and replace (1wol Rod. tie, assembly—remove and replace Rod. tie. assembly—repair 1401—Steering Gear: Arm, pitman with ball stud—remove and replace (includes removing steering gear) Gear, steering—rebuild (removed) Gear, steering—remove and replace 1410—Hydeaulic Gear Pum Pump, hydraulic gear, assembly—remove and replace 1410—Hydraulic Conteol Valv ve, hydraulic control, assembly—remove and replace includes removing and installing steering gear) Group 15—Frame and Brackets 1501—Frame Assembl Frame assembly—repair Shackle. lifting—remove and replace 1503—Pintle and Lifting Shackles: Pintle, assembly—remove and replace Pintle, assembly—rebuild 1504—Spere Wheel Carrier and Davi Davit, spare wheel, assembly—remove and replace (any one telescoping section) 1506—Filth Wheel. Wheel, fifth, assembly—remove and replace Pin, locking, assembly—remove and replace Group 16—Springs and Shock Absorbers 1601—Front Springs, Shackles, and Attaching Parts: Bearing, bushing type—remove and replace each Shackles and bolu—remove and replace (all) Springs, front suspension, assembly—remove and replace (one) sar Springs and Suspension: Bearing, trunnion—remove and replace (one) Bolt, center, spring—remove and replace (one} Housing, insulator, shock, assembly—remove and replace (one) Rod, torque—remove and replace (one) Seal, oil, trunnion bearing—remove and replace (one) Spring, rear assembly-—remove and replace (one) 1604—Shock Absorbers: ‘Absorber, shock, front—remove and replace (one) Group 18—Body, Cab, and Hood 1801—Body and Cab Panels, 8, Sills, Cowl, ‘assembly—remove and install 1801—Doors: Door, assembly—remove and replace transfer of glass and hardware) (one) Hinge, door half-remove and replace (one! Regulator, door window—remove and replace 1801—Hood: Catch hood lock, assembly—remove and replace Hinge, hood—remove and replace (one) Hood, assembly—remove and replace . 1802—Fenders and Running Boards: Boards, running—remove and replace (one) Fender, front-remove and replace (one) Mantoure 0s 40 25 19Table 1-3. ime Schedule—Continued Maintenance operation Group 18—Body, Cab, and Hood—Continued 1805—Cab Floor Tunnel: Tunnel, cab, floor—remove and replace 1806—Upholstery, Seats, Seat Adjusters, and Supports. Cushion, seat, assembly—remove and replace Cushion. seat, backrest, assembly—remove and install Regulator. operator's seat. complete—remove and replace 2001—Winch Assembly: Band, constant drag, brake-adjust (one) Band, constant drag, brake—remove and replace (one! Cable, assembly—remove and replace (one) Pin, shear—remove and replace {one} wembly—remove and Winch, assembly and mounting—remove and repli Winch, assembly—rebuild (one) 2001—Winch Drive Shat Joint, universal, drive shaft—remove, repair, anc . propeller, assembly—remove and replace 2004—Power Take-Off Assembly (Transmission in Vehicle). Clutch, sliding, drive shaft—remove and replace Fork, shifter, assembly—remove and replace Shatt, drive, power take-off—remove and replace Group 21—Bumpers and Guards 2101—Front Bumper and Brush Guards: Bumper, front—remove and replace Guard, headlight—remove and replace Guard, radiator—remove and replace Group 22—Body, Chassis, and Hull Accessory Items 2201—Canvas Items: Cover, top. assembly—remove and replace Group 22—Body, Chassis, and Hull Accessory Items 2202—Accessory Items: Control, windshield 1 wsembly—remove and replace ssembly—remove and replace ide, assembly—remove ‘and replace {one} Group 47—Gages (Non-Electricall 4701—Speedometer Assembly: Shaft, flexible, assembly—remove and replace Speedometer, assembly—remove and replace 4701—Tachometer Assembly Shaft, flexible, with core, assembly—remove and replace Tachometer assembly—remove and replace Mantoure ot 03 058 05 03 02 0.2 03 05 05CHAPTER2 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS Section 1. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT 2:1. Tools and Equipment Standard and commonly used tools and equipment having general application to the materiel listed in this manual are authorized for issue by tables of allowances (TA) and tables of organization and equipment (TOE). 2.2, Special Tools and Equipment The special tools and equipment required to perform the direct and general support maintenance operations described in this technical manual are listed in Table 2-1 and illustrated in figures 2-1 through 2-5. References and illustrations indicating the use of these tools are sted in the table. 2-3, Maintenance Repair Parts Direct and general support repair parts are listed and illustrated in TM 9-2320-206-34P which is the authority for requisitioning replacements.© © Z mS | C5 CCA) CAFigure 2-2. Special tools and equipment.= aFigure 2-5. Special tools and equipment. AT 34870-ynurx20 suey aovjdax pur 2nouiry Buywoq swar yoys up selo-ere-oz1s 9RL6-69S-01 64 2£99-9¢8-0215 $1Z6L01-0215 synunypo] 1yoys uyour ayeys wound dno Bul 0929-102-0% ‘¥8E6-69S-021¢ “Hp axe qos} “2u09 Buy 2826-69: Ez TO-ENE-0ZTE ZeLO-EPE-OZIS oc99-o88+ 892972 afuvy uowedwos axoway O-fHE-0619 spin jana] ava Suy0016 yetueD 1998 Buts091 "8S29-LOL-OZIS PUY'EBES-69S-0ZIS “ZZI0 “PE0ZTS “T8Z9-LOL-OZLS 81998401 pu s9A0WIOs “avZo-LOL-OZIS 2aqINd “StL PUP OfZIWN ‘E21 — quays you % seomjder pus axouey ?STUNVH -a¥aB aesanat uotsay welLeLe-ozis $169 ESL oF 6Z1-086-016F STLO-E9E-016F “CARTIW PUY DIVEZTN—sI008 “POEL-EL-ORLS s90|das paw 3 wwowdbg woddng pu we, ‘Roos 1eIV0dS “1-2 814% a ~ -wv = —_ 9 |sz Auyenoq adh Buyyenq sonjdos puv ssowoy| -gy-y | zz | 91L6-zeS-OZ1S “WSOVIdaY GNV USAOWSY s | sz Hoyeoq royd sxoumy) te | ze | 9TTO-evE-ozIS “Aauveg tnd | YaTINd aire | are + | sz omp yomp uoaup sony] pire | ore | r909-zve-016F “MY ONINITY 9SIG HOLATD (rare | ce (24s z | sz “nu Supsnfpe Suys90q joaym 1uos5 soe|das pur asowey | (9) -FS-5 080-805-0215 ‘you joey ywosy “souueds = HONIMA, ‘anu Sunsnf 1 | oz | -pe suneaq seas yeys ouyds uowsmusues soxdex pu axowey 9106-1SE-02 1S | -ru ouyds uowsmeuEn ‘souueds + HONTHA est Ist wer oer a4 oes ov | we Projesd Hujwaq sopsuen 40 jepues2P 4924) oct | 986-s29-0299 -sovvoy IVS waeziW 6 | re | ‘otvect—ine ofuey sopigp somod somdes pu sroury oL11-666-0218 s2plaip temod “12490 : HONSUA a | + “182 Yo Fuyenoy (enussoymp s9yIWD axw 104} eoejday, 629-202-0218 929] PEE 1wOH] “1928 IO -WIOVTATY a ve ‘1826 [Jo 49A09 ypeYs sarpYs 204u9y ore T8Z9-LOL-OTTS | YoIUSUEN KeyrHe wor NO >YIDVITY word 9 |e | Auye2q roads yoys wow uowd axup uowmusuen soxdoy| vere | ove | eszotoz-ozts | sup uowmusuEN “Sue2q > MIOVTdTU s | +2 8816-69¢-021¢ -rurof yresoayun usage + | Fe LBL6-69S-0718 un “1898 0 = IOV TdT e | re vqors | os | oert-err-ozis “youaim 199908 =.LAXDOS ee cusounoyes exuon fox tg an —— ONS2-4. Fabricated Tools ‘The fabricated tools listed in Table 2-2 and the dimensioned detail “drawings furnished herein apply only to direct support and general support chops to enable these maintenance organizations to fabricate these tools locally, if desired. These tools are of chief value to maintenance organizations engaged in rebuilding a large number of identical components; however, they are not essential for rebuild and are not available for issue. The data in Table 2-2 is furnished for reference only. 1/4 X30 DEG [1/4 x 9 oxo be t eh" Taes ea -4---4-: ! ft ' aan zene ||| [aoe 274 1 ft 2éyme | satan || 35990 |] [aes 27288 2a |i ith bE --}--f---¢--44--4--4 bedava t 214.570 ate 374 —a 58 739 1341/4 Figure 2-6. Fabricated steering knuckle-to-housing A NOTE: AlL DIMENSIONS SHOWN ARE INC INCHES RA PD 374441 ing tool.1/M6X 45DEG 1/64 1/1 UNDERCUT A L —— ~----4 ——a) A ~ USE WITH HANDLE~ esti 5120-473-5900 BUSHING-TYPE BEARING REMOVER AND REPLACER Tem LOCATION. aytele I. | POWER-TAKE-OFF BEARING 1.120] aya [ tay TL | HAND BRAKE OPERATING SHAFT © [a7 [90s [ore TT | FRONT SPRING AND BRACKET [yas] 2 | 3 IZ | REAR SPRING TRUNNION 3.990] 4.3/16| 4.3/8 ae eet a S53! —_— ---4 — FACET] use wire nanote- 1.0—>} 5120-473-5922 al ‘OWL SEAL REPLACER Tem Location alele _- tS X_ | PoweR.TAKe.OFF FLANGE | 2 fidiel aie AH | FRONT Axte HOUSING INNER vaya] 2aya[ 2474 am | Front axis HOUSING OUTER 3 [4 [ai ‘XM | FRONT WHEEL HUB 7Af2| 9 | 8-3/4 HE | FRONT AXLE END PIVOT SHAFT 2 [see [ 3-178 FRONT AXLE END 2ND REDUCTION nar 5 ” XE | evel GEAR RETAINER ahaa NOTE, AIL DIMENSIONS SHOWN ARE IN INCHES ORD E73509 Figure 2-7. Fabricated bushing type bearing removers and replacers and oil seal replacers. 2-10ae ore roe —__] [Wrench T vocanon me » Tele fole]-le [«]2 econ | Tae Tarn foam [ove] | 2 | 290 [aselrare Taneaason coer [2 WRX se [sare orn | a | 2sr| exnre| mar liane Tearsmsgon cower TER7™ Tam [osre |e | oa | 2a] v9 fare brane] Ton An Be Trex ‘2ND_REDUCTION Y ci M2 lays |as3ji6| 42/0 a | 34/2) — a frane ieee | mor sar v We? faave| wand sve] ame [oon] — | [rare oH ten to v mee [aan | zone] sae] oe | aval — | « fare a A SeST Go AO Oi ERSTE Figure 2-8. Fabricated bearing nut wrenches.2-12 DRILL (1) 3/16 HOLE | 7/@- 12 POINT socKet (FSN 5120-181-6816) FILLET WELD TEs, EAD | 7 If yg I ea NOTE, ALL DIMENSIONS ARE IN INCHES ORD £73511 Figure 2-9. Fabricated differential bearing preload tool. mame douemus Figure 2-10, Transmission ing sling bracket—M123A1C, M123E2.At 34872 » Figure 2-11. Fabricated transmission lifting sling bracket—M123A1C, M123E2, 213“wnopemieaen Zatz IW 20 OLVETTWL te | ssouo: oy amd puo oreo sojeuens Jo anus doy uy (imauy [eye or | 20 otyectiy sxoues oF s0K00 sage [vere 62 | yenusieyyp wo propeud Suys¥9q 10 pro, Fuyjos auuumep oy, [¥eI-s | 9-9 1nez “ynuypo] 2908 jog apse seas eisuy pur anowssog, fpors | ers sva8 yonog opcw seas yn 8 res | iy ee Age -ynu ayays roayd ysieuy pu anomes og | wep | $I+ ond pus apes quods nu Buseog = HONAMA, ies 1998 oA0q Uotlonpa! Xi-¢ | vouperes Bupsraq 908 janoq uonompos puodse ut j2os yo year og, | “2-4 me NO PHSOV AM ae xz “sonoo souyeias Buysvoq 2}xesanu ut [808 ast 98 WO EHAOVTA MIAL “aanoo Suyenoy 1008 fonoq uonionpou pays ut ass 8 ADVI use nave -Auyenoy axe vuosy wy eyuae yo somoesuroy | etc | ose aXe ruo4y seIMo >" WO FWA) ‘ea8 jahoq woonpay pubes alee nu 1998 janaq uostonpas puoses jreuy pux sxomssos, | Sey | zI+ pus axe auosy “anu Bun ‘haw souynias 1ie-z | Suuwoq sus yeys puw saowias of, [ash-¢ saqua9 uoyssyuisuen “ine Bs “anu sauuy Tez | fuyreq seruso ayeys cyrus uopsueuen yreuy puw axouias og, face Jeyuao uoqerwasuesy “ina 18% anu uolutd Surat uy woes uHUEN [jeeU! puv arowasoy LFop-¢ | oo-€ uyeu uoyssywsuen “nu SujsEag TAL “Buysnoy 9pxv 1uosy ut yee yo s9UUr meus oy, LqIZ-% | Lo-4 3x8 wosy “s9UU ALt ‘afuey sjooyer somod ut jwor yo teat of, | Tze | vSe-e “aBuny jjo-oyn s9mod wav “uoqaun Tuojuunsy Buysds seas Suueeq adk AIL? | Saude seas ut eBuyzwaq eddy Burysnq yesuy pue arowss of [17-6 6 Suysng :YdOVIdaY GNV WIAOWAY “wyptq fuyde yuo uy pue “reyoeaq pur Bulade 1004) “Butseaq 9041 s2t0 amass oon my edosvog eds Bong ymin pu enous ox | 56 | 6 Suyeng :HIOVTTY GNY WIAOWSY “are oddae 23 oq adh Buyysng rea: puw exours oy, | “91-9 Juyng “WIOVITY GNV YaAOWTL “yorayer somod uLoq Le “Auysvog odes Suryeng yo-24M somod yorsur pur ssouszoy, | fore | HE odds ung -UGOVTETH NV 3AOWSH 9-¢ | uyenoy 2908 j2s0q voronpas pays pu ase | vee wena | wie ov “a t ce oem M100, par mang Bz 19%L 214Section Il, TROUBLESHOOTING 25. General. 4. This section contains inspection and troubleshooting procedures to be performed both while a disabled component is still mounted in the vehicle and after it has been removed. Refer to Table 2-3. Information in this section is for use of Army maintenance personnel in conjunction with and as a supplement to the troubleshooting section in the pertinent organization maintenance manual Itprovides the continuation of instructions where a remedy in the organizational maintenance manual refers to supporting maintenance personnel for corrective action. 6. Operation of a deadlined vehicle without a preliminary examination can cause further damage to a disabled component and possible injury to personnel. By careful inspection and troubleshooting, such damage and injury can be avoided and, in addition, the causes of faulty operation of a vehicle or component can often be determined without extensive disassembly. 2.6. Procedures. 2. The inspections made while the component mounted in the vehicle are for the most part visual and are to be performed before attempting to operate the vehicle. The object of these inspections is to avoid possible damage or injury and also to determine the condition of and when possible, what is wrong with the defective component. b. The troubleshooting performed while the component is mounted in the vehicle is that which is beyond the normal scope of the using organization. Check the troubleshooting section of TM 9-2320-206-20, then proceed as outlined in Table 2-3. These troubleshooting operations are used to determine if the fault can be remedied without removing the component from the vehicle and also, where subsequent removal is necessary, to indicate when repair can be made without complete disassembly of the component. c. Inspection after the component is removed from the vehicle is performed to verify the diagnosis, made when the component was in the vehicle, to uncover further defects, or to determine faults if the component alone is received by the supporting maintenance. This inspection is particularly im- portant in the last case because it is often the only means of determining the trouble without completely disassembling the component. Table 2-3. Troubleshooting Maltneton Probable Cause Corrective Action 1, Lubricant leakage at output shaft seal. 2. Lubricant leakage at transfer shifter shaft seals. 3. Lubricant leakage at power take- off shaft seal. 4. Lubricant leakage at 5. Gear chatter and noise. ket. 6. Slipping out of gear. 7. Hard shifting 8. Leakage at vheel hub. 9. Leakage at third reduction bevel gear housing cover. 10, Leakage at axle housing (banjo). 11, Loss of lubricant in axle end housing not due to v leakage. 12, Loss of pul power. 13, Continuous axle noise. TRANSMISSION AND TRANSFER ASSEMBLY a. Defective seal 6. Damaged flange hub 4. Defective seal 6. Defective shifter shaft. Defective seal Defective gasket Worn gear teeth and bearings. ‘Worn sliding clutch Worn or damaged shifting components. FRONT AXLE ASSEMBLY 4. Defective seal 6. Damaged hub a. Damaged gasket b. Damaged cover Loote bolts Defective axle shaft seal Broken axle Wheel bearings out of adjustment, 1b. Gear hum or growl Replace seal (para 3-19 and 3-21). Replace drive flange hub (para 3-19 and 3-21). Replace seal (para 3-22 and 3-28). Replace shifter shaft (para 3-22 and 3-28). Replace power take-off shaft seal (para 3-19 and 3.21). Replace gasket Replace gears and bearings (Chapter 3). Replace sliding clutch (Chapter 3) Replace shifting components (Chapter 3). Replace seal (para 4-3 and 45). Replace hub (para 4-3 and 45) Replace gasket (para 4-3 and 45). Replace cover (para 4.3 and 45). Retorque bolts (para 1-6). Replace axle shaft seal (para 4-19 ‘and 4-21). Replace axle shaft (par 10). Adjust bearings (para 4-3 through 4- 3). Worn gears (para 4-13 through 4 15). 4-8 and 4-Table 2-3. Troubleshooting —Continued Mallnetion| Probable Cause Corrective Action 14. Wheels fail to return to straightahead position after turn. 15, Wander or failure to steer straight. 16. Tire scuffing 17. Lubricant leakage at propeller shaft yokes or flanges. 18, Tires scuffed or worn unevenly. 19, Gear hum or growl. 21, Hard steering 22, Wander or weaving. 23. Insufficient brakes. 24. Brakes apply too slowly. 25. Brakes release too slowly or do not releate. 26. Brakes do not apply. Brakes grab. 28. Noisy brakes 29. Uneven brakes 30. Air pressure will not rise or slow to rise 2-16 FRONT AXLE ASSEMBLY—Continued a.Incorrect caster caused by damaged axle or suspension part Tight steering gear Insufficient caster . Looe steering linkage. Insufficient toe Insufficient or negative camber. Worn steering trunnion or bearings. . Loose wheel bearings Incorrect, REAR AXLE ASSEMBLY 4. Defective seal ‘6. Damaged yoke or flange. Suspension members and torque rod ‘linement. Worn gears or bearings STEERING GEAR AND LINKAGE 2. Defective gaskets b. Defective seal 4. Defective pump b. Defective control valve. «. Defective power cylinder. 2. Excemsive lever shaft lash. b. Worn steering gear parts. SERVICE BRAKE SYSTEM Defective application valve. 4. Leaking brake chamber (front) or brake cylinder (rear). b. Restricted sir line € Defective or improperly adjusted application valve. d. Defective quick release valve. a. Defective quick release valve. b. Defective relay valve. ¢. Defective application valve. Sutotround brakedrums. ‘4. Defective brakeshoe assembly. Scored or damaged brakedrum. Outof-round brakedrums Leak at application valve intake. Refer to para 4-24. Repair steering gear (Chapter 7). Refer to paragraph 4-4. Refer to TM 9-2320-206-20. Refer to TM 9-2320-206-20. Refer to paragraph 4-24, | Replace trunnion or bearings (para + 3 and 4.5), Adjust bearings (para 4.5). Refer to TM 9-2320-206-20. Replace seal (para 5-11, 5-15, or 5+ 16). Replace yoke or flange (para 17 of 5-18). Refer to TM 9-2320-206-20. 16,5 Repair (para 5-11, 5-12. or 5-13). Replace gasket and retorque (para 9 through 7-13). Replace seal (para 7-11 through 13). Replace per TM 9-2320-206-20. Repair (para 7-10). Repair cylinder (para 7-10). Adjust (para 7-12 and 7-13). Repair steering gear (para 7-9 through 7-13). Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Replace per TM 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Repair per TM 9-1827A. Replace TM 9-2320-206-20, Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Refer to TM 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20. Repair (para 6-3). Replace per TM 9-2320-206-20. Repair (para 6-3). Replace per TM 9-2320-206-20. Repair (para 6-3). Replace per TM 9-2320-206-20. Repair (para 6-3). Replace per TM. 9-2320-206-20. Repair per TM 9-1827A. Replace per TM 9-2320-206-20.Matinction 31. Wheels pounding 32. Lubricant leakage 33. Winch noisy during operation, 34, Heater fails to start when control switch is turned on. 35. No heat output, or low heat output. 36. Indicator light inoper 37. Indicator light always on. 38. Heater operates several minu then stops. 39. Blower will not stop when hes js turned off. 40. Heater smokes excessively or bangs upon starting. 41. Blower runs, but heater fails to ignite. 42, Inadequate heat output. Table 2-3.Troubleshooting—Continued Probable Cause WHEELS AND TIRES 4! Bent wheel 6. Tire and wheel assembly out of WINCHES Detective seals or gaskets Damaged internal parts PERSONNEL HEATER— MI23A1C, M123E2 a. Emergency switch off. 6. No fuel pressure ¢. Defective electrical cireuit. d. Defective heater component. Jo fuel pressure jee in fuel system ¢. Defective component d. HILO switch in LO position. 2. Defective lamp 6. Defective wiring or lamp holder. Defective component 1. Restriction in fuel lines b. Defective fuel control valve. ¢. Defective flame detector switch. a. Defective flame detector switch. b. Defective blower motor wiring. with HI-LO switch in HI position. +b. Defective fuel control valve. a Sta 42. No or low fuel pressure 6. Restriction in fuel line . Defective electrical wiring. d. Defective preheat resistor. ¢. Defective igniter f. Defective fuel contro! valve. 4.Fuel pump filter elemert ¢. Extreme cold weather d. Det ‘component Corrective Action Replace per TM 9.2320-206-20. Replace tire and wheel assembly as required. Replace per TM 9-8617, ir gear boxes and the fai ee (Chapter 17). Replace components per TM. 9-2320-206- 20 and TM 9-861 Set switch to ON position. Open fuel shutoff defective wi Repair or replace defective component or replace heater (para 12- 38 and 12-39), Open fuel shutoff cock Remove ice from fuel line. Clean fuel filter element and replace if damaged (TM 9-2320-206-20). Repair or replace defective component or replace heater (para 12- 38 and 12-39), Switch to HI position Use PRESS-TO-TEST feature. Replace lamp if defective (TM 9- 2320-20620), Repair defective wiring herness or replace lamp (TM 9-2320-206-20). Repair defective component or replace heater (para 12-38 and 12- 39). Clean fuel filter element, and replace if damaged (TM 9-2320-206-201, Replace fuel control valve (para 12- 39). Replace flame detector switch. Replace flame detector switch (para 12:39), Repair defective wiring harness (para 12-401, Refer to operating instructions (TM 9-2320-206-10) Replace fuel control valve (para 12- 39). Check fuel shutoff cock position. Clean fuel filter element and replace if damaged (TM_9-2320-206-20). Repair defective wiring harness (para 12-40), Replace preheat resistor (p Replace igniter Remove fuel filter element and replace if damaged (TM 9-2320-206-10). Adjust radiator cover (TM 9-2320- 206-101. Repair defective component orTable 2-3, Troubleshooting —Cont Malfunction Probable ane defrosting, 4. 