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WAR DEPARTMENT TECHNICAL MANUAL
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WAR DEPARTMENT TECHNICAL MANUAL
TM 9-805
For supersession of Quartermaster Corps 10series manuals, see paragraph 1 d
1V2-TON
4x4 TRUCK
(Chevrolet)
WAR DEPARTMENT 30 DECEMBER 1943
DISSEMINATION OF RESTRICTED MATTER
No person is entitled solely by virtue of his grade or position lo knowl-
edge or possession of classified matter. Such matter is entrusted only
to those individuals whose official duties require such knowledge or
possession. (See also paragraph 234, AR 380-5, 15 March 19+4.)
WAR DEPARTMENT
Washington 25, D. C., 30 December 1943
TM 9-805IVi-ton 4x4 Truck (Chevrolet), is published for the
information and guidance of all concerned.
[A. G. 300.7 (22Nov 43)]
BY ORDER OF THE SECRETARY OF WAR:
G. C. MARSHALL,
Chief of Staff.
OFFICIAL:
J. A. ULIO,
Major General,
The Adjutant General.
DISTRIBUTION: X.
(For explanation of symbols, see FM 21-6.)
TM 9-805
Ul 13
U6-TON 4x4 TRUCK I <\ 4" 3
(Chevrolet)
CONTENTS
PART ONE-VEHICLE OPERATING INSTRUCTIONS
Paragraph! Pagei
SECTION I Introduction ................... 1 5-8
II Description and tabulated data . 2-4 9-12
III Driving controls and operation. . . 5-10 13-23
IV Auxiliary equipment controls and
operation .................... 11-15 24-27
V Operation under unusual
conditions ................... 16-21 28-30
VI First echelon preventive mainte-
nance service ................ 22-26 31-41
VII Lubrication ................... 27-29 42-49
VIII Tools and equipment stowage on
vehicle ...................... 30-32 50-51
PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS
IX Record of modifications ......... 33 52
X Second echelon preventive
maintenance ................. 34 53-73
XI Organization tools and equipment 35-36 74
XII Trouble shooting ............... 37-55 75-95
XIII Engine Description, data, mainte-
nance, and adjustment in vehicle 56-65 96-112
XIV Engine-Removal and installation 66-67 113-117
XV Clutch ........................ 68-70 118-124
3 M5746M
TM 9-805
li/a-TON 4x4 TRUCK (Chevrolet)
PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS (Cont'd)
Paragraphs Pages
SECTION XVI Fuel system 71-76 125-130
XVII Intake and exhaust system 77-78 131-133
XVIII Cooling system 79-84 134-139
XIX Electrical system, instruments,
and gages 85-95 140-171
XX Transmission 96-98 172-174
XXI Transfer case 99-102 175-177
XXII Propeller shafts 103-105 178
XXIII Front axle 106-114 179-185
XXIV Rear axle 115-119 186-190
XXV Brake system 120-130 191-206
XXVI Wheels, wheel bearings, hubs, and
tires 131-134 207-212
XXVII Springs and shock absorbers 135-138 213-216
XXVIII Steering gear 139-145 217-221
XXIX Cab, body, and frame 146-148 222-226
XXX Chassis sheet metal 149-153 227-229
XXXI Power take-off 154-159 230-234
XXXII Winch 160-162 235-241
XXXIII Hoist 163-166 242-247
XXXIV New vehicle run-in test 167-169 248-252
XXXV Shipment and temporary storage 170-172 253-257
REFERENCES 258-259
INDEX 260
TM 9-805
PART ONE-VEHICLE OPERATING INSTRUCTIONS
Section I
INTRODUCTION
Scope
Paragraph
1. SCOPE.
a. This technical manual* is published for the information and
guidance of the using arm personnel charged with the operation and
maintenance of this materiel.
b. In addition to a description of l^-ton 4x4 truck (Chevrolet),
this manual contains technical information required for the identifi-
cation, use, and care of the materiel. This manual is divided into two
parts. Part One, section I through section VIII, contains vehicle
operating instructions. Part Two, section IX through section XXXV,
contains vehicle maintenance instructions for using arm personnel
charged with the responsibility of doing maintenance work within
their jurisdiction.
c. In all cases where the nature of the repair, modifications, or
adjustment is beyond the scope or facilities of the unit, the respon-
sible ordnance service should be informed so that trained personnel
with suitable tools and equipment may be provided, or proper in-
structions issued.
d. This technical manual supersedes the organizational mainte-
nance instructions in the following Quartermaster Corps publica-
tions:
TM 10-1127
TM 10-1203
Changes Nos.