46. 49. Heater overheats, to run. Fuel odor. Burned fuel odor. No heat output. or low heat output. Indicator light inoperative. ). Heater operates several minutes, then stops, - Blower will not stop when heater is tuned off. . Heater amokes excessively of bangs upon starting. Blower runs, but heater 2-18 PERSONNEL HEATER MI23A1C, M123E2—Continued a. Improperly adjusted heater control ble. b, Improperly adjusted defroster control cable. c. Defroster ducting loose or damaged. 4. Defective overheat switch. b, Defective fuel control valve. 4 Fuel leak. b. Too heavy grade of fuel. ¢ Defective heat exchanger. COOLANT HEATER— ‘MI23A1C, M123E2 0 fuel pressu . Defective electrical circuit. . Defective heater component. No fuel pressure . Ice in fuel system ¢ HI-LO switch in LO position. d. Defective heater component. Defective lamp a. Restriction in fuel line. b. Defective fuel control valve. Defective flame detector itch. Defective flame detector switch. b. Defective wiring 4. Defective flame detector switch +b, Defective fuel control valve. 4.No fuel pressure or low fuel pressut 6. Restrict fuel line. ¢. Defective electrical wiring. d. Defective preheat resistor. ¢, Defective i J. Defective fuel control valve. Adjust cable (para 12-22). Adjust cable (para 12-22) ten clamps or repair ducting (TM 9. 6-20, Replace overheat Replace fuel control valve (para 12- 39). ighten fuel lines or replace defective component. Replace defective component. Remove restriction. Replace exhaust tube if damaged (para 12-22). Change to suitable grade of fuel (TM 9-2320-206-10). Replace heat exchanger (para 12-40). Open fuel shutoff cock (para 12-44). Repair defective electrical harness. Repair or replace defective component or replace heater (para 12- 43 and 12-46). Open fuel shutoff cock (para 12-44). Remove ice from fuel line. Clean fuel iter element and replace if 1320-206-20). Switch to HI position (pa Repair or replace defective component or replace heater (para 12- 45). Use PRESS-TO-TEST feature. Replace lamp if defective (TM. 9- 2320.206-20). pI if damaged (TM. 9-2320-206-201, Replace fuel control valve (para 12- 451. Replace flame detector switch (para 12455. Replace flame detector switch (para 12-45), Repair defective witing harness. Replace flame detector switch (para 12-45), Replace fuel control valve (para 12- 451. Check fuel shutoff cock position (para 12-27 Clean fuel filter clement and replace damaged (TM 9-2320-206-20. and changes thereto). Repair defective wiring harness. Replace preheat resistor (para 12- 451. Replace igniter assembly (para 12- 45). Replace fuel control valve (para 12- 1.Table 2-3. Troubleshooting—Continued Probable Cause Corrective Ati 55. Heater overheats but continues to run. COOLANT HEATER— M123A1C, M123E2—Continued 42. Coolant shutoff cocks partially or fully closed. b. ee erystals in fuel ©, Extreme cold weather. d. Defective heater component. 4. Defective overheat awiteh. b. Detective fuel control valve. Open shutoff cocks fully (para 12- 22), Remove ice from fuel systems. Clean fuel filter element and replace if damaged (TM 9-2320-206-20). Adjust radiator cover Repair defective component or replace heater (para 12+ Replace heater assembly (para 12- 441. Replace fuel control valve (para 12- 56, Fuel odor 2. Fuel leak b. Defective component 451. ‘Tighten fuel lines or replace defective ‘component. Replace defective component. Section II], GENERAL MAINTENANCE 2-7. General Paragraphs 2-7 through 2-11 contain repair instructions or reference thereto which are the responsibility of direct support and general support maintenance as authorized by the maintenance allocation chart. These instructions are general in nature (not specific to one component or assembly) to the end item; otherwise, the instructions would ) have to be repeated several times throughout the manual. Specific instructions for individual component maintenance are covered in the ap- propriate com ponent paragraphs. 2-8. Cleaning 4. General. The procedure for cleaning is the same for a great percentage of the parts and components which comprise the subassemblies. To avoid repetition of instructions, the general procedures for cleaning are detailed in b.through e. below. Any cleaning procedures which are peculiar to a specific part or component are covered in the section or paragraph relating to that item. Bearings should be cleaned as specified in TM 9-214. CAUTION Do not direct stream of water against the exterior mounted air cleaners, grilles, or exhaust openi b. Cleaning Instructions. The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and con- scientious effort are required in all cleaning operations. The presence of dirt or foreign sub- stances is a constant threat to satisfactory vehicle component operation and maintenance. The following apply to all cleaning operatio (1) Clean all parts before inspection, after repair, and before assembly. (2) Hands should be kept free of any ac- cumulation of grease which can collect dust and grit. (3) After cleaning. all parts should be covered or wrapped in plastic or suitable paper to protect them from dust and dirt. c. Metallic Parts. (1) Clean inner and outer surfaces or metallic parts and all areas subject to oil and grease with drycleaning solvent or mineral spirits paint thinner. (2) Remove sludge and gum depe-its using a stiff brus! WARNING Particles blown by compressed air are hazardous. Make certain the air stream is directed away from the user and other personnel in the area. (3) Use clean, dry compressed air to blow out and dry all tapped holes in metallic parts. d. Oil Passages. All oil passages must be clean and free of obstructions. (1) Clean passages with wire or suitable probe to break up any sludge or gum deposits. (2) Wash passages by flushing with drycleaning solvent or mineral spirits paint thinner. (3) Dry passages by blowing them out with compressed air. (4) Coat parts with proper lubricant after cleaning to prevent rust or corrosion. e. Bearings. ‘1) Bearings require special cleaning. After removing surface oil and gum deposits, place bearings in hot oil (140° F.) to loosen congealed and grease. Wipe bearings dry: do not use compressed air. After cleaning, coat bearings with a. light film of oil and wrap in paper until parts are inspected and assembled. 219(2) Steam cleaning may be used for removing ~ccumulations of grease and dirt after drycleaning solvent has been applied. . Inspection a. General. Procedures for inspection will be the same for a great percentage of the parts and components which comprise the vehicle subassemblies. To avoid repetition of instructions, the general procedures for inspection are detailed in 6. through h. below. Any inspection procedures which are peculiar to specific part or component are covered in the section or paragraph relating to that, item. Certain components are precision built, and the repair and replacement standards found in ‘Table 1-2 for the component parts have been fixed at extremely close tolerances. Be sure to use modern inspection equipment for inspecting component parts having extremely close tolerances. b. Metallic Parts. The below listed procedures are standard procedures that should be followed when inspecting metallic parts. After performing the procedures below, refer to Table 1-2 and check that all parts are within dimensional limits. (1) Ferrous parts. All ferrous parts should be inspected for cracks by performing a magnetic particle test as specified in Military Specification, MIL-1-6868C. (2) Nonferrous parts. All nonferrous parts should be inspected for cracks by performing a magnetic particle test as specified in Military Specification, MIL-I-25135C. (3) Rust. Inspect all ferrous parts for rus Rust on mating surfaces is cause for reject of both mating parts. (4) Burrs. Inspect gear teeth, ret grooves, and mating surfaces for burrs. (5) Nicks and scratches. Inspect mating and polished surfaces for nicks and scratches. Nicks and scratches on mating or polished surfaces are sause for rejection. (6) Parts with external threads. Inspect these parts for damaged threads; if threads are damaged the part must be replaced. (7) Threaded holes. Inspect all threaded holes for damaged threads and obstructions which may be wedged at the bottom of the hole. (8) Sheet metal parts. Inspect all sheet metal parts for bent corners, distortion, cracks, tears, broken corners, and defective welds. (9) Wear. All parts should be inspected for wear using suitable measuring instruments. Refer to Table 1-2 for repair and replacement standards. c. Nonmetallic Parts. No inspection is prescribed for nonmetallic parts such as packings. gaskets. seals, nonmetallic washers. filter elements. and locknuts of the fiber-inserted type. All such parts are automatically classified as unserviceable when 2-20 removed during disassembly and discarded unless otherwise specified. d. Bearings. Inspect bearings as prescribed in TM 9-214, e. Springs.Inspect springs for distortion, broken ends, and proper spring rate. f. Hardware. Discard all cotter pins and lockwashers during disassembly. Inspect all nuts, bolts, and screws for damaged threads and heads that could prevent proper wrench fit. Replace all damaged hardware. &- Gears.In many cases, the experience and good judgement of the inspector will determine whether a gear must be replaced. The following are a few of the more common inspection procedures to be used when inspecting gears. (1) Nicks id burrs. Inspect get teeth, splines, and bearing contact surfaces for nicks and burrs. Nicks and burrs that extend below the hardened surface of the gear teeth are cause for rejection of the gear. (1) Gear hubs. Inspect hubs gouges, burrs, and nicks. (3) Gear splines. Inspect splines for twisting burrs and scores. (4) Gear bearing journals. Inspect bearing journals for scores and galled spots. Reject gear i journal is scored or galled. (5) Wear. All gears should be checked for wear using suitable measuring instruments, refer to Table 1-2 for repair and replacement standards. h. Canvas Parts. Inspect all canvas parts for tears, fraying, defective stitching, loose eyelets and fasteners, and illegible markings. 2-10. Repair 4. General. Procedures for repair will be the same for a great percentage of parts and components which comprise the vehicle subassemblies. To avoid repetition of instructions a few of the more common repair procedures that may be used are listed below. Any repair procedures which are peculiar to a specific part or component are covered in the paragraph relating to that item in this manual, b. Cracks. Parts that are cracked may be repaired by welding as long as it does not distort or impair the strength of the part. Heat treated parts cannot be welded or heated unless otherwise specified. Welding procedures should be accomplished as specified in TM 9-237. c. Rust. Rust on polished nonmating surfaces may be removed with a fine oxide abrasive paper and the surface polished with crocus cloth. After repair, remove all abrasive deposits and rust by cleaning part as specifi paragraph 2-8. After removal of rust deposits. verify that the part is within the specified in Table 1-2. should be for scores,d. Burrs. Burrs should be removed from gear teeth. retaining ring grooves, and mating surfaces. A smooth file or hone may be used. e. Threaded Holes. Damaged threaded holes may be repaired by retapping the hole. If this is undesirable or ineffective, the hole may be drilled oversize, a suitable insert or bushing installed, and then drilled and tapped to the original thread size. f. Sheet Metal Parts. Sheet metal parts that are damaged may be repaired as long as there are no damaging effects (refer to TM_ 10-450). & Nicks and Burrs on Gears. Small and / or burrs on the engaging ends of the teeth may be removed with a small honing stone. This is only practical for minor defects. Fractures that extend below the hardened surface of the teeth are cause for rejection. h. Gear Hubs. Minor imperfections may be smoothed out by honing. i. Painted Surfaces. Damaged painted surfaces should be repainted as soon as possible to prevent corrosion. Before painting. insure that all surfaces are clean and dry. j- Canvas. All canvas parts should be repaired in accordance with TM 10-269. 2-11, Assembly a. General. Extreme care must be exercised in all component assembly operations to insure satisfactory performance. Step-by-step procedures for assembling various components are covered in the paragraphs relating to the specific component. nicks In addition observe the practices listed in. through i. below. b. Cleanliness. Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute quantities, are abrasive. Parts must be cleaned as specified and kept clean. Wrap or cover parts and components when assembly procedures are not immediately completed. c. Preformed Packings. Lubricate all preformed packings and their associated grooves with hydraulic fluid, MIL-H-5606. d. Metallic Parts. Lubricate all metallic parte with lubricant utilized in the component during operation (refer to LO 9-2320-206-12). e. Locking Procedures. Installation of cotter sand lockwire shall be accomplished as ied in MS33540. f. Torque Values. Critical torque values are specified in the assembly procedures. When not d, bolts, screws, and nuts are to be tightened in accordance with standard torque values g. Hydraulic and Fuel Components. All hydraulic and fuel components must be kept thoroughly clean at all times. Plug all open ports until the component is installed in the vehicle. A. Oil Seals. When replacing lip type seals, place g-loaded side toward oil. Coat housing contact surface with a nonhardening sealer to prevent leaks. Lightly coat lips of seals with grease (GAA). Pressing Operations. All pressing operations should be accomplished using a suitable press and adapters unless otherwise specified. Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS 2-12. General 4, Paragraphs 2-12 through 2-33 contains information for the guidance of personnel performing major repair work on the 10-ton, 6x6, M123 M123C, M123AIC, M123E2 and M125 series vehicles. It provides an assembly line procedure for the disassembly of the vehicle into its major components. It designates what constitutes a major component, illustrates the points of connection between major components, and states briefly what must be done. The points of connection are in- ‘ted on many of the items by a circle on the illustrations. When referring to TM 9-2320-206-20 for information, be sure to obtain information on the correct series, M123A1C, M125; ete, for the Particular vehicle on which the maintenance is being performed. &. Disconnect battery ground cable and drain the fuel tanks and air reservoirs (TM 9-2320-206- 20) before starting to disassemble the vehicle. It is not necessary to drain the radiator, engine crankcase, transmission, and differenti Batteries a, Removal. Refer to TM 9-2 b. Installation. Refer to TM 2-14, Fifth Wheel a, Removal. Refer to TM 0. -206-20. 9-2320-206-20. 20-206-20, b, Installation. Refer to TM 9-2320-206-20. 2-15, Cargo Body a. Removal. (1) Remove tarpaulin, end curtains, bow assemblies, spare tire, and spare tire davit. Refer to TM 9-2320-206-20. (2) Disconnect electrical wiring to stop and taillights, and disconnect trailer connector hafness clips: then pull harness free of body. (3) Remove four nuts, washers, inner and outer compression springs. and bolts from two mounting brackets located one on each side near front of body. (4) Remove six nuts and capscrews securing cargo body assembly to six side-niounting brackets 2.21located three on each side: then lift body assembly from chassis. (5) Remove cotter four hinges securing tailgai tailgate off body. b. Installation. (1) Position tailgate hinge section in body inge section, and install four hinge pins. (2) Secure hinge pins by installing cotter pins in each end of hinge p (31 Lower body to chassis then secure body to six side-mounting brackets. located three on each side, with six capserews and nuts. (4) Secure two mounting brackets, located one on each side near front of cargo body, to chassis with four inner and outer compression springs. washers. bolts. and nuts. (5) Install trailer connector harness clip and attach wiring harness to body. (6) Connect electrical wiring to stop and taillight connectors, located behind nuts. YAL_GE= ee ins and hinge pins from to body: then lift (4) Remove muffler hanger brackets by 2.22 (71 Install spai assemblies, tarp: tire davit, spare tire, bow and end curtains, Refer to 2-16. Fi a. Removal. Refer to TM 9-2320-206-20. b. Installation. Refer to TM 9-2320-206-20. 217. Rear Winch, NOTE ‘The following procedure is for the removal of dual rear winch, but also applies to removal of single rear winch. a. Removal. 111 Remove fuel tank. Refer to TM 9-2320- 2320. 0. (31 Remove fuel tank brackets (fig. 2-12) by removing four nuts, lockwashers, and bolts at each bracket. MOUNTING BOLTS RA PD 372900 Figure 2-12. Fuel tank removed. removing two nuts, lockwashers, and bolts at each bracket (fig. 2-13). (Figure 2-13. Fuel tank brackets removed. (5) Remove thirteen nuts and bolts securing (6) Disconnect drive shaft at lower pillow winch and mounting frame to each vehicle frame block (fig. 2-14) by removing four nuts and bolts sidemember. securing the drive shaft to the drive flange. RAPD 371998 Figure 2-14, Lower chain pillow block—dual winch. Google 2 oO(7) Disconnect air lines secured to winch (8) Disconnect remote throttle control (fig. 2+ Irame and winchtes). 15) and remove bowden wire where “lamped to winch frame. ( Figure 2-15, Single winch—M123C. MI23A1C, 224 y Google es OL° (9) Remove spare tire and remove two upper sections of davit (fig. 2-16). (10) Remove hitchhiker and hose by removing four nuts and bolts securing mounting bracket (fig. 2-15) to winch and tread plate. (11) Disconnect trailer receptacle (fig. 2-15) from tread plate and winch by removing four bolts and self-locking nuts. (12) Remove winch tread plates. Refer to TM 206-20. 13) Place four-leg chain sling (fig. 2-17) as follows: One leg around each drum and cable, and one leg on each eye below each swivel. (14) Lift winch assembly from chassis using heavy-duty crane for dual winch (fig. 2-17). 0. Figure 2-17. Removing dual winch asiembly. ,Google 7% ‘RD £73293 Figure 2-18. Installing dual winch assembly. b. Installation. (1) Secure winch assembly in chain sling as in 13) above, and lower winch to frame (fig. 2-18). Aline mounting holes with drift pin. (2) Install 13 bolts and self-locking nuts to secure each winch frame mounting to its respective sidemember. (3) Install air reservoir. Refer to TM 9-2320- 206-20. (4) Install muffler hanger brackets by securing each bracket with two bolts, lockwashers, and nuts. (5) Install fuel tank brackets by securing each bracket to the frame sidemember with four bolts, lockwashers, and nuts. (6) Install fuel tanks. Refer to TM 9-2320- 206-20. (7) Install tread plates. Refer to TM 9-2320- 206-20. 2.26 (8) Secure trailer receptacle (fig. 2-15) to rear tread plate with two bolts and self-locking nuts, and to winch platform with two bolts and self-locking nuts. (9) Secure hitchhiker by securing mounting bracket (fig. 2-15) to winch tread plate with two bolts and self-locking nuts and to the winch platform with two bolts and self-locking nut (10) Connect remote throttle control ( 15) and install clamp on bowden wire. (11) Install spare tire and two upper sections of davit (fig. 2-16). (12) Connect two ai hitchhiker mounting nector nuts. (13) Connect propeller shaft to winch drive flange at lower pillow block with four bolts and self- locking nuts. lines to fittings under ‘acket by tightening con-(14) Start engine and test operation of winches 2-18. Front Winch—M125. per operator's manual (TM 9-2320-206-10). 2. Removal. (1) Drain air reservoir. (2) Remove front bumper. Refer to paragraph 2.20b. OPERATING | VALVE AiR ‘CABLE TENSIONER LEVER ARM oe COTTER PIN AND CLEVIS PIN BLOCK AIR ‘CHAMBER AT 34874 Figure 2-19. M125 with bumper removed. (3) Remove three bolts, flat washers. and self-locking nuts from lower pillow block (figs. 2-19 and 2.201. 2.27 oogleBA ro aan Figure 2-20, Front mounted winch drum shaft and upper pillow block. (4) Loosen the other bolt and nut and tilt pillow block up to remove drive chain from sprocket. (5) Slip chain off winch input shaft sprocket. (6) Disconnect air tube (fig. 2-19) to air chamber at chamber by removing tubing nut. (7) Disconnect air tubes at winch operating valve in similar manner (fig. 2-19). (8) Disconnect air supply tube from fit 2-28 left rear corner of winch installation by removing tubing nut. (9) Remove two bolts, self-locking nuts, and lockwashers securing winch to left frame sidemember extension (fig. 2-21). (10) Secure two-leg chain (fig. 2-21) around winch by hooking each chain through opening in base of each side of level wind assembly. GoogleSIDEMEMBER EXTENSION Figure 2-21. Removing front mounted winch. (11) Remove two bolts securing winch to right frame sidemember extension (fig. 2-21). (12) Remove cotter pin from lower clevis pin ‘on cable tensioner lever arm through to air chamber, and remove clevis pin (fig. 2-19). (13) With a hoist, lift winch assembly clear of -sidemember extensions (fig. 2-21), and lower to ground. 6. Installation. (41) Install two-leg chain sling on winch as in removal 2-18 (2) Lift winch assembly into position on frame jdemember extension joning spacers under ich before dropping into position (fig. 2-21). (3) Install clevis pin through cable tensioner lever arm at air chamber, and secure with cotter pin. (4) Use drift pin to aline mounting holes and install two bolts through left frame sidemember extension, and secure with two self-locking nuts. (5) Install two bolts into spacer and right frame sidemember extension, and secure with two nuts. (6) Connect air supply tube at tee located at left rear corner of winch by tightening tubing nut. (7) Connect air tubes to winch operating valve and air chamber in similar manner. (8) Position winch drive chain sprocket on winch input shaft. (9) Position winch drive chain over sprocket on lower pillow block and install three bolts, self- locking nuts, and flat washers. (10) Adjust drive chains. Refer to TM 9- 2320-206-20. (11) Install front bumper. Refer to paragraph 2.20. (12) Close air reservoir drain. (13) Start engine and test winch operation per operator's manual. 2.292-19. Hood (Fig. 2-22.) a. Remoi (1) Release hood latches located at each side at front of hood. (2) Remove eight bolts and nuts securing left and right rear hood hinges to cab cowl. HOOD SIDE PANEL HOOD LATCH i= SHIELD BRACE FRONT (3) Lift off hood. b. Installation. (1) Position hood on vehicle. (2) Secure left and right rear hood hinges to cab cowl with eight bolts and self-locking nuts. (3) Secure hood in closed position with latches ‘on each side at front of hood. HOOD HINGES RUNNING, ay WINCH TREAD PLATE FUEL TANK AT 34875 Figure 2-22. Hood, hood side panels, and front and rear fenders. 2-20. Front Bumper Bar a, Removal—M 123 Series (Fig. 2-23). (1) Remove six bolts and nuts securing left and right upper gussets to frame sidemembers. (2) Remove four bolts and nuts from left and right bottom gussets. (3) Use hoist and remove bumper. 6. Removal—M125 (Fig. 2-24). (1) Disconnect winch cable at winch chain by removing bolt and nut securing cable clevis through chain links. (2) Remove six bolts and nuts securing left and right bumper upper gussets to top of frame sidemember. (3) Remove four bolts and nuts securing left and right bottom mounting gusset plates and spacers to frame sidemember. (4) Remove four bolts and nuts securing bottom mounting gusset plates and spacers to bumper. (3) Use hoist and remove bumper. c. Installation—M 123 Series (Fig. 2-23). (1) Use hoist; lift bumper into position on frame sidemembers. 2-30 (2) Secure upper bumper gussets to top of frame sidemembers with six bolts and self-locking nuts. (3) Secure lower bumper gussets to bottom of frame sidemembers with four bolts and self-locking nuts. d. Installation—M 125 (Fig. 2-24). (1) Use hoist; position bumper on frame sidemember extensions. (2) Secure upper bumper gussets to frame sidemembers with four bolts and self-locking nuts and two bolts and self-locking nuts. Do not tighten at this time. (3) Secure lower gusset plates and spacers to bottom of bumper with four bolts and self-locking nuts. (4) Secure lower gusset plates and spacers to frame sidemembers with four bolts and self-locking nuts. (5) Tighten bolts referenced in step (2) above. (6) Connect winch cable clevis to winch chain link with special 1% shoulder bolt and nut. ( ¢TOWING SHACKLE Figure 2-24. Front bumper disconnect points—M 125, . 231 Google ‘2.21, Brush Guards a, Removal—M123 (Fig. 2-23). (1) Remove two bolts and nuts securing upper brush guard to left and right brush guard brackets. (2) Disengage brush guard brackets. (3) Remove two bolts and nuts securing upper brush guard to each side of lower brush guard. 14) Remove upper guard. 151 Remove four bolts and nuts securing lower brush «ward to left and right frame sidemember. (0) Remove lower brush guard. b. Removal—M125 (Fig. 2-23). (1) Remove two bolts and nuts securing upper brush guard to left and right brush guard brackets. (2) Push brackets up. (3) Remove two bolts and nuts securing brush xuard to lower mounting brackets on frame sidemembers. (4) Lift off brush guard. c. Installation—M 123 (Fig. 2-23). (1) Secure lower brush guard to left and right frame sidemembers with four bolts and self-locking nuts. (2) Position upper guard on lower guard and secure with two bolts and self-locking nuts. (3) Pull left and right upper brush guard brackets down into position next to upper brush guard. (4) Secure upper brush guard brackets to upper brush guard with bolts and self-locking nuts. d. Installation—M125 (Fig. 2-23). (1) Position upper brush guard on lower mounting brackets attached to frame sidemembers. (21 Secure upper brush guard to lower mounting brackets with two bolts and self-locking nuts. (3) Pull upper mounting brackets into position and secure to upper brush guard with two bolts and self-locking nuts. 2-22, Hood Side Panels (Fig. 2-22.) a, Removal—M123, M123C, and M125. (1) Raise hood and lock in position with hook located on left side at top of cab cowl (2) Disengage top front and rear catches by pushing up. and lower panel upper edge toward fender. (3) Release catch on front hinge and pull forward until hinge pins are disengaged, and remove panel. b. Removal—M123A1C and M123E2. (1) Remove left hood side panel by following steps a(1) through a.(3) above. (21 Remove right hood side panel by first loosening air cleaner inlet tube hose (fig. 2-57), and then following steps a.(1) through @.(3) above. 2-32 c. Installation—M 123, M123C, and M125. (1) Lay panel horizontally on fender and aline pins on front and rear of panel with holes in latches on fender. Push on front of panel at safety clip and slide panel towards rear and seat into position. (2) Raise panel and lock into position by pushing top front and rear catches down toward fender. (3) Release hood lock on left side at top of cowl and lower hood into position. d. Installation—M123A1C and M123E2. (1) Install left hood side panel by following steps c.(1) through c.(2) above. (2) Install right hood side panel by following steps ¢.(1) through c.(2) above and then secure air cleaner inlet tube hose (fig. 2-57). 2-23. Front and Rear Fenders (Fig. 2-22). 2, Removal—Front Fender. The following instructions for removal of front fender apply to both right and left side. (1) Working in wheel well, disconnect turn signal and marker light at quick disconnects located in protection box mounted on underside of front fender in back of turn signal light. Remove two nuts and bolts securing two turn signal wiring clamps to underside of fender, and remove wire and clamps. (2) Remove screw, washer, and self-locking nut securing fender shield brace to headlight guard. (3)/Remove three screws, washers, and self- locking nuts, securing power steering hose clamps to fender shield in wheel well, then remove lock nut, spring. and screw securing fender shield to mounting bracket located near left exhaust pipe. (4) Disassemble three shock mounted bolts securing front edge of fender to front bumper support plate by removing three lock nuts, three serews, six flat washers, six rubber spacers, and three springs. (5) Cut locking wire and remove three screws, springs, and six flat washers securing underside of upper rear fender to cab. Remove two self-locking nuts, screws, springs, rubber spacers, and flat washers securing rear edge of fender to running board, and remove fender. b. Removal—Rear Fender. The following instructions for removal of rear fender apply to both right and left side. (1) Remove two self-locking nuts and bolts securing front of fender to winch tread plate. Remove three self-locking nuts and screws 1£ cross-fender support to frame sidemember. (3) Remove three self-locking nuts, washers. and screws securing bottom of fender to brace located near fuel tank, and remove fender. sect (¢. Installation—Front Fender. (1) Place front fender in position on vel and install two shock mounted screen assembli consisting of two screws, flat washers. springs. spacers, washers, and self-locking nut—to secure rear edge of fender to running board. Do not tighten nuts at this time. (2) Install three screws, flat washers, and springs to secure underside of upper rear fender to cab. Do not tighten. (3) Install three shock mounted screen assemblies—consisting of three screws, flat washers, springs, rubber spacers, and self-locking nut—to secure front edge of fender to front bumper support plate. NOTE At this time tighten screws in above three steps to proper torque, and secure screws in step (2) with locking wire. (4) Working in wheel well, install screw, spring, flat washer, and self-locking nut to secure fender shield to mounting bracket located near exhaust pipe. (5) Secure three power steering hose clamps to fender shield in left fender wheel well with three serews, springs, and self-locking nuts. (6) Secure fender shield brace to headlight guard with screw, washer, and self-locking nut. (7) Position turn signal wire to two clamps on underside of fender, and secure with two bolts and self-locking nuts, then connect turn signal and marker light wire to quick disconnects located in protection box on underside of fender. d. Installation—Rear Fender. (1) Position rear fender, and secure to winch tread plate with two self-locking nuts and bolts. (2) Secure cross-fender support to frame sidemember with three screws and self-locking nuts; then secure bottom of fender to brace located near fuel tank with three screws, flat washers, and self-locking nuts. 2-24, Running Board a. Removal. (1) Remove four self-locking nuts and bolts attaching spare gas can bracket to top of left running board. (2) Remove two self-locking nuts and bolt from each end at top where running board is secured to channel supports. (3) Remove two self-locking nuts, screws, springs, rubber spacers, and flat washers securing running board to rear edge of front fender, and remove running board. b. Installation. (1) Position running board on two channel supports that are attached to frame sidemembers, and secure with four screws and self-locking nuts. (2) Secure running board to rear edge of front fender with two shock mounted screws, consisting of two screws, flat washers, springs, spacers, washers, and self-locking nuts.RUNNING BOARD BOLT |SELF-LOCKING NUT Figure 2-25, Removal of running board. 2.25. Steering Angle Drive and Column Assembly a. Removal (Fig. 2-26). (1) Remove steering wheel. Refer to TM 9- 2320-206-20. (2) Remove differential brake control valve and hand control valve from steering column. Refer to TM 9-2320-206-20. (3) Remove two bolts, lockwashers, and nuts securing steering column to clamp at instrument panel. (4) Disconnect horn wire connection at junction box on bottom of steering column. Refer to TM 2320-206-20. (5) Remove clamp bolt and nut from drive shaft yoke at gear angle drive. Loosen yoke setscrew. (6) Remove self-locking nuts securing angle drive (fig. 2-26) to frame sidemember, and remove two self-tapping screws and lockwashers securing 2.34 lower shield to drive shaft shield, and remove shield. (7) Pull angle drive and steering column assembly down, and remove. b. Installation (Fig. 2-26). (1) Insert angle drive and steering column assembly through floorboard, and position angle drive (fig. 2-26) on frame sidemember. Install two bolts (from inside frame sidemember), posi shield over bolts, and secure with two self-locking, nuts. (2) Connect drive shaft to angle drive, and install bolt and lockwasher. Tighten setscrew and secure with locking wire. (3) Connect horn wire to junction box at bottom of steering column. Refer to TM 2320-206- 20. (4) Secure steering column to instrument panel with one clamp secured by two bolts, lock- ( washers, nuts.(5) Install hand control valve. Refer to TM 9- 2320-206-20, (6) Install different on to TM 9-2320-206-20. ake control valve. (7) Install steering wheel. Refer to TM 9- 2320-206-20. (8) Adjust steering column. Refer to TM 9- 2320-206-20. > Figure 2-26. Steering angle drive. 2-26. Steering Gear with Control Valve a, Removal (Fig. 2-27). (1) Remove four bolts and self-locking nuts securing bottom of spare fuel can container to left running board. (2) Remove side panel located under operator's door by removing one screw and self- locking nut securing panel brace to front running board channel support. Remove two self-locking nuts and screws attaching lower left front corner of panel to support; remove one self-locking nut and screw securing rear of panel bottom to rear running board support channel, and remove panel.r SIDE PANEL AT 34878 Figure 2-27. Side panel removed under operator's door. NOTE Removal of the above pane! will expose the steering assembly for removal. Before proceeding further, place a suitable jack under steering gear assembly. (3) Remove two running board channel supports from frame sidemember (fig. 2-27.1) by removing three bolts and nuts from each support. (4) Remove drag link from pitman arm (fig. 2- 27. 1) by removing cotter pin from end of drag link, and unscrewing end plug. Then remove drag link from ball stud on pitman arm. (5) Remove two quick disconnect hydraulic hoses from control valve unit. Then remove hose clamp from steering gear housing by removing mounting bolt (fig. 2-27. 1). (6) Remove clamp bolt and nut from drive shaft yoke at steering gear. Remove drive shaft. (7) Remove two top and two bottom self- locking nuts, lockwashers, and bolts securing steering gear assembly to frame mounted bracket. Then move assembly back two inches until yoke assembly is disconnected from steering gear assembly camshaft. and slide steering gear assembly out under running board.JFRAME MOUNTED. BOLTS CLAMP BOLT “RUNNING BOARD CHANNEL SUPPORT JQUICK DISCONNECT Figure 2-27 1. Removal of steering gear with control valve. b. Instal (1) Using a jack, position steering gear assembly so that the assembly camshaft is con- nected to rear yoke of steering angle drive shaft. Then position assembly to frame-mounted bracket under driver's door. (2) Secure steering gear assembly to frame bracket with two top and two bottom mounting bolts, lockwashers, and self-locking nuts. Install clamp bolt and nut to secure steering angle drive shaft yoke to camshaft of steering assembly. (3) Secure two hydraulic pump hose quick disconnect fittings to steering control valve unit. Clamp hose to steering gear housing cover bolt and clamp. (4) Connect drag link to pitman arm. Refer to Refer to TM 9-2320-206-20. (5) Install side panel under operator's door by securing panel lower left front corner to running board front channel support with two screws and self-locking nuts. Install one screw and self-locking nut to secure front panel brace to front running board channel support and secure rear of panel bottom to rear running board support with one serew and self-locking nut. (6) Install four bolts and self-locking nuts to secure bottom of spare fuel can container to left running board. 2-27. Cab Assembly General. The cab assembly consists of the cab, cab tarpaulin, cab top frame, driver's seat, companion seat, instrument panel, windshield, doors, and all accessories on the cab. 6, Removal. (1) Disconnect wiring at instrument panel. Refer to TM 9-2320-206-20. (2) Disconnect air lines Refer to TM 9-2320-206-20. (3) Disconnect cold weather starting fuel t instrument panel. 2.37pump line; M123A1C and M123E2 only. Refer to TM 9-2320-206-20. (4) Disconnect personnel and/or engine heater components if vehicle is so equipped. Refer to TM 9-2320-206-20. (5) Disconnect starter linkage; M123, M123C, M125 only. Refer to TM 9-2320-206-20, (6) Disconnect brake treadle. Refer to TM 9- 2320-20620. (7) Disconnect speedometer cable at transmission. Refer to TM 9-2320-206-20. (8) Disconnect accelerator linkage. Refer to TM 9.2320-206-20. (9) Disconnect choke control cable; M123, M123C, and M125 only. Refer to TM 9-2320-206- 20. (10) Disconnect air cleaner indicator line from intake manifold assembly; M123A1C and M123E2 only. Refer to TM 9-2320-206-20. (11) Disconnect air governer to compressor line. Refer to TM 9-2320-206-20. (12) Disconnect ground strap at engine. Refer to TM 9-2320-206-20. (13) Disconnect tachometer drive cable from engine. Refer to TM 9-2320-206-20. (14) Disconnect generator cable at generator; M123, M123C, and M125 only. Refer to TM 9- 2320-26-20. (15) Disconnect alternator cable at alternator; M123A1C and M123E2 only. Refer to TM 9- 2320-206-20. EAR crosamemaee mw ‘ FHONT i BREE ecurtinc| RACKETS ‘AT 348860 Figure 2-28. Cab points of disconnect. (16) Remove 20 bolts and lockwashers securing floor tunnel to cab floor U7) Remove assembly over power-t levers: then remove boot (fig. 2-31). (18) Remove four knobs from control levers; then place all control levers in neutral position and lift off floor tunnel. (19) Remove two nuts, four flat washers, two springs and two hexagon head screws securing cab rear to crossmember (fig. 2-28). (20) Remove two cotter pins, castellated nuts, four flat washers, springs and hexagon-head bolts 2. securing cab front sidemembers (fig. 2-28). (21) Use sling and crane, and lift cab assembly off vehicle. ¢. Installation. U1) Use sling assembly into po: mounting brackets to ind crane, and lower cab n over two front mounting brackets on sidemembers and cab rear crossmember (fig 28). (2) Position insulators between each front mounting bracket and rear crossmember. (3) Secure cab to front mounting brackets with two hexagon-head bolts, washers, spriags, castellated nuts, and cotter pins. (4) Secure cab to rear crossmember wi.h two bolts, springs, washers, and self-locking nuts. NOTE Tighten front mounting bolt nuts until one inch of bolt extends below frame sidemember and tighten rear mounting bolt nuts until 1% inch of bolt extends below frame sidemember for correct spring compression. (5) Place control levers in neutral and lower floor tunnel over control levers; then aline tunnel with bolt holes in floor (fig. 2-31). (6) Secure floor tunnel with 20 bolts and lockwashers (fig. 2-31). (7) Slide boot assembly over control levers, then secure boot to floor tunnel with six self-tapp! serews, and install four knobs on control lever (8) Install floorboard tunnel. Refer to TM 9- 2320-206-20. (9) Connect alternator cable to alternator; MI23A1C and M123E2 only. Refer to TM 9- 2320-206-20. (10) Connect generator cable to generator; M123, M123C, and M125 only. Refer to TM 9- 2320-206-20. (11) Connect tachometer drive cable to engine. Refer to TM 9-2320-206-20. (12) Connect ground strap at eng’ TM 9-2320- 206-20. (13) Connect air governor to compressor line. Refer to TM 9-2320-206-20. (14) Connect air cleaner indicator line to intake manifold assembly; M123A1C and M123E2 only. Refer to TM 9-2320-206-20, (15) Connect choke control cable; M123, M123C, and M125 only. Refer to TM 9-2320-206- 20. (16) Connect accelerator linkage. Refer to TM 9-2320-206-20. (17) Connect speedometer cable to trans- ion. Refer to TM 9-2320-206-20. (18) Connect brake treadle. Refer to TM 9- 2320-206-20. 