1 through 4
TM 10-1431
TM 10-1461
TM 10-1557
TM 10-1559
Dote Nome
1 March 1942 1^-ton Truck, 4x4 (Chevrolet)
1 March 1942 1^-ton Truck, 4x4 (Chevrolet)
28 June 1943 1^-ton Truck, 4x4 (Chevrolet)
1 April 1942 l^-ton Truck, 4x4 panel
(Chevrolet)
15 July 1942 1^-ton Truck, 4x4 (Chevrolet)
1 August 1942 1 j4-ton Truck, 4x4 (Chevrolet)
*To provide operating instructions with the materiel, this technical manual has
been published in advance of complete technical review. Any errors or
omissions will be corrected by changes or, if extensive, by an early revision.
TM 9-805
t-TON 4x4 TRUCK (Chevrolet)
RA PD 33077
Figure 1 Chevrolet I '/a -Ton, 4x4 Truck
Model G-7103-Chassis with Cab
Model 6-7113-Cab Tractor
RA PD 33078
Figure 2Chevrolet 1 '/2 -Ton, 4x4 Truck
Model G-71 OS-Panel
TM 9-805
INTRODUCTION
RA
33080
Figure 3Chevrolet I '/2 -Ton, 4x4 Truck
Model G-7106-Dump less Winch
Model O-7116-Dump with Winch
RA PD 33079
Figure 4Chevrolet 1 '/2 -Ton, 4x4 Truck
Model G-7107-Cargo less Winch
Model 6-7!17-Cargo with Winch
TM 9-805
1V2-TON 4x4 TRUCK (Chevrolet)
RA PD 33081
Figure 5-Chevrolet I '/2 -Ton, 4x4 Truck
Model G-7J3-Telephone Earth Borer
RA PD 33082
Figure 6Chevrolet I '/2 -Ton/ 4x4 Truck
Model G-7173Telephone Maintenance
TM 9-805
2-3
Section II
DESCRIPTION AND TABULATED DATA
Paragraph
Description 2
Differences among models 3
Data 4
2. DESCRIPTION.
a. General. The information in this manual covers several models
of the Chevrolet 1%-ton 4x4 truck. These models all have 145-inch
wheelbase and dual rear wheels. They use the same engine, trans-
mission, transfer case, and front and rear axles, with the exception
of the telephone earth borer and telephone maintenance trucks which
use a different rear axle and transfer case. Each vehicle has a serial
number and load data plate (fig. 7) located on the left side of the
windshield header panel. The various models are identified as
follows:
Model Typ. of Vehicle
G-7103 Chassis with cab
G-7113 Cab tractor
G-7105 Panel
G-7106 Dump less winch
G-7116 Dump with winch
G-7107 Cargo less winch
G-7117 Cargo with winch
G-7163 Telephone earth borer
G-7173 Telephone maintenance
3. DIFFERENCES AMONG MODELS.
a. Model G-7103Chassis with Cab (fig. 1). This model does not
have any body other than the cab mounted on it.
b. Model G-7113-Cab Tractor (fig. 1). This vehicle is the same
as model G-7103 except that it has a fifth wheel for hauling semi-
trailers.
c. Model G-7105Panel (fig. 2). This model is equipped with a
panel body constructed so that the cab is part of the body. There is
no partition between the cab and the body, as it is a single unit.
d. Model G-7106-Dump Less Winch (fig. 3). This vehicle is a
chassis and cab (G-7103) with a body mounted behind the cab. A
hydraulic hoist is installed between the chassis and the body. The
rear end of the body is pivoted to the frame so that the front of the
body can be raised, and permit the operator to dump the load when
desired. The body is provided with stake pockets to permit the
installation of side racks, bows, and tarpaulin.
e. Model G-7116-Dump with Winch (fig. 3). This vehicle is
the same as model G-7106 but, in addition, it is equipped with a
winch at the front of the frame.