6 Refer to(19) Connect starter linkage; M123, M123C, and M125 only. Refer to TM 9-232(-206-20, (20) Connect personnel and/or engine heater components if vehicle is #0 equipped. Refer to TM 9-2320-206-20. (21) Connect cold weather starting fuel pump line; M123A1C and M123E2 only. Refer to TM 9-2320-206-20, (22) Connect air lines at instrument panel. Refer to TM 9-2320-206-20. (23) Connect wiring at Refer to TM 9-2320-206-20, 2.28. Propeller Shaft 4, Removal. Refer to TM 9-2320-206-20. 6. Installation. Refer to TM. 9-2320-206-20. 2-29. Power plant—M123, M123C, and M125 4. General. The following procedure is for removal of the powerplant. It includes the engine and accessories, radiator, transmission and transfer assembly, and handbrake assembly. It is removed a unit to facilitate replacement of the engine or other major components. b. Remou (1) Position vehicle with relation to lifting facilities. (2) Block movement. (3) Disconnect battery ground cable and cover connector with insulating tape. CAUTION Failure to prevent the battery ground cable strument panel. vehicle wheels to prevent terminal from accidental dangerous fire and expl ‘ing constitutes ion hazard. (4) Drain compressed air reservoirs. Refer to TM 9-2320-206-20. NOTE Do not drain engine lubrication or cooling system. (5) Release front hood latches, then raise and lock hood in position. (6) Remove hood side panels, paragraph 2-22 2. Refer to NOTE Procedures listed in steps (7) through (12) apply to working at front of M123 and M123C vehicles. (7) Remove upper brush guard. Refer to Paragraph 2-21 2., steps (1) through (4). (8) Remove lower brush guard. Refer to paragraph 2-214., steps (5) and (6). (9) Remove front bumper. Refer to paragraph 2-204., steps (1) through (3). (10) Remove two bolts, flat washers, and lockwashers securing upper radiator shield support to left and right headlight bracket; then remove shield support (fig. 2-21). (11) Remove four bolts, washers, and self- locking nuts securing left and right headlight panel bracket assembly to fenders (fig. 2-21). (12) Remove two screws, washers and self- locking nuts securing headlight bracket offset brakes to each fender; then remove headlight bracket with panel assembly (fig. 2-29). 2.39Figure 2-29, Headlight panel bracket assembly removed. NOTE steps (13) through Procedures listed (22) apply to working at front of M125 vehicle. (13) Remove front bumper and winch chain {para 2-20b steps (1) through (5) 1. (14) Remove front winch assembly (para 18a. steps (1) through (13) ). 2-40 a FO 383380 221 bs (151 Remove upper brush guard (pai steps (1) through (4) ). (16) Remove four bolts and self-locking nuts securing left and right side of radiator protector plate to frame sidemember extension: then remove radiator protector plate (fig. 2-30).’AR TUBE TO ‘DIAPHRAGM. BOLT AND SELF| LOCKING NUT RADIATOR PROTECTOR. LATE RA Po 383382 Figure 2-30. Winch disconnect points—right side. (17) Remove upper radiator shield support {step (10) above). (18) Remove headlight panel assembly (steps (11) and (12) above. (19) Loosen two bolts securing brush guard base bracket to inboard fender. (20) Remove two rear bracket mounting screws, and loosen two front mounting screws attached to brush guard base bracket. (21) Swing upper brush guard base bracket forward and aline with frame sidemember (22) Remove two bolts and self-locking nuts securing upper brush guard top brackets to frame sidemembers; then remove upper brush guard top brackets. bracket NOTE Procedures listed in steps (23) through (35) apply to working inside cab. (23) Remove four. screws, lockwashers and nuts securing companion seat legs to cab floor, then remove sea (24) Remove four knobs from control levers (fig. 2-31). (25) Remove six screws securing boot assembly over power take-off and transfer control levers; then remove boot (fig. 2-31). (26) Remove 20 bolts and lockwashers, securing floor tunnel to cab floor (fig. 2-31). (27) Place all control levers in neutral position and lift off floor tunnel. 2-4190 383383 Figure 231, Floor tunnel disconnect points. (28) Remove four bolts and lockwashers securing handbrake crose-shaft lever mounting brackets to transmission hous (fig. 2-32). (29) Disconnect linkage at handbrake drum by removing cotter pin and clevis pin securing rod clevis to brake lever. (30) Disconnect handbrake control rod at center of crose-thaft by removing cotter pin and clevis pin securing clevis to lever (fig. 2-32). (31) Remove six bolts and lockwashers securing handbrake lever mounting bracket to transmission (fig. 2-32). (32) Slip handbrake lever assembly forward from under cab crossmember (fig. 2-32). (33) Remove three cotter pins, washers, and clevis pins securing control lever rods to transmission (fig. 2-32). (34) Remove six bolts securing shifter cover with control levers to transmission (fig. 2-32). (35) Move ion control lever assembly forward, twisting to right to clear control rods of frame crossmember, and lift out.Figure 2-32, Transmission control lever and handbrake linkage disconnect points, NOTE rod end to starter bellerank link, and sep: Procedures listed in steps (36) through from clevis. (45) apply to working on left side of engine. (37) Remove oil pressure gage cable from oil (36) Remove cotter pin securing starter pedal pressure gage se! g unit located at rear of engine above flywheel housing (fig. 2-33). te link 2-43 y Google ‘Figure 2-33. Oil pressure gage sending unit. (38) Remove three bolts and lockwashers securing left exhaust pipe to exhaust manifold (fig. 2-39), EXHAUST MANIFOLD Figure 2-34. Exhaust pipe disconnect points. 2-44(39) Remove self-locking nuts securing throttle control rod joint to throttle lever, and separate joint from lever (fig. 2-35). (40) Loosen setscrew securing choke control es 4 ah. = PGR cgi NNN ~) cable to carburetor choke control lever; then remove control cable (fig. 2-35). (41) Remove bolt and lockwasher securing ground strap from engine to firewall (fig. 2-35). Figure 2-35. Carburetor controls disconnect points. (42) Remove bolt, lockwasher, and self- locking nut securing bonding strap from radiator to fender at the fender. (43) Disconnect all breather lines at left air cleaner body (fig. 2-37). (44) Loosen two clamps at end of air cleaner to carburetor tube, and slide tube free of left cleaner outlet (fig. 2-37). (45) Remove four air cleaner support bank clamp bolts and lockwashers, and lift out air cleaner (fig. 2-37). NOTE Procedures listed in steps (46) through (59) apply to working on right side of engine. (46) Disconnect hose from air compressor to compressor governor at governor (fig. 2-36). (47) Remove wire from temperature sending unit located near top of right exhaust manifold (fig. 2:36), (48) Disconnect low tension wire at connector on forward end of distributor body (fig. 2-36). (49) Remove three bolts and lockwashers securing right exhaust pipe to exhaust manifold (fig. 2-34). (30) Disconnect carburetor fuel tube flange nut from elbow at carburetor (fig. 2-36). (51) Disconnect generator cable from elbow connection on top of generator (fig. 2-36). (52) Remove bolt and lockwasher securing generator cable and bracket to water outlet flange (fig. 2-38) and move cable and bracket to rear of engine compartment. 2-45Figure 2-36. Disconnect points on right side of engine. (53) Disconnect all breather lines at right air cleaner body (fig. 2-37). (54) Loosen two ps at end of ‘leaner to carburetor tube, and slide tube free of air cleaner outlet (fig. 2-37). (55) Remove engine oil level gage ( 2.37). 2-46 (56) Remove nut from spark plug cable bracket bolted on cylinder head valve cover. (57) Move breather line and spark plug cable to rear to clear right air cleaner. (58) Remove four air cleaner support band clamp bolts and lockwashers and lift out air cleaner 2.37).iS RYDRAULIC RESERVOIR IM VENT TUBE PEABUCHT Pa Y ack er oi nie scorer NG fp es mt Ke wh Figure 2-38. Engine compartment with air cleaners and air induction pipes removed. 2-47(50) Remove bolt, lockwasher, and self- locking nut securing ground strap from radiator to fender at fender (fig. 2-37). (60) Position powerplant lifting sling over engine compartment so that short chain is over intake manifold and long chain is over flywheel housing (fig. 2-52). (61) Attach lifting hooks to lifting eyes on intake manifold and flywheel housing (fig. 2-52). (62) Operate hoist and take up slack. CAUTION Hoist minimum capacity: 2/4 tons. NOTE Procedures listed in steps (63) through (100) apply to working under vehicle. (63) Loosen wingnuts on side panel under right front fender. (64) Remove panel from hinges by pushing toward the rear of the vehicle. (65) Reach through area provided by removal of panel in step (64) and unscrew coupling nut securing tachometer cable to tachometer drive unit (fig. 2-39). Figure 2-39. Tachometer cable disconnect points.(66) Disconnect headlight wiring by un- spring eyebolts, from each side of vehicle. (fig. 2- coupling six connectors, located near left and right 40). ? BF SPRING levEBOLT) Figure 2-40. Headlight wiring disconnect points—right side. . (67) Disconnect two oil filter hoses at quick oil pan of engine, by turning wingnuts coun- disconnect fittings, located at the side of the lower _terclockwise (fig. 2-41). PAPO 371889 c ) Figure 241. Oil filter disconnect points. 249 oogle(08) Remove stud nut and lockwasher securing magnetic switch ground cable to top of securing starter-to-magnetic switch cable to bottom magnetic switch (fig. 2-42). N of magnetic switch (fig. 2-42). (70) Remove bolt and lockwasher securing (69) Remove stud nut and lockwasher bonding strap to lower right rear of engine (fig. 2- 42). STARTER Switch = tea Mpa as Ma cuTcH HOUSING, Figure 2-42. Starter cable disconnect pointsNOTE Discard removed gaskets for exhaust ifolds and muffler flanges. (71) Remove four bolts and self-locking nuts 1g exhaust pipe to muffler. 72) Remove bolt and nut securing exhaust m pipe frame clamp to mounting bracket at rear step (73) Carefully maneuver exhaust pipe down a hanger. through engine compartment and remove. (74) Disconnect pressure hose from hydraulic 2-43). pump at quick disconnect fitting (fi Figure 2-43, Hydraulic pump pressure hose disconnect points. . 251 Google ‘(75) Disconnect hydraulic pump pressure (76) Disconnect hydraulic pump feed hose at relief valve hose quick disconnect fitting at a point quick disconnect fitting on left side of step hanger in ely above steering gear assembly. (fig. 2-44). Figure 2-44. Hydraulic pump feed hose disconnect points.Disconnect carburetor fuel tube at hose connection above rear of steering gear assembly at _ reservoir at connection at right rear of t tame sidemember. (fig. 2-45). ‘AIR HOSE TO RESERVOIR TANK’ All HOSE FROM COMPRESSOR Figure 2-45, Compressor hose to reservoir tank disconnect points. 253(79) Remove eight self-locking nuts securing (80) Support free end of propeller shaft to front propeller shaft companion flange to transfer prevent damage to front universal joint. ( front drive companion flange; then separate flanges (fig. 2-46) PROPELLER SHAFT COMPANION | FLANGE TRANSFER SECTION COMPANION FLANGE Figure 2-46. Front propeller shaft disconnect point 2.54(81) Remove cotter pin and clevis pin from link at top of clutch adjusting lever (fig. 2-47). even 14 ro 380095 Figure 2-47, Clutch linkage assembly. (82) Disconnect air tube from tee on right frame sidemember. (83) Disconnect air tube from quick release valve on left fram lemember. (84) Remove eight bolts and self-locking nuts securing front spring rear bracket crossmember to each front rear bracket (fig. 2-48). (85) Remove crossmember and air tube, disconnected in steps (82) and (83) above, unit. ~ 2-55 Google ‘(86) Disconnect speedometer cable at transfer securing winch drive FRONT SPRING ee FRONT. SPRING REAR BRACKET Figure 2-48, Crosmember disconnect points. ‘housing by loosening connector nut. companion flange of the transmission; then 2.56 (87) Remove four bolts and self-locking nuts separate flanges flange to power take-off | 2-49). wre one suart © “iriver one "AND FLANGE e POWER TAKEOFF FLANGE (TRANSMISSION) CROSS SHAFT Figure 2-49. Winch drive shajt disconnect points, Google 2008(88) Remove 12 self-locking nuts securing (89) Support propeller shaft to avoid damage forward rear propeller shaft companion flange-to- to universal joint and flange. transmission output shaft companion flange: then ) separate flanges (fig. 2-50). Figure 2-50. Rear propeller shaft disconnect points. (90) Remove four self-locking nuts, lock- engine supports to mounting bracket (fig. 2-47 and 8, bolts and eight insulators securing rear 2-51), Figure 2-51. Engine rear support disconnect points. t Gooale 287 i(91) Remove eight self-locking nuts and bolts CAUTION securing engine front supports to left and right Lift and move powerplant carefully to frame sidemember brackets. prevent damage to protruding p (92) Remove two top bolts first from each side (95) Lower powerplant onto universal of engine front support. transporter, so it is supported at lower oil pan face (93) Operate hoist attached in steps (60) and _ in front, and against flywheel housi (61), lift power plant and move forward until hand 2-52, 2-53, and 2-54). brakedrum contacts front axle differential com- (96) Secure rear crossbars of univer panion flange. transporter in position to prevent spreading (fi (94) Lift power plant clear of vehicle. 54). (97) Remove sling when power plant is securely seated on transporter. t rear (figs. POWER PLANT UFTING SLING ryywneet Housine f UNIVERSAL TRANSPORTER Figure 2-52. Powerplant position on universal transporter. 258Figure 2-54. Powerplant—right rear view.e. Installation. (1) Attach lifting sling to powerplant at lifting eyes on intake manifold and flywheel housing (fiz. 2-52 and 2-54). NOTE Hoist minimum capacity: required. (2) Attach hoist to lifting sling and take up slack. (3) Raise powerplant over vehicle so front drive companion flange of transmission is just beyond companion flange of front axle differential. (4) Carefully lower powerplant into engine compartment and move rearward, raising powerplant rear supports over rear mounting brackets. (5) Lift rear of powerplant and install four rear support upper insulators, bevel side up. (6) Install four bolts through support upper insulators and rear mounting brackets (fig. 2-51). 2% tons fe ant I TRANSMISSION | BELL HOUSING. . ‘BOLT AND Pe esiccn 2 ws Figure 2-55, Adjusting end mot (13) Remove powerplant lifting sling from lifting eyes at intake manifold and flywheel housing. NOTE Procedures listed in steps (14) through (36) apply to working under vehicle. (14) Aline forward rear propeller shaft companion flange on transmission output companion flange studs and secure flanges with 12 self- locking nuts (fig. 2-50). (15) Secure winch drive shaft flange to power take-off flange with four bolts and self-locking nuts (fig. 2-49). 2-60 (7) Install two top bolts first in engine front support. (8) Aline holes in front left and right frame sidemember mounting brackets with holes in front supports. (9) Install eight bolts through brackets and front supports and secure with self-locking nuts. (10) Install four lower insulators, bevel side down, on bolts installed in step (6) above and secure with four self-locking nuts (fig. 2-51). (11) Adjust powerplant end motion by serting 0.015 feeler gage between transmission mounting bracket and head of adjusting bolt at each end of left rear powerplant support bracket (fig. 2-55). (12) Adjust bolts until slight drag is felt on feeler gage when removing; then tighten locknut (fig. 2-55). ich side of aa t powerplant rear mount. (16) Insert speedometer cable into drive unit at transfer housing and tighten connector nut. (17) Secure front spring rear bracket crossmember, with air tube attached, to brackets on frame sidemembers with eight bolts and self- locking nuts (fig. 2-48). (18) Secure air tube to tee connector located where front spring rear bracket crossmember at- taches to right frame sidemember (19) Secure left side of air tube to quick release valve on left frame sidemember. (20) Install clevis pin through link on top ofeluteh adj (fig. 2-47). (21) Connect front propeller shaft companion flange to transfer front drive companion flange with eight bolts and self-locking nuts so that bolt heads are to rear (fig. 2-47). NOTE Installing above bolt heads to rear is es sential for clearance between drive flange bolt and transfer case boss. (22) Connect comprestor-ro-reservoir air hose at a point just to right rear of transfer section of transmission assembly (fig. 2-45). (23) Connect carburetor fuel tube to hose connection above rear of steering gear assembly at frame sidemember. (24) Connect hydraulic feed hose to quick disconnect fitting on left side of step hanger (fig. 2- 44). (25) Connect pressure relief valve hose to quick disconnect fittings at top of steering gear assembly. (26) Connect pressure hose to hydraulic pump (fig. 2-43). (27) Maneuver exhaust pipe up throug! engine compartment. (28) Place new gasket between exhaust pipe flange and muffler flange, and secure flanges with four bolts and self-locking nuts. (29) Secure exhaust pipe frame clamp to mounting bracket at rear step hanger with bolt and self-locking nut. (30) Secure bonding strap from firewall to lower right rear of engine with bolt and lockwasher fig. 2-42). (31) Secure ground-to-magnetic switch cable to stud on top of magnetic switch with lockwasher and locknut (fig. 2-42). (32) Secure starter-to-magnetic switch cable ‘on stud on bottom of magnetic switch with lockwasher and locknut (fig. 2-42). (33) Connect two oil filter hoses at quick disconnect fittings by turning wing nuts clockwise (fig. 2-41). ting lever, and secure with cotter pin NOTE Match circuit numbers stamped on each wire with corresponding circuit numbers amped on mating part of connector. 34) Connect six headlight wire connectors on each side of vehicle located near left and right front spring eyebolt (fig. 2-40). (35) Insert end of tachometer cable into tachometer drive unit mounted behind idler pulley assembly and tighten coupling nut (fig. 2-39). (36) Connect tachometer drive unit ace panel door to hinges under right front fender and close door. NOTE Procedures listed in steps (37) through (50) apply to working on right side of engine. (37) Secure ground strap from radiator to fender with bolt, lockwasher and self-locking aut (fig. 2-37). (38) Lift right air cleaner into position, and aline outlet with carburetor air tube (fig. 2-37). (39) Secure upper and lower support bands with four bolts and lockwashers (fig. 2-37). (40) Slide carburetor air tube over cleaner outlet, and secure with two clamps (fig. 2-37). (41) Connect all breather lines to cleaner body (fig. 2-37). (42) Install spark plug cable bracket on cylinder head, and secure with nut. (43) Install oil level gage. (44) Secure generator cable bracket and generator cable to water outlet flange with bolt and lockwasher (fig. 2-56). (45) Connect generator cable to connector elbow at top of generator (fig. 2-36). (46) Connect fuel tube to elbow connection on top of carburetor (fig. 2-56). (47) Position new gasket between right exhaust pipe and right exhaust manifold, and secure pipe to manifold with three bolts and lockwashers (fig. 2-34). (48) Secure ignition low tension wire to connector on front of distributor body (fig. 2-56). (49) Connect temperature gage wire to sending unit located near top of right exhaust manifold (fig. 2-56). (50) Connect compressor governor air huse to governor (fig. 2-56). 