TM 9-805
1 V2 -TON 4x4 TRUCK (Chevrolet)
f. Model G-7107-Cargo Less Winch (fig. 4). This model is the
same as the dump truck (G-7106), except that it does not have a
hoist, and the body is mounted rigidly to the frame with U-bolts.
g. Model G-7117Cargo with Winch (fig. 4). This vehicle is the
same as cargo truck G-7107, except that it is equipped with a winch
mounted at the front of the frame.
h. Model G-7163-Telephone Earth Borer (fig. 5). This vehicle
has a special body, and is equipped with an earth boring machine
for post hole digging and a center-mounted winch.
i. Model G-7173Telephone Maintenance (fig. 6). This vehicle
has a specially designed body that has several compartments built
into the side panels. These compartments are accessible through
doors in the outside of the side panels. It is equipped with pole-
setting equipment used in conjunction with a center-mounted winch.
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TM 9-805
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DESCRIPTION AND TABULATED DATA
TM 9-805
1 Va-TON 4x4 TRUCK (Chevrolet)
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TM 9-805
Section III
DRIVING CONTROLS AND OPERATION
Driving controls 5
Instruments and miscellaneous controls 6
Lighting controls 7
Instruction plates 8
Operation of the vehicle 9
Towing the vehicle .- 10
5. DRIVING CONTROLS.
a. Introduction. The driver of one of these vehicles must be
thoroughly familiar with the various controls and their proper use.
The instruments and driving controls are illustrated in figure 7,
which should be referred to for the key letters shown in the follow-
ing paragraphs.
b. Carburetor Choke (T). This control is used when starting a
cold engine. Pulling out choke control button shuts off the air to
the carburetor, providing a rich mixture. The choke button must be
pushed in when the engine starts. If the engine is warm, the use of
the choke is unnecessary.
c. Ignition Switch (V). This switch is to turn on the ignition
when starting the engine. The switch is off when the lever is pointed
straight down.
d. Hand Throttle ( W). The hand throttle is located on the instru-
strument panel to the right of the ignition switch; pulling this button
opens the throttle. This control may be used when starting or, if it
is desired, to run the engine at a constant speed.
e. Clutch Pedal (AA). The clutch pedal is used to disengage the
engine from the transmission when shifting gears. CAUTION: The
clutch must never be engaged quickly when the vehicle is in gear.
Driving with foot on pedal will cause wear of clutch facings and
throwout bearing. There must be 1 inch of free travel of the clutch
pedal before the clutch starts to disengage.
f. Brake Pedal (AB). Pressing on the brake pedal applies the
hydraulic brakes at all four wheels. Avoid driving with foot on brake
pedal, as brakes will be partially applied and cause rapid wear of
lining.
g. Accelerator (AC). The accelerator is operated by the right
foot to control the speed of the engine.
h. Cranking Motor Switch Pedal (AF). Pressing down on pedal
with foot engages the cranking motor and flywheel gears, and also
closes the cranking motor switch, completing the electrical circuit
between battery and cranking motor. Rotation of cranking motor
armature through the gears, cranks the engine. When the engine
starts, foot must be removed from pedal immediately.
i. Transmission Gearshift Lever (AD). The transmission gear-
shift lever is used to select various gear ratios provided in the trans-
13
TM 9-805
-TON 4x4 TRUCK (Chevrolet)
AROAD SPEED PLATE
BSERIAL NUMBER AND LOAD DATA
PLATE
CWINDSHIELD WIPER SWITCH
DSHIFTING DIAGRAM PLATE
ECOOLING SYSTEM CAUTION PLATE
FWINCH OPERATION INSTRUCTION
PLATE
GWINDSHIELD QUADRANT ADJUSTING
SCREWS
HREAR VIEW MIRROR
IINSTRUMENT LIGHTS
JWINDSHIELD CENTER LOCK
KGLOVE COMPARTMENT LOCK
LTEMPERATURE INDICATOR
MFUEL GAGE
NSPEEDOMETER
OOIL PRESSURE GAGE
PAMMETER
QPUBLICATION DATA PLATE
RBLACKOUT DRIVING LIGHT SWITCH
SLIGHT SWITCH
TCARBURETOR CHOKE
UCOWL VENTILATOR CONTROL LEVER
VIGNITION SWITCH
WHAND THROTTLE
XINSTRUMENT LIGHT SWITCH
YFIRE EXTINGUISHER
ZHEADLIGHT DIMMER SWITCH
AACLUTCH PEDAL
ABBRAKE PEDAL
ACFOOT ACCELERATOR
ADTRANSMISSION GEARSHIFT LEVER
AETRANSMISSION REVERSE GEAR LATCH
AFSTARTING SWITCH PEDAL
AGHAND BRAKE LEVER
AHTRANSFER CASE SHIFTING LEVER
(HIGHLOW GEAR)
AlFRONT AXLE SHIFTING LEVER
AJWINCH POWER TAKE-OFF CONTROL
LEVER
AKHOIST VALVE CONTROL LEVER
ALHOIST POWER TAKE-OFF CONTROL
LEVER
RA PD 33052
Figure 7Driving Compartment, Instruments and Controls
14
TM 9-805
5-6
mission. There are four forward speeds and one reverse speed. Re-
verse gear can only be engaged when latch (AE) on gearshift lever
is raised. Lever positions for various gears are shown on shifting
diagram plate (D).
j. Hand Brake Lever (AC). The hand brake lever is used to
control the parking brake at the rear of the transfer case. Pulling the
hand brake lever toward the rear applies the parking brake, while
pushing it forward releases the brake. Whenever the vehicle is
parked, the lever must be pulled toward the rear as far as possible.
Before moving the vehicle, lever must be pushed forward to the
fully released position.
k. Transfer Case Shifting Lever (AH). The transfer case shift-
ing lever is used to select "HIGH" or "LOW" speed range, or
^'NEUTRAL" in the transfer case. See shifting diagram plate (D).
The shifting lever is linked to the front axle control lever in such
a way that it is impossible to shift into the low speed in the transfer
case without the drive to the front axle being engaged.
I. Front Axle Shifting Lever (AI). The front axle shifting lever
permits engaging or disengaging the front axle drive through the
transfer case. When the lever is pushed forward, the front drive is
engaged, and when it is pulled toward the rear, it is disengaged.
The front axle drive should be disengaged when operating on dry,
hard-surfaced roads. However, the front axle should be engaged
when operating on soft-surfaced roads such as sand, dirt, gravel,
or muddy roads, to prevent putting undue strain on the rear axle.
Four-wheel drive should always be used when approaching uneven .
terrain; do not allow vehicle to stall before going into four-wheel
drive.
m. Winch Power Take-off Control Lever (AJ). The winch
power take-off control lever is the lever that controls the power
winch through the power take-off attached to the transmission.
When the winch is not in use, a hinged plate locks the winch control
lever in the neutral position. For shifting positions refer to plate on
windshield head panel (D).
n. Hoist Valve Control Lever (AK). The hoist valve control -
lever is used to control the valve in the hydraulic hoist. When the
hoist is not being used, the lever is pulled back toward the seat.
o. Hoist Power Take-off Control Lever (AL). The hoist power
take-off control lever is used in connection with the hoist valve
lever to operate the hydraulic hoist. Instructions covering the oper-
ation of the winch and hoist controls are contained in paragraph 163.