2-61Figure 2-56. Engine compartment—exhaust pipes and air induction pipes removed. NOTE Procedures listed in steps (51) through (61) apply to working on left side of engine. (51) Secure ground strap from engine to firewall with bolt and lockwasher (fig. 2-35). (52) Secure ground strap from radiator to fender with bolt, lockwasher, and self-locking nut (fig. 2-35). (53) Insert wire from choke cable assembly into connector on choke lever, and tighten setscrew (fig. 2-35). (54) Insert threaded end of joint on throttle control rod into throttle lever on cross-shaft, and secure with self-locking nut (fig. 2-35). (55) Position new gasket between left exhaust pipe and left exhaust manifold and secure pipe to manifold with three bolts and lockwashers (fig. 2- 34). (56) Lift left air cleaner into position, and aline outlet with carburetor air tube (fig. 2-37). (57) Secure upper and lower support bands with four bolts and lockwashers (fig. 2-37). (58) Slide carburetor air tube over cleaner outlet, and secure with two clamps (fig. 2-37). (59) Connect all breather lines to cleaner body (lig. 2-37). (60) Connect oil pressure gage cable to sending unit on top of flywheel housing (fig. 2-33). (61) Engage clevis from starter pedal rod end to starter bellerank link, and secure with cotter pin. 2462 NOTE Procedures listed in steps (62) through (74) apply to working inside cab. (62) Place transmission control lever assembly in position under frame crossmember (fig. 2-32), (63) Secure shifter cover with control levers to transmission with six bolts and lockwashers (fig. 2- 32). (64) Connect control lever rods to transmission with three clevis pins; then secure clevises with three washers and cotter pins (fig. 2-32). (65) Install handbrake lever cross-shaft and mounting brackets on rear of transmission housing, and secure with four bolts and lockwashers (fig. 2- 32). (66) Position handbrake lever and mounting bracket assembly under frame crossmember (fig. 2- 32). (67) Secure mounting bracket to transmission with six bolts and lockwashers. (68) Connect handbrake control rod to clevis in center of cross-shaft by securing with clevis pin and cotter pin (fig. 2-32). (69) Connect linkage at hand brakedrum by securing link to brakeshoe arm with clevis pin and cotter pin. (70) Place contro! levers in neutral, lower floor tunnel over control levers, and aline tunnel with bolt holes in floor (fig. 2-31).(71) Secure floor tunnel with 20 bolts and lockwashers (fig. 2-31). (72) Slide boot assembly over power take-off and transfer control lever; then secure boot'to floor tunnel with six self-tapping screws. (73) Install four knobs on control lever: (74) Position companion seat on cab floor and secure with fovr screws, lockwashers, and nut NOTE Procedures listed in steps (75) through (82) apply to working in front of M123 vehicle. (75) Po yn headlight panel bracket auembly by rotating bottom of panel inward and move fender brace up (fig. 2-21). (76) Secure headlight panel bracket assembly to bottom brace with four bolts, lockwashers, and self-locking nut (77) Pull left and right headlight panel offset braces down into position, and secure each to ite panel with screw, lockwasher, and self-locking nut (fig. 2-21). (78) Position upper radiator shield support across radiator assembly. (79) Secure upper radiator shield support to headlight panel assembly two bolts, lockwashers and flat washers (fig. 2-21). (80) Install front bumper (para 2-20. steps (1) through (3) ). (81) Install lower brush guard (para 2-21¢., step (1) ). (82) Install upper brush guard (para 2-21c., steps (2) through (4) ). NOTE Procedures listed in steps (83) through (93) apply to working in front of M125 vehicle. (83) Position upper brush guard top mounting bracket by pulling bracket forward; secure with two bolts and self-locking nuts. (84) Push upper brush guard base bracket up into position, tighten two front mounting screws, and install two rear screws and nuts. (85) Tighten two bolts securing upper brush guard base bracket to inboard fenders. (86) Install headlight panel assembly (step (75) through (77) above). (87) Install upper radiator shield support (steps (78) and (79) above). (88) Position radiator protector plate on frame sidemember extensions and aline bolt holes (fig. 2-30). (89) Secure radiator protector plate to left and right frame sidemember with four bolts and self- locking nuts (fig. 2-30). (90) Install upper brush guard (para 2-21 d., steps (1) through (3)). (91) Install winch assembly (para 2-186., steps (1) through (13)). (92) Install front bumper and winch chain (para 2-20d., steps (1) through (6)). (93) Remove tape from battery cable terminal and connect battery cable to battery terminal post. CAUTION Check radiator coolant and engine oil lever prior to starting engine. Add coolant if required. (94) Start engine, check operation and proper functioning of all controls. (95) Install hood sidemembers (pat steps (1) through (3)). (96) Lower hood and secure in closed position with latches on each side at front. 2.30. Powerplant—M123A1C, M123E2 4. General. The following procedure is for removal of the powerplant. It includes the engine and accessories, radiator, transmission and transfer assembly, and hand brake assembly. It is removed ‘as a unit to facilitate replacement of the engine or other major components. NOTE When replacing the diesel engine with a new or rebuilt unit, you must remove the entire clutch unit, the power steering pump, the pump bracket, and the pump drive belt. You need these parts hecause the new or rebuilt engines are furnished leas these units, b. Removal. (1) Position vehicle with relation to lifting facilities. (2) Block vehicle wheels to prevent movement. (3) Disconnect battery-to-chassis ground cable from both the running board and under seat batteries at the battery terminal clamp; then cover ground cable terminal with insulating tape. CAUTION Failure to prevent the battery ground cable terminal from accidental arcing constitutes dangerous fire and explosion hazards. (4) Drain compressed air reservoirs; refer to TM 9-2320-206-20. NOTE Do not drain engine lubricant or co system. (5) Release front hood latches then raise and lock hood in position. (6) Remove left hood side panel (para 2-22 b). 2-216, 2463RESTRICTION AIR CLEANER! INDICATOR MOUNTING STRAPS BREATHER MANIFOLD: HYDRAULIC PUMP Lines Figure 2-57. Engine compartment—front view—M123A1C and M123E2. NOTE Procedures listed in steps (8) through (13) apply to working at front of vehicle. (8) Remove upper brush guard (para 2-21 a, steps (1) through (4)). (9) Remove lower brush guard (para 2-21 a., steps (5) and (6). (10) Remove front bumper (para 2-20 a.,steps (1) through (3)). (11) Remove two bolts, flat washers, and lock- wash securing upper radiator shield support to left and right headlight bracket; then remove shield support (fig. 2-21). (12) Remove four bolts, washers, and self- locking nuts securing left and right headlight panel bracket assembly to fenders (fig. 2-21). (13) Remove two screws, washers, and self- locking nuts securing headlight bracket offset braces to each fender; then remove headlight bracket with panel assembly (fig. 2-29). NOTE Procedures listed in steps (14) through (26) apply to working inside cab. (14) Remove four screws, lockwashers, and 2-64 nuts securing companion seat legs to cab floor; then remove seat, (15) Remove four knobs from control levers fig. 2-31). (16) Remove screws securing boot assembly over power take-off and transfer control levers; then remove boot (fig. 2-31). (17) Remove twenty bolts and lockwashers securing floor tunnel to cab floor (fig. 2-31). (18) Place all control levers in neutral position and lift off floor tunnel. (19) Remove four bolts and lockwashers securing handbrake cross-shaft lever mounting brackets to transmission housing (fig. 2-32). (20) Disconnect linkage at hand brakedrum by removing cotter pin and clevis pin securing rod levis to brake lever. (21) Disconnect handbrake control center of crose-shaft by removing cotter clevis pin securing clevis to lever (fig. 2-32). (22) Remove six bolts and lockwashers handbrake lever mounting bracket to ion (fig. 2-32). rod at and sect(23) Slip handbrake lever assembly forward from under cab cross-member (fig. 2-32). (24) Remove three cotter pins, washers, and clevis pins securing control rods to tra (fig. 2-32). (25) Remove six holts securing with control leve (25) Remove ix bolts securing shifter cover with control levers to transmission (fig. 2-32). (26) Move transm ion control lever assembly forward, twisting to right side to clear control rods of frame crossmember and lift out. NOTE Procedures listed in steps (27) through (38) apply to working on right side of engine. (27) Remove five bolts, washers, and two locknuts which secure air cleaner outlet to intake manifold crossover (fig. 2-57). 28) Disconnect glow plug electrical wire (fi 2-61). (29) Disconnect cold weather starting fuel hose from air cleaner outlet (fig. 2-61). (30) Disconnect two mounting straps which secure air cleaner assembly to firewall; then remove air cleaner (fig. 2-57). (31) Replace two bolts removed in step (27) and secure radiator support rod to intake manifold assembly. (32) Disconnect air compressor governor air hose at governor (fig. 2-57). (33) Disconnect air cleaner ai indicator hose (fig. 2-57). (34) Disconnect water temperature sending unit cable at cable connector (fig. 2-58). (35) Remove cable clamp which secures sending unit cable to intake manifold (fig. 2-58). restriction r 5 — 4 Bs ITEMPERATURE: (ORD £73257 Figure 2-58. Engine compartment—right front view—MI23A1C and M123E2, 2465(36) Disconnect tachometer cable from injector pump (fig. 2-61). (37) Disconnect fuel hose from injector pump (fig. 2-58). (38) Disconnect right exhaust pipe band clamp (fig. 2-59) from exhaust manifold. EXHAUST MANIFOLD Figure 2.59. Exhaust pipe disconnect—M123A1C and M123E2, NOTE Procedures listed in steps (39) through (49) apply to working on left side of engine. 139) Disconnect two full-flow oil filter hoses at the filter housing (fig. 2-60). ig Fuut-rLow) OIL FILTER Figure 2-60. Engine compartment—left front view —M123A1C and M123E2.(40) Remove bypass oil filter assembl refer to TM 9-2320-206-20, (41) Disconnect left exhaust pipe band clamp from exhaust manifold (fig. 2-61). (42) Remove cotter pin and clevis pin securing accelerator rod to injector pump (fig. 2-58). (43) Disconnect hand throttle flexible cable from accelerator linkage (fig. 2-60). (44) Remove bolt securing ground strap to engine (fig. 2-60). (45) Loosen hose clamp securing crankcase vent line hose (rom fording breather manifold mounted on firewall) to ion valve; then remove hose (fig. 2-57 and 2-61). TACHOMETE DRIVE. Seal O20 £73240, Figure 2-61. Engine compartment—left side view— MI23AIC and M123E2. (46) Disconnect flexible control cable from crankcase pressurizatis ig. 2-57). (47) Disconnect alternator electrical connection at alternator (fig. 2-60). (48) Disconnect power steering hydr pump reservoir vent hose (fig. 2-60). (49) Disconnect hydraulic pump pres return hoses (fig. 2-57). NOTE Cap all hydraulic connections to prevent foreign objects from entering hydraulic ‘stem. jie re and NOTE Procedures listed in steps (50) through (68) apply to working under vehicle. (50) sonnect headlight wiring by un- coupling six connectors from each side of vehicle; connectors are located near left and right front spring eyebolts (fig. 2-40). (51) Disconnect starter positive cable from starter post (52) Disconnect ground cable between engine and frame at engine. (53) Disconnect wire from oil press sending unit. (54) Disconnect air hose from compressor to reservoir at connection at right rear of transmission (fig. 2-45). (55) Disconnect fuel return line at left rear of engine. (56) Remove eight self-locking nuts securing front propeller shaft companion flange to trai mission front drive companion flange; then separate flanges (fig. 2-46). (57) Support free end of propeller shaft to prevent damage to front universal joint. (58) Remove cotter pin and clevis pin from link at top of clutch a ing lever (fig. 2-47). (59) Disconnect air tube from tee on right frame sidemember. (60) Disconnect air tube from quick release valve on left frame sidemember. (61) Remove eight bolts and self-locking nuts securing front spring rear bracket crossmember to each front rear bracket (fig. 2-48). (62) Remove crossmember and air tube, re disconnected in steps (59) and (60) above, unit. (63) Disconnect speedometer cable at transfer housing. (64) Remove four bolts and self-locking nuts securing winch drive shaft flange to power take-off companion flange of the transmis then separate flanges (fig. 2-49). (65) Remove twelve self-locking nuts securing forward rear propeller shaft companion flange to transmission output shaft companion flange; then separate flanges (fig. 2-50). (66) Support propeller shaft to avoid damage to universal joint and flange. (67) Attach three-leg lifting sling: Two hooks at lifting eyes at rear of each cylinder head cover, and one to lifting eye at front of cylinder head cover (figs. 2-63 and 2-64). (68) Remove four self-locking nuts, lockwashers, bolts, and eight insulators securing rear engine supports to mounting brackets (fig. 2-47 and 2-51). (69) Remove eight self-locking nuts and bolts securing engine front supports to left and right frame sidemember brackets. Remove two top bolts firet from each side of engine front support. 267NOTE Hoist minimum capa required for lifting powerplant. (70) Operate hoist, lift powerplant and move forward until hand brakedrum contacts front axle differential companion flange. (71) Lift powerplant clear of vehicle (figs. 2- 62, 2-63, and 2-64). 2% tons CAUTION Lift and move powerplant carefully to prevent damage to protruding parts. (72) Lower powerplant onto univers ¢ porter. (73) Remove lifting sling when powerplant it securely seated on transporter. Figure 2-62, Powerplant—right front view—M123A1C and M123E2. GoogleFigure 2-63, Powerplant—right rear view—M 123AIC and MI23E2. . 2-69 , Google fiFRONT LIFTING EYE ORO E7sx Figure 2-64. Powerplant—left front view—M123A1C and M123E2. cc. Installation. (1) Attach three-leg lifting sling; two hooks at lifting eyes at rear of each cylinder head cover and one to lifting eye at front of cylinder head cover . 2-63 and 2-64). NOTE 2% tons required for 1. to lifting sling and take up slack. (3) Raise powerplant over vehicle 0 front drive companion flange of transmission is just beyond companion flange of front axle differential. (4) Carefully lower powerplant into engine compartment, and move rearward raising powerplant rear supports over rear mounting brackets. (5) Lift rear of powerplant, and install four rear support upper insulators, bevel side up. (6) Install four bolts through support upper insulators and rear mounting brackets (fig. 2-51). 2-70 (7) Install two top bolts first in each side of engine front support. (8) Aline holes in front left and right frame sidemember mounting brackets with holes in front support. (9) Install eight bolts through brackets and front supports and secure with self-locking nuts. (10) Install four lower insulators, bevel side down, on bolts installed in step (6) above and secure with four self-locking nuts (fig. 2-51). (11) Adjust powerplant end motion by inserting 0.015 feeler gage between transmission mounting bracket and head of adjusting bolt at each end of left rear powerplant support bracket, (fig. 2-55). (12) Adjust bolts until slight drag is felt on feeler when removing; then tighten locknut (fig. 2- 55). (13) Remove powerplant lifting sling from lifting eyes. NOTE Procedures listed in steps (14) through (27) apply to working under vehicle.(14) Aline forward rear propeller shaft ‘companion flange on transmission output companion flange studs, and secure flanges with twelve self-locking nuts (fig. 2-50). (15) Secure winch drive shaft flange to power take-off flange with four bolts and self-locking nuts (fig. 2-49). (16) Insert speedometer cable into drive unit at transfer housing and tighten connector nut. (17) Secure front spring rear bracket crossmember, with air tube attached, to brackets on frame sidemembers with eight bolts and self- locking nuts (fig. 2-48). (18) Secure air tube to tee connector located where front spring rear bracket crossmember secures to right frame sidemember. (19) Secure left side of air tube to quick release valve on left frame sidemember. (20) Install clevis pin through link on top of clutch a (fig. 2-47). (21) Connect front propeller shaft companion flange to transmission front drive companion flange eight bolts and self-locking nuts so that bolt heads are to rear (fig. 2-46). NOTE Installing above bolt heads to rear is essential for clearance between drive flange bolt and transmission case boss. (22) Connect compressor-to-reservoir air hose ‘at a point just to right rear of transfer section of transmission assembly (fig. 2-45). (23) Connect fuel return line at left rear of ting lever, and secure with cotter pin (24) Connect wire to oil pressure sending unit. (25) Connect starter positive cable to starter positive post. (26) Connect ground cable from frame to engine. (27) Connect six headlight wire connectors on each side of vehicle, connectors are located near left and right front spring eyebolt (fig. 2-40). NOTE Match circuit numbers stamped on each wire with corresponding circuit numbers stamped on mating part of connector. NOTE Procedures listed in steps (28) through (38) apply to working on left side of engine. (28) Connect power steering hydraulic pump pressure and return hoses (fig. 2-57). (29) Connect hydraulic pump reservoir vent hose to reservoir (fig. 2-60). (30) Connect alternator electrical connector at alternator (fig. 2-60). (31) Connect flexible control cable to crankcase pressurization valve (fig. 2-37). NOTE Cable must be completely depressed (on instrument panel) and pressurization valve must be fully open. (32) Connect crankcase vent line hose from breather manifold mounted on firewall to pressurization valve and tighten hose clamp (fig. 2- 61). (33) Connect engine ground strap to engine with bolt (fig. 2-60). (34) Install clevis pin through accelerator rod and injector pump arm, then secure with cotter pin ig. 2-58). (35) Connect hand throttle flexible cable to accelerator linkage. NOTE Hand throttle on instrument panel must be fully depressed. (36) Install hew gasket between left exhaust pipe and exhaust manifold, then secure pipe to manifold with band clamp (fig. 2-61). (37) Install bypass oil filter assemblies. Refer to TM9-2320-206-20. CAUTION To Prevent oil filter restriction mount the inlet quick disconnect coupling with the nut on the filter side and the outlet quick disconnect coupling with the nut on the hose side. (38) Connect two full-flow oil filter hoses to filter housing (fig. 2-60) NOTE Procedures listed in steps (39) through (52) apply to working on right side of engine. (39) Install new gasket between right exhaust pipe and exhaust manifold, then secure pipe to manifold with band clamp (fig. 2-59). (40) Connect fuel hose to