6. INSTRUMENTS AND MISCELLANEOUS CONTROLS.
a. Temperature Indicator (L). The temperature indicator indi-
cates the temperature of the liquid in the cooling system at all
times. The dial of the instrument indicates temperature in degrees
Fahrenheit. The driver must watch this instrument closely for any
indication of excessive temperature. Whenever the indicator hand
shows over 180 degrees, the driver must immediately investigate the
15
TM 9-805
1 V,-TON 4x4 TRUCK (Chevrolet)
AFOUR-SPEED TRANSMISSION
AND TRANSFER CASE
BFOUR-SPEED TRANSMISSION,
TRANSFER CASE AND WINCH
SHIFTING DIAGRAM
HOIST HOIST TRANSMISSION TRANSFER CASE
NEUTRALH NEUT
DISENGAGE FROM AXLE DRIVE WHEN
OPERATING ON DRY HARD SURFACED RDS
SHIFTING DIAGRAM ,_
HOIST TRANSMISSION TRANSFER CSE
DISENGAGE FRONT AXLE DRIVE WHEN
OPERATING ON DRY HARD SURFACED RDS
CFOUR-SPEED TRANSMISSION,
TRANSFER CASE AND HOIST
DFOUR-SPEED TRANSMISSION,
WINCH AND HOIST
SHIFTING DIAGRAM
TRANSMISSION TRANSFER CASE
. DISENGAGE FRONT AXLE DRIVE WHEN
'OPERATING ON DRY HARD SURFACED RDS.
EFOUR-SPEED TRANSMISSION,
TRANSFER CASE AND PERFECTION HOIST
FFOUR-SPEED TRANSMISSION,
WINCH AND PERFECTION HOIST
RA PD 33083
Figure 10Gearshlfting Instruction Plates
18
TM 9-805
7-8
turns on the blackout marker lights (fig. 9) and taillight. In addi-
tion, this position permits turning on the blackout driving light when
the blackout driving light switch is pulled out, and also the blackout
stop light when the brakes are applied. To turn on the regular head-
lights, depress the blackout safety button on top of the switch, and
pull the control button out to the second position. In this position,
circuits are established to the regular tail and stop lights. When the
lighting switch button is pulled out to the third position, it provides
a circuit for the service stop light during daylight driving.
b. Blackout Driving Light Switch (K). The blackout driving
light switch is used to turn on the blackout driving light located on
the left front fender (fig. 9). The blackout driving light can be turned
on only when the main light switch is pulled out to first position.
c. Instrument Panel Light Switch (X). This switch is used to
turn on the instrument lights (I) when the light switch is in the
bright headlight position. These lights will not operate with the
light switch in the blackout position.
d. Headlight Dimmer Switch (Z). This is a foot-operated switch
used to select the headlight beam (upper or lower) desired after the
headlights are turned on, by depressing the switch button with the
foot. CAUTION: Always use the lower beam when passing approach-
ing vehicles. This is an important safety rule.
8. INSTRUCTION PLATES.
a. Shifting Diagram Plates (D). Shifting diagram plates are
furnished with each vehicle to give the driver instructions on the
various shifting lever positions. Several different shifting diagram
plates are used, depending on the special equipment installed on
the vehicle as listed below and illustrated in figures 10 and 11.
(1) Shifting diagram plate used with four-speed transmission and
transfer case ("A", fig. 10).
(2) Shifting diagram plate used with four-speed transmission,
transfer case, and winch ("B", fig. 10).
transfer case, and hoist ("C", fig. 10). Used with either Hercules or
Heil hoist and Central Fibre Products power take-off.
transfer case, and hoist ("E", fig. 10). Used with Perfection hoist and
Central Fibre Products power take-off.
transfer case, winch, and hoist ("D", fig. 10). Used with either the
Heil or Hercules hoist and the Wood or Spicer power take-off.
transfer case, winch, and hoist ("F", fig. 10). Used with Perfection
hoist and either Wood or Spicer power take-off.
(7) Shifting diagram plate used on models G-7163 Telephone
Earth Borer truck, and G-7173 Telephone Maintenance truck (fig.