injector pump (fig. 2.58), (41) Connect tachometer drive cable to injector pump (fig. 2-61). (42) Connect water temperature sending unit cable connector (fig. 2-58). (43) Secure sending unit cable to intake manifold with clamp (fig. 2-58). (44) Connect air cleaner dicator hose (fig. 2-57). (45) Connect air compressor governor hose at the governor (fig. 2-57). (46) Remove two bolts which were temporarily installed in paragraph 2-28 a, step (31) to secure radiator support rod to intake manifold crossover assembly. (47) Install air cleaner in position, then temporarily connect two mounting straps that cleaner to firewall (fig. 2-57). restriction in- anNOTE The air cleaner mounting straps should be left loose to make later alinement of hood side panel easier. (48) Aline air cleaner outlet housing and intake manifold crossover assembly bolt holes. (49) Aline radiator support rod bracket on air cleaner outlet bousing (fig. 2-57). (50) Secure parts in steps (48) and (49) above with five bolts, washers, and lockwashers (fig. 2-57). (51) Connect cold weather starting fuel hose to air cleaner outlet (fig. 2-61). (52) Connect glow plug electrical wire (fig. 2- 61). NOTE Procedures listed in steps (53) through (65) apply to working inside cab. (53) Place transmission control lever assembly in position under frame crossmember (fig. 2:32). (54) Secure shifter cover with control levers to transmission with six bolts and lockwashers (fig. 2- 32). (35) Connect control lever rods to transmission with three clevis pins, then secure cle with three washers and cotter pins (fig. 2-32). (56) Install handbrake lever cross-shaft and mounting brackets on rear of transmission housing, and secure with four bolts and lockwashers, (fig. 2- 32). (51) Position handbrake lever and mounting bracket assembly under frame crossmember (fig. 2- 32). (58) Secure mounting bracket to transmission with six bolts and lockwashers. (39) Connect handbrake control rod to clevis in center of cross-shaft by securing with clevis pin and cotter pin (fig. 2-32). (60) Connect linkage at hand brakedrum by securing link to brakeshoe arm with clevis pin and cotter pin. (61) Place control levers in neutral, lower floor tunnel over control levers and aline tunnel with bolt holes in the floor (fig. 2-31). (62) Secure floor tunnel with twenty bolts and lockwashers (fig. 2-31). (63) Slide boot assembly over power take-off and transfer control lever, then secure boot to floor tunnel with six self-tapping screws. (64) Install four knobs on control levers. (65) Position companion seat on cab floor and ( secure with four screws, lockwashers, and nuts. NOTE Procedures listed in steps (66) through (80) apply to working in front of veh (66) Position headlight panel bracket assembly by rotating bottom of panel inward and moving fender brace up (fig. 2-21). (67) Secure headlight panel bracket assembly to bottom brace with four bolts, lockwashers, and self-locking nuts. (68) Pull left and right headlight panel offeet braces down into position, and secure each to its panel with screw, lockwasher, and self-locking nut (fig. 2-21). (69) Position upper radiator shield support across radiator assembly. (70) Secure upper radiator shield support to headlight panel assembly with two bolts, lockwashers, and flat washers (fig. 2-21). (71) Install front bumper (pai (2) through (3)). (72) Install lower brush guard (pa p (1). (73) Install upper brush guard (para 2-21, steps (2) through (4). (74) Remove tape from battery cable ter- minals and connect cables to running board battery and under seat battery terminal posts. CAUTION Check radiator coolant and engine oil level prior to starting engine; add if required. (75) Start engine, check operation and proper functioning of all controls. (76) Install left hood side panel (para 2- 22d.). (77) Install right hood side panel (para 2- 22d). (78) Secure air cleaner inlet tube to right hood side panel with hose clamp (fig. 2-57). (79) Tighten air cleaner mounting stra temporarily installed in step (47) above (fig. 2. (80) Lower hood and secure in closed position with latches on each side at front. 2.31. Front Axle a. Removal. (1) Place vehicle on level surface, apply handbrake and block rear wheels. (2) Drain oil from axle housing and remove filler plug (fig. 2-65). 2-20c, steps 221 eyFigure 2-65, Disconnecting shock absorbers.(3) Open drain cocks on air reservoirs to ‘ir hose at left and right brake chaust ain (4) Disconnect ai chambers (fig. 2-66). 0 Figure 2-66, Front brake chamber—installed. Google(5) Remove cotter pin at front end of drag link and back out screw plug until steering lever ball can be slipped out of slot (fig. 2-67). Figure 2-67. Front axle drag link. Google 7 fi(6) Remove cotter pin and castellated nut securing shock absorber link (left side) to lower bracket; then disengage link. Repeat operation at right side (fig. 2-65). (7) Remove eight self-locking nuts and bolts securing front propeller shaft to differential shaft and separate flanges. END ASSEMBLY CASTER PLATE bowen (8) Support free end of propeller shaft to prevent damage. (9) Remove eight nuts from four U-bolts securing front axle to left and right springs. Do not remove U bolts (fig. 2-68). ‘ORD £73289) Figure 2-68. Front axle-to-spring attaching parts. (10) Adjust two truck support stands to desired height and locate under frame sidemembers to rear of front of axle. NOTE Vehicle must be raised high enough for wheels to clear front bumper. (11) Insert pole into fill hole in axle housing to prevent housing from turning over, and lift out four, U bolts; then remove from axle from under vehicle. (12) Remove wheels. Refer to TM 9-2320- 206-20. b, Installation. (1) Install wheels. Refer to TM 9-2320-206- 20. 2-16 (2) Insert pole in axle housing fill hole to under vehicle, and i (3) Lower vehicle to seat U-bol truck support stands. (4) Position shock absorber link brackets on bottom of both forward U bolts, and secure all U bolts by installing two nuts on each bolt (fig. 2-68). Tighten with torque wrench to 800-860 foot- pounds. (5) Insert left and right shock absorber links through U bolt brackets and secure each with castellated nut and cotter pin (fig. 2-65). (aft to dif- t bolts and (6) Connect front propeller ferential companion flange with nuts. Torque to 45-50 foot-pound (7) Install and adjust drag link. Refer to TM. ) 9-2320-206-20. (8) Connect air line to left and right brake chamber (fig. 2-66). (9) Close drain cocks on ai (10) Remove pole from hot reservoirs. ing fill hole and fill housing with lubricant to proper level. Refer to LO 9-2320-206-12. 2-32. Front Spring a, Removal. Refer to TM 9-2320-206-20. b. Installation. Refer to TM 9-2320-206-20. 2-33. Rear Suspension a, General. The rear suspension consists of two rear axle assemblies, two rear spring assemblies, two torque rods and trunnion mounting in a singl structure (fig. 2-69). RA PD 374445 Figure 2-69. Rear suspension (bogie)—top view. 2ab. Removal. (3) Disconnect front propeller shaft from (1) Disconnect two air hoses at forward-rear bogie. axle and two hoses at rear-rear axle brake double (4) Remove two cotter pins and hexagon nuts check valves (fig. 2-70). at forward and rear torque rod studs; then (2) Disconnect air hoses at forward-rear and disconnect torque rods at frame (fig. 2-70). ( -70). rear-rear axle brake quick release valves (fi DOUBLE CHECK 5 ‘QUICK RELEASE ai HEX NUTS Figure 2-70. Rear suspension connection points. 278(5) Raise rear of vehicle with crane until wheels are almost, but not entirely, clear of ground. (6) Remove four hexagon nuts, lockwashers, and hexagon-head bolts securing each trunnion mounting bracket cap to bracket and remove cap (fig. 2-71). co ue Vo REAR SPRING TRUNNION| BRACKET REAR SPRING TRUNNION BRACKET CAP a7 wee SPECIAL HEX-HD BOLT J p ¢. Installation. (1) Use crane or hoist; raise frame high enough to permit installation of rear suspension (bogie), and remove A frames. (2) Roll rear suspension under frame and position trunnion under trunnion brackets. (3) Lower frame and install two trunnion bracket caps using eight hexagon-head bolts, lockwashers and hexagon nuts (fig. 2-71). Tighten bolts to 250-300 foot-pounds torque and remove lifting hook. (4) Slide new felt washer and flat washer, in a Ape mK (7) Continue lifting frame until trunnion brackets are clear of axles; then roll bogie rearward from under vehicle. (8) Position A frames (horses) under frame and lower frame onto horses; then remove lifting hook (fig. 2-71). HEX NUT ‘AT 34887 Figure 2-71. Frame assembly mounted on A frame. that order, on front and rear torque rod studs and insert stud in torque rod brackets on frame. (5) Secure rods with hexagon castellated nut; tighten nut to 1.125 to 1.245 foot-pounds torque and lock with new cotter pin (fig. 2-70). (6) Connect air hoses at forward-rear and rear-rear axle brake quick release valves ( (7) Connect two air hoses at forwar and two air hoses at rear-rear axle air brake double check valves (fig. 2-70). (8) Connect propeller shaft to forward-rear axle. 279CHAPTER3 REPAIR OF POWERPLANT Section |, ENGINE ASSEMBLY 3-1. General Removal or replacement of the engine is facilitated by removal of the powerplant. This section contains instructions for removal and installation of components of the powerplant. 3-2. Removal—M123, M123C and M125 a. Remove Powerplant. Refer to par 294. b, Remove Transmission. Refer to paragraph 3- 42. ¢. Remove Clutch. Refer to paragraphs 3-6 and 3-7. d. Remove Radiator. Refer to TM 9-2320-206- 20. 3-3. Installation—M123, M123C and M125 2. General. Any cables, connections, parts, and accessories not furnished with replacement engines, must be removed and installed on replacement engine before installation into the truck. Refer to pertinent paragraphs in TM 9-2320-206-20 to cover removal and ation of any of these item: b. Install Radiator. Refer to TM 9-2320-206- 20. ¢. Install Clutch, Refer to paragraph 3-11. d. Install Transmission. Refer to paragraph 3- 47, ph 2- e. Install Powerplant. Refer to pi Removal—M123A1C and M123E2 2. Remove Powerplant. Refer to paragraph 2- 30. b. Remove Transmission. Refer to paragraph 3- 42. c. Remove Clutch. Refer to paragraphs 3-6 and ph 2-29, 3-7. d. Remove Radiator. Refer to TM 9-2320-206- 20. 3-5. Installation—M123A1C and M123E2 2. General. Any cables, connections, parts, and accessories not furnished with replacement engines must be removed and installed on replacement engine before installation into the truck. Refer to pertinent paragraphs in TM 9-2320-206-20 to cover removal and installation of any of these items. 6, Install Radiator. Refer to TM 9-2320-206- 20. ¢. Install Clutch. Refer to paragraph 3-11. d. Install Transmission. Refer to paragraph 3- 41. @. Install Powerplant. Refer to paragraph 2-30. Section II, CLUTCH ASSEMBLY 3-46. General Removal of the clutch necessitates removal of the transmission from the powerplant. 3-7. Removal a, Remove Powerplant. Refer to paragraph 2- 29 or 2-30. b. Remove Transmission. Refer to paragraph 3- 42. ¢. Remove Clutch. (1) Install three 7/ 16-14x2 7/8 shipping bolts and 7/ 16-inch flat washers as shown in figure 3-1. Tighten to remove pressure from backing plate assembly. utRELEASE Lever Figure 3-1. Removing pressure plate and backing assembly from flywheel. 32 (2) Proceeding clockwise around the backing plate, remove twelve bolts, lockwashers, and spacers securing the pressure plate with backing plate assembly (fig. 3-1) to the flywheel. Remove pressure plate with backing plate (3) Lift out two clutch-driven (18, fig. 3-7) and intermediate pressure plate (19, fig. 3-7). (4) Remove pilot bearing using puller (5, fig. hown in figure 3-2. 2-5),Figure 3-2. Removing pilot bearing with puller. ~ 33 Google fd. Remove Clutch Release Bearing and Collar (2) Disconnect release collar spring from eye (Fig. 3-3). at the top of release col (1) Remove nut and lockwasher securing (3) Slide release collar and bearing with release bearing lubrication fitting through base of lubrication hose forward off main drive pinion. ¢ clutch bell housing. a LUBRICATION. ( i LOCK WASHER. Bi FITTING = RA PD 383406 nur —_B, Figure 3-3. Clutch release bearing and yoke.e. Remove Clutch Release Shaft and Yoke. loosening clamp bolt locknut securing lever to (1) Remove release lever (fig. 3-4) by clutch release shaft. BOLT AND SELF-LOCKING NUT AT 34989, Figure 3-4. Clutch and clutch linkage. (2) Remove adjusting lever (fig. 3-4) by sliding lever from release shaft.(3) Remove hexagon nut, lockwasher and through bell housing. This will also disengage yoke hexagonshead locking bolt securing yoke on shaft from release shaft. (fig. 3-5). (5) Remove and discard preformed packing (4) Using soft drift, tap release shaft (fig. 3-5) from each end of shaft. PREFORMED PACKING HOUSING | on | Figure 3-5. Removing clutch release shaft. sembiy inary. Before disassembling the pressure with backing plate assembly, punchmark PIN, PULL DOWN backing plate, pressure plate, clutch release lever WASHER, PULL DOWN) and thrust washer to assure assembly in o1 SHAFT, SCREW: PLATE, CLAMP position. NOTE! WHEEL HAND The key symbols noted in parentheses are in figure 3-7, unless otherwise indi b. Pressure Plate Assembly. U rebuilder, disassemble pressure with backing plate assembly as shown in (1) through (8) below. REBUILDER, (1) Place pressure plate assembly (1) on CLUTCH ~ PLATE, PRESSURE, clutch rebuilder (fig. 3-6) 4-6-2400" BY W.HACKING, SSEMBLY ~~ ono £75221 any Figure 3-6. Pressure plate with backing plate assembly on clutch rebuilder. 36(2) Screw shaft extension into end of screw shaft and place clamp plate over the screw shaft. Insert three 2%-inch long sleeves between the ) spring cups on backing plate and the clamp plate, 1. Clutch pressure plate assembly 2. Clutch release lever spring 3. Clutch release lever straight pin 4. Clutch release lever plain washer 5. Eyebolt lockwasher 6. Eyebolt outer nut 7. Eyebolt inner out 13. Compressi 8. Pressure plate eyebolt 9. Pressure plate eyebolt fulcrum 10. Clutch release lever 11. Thrust washer 12, Clutch backing plate spring—inner one sleeve under each arm of clamp plate. Si pulldown washer over the screw shaft exten: and insert the pulldown pin through the fi extension above the washer (fig. 3-6). nm, t hole in 16. Eyebolt pin 17, Clutch pressure plate 18. Driven friction clutch disc 19, Intermediate pressure plate Figure 3-7. Clutch assembly—exploded view. (3) Turn handwheel on clutch rebuilder counterclockwise until the clutch pressure springs are fully compressed. (4) Compress clutch release lever springs (2) and pull out release lever spring pins (3). Lift off the six release lever spring washers (4) and the six release lever springs (2). (5) Bend down tang of each eyebolt lockwasher (5), then remove the pressure plate eyebolt outer nut (6), lockwasher (5), and eyebolt inner nut (7) from each of the six eyebolts (8). Lift off six pressure plate eyebolt fulcruma (9); then lift the six clutch release lever and bushing assemblies (10) off the eyebolts and out of the release lever thrust washer. Remove the release lever thrist washer (1) with retainer wire installed. (6) Slowly turn the handwheel on clutch rebuilder clockwise until all pressure is removed from the backing plate (12). Remove pulldown pin and lift off the pulldown washer, clamp plate, and three spacers. (7) Lift off the clutch backing plate (12) and remove 18 inner (13) and 18 outer clutch pressure springs (14). Note that there are heat-insulating washers (15) in the spring pockets in pressure plate. If these washers are removed, be sure to keep them for assembly. (8) Do not remove the six eyebolts (8) or pins (16) from the pressure plate; (17) nor the six pivots from the release levers. 3-9. Cleaning, Inspection, and Repair a. Cleaning. General instructions for cleaning are covered in paragraph 2-8. b. Inspection and Repair. (1) Flywheel. (a) Check contact surface for roughness aand cracks, using straightedge and feeler gage (fig. _surface is rough enough to scuff. 3-8). If 0.015-inch feeler gage will slide under ce the flywheel. straightedge, or cracks are 0.020-inch wide, or Figure 3-8. Checking flywheel contact surfaces,(b) Check alinement of intermediate plate driving lugs, using mechanics square (fig. 3-9) on the bolting face of flywheel. Remove cotter pin, loosen castellated nut, and adjust any lug not square with flywheel face. Tighten nut,,and secure with new cotter pin after alinement. Figure 3-9. Checking driving lug alinement. ing. After removal from 3-2), clean and repack grease, leaving hollow for shaft. (3) Driven disk assemblies. Inspect driven disk assemblies for loose rivets which fasten the splined hub to the disk, and if loose, replace driven ‘assembly. Check condition of splines in hub; replace disk assembly if splines are worn or dam aged. Inspect facings and if worn thin, torn, oil soaked, or glazed, replace d 1(4) Intermediate pressure plate (fi Check with straightedge and feeler gage 3-10). (a) above. Inspect for excessive wear or distortion. in (1) If warped, replace plate. PRESSURE PLATE RA PO 383409 Figure 3-10. Intermediate pressure plate installed. 3-10 A(5) Pressure plate (fig. 3-11). (a) Place pressure plate on surface plate of clutch rebuilder and, using a feeler gage between, face of pressure plate and surface plate, check pressure plate for warp. If warped, replace plate. Inspect pressure plate for heat-checking, burnin, PLATE, PRESSURE—) 83321795 GAGE, FEELER or breakage. If plate is only slightly heat-checked, it may be resurfaced on a lathe or surface grinder. NOTE Do not remove more material than necessary, and do not permit plate to become out of balance. STRAIGHT EDGE RA PO 372522 Figure 3-11. Checking pressure plate Jor warp. (b) Inspect eyebolt mounting lugs for condition. If broken or distorted, replace pressure pla (c) Inspect eyebolts for damaged threads, bent bolts, and excessive wear in eyes (cau wobble). Replace eyebolts and/or pins if necessary. To replace eyebolts, drive out pin which Using a drift, remove eyebolt and position new one between mounting lugs and drive in pit (d) Check heat-insulating wa serviceability. Replace if necessary. (6) Backing plate. (a) Place backing plate on surface plate of clutch rebuilder, and using feeler gage between backing plate and surface plate, check backing plate for warp in same manner as described in (3) above for pressure plate. If warped, replace backing plate. (6) Examine backing plate for cracks. Replace if necessary. (c) Check spring cups for condition and tightness in backing plate. If loose, tack-weld _spring cups in place. Replace spring cups if necessary. (d) Inspect release lever pivots for excessive wear by positioning lever on pivot and noting if there is any side play. Replace pivots, if necessary, by drilling out heads of pivot pins, driving out pin prying off pivots, and installing new pivots and pivot pin (1) Release levers. (a) Inspect clutch release levers for cracks or signs of wear. Replace if necessary. (6)Using 11 / 16-inch ball and straightedge (fig. 3-12), check each release lever for warp. If dimension A exceeds 11 / 32 inch when measured ata point where dimension B is 2% inches, replace the lever. (c) Check release lever bushings, and if excessively worn, press out old bushings and press in new ones. STRAIGHT EDGE AT 34892 Figure 3-12, Checking release lever for warp. using ball. an(8) Release lever thrust washer. (a) Examine release lever thrust washer for cracks and wear. Replace if necessary. (6) Check fit of thrust washer on release levers. If loose, replace thrust washer. (c) Inspect condition of retaining ring and replace if bent or broken. Inspect fit of snapring i thrust washer groove, and replace if loose. (9) Clutch pressure springs. Inspect pressure springs for length and for tension. The condition of spring can be determined to a large degree by its color. If the paint is burned off, tension has been changed. Use a test springs. If a spring tester is not av: ‘compare each spring with a new one to judge free length and tension; replace all springs if free length varies between any springs. (10) Release bearing and collar. “(a) Inspect release collar, and replace if defective. (b) Inspect throwout bearing in accordance with TM 9-214, Replace if defective. (11) Release shaft and yoke. (4) Inspect release shait for pitting, scoring, and excessive wear, and replace if defective. (b) Inspect yoke for wear and damage. Replace if defective. (12) Clutch release shaft and linkage (fig. 3- 4). Check clutch release shaft for looseness in bushings and levers for security of attachment. Replace defective parts. the backing plate, pressure plate, clutch release levers and thrust washer were punchmarked to assure assembly in original position. Look for punchmarks and assemble in proper order. NOTE The key symbols noted in parentheses are in figure 3-7, except where otherwise indicated. b. Pressure Plate Assembly. (1) Place pressure plate rebuilder and center it. (2) Place 18 heat-insulating washers (15) and (17) on clutch 212 inner (13) and outer (14) pressure springs in spring pockets in pressure plate (fig. 3-13). ‘COMPRESSION, SPRING, ‘ure: ‘COMPRESSIO' PLATE, PRESSURE-| ‘ono £75323 Figure 3-13. Pressure springs installed on pressure plate, (3) Position backing plate assembly (12) on pressure springs (13) and (14) with eyebolts (8) protruding through holes in backing plate, and aline punchmarks made at disassembly. If pressure plate was refaced, metal washers of same thickness as the cut taken off the pressure plate must be inserted in the 18 spring cups. If flywheel and intermediate plate were also refaced, thickness of washers must equal the cut taken off pressure plate, intermediate plate, and flywheel. Total cuts must not exceed 3 / 16 inch. Be sure washers seat fully in spring cups and that they are large enough in diameter to remain centered. For assembly con- venience, use shellac to retain washers in cups. (4) Screw shaft extension (fig. 3-14) into end of screw shaft and set three 24-inch long distance sleeves, equally spaced, on spring cups. Place clamp plate over screw shaft extension with each leg resting on a distance sleeve; then slip pulldown Washer over shaft extension and insert pulldown pin through first hole in extension above washer.PIN, PULL DOWN — [Le EXTENSION SHAFT TL mate, cose WASHER, PULL DOWN, PLATE, BACK: ASSEMBLY PRESSURE, Figure 3-14, Mounting backing plate on pressure plate. (5) Place six 14-inch long distance blocks around edge of pressure plate (fig. 3-15); then turn handwheel counterclockwise until pressure springs ‘compressed and backing plate is res distance blocks. CLAMP i: PLATE, PRESSURE, CLUTCH Me ‘iy BLOCK, DISTANCE 1-1/8 LONG ‘ORD £75325 Figure 3-15. Pressure with backing plate assembled. release lever spring (6) Position six clutch rebuilder clamp assemblies in slots provided in clutch rebuilder and over top of backing plate. Turn knurled nuts either direction as necessary to aline clamps; then tighten clamps securely with an open end wrench or a rod inserted through adjusting nut. (7) Turn handwheel on “clutch on clutch rebuilder clockwise and remove pulldown pin, pulldown washer, clamp, three distance sleeves and shaft extension. (10) on release lever pivots and eyebolts (8). Place (2) on pivot pins with small diameter of springs against the levers, place spring washers (4) on springs, compress springs by hand, and insert spring pins (3) in pivot pins. (9) Position eyebolt fulcrums (9) on release levers, with wedge side down, and run inner nuts (7) down on each eyebolt until convex surface of each finger 2.0575 to 2.0675 inches from the clutch rebuilder machined surface (10) Install lockwasher (5) on each eyebolt; then install eyebolt outer hexagon nut (6) and lock adjustment by bending tang on lockwasher up against nut. (11) Position release lever thrust washer (11) over ends of release levers, and lock it with retainer wire. 33(12) Position clutch rebuilder indi screw shaft of clutch rebuilder, and turn it around washer (figure 3-16), to check parallel. Adjust release levers as necessary. weston] ( WASHER, THRUST BA PD 373208 Figure 3-16. Checking thrust washer for parallelism, using indicator. 3-11. Installation 2. General, This procedure is based on using new of reconditioned parts, and when completed will permit as many ments (under the same operating conditions) as a new clutch. b. Flywheel. Replacement of flywheel will be performed in accordance with TM 9-2815-213-34. ¢. Pilot Bearing. Drive into place in recess in flywheel, using driver which contacts only outer race of bearing (fig. 3-2). Shielded side of bearing should face outward. d. Driven Disks and Intermediate Pressure Plate. (1) Install small end of clutch disk alining bar (fig. 3-10) in the pilot bearing, and slide driven disk over bar with long hub extension facing flywheel. (2) Install intermediate pressure plate (fi 10) on the driving lugs, and check for free sliding fit. (3) Slide second driven disk on bar with long hub extension facing out. (4) Engage key in bar with spline in hub and push disk against intermediate plate. e. Clutch. (1) Install the pressure plate backing plate assembly (fig. 3-17), using @ spacer under each of the twelve bolts and lockwashers between the flywheel and the backing plate. (2) Tighten bolts to 25 to 28 foot-pounds torque. a4 (3) Remove three shipping bolts and washers installed at time of disassembly, and remove alining 7 sre | = PILOT STUD, (NOT USED ON miz3aic AND M123E2) Fget 1. tantingrane pir oth bctngpiew ‘assembly.f. Installing Clutch Release Shaft (Fig. 3-18). (1) Using soft drift pin, tap clutch release shaft (1) through bushing (2) on left side of pros bell housing. (2) When shaft clears mounting bose, slip ‘clutch release yoke (3) on shaft so legs of yoke are facing upward and resting against drive pinion cover. (3) Position new preformed packin; grooves on each end of shaft and tap bushing (2) on right hand side of how of shaft is flush with housing face. (4) Aline yoke on shaft, insert key (5) in |. Clutch release shaft Bushing Clutch release bearing yoke Preformed packing 5. Key 5. Bolt keyway of yoke and shaft, and secure yoke to shaft with bolt (6), lockwasher (7), and nut (8). (5) In: se collar assembly (9, . 3-18) over spli ide collar and bearing fig. 3-18) with bes of main drive pinion, and back against collar. (2) Install release collar spring by hooking end into eye at top of collar. AT 34894 1. Lockwasher 8. Nut 9. Clutch release collar assembly 10. Lubrication hose 11, Bearing Figure 3-18. Clutch release mechanism—exploded view. (3) Insert lubrication hose (10, fig. 3-18) behind clutch release shaft and place fitting through base of housing; then secure lubricating fitting lockwasher and nut. h. Install Transmission. Refer to paragraph 3- 41, i, Adjust Clutch. Refer to TM 9-2320-206-20. 315Section 111, TRANSMISSION OIL PUMP. 3-12. General Removal of the oil pump necessitates removal of the transmission from the powerplant. 3-13, Removal 2, Remove Powerplant. Refer to paragraph 2- 29 or 2-30. b. Remove Transmission. Refer to paragraph 3- 42. ©. Remove Oil Pump. (1) Remove six screws (39, fig. 3-44) and 316 lockwashers (40), securing oil pump inspection hole cover (41) to bell housing; then remove cover and discard ket (42). (2) Remove four hexagon-head screws (12, fig. 3-39) and lockwashers (13) securing oil pump (14) to transmission case. (3) Pull pump forward until key inserted in oil pump drive shaft is free of countershaft (15, fig. 3- 44); then remove pump and discard gasket (15, fig. 3-39).MAIN DRIVE PINION. BEARING COVER ASSY = COLLAR ASSY} —< Figure 3-19. Transmission oil pump and clutch relase mechanism installed. 3-14, Cleaning and Inspection leakage, damage to pump housing and sha‘ "a. Cleaning. Refer to paragraph 2-8. nicks and burrs. Replace pump if b. Inspection. Inspect pump for evidence of noted. a73-15. Test a, Using spare gasket, bolt pump to improvised plate machined in accordance with figure 3-20. (a y2xist = (4) 1/16 X45° CHAMFER Note: ‘ALL. DIMENSIONS. SHOWN ARE IN INCHES, SECTION A-A A PO 374531 Figure 3-20. Plate for testing transmission oll pumps. b. Install one of the pipe plugs (fig. 3-21) and apply 90 psi air pressure to other port and test for air leaks using « solution of soap and water. No leaks are permitted, except where shaft enters pump. femove air pressure fitting and install pipe Secure relief valve spring screw (fig. 3-21) with locking wire through drilled head of pipe plug. Figure 3-21, Transmission oil pump assembly. 38‘3-16. I a. Install Pump. (1) Apply gasket sealer to face of pump (14, fig. 3-39), and position gasket (15) #0 that ports on yes of pump are uncovered. (2) Position oil pump assembly on front of transmission, making sure to aline key in pump shaft with keyway in countershaft bore (15, fig. 3- 44) and mount. (3) Secure oil pump to four screws (12, fig. 3-39) and lockwashers (13). Tighten screws to 70 to 90 foot-pounds torque. (4) Apply gasket cement and position gasket (42, fig. 3-44) on bell housing to install oil pump inpection hole cover (41). (5) Position and secure cover to bell housing smission case with (43. fig. 3-44) with six screws (39) and lockwashers (40). CAUTION Pump must be primed prior to use to prevent damage to transmission. (6) Remove inlet line from transfer and fill line full of oil to prime pump. Start engine and then crack line at power take-off to insure a steady flow of oil. If steady flow of oil is not indicated, stop engine immediately and investigate to prevent damage to transmission assembly. b. Install Transmission. Refer to paragraph 3- 47. ©. Install Powerplant. Refer to paragraph 2- 29¢. or 2-30c. Section IV. POWER TAKE-OFF 3-17. General Many of the operations described in this section can be performed with the transmit Hed in vehicle, but for maximum accessibility and ef- ficiency the powerplant is removed from the vehicle. 3-18, Removal Remove Powerplant. Refer to paragraph 2- 29 or 2-30. b. Remove Upper Shifter Cover With Levers. Refer to paragraph 3-30. c. Remove Shift Shaft Carrier Cover. Refer to paragraph 3-36. d. Remove Transfer Case Top Cover. NOTE The key symbols noted in parentheses are in figure 3-25, except where otherwise indicated. (1) Remove 12 hexagon-head screws (1) and lockwashers (2) securing transfer case cover to and remove cover (3). Be careful not to let shift rail ball springs (fig. 2-14) fall into case. Discard cover gasket (4). NOTE Remove two center bolts last to keep cover from cracking. (2) Remove three sl rail ball springs (5), and use pencil magnet to lift out three shifter shaft balls (6). (3) Cutlocking wire and remove special screw (fig. 3-22) securing power take-off shifter fork (10, fig. 3-25G) to power take-off shifter shaft (11). Pull out shifter and slide out shifter (fig. 3- then remove oil seal (31, fig. 3-25G) from shifter shaft opening in transfer case. 319,3:20 FRONT DRIVE BALL SOCKET SHIFTER § | HEX-HEAD SCREW FRONT DRIVE SHIFTER SHAFT SHIFT RAIL BALL SPRING SHIFT RAIL | HIGH AND Low BALL SPRING — RANGE SHIFTER HEX-HD "OFF SHIFTER \ POWER-TAKE-OFF SCREW e SHIFTER SHAFT. ‘TRANSFER CASE (ORD.E73519 Figure 3-22. Transfer case with cover removed. GoogleA™~ POWER-TAKE-OFF. SHIFTER POWER-TAKE-OFF SHIFTER SHAFT /ER-TAKE-OFF SHIFTER FORK a\\, POWER-TAKE-OFF N SHIFTING FORK SHAFT Figure 3-23. Removing and installing power take-off shifter and shifter e. Remove Oil Lines. Unscrew connector and remove tubing connecting power take-off housing remove oil line connecting transmission oil pump _with transmission shift shaft carrier cover. with power take-off housing. Unscrew fitting, and 321f. Remove Power take-off. by hand; and engage the high- and low-range speed (1) Lock shaft to prevent rotation (fi sliding clutch, the power take-off sliding clutch, and and 3-251): Engage second- and th front drive sliding clutch in the transfer section by sliding clutch, and reverse sliding and first-speed moving into position by hand. clutch gear in trananission by moving into position SECOND AND THIRD pe SPEED SUDING : ; | GEAR SPLINED | NV \\ AWN \ AN ie of SECOND SPEED REVERSE SLIDING B GEAR ASSY AND FIRST SPEED CRUTCH GEAR Faure 524 Mare shat, pnars, and ctatches in becked position. 12) Remourootter pin 17 fig. & ndusing power take-off flange (9) to power take-off flange SNR at were bse hevagan mat tS! securing housing 1121,(3) Remove six hexagon-head screws (10. fig. 3-25) and lockwashers (11) securing power take-off housing to transfer case end plate, and pull out housing (12) until shifter fork shaft (24) is clear of transfer case. Discard gasket (13). |. Hexagon-head screw - Lockwasher ‘Transfer case cover 9. Shifter shaft ball Cotter pin . Hexagon nut 9. Power take-off flange 10. Hexagon-head screw 11, Lockwasher 12, Power take-off housing 13. Gasket 14. Hexagon-head screw 15. Lockwasher 1 2 3. s 8. Shift 6. 1 8. AT 34896 16. Bearing retainer 17. Gasket 18, Oi seal 19. Shaft 20. Bearing 21. Clutch gear 22. Shifter fork 23. Hexagon nut 24. Shifter fork shaft 25. Cotter pin 26. Hexagon-head screw 21. Lockwasher 28. Oil restrictor screw 29. Gasket Figure 3-25. Power takeoff—exploded view. a, Remove hexagon nut (8) securing flange (9); and remove drive flange, using suitable puller. b. Remove four screws (14) and lockwashers (15) securing bearing retainer (16) to housing (12), and ve the retainer. Discard ket (17) and reme il seal (18) from retainer, and discard seal. ¢. Pull shaft (19) and bearing (20) out of housing, leaving clutch gear (21) and engaged shifter fork (22) in place. Using suitable equipment, press bearing off shaft. d. Disengage clutch gear (21) from shifter fork (22), and remove gear and fork from housing. e. Remove cotter pin (25) and hexagon nut (23) securing shifter fork shaft (24) to fork (22) and remove shaft. 3-20. Cleaning, Inspection, and Repair 4. Cleaning. Instructions for cleaning, inspection, and repair are covered in paragraphs 2-8 through 2-10. Specific instructions for inspection and repair are covered in following steps. b. Inspection and Repair. (1) Inspect bearing in accordance with TM 9- 214. Replace defective bearing using arbor press. 324(2) Inspect splines on power take-off drive shaft for signs of twisting. Replace defective shaft. Inspect threads on end of shaft and inspect companion flange nut for stripped threads. Replace if necessary. (3) Inspect sliding clutch for signs of wear at teeth and splines, chipped areas, or spots where case-hardening is worn through. Check spline clearance of clutch on shaft (Table 1-1). Replace defective clutch. (4) Inspect shifter fork in sliding clutch and check clearance (Table 1-2). Replace fork if clearance is excessive. (5) Inspect power take-off housing and bearing retainer to be sure that they are not cracked, broken or otherwise damaged. Replace if necessary. 3-21. Assembly NOTE ‘The key symbols noted in parentheses are in figure 3-25, except where otherwise indicated. a. Press bearing (20) on drive shaft (19) arbor press, making sure that lockring is facing toward end of shaft. b. Install shifter fork (22) on shifter fork shaft (24), and tighten nut to 137 to 167 foot-pounds torque. Then install cotter pin (25). c. Insert sliding clutch (21) in housing (12) and engage fork (22) in groove. External clutch teeth must face in. d, Inset ball bearing (20) and drive shaft (19) in housing (12), locate fork-engaged clutch gear (21), and press bearing (20) in place. e. Install oil seal (18) in retainer (16) with lipped edge of seal facing bearing using fabricated replacer (XV. fig. 2-7) as shown in figure 3-254. f. Position new drive shaft bearing cover gasket (17) and bearing retainer (16) on housing (12) and secure with four hexagon-head screws (14) and lockwashers (15). Tighten screws to 24 to 34 foot- pounds torque. g. Install drive flange (9) and tighten nut hand- tight. ‘h, Asembly of power take-off will be completed a lation (para 3-22). Y HANDLE foateent| REPACER POWER TAKE-OFF DRIVE SHAFT BEARING RETAINER \ AT 34097 Figure 3-254. Installing oil seal 3-22. Installation NOTE The key symbols noted in parentheses are in figure 3-25, except where otherwise indicated. Install Power Take-Off Assembly. (1) Position new housing gasket (13) on transfer case end plate, insert shifter fork shaft (24) in hole in case, and aline shaft (12) up against end plate and secure with six hexagon head screws (10) and lockwashers (11). Tighten screws to 70 and 90 foot-pounds torque. (2) Tighten hexagon nut (8) with socket wrench and insert cotter pin (7). (3) Install new oil seal (31, fig. 3-25G) in transfer case power take-off shaft installation opening (fig. 3-23), using replacer (7, fig. 2-4) shown in figure 3-30. (4) Engage power take-off shifter (fig. 3-23) with the power take-off shifter fork shaft, and insert shifter shaft through shifter. Secure shifter withhexagon-head screw and lockscrew with locking wire. b, Install Transfer Case Top Cover. (1) Insert three shifter shaft (detent) balls (6), and insert three shift rail ball springs (5) in top of transfer cave (fig. 3-25). (2) Using new gasket (4), position transfer case cover (3) on transfer case, and secure with 12 hexagon head screws (1) and lockwashers (2). Tighten screws to 18 to 28 foot-pounds torque. NOTE When tightening case cover bolts tighten two middle bolts and bolts over two spring cups first to prevent case from cracking. ¢. Install Shift Shaft Carrier Cover. Refer to paragraph 3-40. d, Install Upper Shifter Cover with Levers. Refer to paragraph 3-34. ‘e. Install Powerplant. Refer to paragraph 2-29. or 2-30c. Section V. TRANSFER 3-23. General Removal or replacement of the transfer section necessitates removal of the transmission from the powerplant. The transfer section must be partially disassembled to remove. 3-24, Removal a. Remove Powerplant.Refer to paragraph 2-29 or 2-30. b. Remove Handbrake. (1) Remove 12 hexagon nuts securing the brake drum (fig. 3-37) on the mai e shaft drive flange and remove drum. (2) Remove cotter pin and clevis pin at handbrake lever (fig. 2-32). Remove two hexagon- head screws and lockwashers from each of the two croseshaft brackets and remove brackets and linkage. (3) Remove four hexagon nuts (fig. 2-32) and hexagon-head screws securing handbrake support and handbrake assembly to transmission. Remove handbrake and support. ¢. Remove Upper Shifter Cover. Refer to paragraph 3-30, d. Remove Shift Shaft Carrier Cover. Refer to Paragraph 3-36. e. Remove Transfer Case Top Cover. Refer to paragraph 3-184 f. Remove Power Take-Off. Refer to paragraph 3-18f CAUTION Before proceeding with further disassembly, the transmission case, transfer case, and the transfer case end plate should be marked to insure that these mated parts will be used together at assembly. NOTE Remove drain plugs from transfer case (TM 9-2320-206-20) and drain all lubricant into suitable container. g Remove Speedometer Gear. Unscrew eedometer driven gear lift out speedometer ge NOTE re 3-25B illustrates transfer case end plate and speedometer gear installed. 325TRANSFER CASE END PLATE ‘SPEEDOMETER DRIVEN| GEAR SLEEVE COUNTERSHAFT| REAR COVER MAIN DRIVE SHAFT DRIVE FLANGE DOWEL BOLT HEX-HEAD SCREW DOWEL BOLT B MAIN DRIVE SHAFT BEARING COVER ‘ORD £73521 Figure 3-208. Transfer case end plate installed. h. Remove Transfer Case End Plate. NOTE The key symbols noted in parentheses are in figure 3-25C, except where otherwise indicated. (1) Remove cotter pin (1), and using socket wrench, remove nut (2) securing front drive shaft drive flange (3). Use mallet and remove fla (2) Remove cotter pin (4), and, us hexagon socket wrench, remove hex. securing main drive shaft flange (6) on main drive shaft, and remove flange. (3) Remove six hexagon-head screws (7) and lockwashers (8) securing counter-shaft rear cover (9) to transfer end plate. Remove cover and shims (10) and wire together for use at assembly. 3-26 (4) Remove six hexagon-head screws (11) and lockwashers (12) securing main drive shaft bearing cover (13) to end plate, and remove cover. Remove cover shims (14) from end plate, and remove seal (15) from cover (13). Wire shims and cover together for use at assembly. (5) Remove 14 hexagon-head screws (7), three hexagon-head screws (16),and 17 lockwashers (17) securing end plate (22) to transfer case. (6) Remove two hexagon nuts (18), lockwashers (19), and flatwashers (20) from dowel bolts (21) at lower left and upper right corners. (7) Drive out two dowel bolts with soft mallet, lift off end plate (22). and discard gasket (23). (8) Remove breather (24) and two bearing set cups, (27) and (28), from end plate.|. Cotter pin . Hexagon nut . Front drive flange |. Cotter pin . Hexagon nut . Main drive flange . Hexagon screws Lockwashers Countershaft cover Countershaft cover shims AT 34898 28. Bearing set cup Figure 3-25C. Transfer case end plate, covers, and drive flange—exploded view. NOTE ‘The key symbols noted in parentheses are in figure 3-25G, except where otherwise r Shafts. 1g wire and remove two special screws (fig. 3-22) securing high- and low-range r fork (1) on shaft. (2) Pull high- and low-range shaft (2) forward until free of transfer case, lift out high- and low- range speed shifter fork (1),and remove oil seal (31) from shaft opening in transfer case. (3) Cut locking w (4) Pull out front drive shifter shaft (4), lift out front drive ball socket shifter, and remove oil seal (31) from shaft opening in transfer case. j. Remove Front Drive Bellcrank (Fig. 3-25G.). (1) Remove four hexagon-head screws (5) and lockwashers (6) securing front drive bellerank pivot pin support assembly (7) on transfer case. (2) Remove support assembly (7) and (8), and lift out bellerank (9). NOTE Figure 3-25D__ illustrates bellcrank installed. ket front drive 327FRONT DRIVE BELL CRANK POWER-TAKE-OFF CLUTCH NUT le FRONT DRIVE BELL CRANK PIVOT PIN SUPPORT ASSY } My } oN « B . # a: ° e ‘Ono €73522 Figure 3-25D. Transfer case end plate removed, 3-284) with one-inch by six-foot bar to remove nut 3-25E). Discard nut. k. Remove Power Take-off Drive Shaft Clutch. (1) Use cape chisel to break out staked portion of nut (12); then use special socket wrench (2, fig. ye MAIN DRIVE SHAFT HELICAL| GEAR ee | uy MAIN ORIVE SHAFT © DRIVE FLANGE SPACER Figure 3:25E. Removing main shaft rear bearing locknut. ‘ORD £73522 309 Google(2) Insert special adapter (7, fig. 2-1) into main shaft and, using heavy duty puller, remove drive shaft clutch (13) from shaft (fig. 3-25F). POWER-TAKE-OFF DRIVE SHAFT CLUTCH ‘ORD £73524 Figure 3-25F. Removing power take-off shaft clutch. 1. Remove Main Shaft Low-Range and High- Range Gears. (1) Place heavy duty puller behind high-range gear (16), and remove in turn straight roller bearing (14), thrust washer (15), high-range gear (16), and sleeve (17). (2) Lift off sliding clutch (18), and remove low-range gear (19) and sleeve (20), and remove key (24, fig. 3-40) from main shaft. m. Remove Countershaft. Lift out countershaft assembly, with bearings installed (21), from transfer case as an assembly. Do not remove gears 3:30 unless inspection (para 3-26) reveals the necessity for replacement. If disassembly is required, use the following procedure. (1) Using puller, remove speedometer drive worm gear (23) from end of countershaft. (2) Place countershaft assembly (21) in 100- ton arbor press, and remove rear bearing (25). (3) Invert countershaft, and using press, remove front bearing (26) and gear (27); then remove key (29) from countershalt. NOTE Oil the shaft to aid gear removal. (|. High and low-range shifter fork . High and low-range shifter shaft . Froat drive ball socket shifter . Front drive shifter shaft 5. Hexagon-head screw 5 . Lockwasher Front drive bellerank pivot pin support assembly . Gasket . Bellerank Power take-off shifter fork shaft Power take-off shifter fork shaft Power take-off clutch nut Drive shaft chutch Straight roller bearing Thrast washer . High-range gear assembly 1 2. 3. 4 5. 6. 1. 8. 9. 10. 1 12. 13, 16 1s, 16, 5] 13 2 AT 34099 Figure 3-25G. Transfer case—exploded view. n, Remove Transfer Case (Fig. 3-25H). (1) Cut locking wire and remove seven special hexagon head screws inside case (three on right side and four on left side). (2) On outside of case, remove twoshexagon- head screws and lockwashers. (3) Remove hexagon nut and lockwasher from dowel bolt in lower right corner, and drive out dowel bolt with soft-faced hammer. (4) Carefully pry transfer case from trane- mission, and discard gasket (22, fig. 3-256).i 5) ; CCOUNTERSHAFT REAR BEARING COVER TRANSFER CASE GASKET TRANSFER CASE TRANSMISSION MAIN SHAFT ASSY MAIN Dj 1AF RIVE SHAFT en eras Figure 3-25H. Transfer case separated from transmission, 3-25. Disassembly General. The transfer is partially disassembled during removal (para 3-24). The following steps will complete disassembly. NOTE ‘The key symbols noted in parentheses in figure 3-28, except where otherwise indicated. 3.32 ». Front Drive Shifter Fork and Shaft. (1) Lay transfer case on bench as illustrated in figure 3-26 and remove cotter pin (35) from front drive shifter fork shaft (34). (2) Use drift small enough to clear main drive shaft gear, and drive shaft (34) through front drive shifter fork (33) and out through front of transfer case; then remove fork from case.Figure 3-26, Front drive shifter fork and shaft in Drive Shaft Assembly. Lift out main ft and gears as.an assembly (13) from (24). Do not remove gears unless inspection (pai 6) reveals the necessity for replacement. If sembly is required, use following procedure. (1) Slip off drive flange spacer (14) from end of main driveshaft (15). On opposite end of shaft, remove four hexagon-head screws (16) from front bearing clamp (17), and remove clamp. (2) Place shaft (15) in arbor press, and remove front bearing (18). Slide off gear (19) and front drive sliding clutch (20). (3) Invert main drive shaft (15), and using FRONT DRIVE SHIFTER FORK ‘7 | SHIFTER FORK DRIVE SHAFT |e AT 34900, ed in transfer case. arbor press, remove gear (21) and rear bearing (22); then remove key (23) from shaft. d. Front Drive Shaft. (1) Lay transfer case on bench and remove front drive flange (3, fig. 3-25C), using standard puller kit. (2) To remove front drive shaft bearing cover, remove three hexagon-head screws (1) and lockwashers (2) securing front drive shaft bearing cover to transfer case (24), and remove cover (3) and shims (4). Remove oil seal (5) from cover, and wire shims to cover for use at assembly.(3) Position transfer case (fig. 3-27) and, using Front bearing (7) and front bearing cup will be drift and hammer, drive out front drive shaft (6). forced out with shaft. Figure 3.27. Removing front drive shaft. (4) Lift out front drive gear (9), front drive Do not remove rear bearing cup (12) unless in- shaft bearing spacer (10), and rear bearing (11). _spection (para 3-26) warrants it.|. Hexagon-head screws Lockwashers . Front drive shaft bearing cover Front drive shaft bearing cover shim 5. Oil seal 5. Front drive shaft Front bearing Front bearing cup . Front drive gear 1. Front drive shaft bearing spacer opeepe |. Main drive shaft assembly 1. Drive flange spacer 5. Shaft Hexagon-head socket screw AT 34901 19. Gear 20. Front drive sliding clutch Gear 22, Rear bearing 23. Key 24, Transfer case 25. Magnetic plug 26. Gasket 27. Magnetic plog 28. Gasket 29. Oil strainer assembly 30. Capscrews 31. Lockwashers 32. Gasket 3. Fork 34. Shalt 35. Cotter pin Figure 3-28. Transfer came, gears, and shafts—exploded view. e. Oil Strainer Cover Assembly. (1) Remove magnetic plug (25) and gasket (26) from bottom of case (24); then remove magnetic plug (27) and gasket (28) from oil strainer assembly (29). (2) Remove three capscrews (30) and lockwashers (31) securing oil strainer assembly cover (29) to transfer case (24) and remove cover assembly. Remove and discard oil » gasket (32). 3-26. Cleaning, Inspection, and Repair 2. General. Instruction for cleaning, inspection, and repair are covered in paragraphs 2-8 through 2- 10. Specific instructions for inspection and repair are covered in b. below. b. Inspection and Repair. (1) Examine transfer case for cracks. Replace if cracks are evident, Inspect all machined surfaces for nicks or deep scratches. Remove nicks or raised metal with fine mill file. Check magnetic plug f damaged threads and for magnetic weaknes replace defective plug. Check filland drain plugs for tightness and check for condition of thread replace if necessary. Return plugs to case to avoid loss. Inspect oil strainer cover assembly to be sure that the screen and the cover are not damaged. Replace all damaged parts. Inspect all tapped holes for damaged threads. Holes with damaged threads may be drilled and tapped for threaded inserts of the proper size. (2) Inspect gear teeth for chipped area spots where case-hardening is worn through. Small nicks in gears can be carefully honed out. Replace 3:35any gears with chipped, cracked, broken or excessively worn teeth. (3) Inspectsliding clutch splines for fit on shaft (Table 1-2), and check fit of shifting fork in sliding clutch. Replace defective parts. (4) Inspect the machined surfaces on each shaft to see‘that they are not scored or pitted. Inspect keyways in shafts, if gears have been removed, to be sure that they are not damaged. Replace shafts if necessary. (5) Inspect bearings in accordance with TM 9- 214, Replace defective bearings. (6) Inspect all keys for condition; replace if damaged. (7) Inspect drive flange hubs for scoring or ridges indicating wear. Reface or replace damaged flanges. (8) Inspect shift rail springs to be sure that they are not broken or damaged. Check springs in spring tester for proper tension (Table 1-2). Replace weak springs. 3-27, Assembly NOTE The key symbols noted in parentheses are in figure 3-28, except where otherwise indicated. 4, rront Drive Shaft. (1) If front drive shaft, gear, and bearings were disassembled during inspection and repair, install front bearing cone (7) with taper up, on threaded end of shaft (6), and seat against splines. (2) Lay transfer case (24) on bench (fig. 3- 27); and install rear bearing cup (12) from front opening of case, and seat shoulder against boss. (3) Position rear bearing (11) in cup (12), aline spacer (10) and front drive gear (9) over bearing (11), and insert front drive shaft (6). (4) When shaft (6) has started into all p: press on rear bearing (11) until seated Position beariig cup (8) to seat against bearing (7). (5) Install seal (5) in front drive shaft bearing cover (3); then position shim (4) and cover (3) over bearing (7), and fasten to case (24) with three hexagonhead screws (1) and lockwashers (2); tighten screws to 70 to 90 foot-pounds torque. (6) Wrap several turns of cord (fig. 3-29) around front drive shaft splines and attach special scale (10, fig. 2-4) to cord. Pull scale with slow steady pull to keep front drive shaft turning. Scale should read 14 to 2 pounds. Add or remove shims (4) to obtain correct preload.FRONT DRIVE SHAFT FRONT DRIVE SHAFT BEARING COVER SHIMS ‘ORD £73549 Figure 3-29. Checking front drive shaft bearing preload. b. Oil Strainer Cover Assembly. (1) Using new gasket (32), insert oil strainer cover assembly (29) in transfer case (24), and secure with three cap screws (30) and lockwashers (31). Tighten screws to 18-28 foot-pounds torque. (2) Assemble gasket (28) to magnetic plug (27), and install plug in cover of oil strainer (29). (3) Assemble gasket (26) to magnetic plug (25), and install plug in bottom of transfer case. c. Main Drive Shaft. If inspection of main drive shaft assembly (13) did not require disassembly, ion shaft with all components in case (24) and go to step d.below. If assembly of main drive shaft is required, use following procedure. 337(1) Install key (23) in keyway of shaft (15). (2) Oil shaft to aid gear installation, and using arbor press, force on gear (21) with hub extension facing up. Press on rear bearing (22) with taper up, (3) Invert main drive shaft, and position front drive sliding clutch (20) on shaft with hub facing up. (4) Slide gear (19) on main drive shait (15) with hub end down, and make sure teeth of clutch (20) mesh with teeth of gear (19); then press front bearing (18) on shaft. (5) Install front bearing clamp (17) on shaft (15), and secure with four hexagon-head socket screws (16). Stake clamp with punch against screws. d. Front Drive Shifter Fork and Shaft. (1) Lay transfer case on its side, and from the drive front drive shifter fork shaft (34) lly into case. rea part NOTE Assemble shaft (34) in case so that threaded end of shaft is facing toward front of case and so cotter pin hole is exposed as illustrated in figure 3-26. (2) Position front drive shifter fork (33) over sliding clutch (20), and drive shaft (34) through fork and into boss of case. (3) Insert cotter pin (35) in shaft (34) to lock shaft in pos e. Countershaft (fig. 3-256). (1) Assemble key (29) in keyway of countershaft (24); and, using suitable equipment, press gear (27) on shaft with hub end down. (2) Press front bearing (26) and cup (20) on shaft (24) with taper up. Invert shaft, press on rear bearing (25) with taper up, and assemble speedometer drive worm gear (23) on shaft. NOTE Countershaft assembly will be placed in trangfer case during installation procedures (para 3-28). 3-28, Installation a. Install Transfer Case. (1) Apply gasket sealer to transmission case (19, fig. 3-44) and position new gasket (22, fig. 3- 25G) to case. (2) Position transfer case (24, fig. 3-28) over transmission main shaft retainer (7, fig. 3-40) and push flush to ion case. (3) Drive special dowel bolt in lower right comer inside transfer case, and secure bolt finger- tight with flat washer, lockwasher, and hexagon nut. (4) Install two hexagon-head screws and lockwashers on outside of transfer case to transmission case, and install seven hexagon-head screws inside transfer case (three on right side and four on left side) to secure transfer and transmission cases together. 3:38 (5) Tighten all above screws and nuts to 115 to 145 foot-pounds torque, and lock with safety wire. >. Install Front Drive Bellerank, Front Drive Shifter Shaft, and Front Ball Socket. NOTE The key symbols noted in parentheses are in figure 3-25G, except where otherwise indicated. (1) Using new gasket (8), position front drive belicrank pivot pin support assembly (7) on transfer case; and, reaching down inside case, slide front drive bellcrank (9) on pivot pin of support assembly (7), guiding lower end of bellerank into front drive shifter fork (33, fig. 3-28). (2) Secure support (7) with four hexagon- head screws (5) and lockwashers (6). Tighten screws to 70 to 90 foot-pounds torque. (3) Install new oil seal (31) in transfer case front drive shifter shaft installation opening (fig. 3- 22), using replacer (7, fig. 2-4). (4) Position front drive ball socket shifter (3) on bellcrank (9) and install front drive shifter shaft (4), passing it through ball socket shifter (3). Secure shifter on shaft with special hexagon-head screw (30) and tighten to 45 to 55 foot-pounds torque. Lock screw with safety wire (fig. 3-22). ¢. Install Countershaft. Place countershaft amembly (21) in transfer case, engaging countershatt low-range helical gear (27) with front main drive shaft gear (19, fig. 3-28). CAUTION Oil ports are to be alined on power take-off shaft and sleeves. To insure proper lubrication of gears and transfer case, back to transmission, d. Install Sliding Clutches, Bearing, Sleeves, and Gears on Transmission Main Shaft. (1) Slide main shaft low-range gear assembly (19) on low-range gear splined sleeve (20) with hub of teeth of gear against external teeth of splined ‘leeve; then check for end play (0.004-0.008) with ge between mating faces of gear and sleeve. (2) Position sliding clutch (18) over sleeve (20) and check tooth mesh and clutch action with gear (19), (3) Slide assembled gear (19) sleeve (20) and clutch (18) on transmission main shaft (3, fig. 3 40), with external teeth of sleeve facing toward rear of transfer section. (4) Install two keys in keyway of transmission shaft and slide on high-range gear assembly (16). Position sleeve (17) on shaft and insert in bore of gear (16). Aline keyways with keys in shaft and Press on gear and sleeve. (5) Position thrust washer (15) on transmission main shaft (3, fig. 3-41) alining keyway with key in shaft; then place bearing (14) appower take-off clutch (13) on shaft and press into Position. (6) Secure clutch (13) on main shaft with power take-off clutch nut (12). Use wrench (2, fig. 24), and torque to specification. Secure nut by staking. Figure 3-25E illustrates wrench assembled to power take-off clutch nut. e. Install High- and Low- Range Shifter Fork and Shaft. (1) Install new oil seal (31) in transfer case high- and low-range shaft installation opening (tig. 3-30), using replacer (7, fig. 2-4). (2) Reach down inside top of transfer section Engage high- and low-range speed shifter fork (1) in sliding clutch (18), and install high- and low- range shifter shaft (2) passing it through the fork and transfer case. (3) Secure shifter fork on shaft with two hexagon-head screws (30). Tighten screws to 45 to 55 foot-pounds torque, and lock in position with safety wire. Figure 3-22 illustrates gears and shifter parts installed in transfer case. . TRANSFER CASE 2 HIGH AND LOW SHIFTER SHAFT POWER TAKE-OFF SHAFT OPENING AT 34902, Figure 3-30. Installing oil seal. f. Install End Plate. NOTE The key symbols noted in parentheses are in figure 3-25C, except where otherwise indicated. (1) Install bearing cups (27) and (28), and beather (24) in end plate (20). (2) Apply gasket cement to transfer case; and, using new end plate gasket (23), position end plate (22) to transfer case. (3) Drive in two dowel bolts (21) in the upper right and lower left corners of end plate to lock plate in position. Install wo flat washers (20) lockwashers (19), and hexagon nuts (18) on dowel bolts. (4) Secure end plate to transfer case with 14 hexegon-head screws (7), three hexagon-head screws (16), and 17 lockwashers (17); then, ighten all screws to 70 to 90 foot-pounds torque, and nuts in step (3) above to 67 to 87 foot-pounds torque. (5) Install oil seal (15) in main drive shaft bearing cover (13); then position in drive shaft bearing cover shims (14) and main drive shaft bearing cover (13) on transfer case end plate (22), and secure cover with six hexagon-head screws (11) and lockwashers (12). (6) Remove front drive bellerank pivot pin support assembly (para 3-24). (1) ), and working through the opening with pinch bar, check end play of main drive shaft with dial indicator (fig. 3-31). Add or remove shims (14) to obtain correct end play (Table 1-2). After correct adjustment has been made, tighten screws (11) to 155 to 185 foot- pounds torque. (7) Position transfer case countershaft rear bearing cover shims (10) and countershaft cover assembly (9) on transfer case end plate (22), and ‘secure with six hexagon-head screws (7) and lockwashers (8). (8) Install dial indiacator inside 32), and working through opening in case pinch bar, check countershaft end-play. Add or remove shims (10) to obtain correct end play (Table 1-2). After correct adjustment has been made, tighten screws to 70 to 90 foot-pounds torque. (9) After correct end play of main shaft and countershaft has been obtained, replace front drive bellcrank support (para 3-386. (1) ). (10) Lock transmission in first and fifth gears (papa 3-18f. (1) ), and install front drive shaft flange (3). Secure flange with hexagon nut (2); tightened to 800 to 1,200 foot-pounds torque and lock nut with cotter pin (1). (11) Install main drive shaft flange (6), secure with hexagon nut (5), tightened to 80 to 1,200 foot- pounds torque, and lock nut with cotter pin (4). 3.39

TM 9-2320-206-34

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