ID-
19
TM 9-805
T/2-TON 4x4 TRUCK (Chevrolet)
SHIFTING DIAGRAM
WINCH
BRAKE
TRANSMISSION
TRANSFER CASE
LOW I
WINCH fWD
NEUT.
DISENGAGE FRONT AXLE DRIVE WHEN
OPERATING ON DRY HARD SURFACED RDS.
RA PD 33084
Figure 11 Shifting Diagram, Telephone Maintenance Vehicles
b. Cooling System Draining Caution Plate ("E", fig. 7). This
plate gives the driver instructions for draining the cooling system.
c. Power Winch Operation Instruction Plate (F). This plate
gives the driver instructions regarding operation of the winch.
d. Maximum Permissible Road Speeds Plate (A). This plate
gives the maximum permissible road speeds at which the vehicle
shall be driven in the various gear positions with the transfer case
in "HIGH" or "LOW" gear. Figure 12 shows a reproduction of this
plate.
RA PD 33085
Figure 12Maximum Permissible Road Speeds Plate
e. Serial Number and Load Data Plate (B). This plate shows
the model number, serial number, and load data. This information
varies with the different models; therefore, attention must be given
to the load data plate on the vehicle being operated.
f. Publication Data Plate (Q). This plate shows the numbers
for the parts list and maintenance manual that apply to the vehicle.
20
TM 9-805
9. OPERATION OF THE VEHICLE.
a. Preliminary Instructions. Before attempting to start the
engine or operate the vehicle, make the before-operation inspections.
1). Starting the Engine.
(1) Place the transmission gearshift lever and transfer case shift
lever in neutral (see shifting diagram plate).
(2) Pull out hand throttle about % inch. NOTE: This is not
necessary if engine is warm.
(3) Pull out on choke button to obtain proper fuel and air mix-
ture for starting. If the engine is warm, choking will be unnecessary.
(4) Turn ignition switch to "ON" position.
(5) Step on starter pedal to crank the engine. Release pedal as
soon as engine starts.
(6) Push in on choke button and adjust hand throttle to obtain
even idling. When engine is cold, it should be run several minutes
before attempting to move the vehicle.
c. Starting the Vehicle.
(1) Push clutch pedal downward to disengage the clutch.
(2) Shift transfer case shift lever into either "HIGH" or "LOW"
speed position (see shifting diagram plate).
(3) Move transmission gearshift lever to the left, and forward into
first gear position.
(4) Release the hand brake lever.
(5) Step down on accelerator pedal to speed up the engine. En-
gage clutch pedal slowly, and push accelerator pedal down as neces-
sary to pick up the load and prevent stalling the engine as the truck
starts to move.
(6) As truck speed increases, release accelerator pedal, depress
the clutch pedal, move the gearshift lever to "NEUTRAL", and then
to the next higher speed. Step down on accelerator, and engage clutch
as explained in previous paragraph. Repeat this operation until trans-
mission is in high gear.
d. Shifting Gears in Transfer Case. The transfer case may be
operated in either "HIGH" or "LOW" speed range when the front
axle is engaged, but cannot be operated in "LOW" speed range when
the front axle is disengaged.
(1) To engage the front axle, shift the transfer case into neutral,
and move front axle shift lever forward.
(2) To disengage the front axle, shift the transfer case into neu-
tral, and move front axle shift lever toward the rear.
e. Shifting Gears in Transfer Case from High to Low Speed.
This shift must not be attempted except when the vehicle is being
operated at low speeds or at a standstill. Front axle must be engaged
for this shift.
(1) Depress the clutch pedal, and move transfer case shift lever
to neutral position.
21
TM 9-805
9-10
1 V2-TON 4x4 TRUCK (Chevrolet)
(2) Engage clutch pedal, and accelerate engine to approximately
twice that of vehicle speed.
(3) Depress clutch pedal again, and move shift lever forward
(without applying excessive pressure) into "LOW" speed position.
Then release clutch and accelerate engine.
f. Shifting Gears in Transfer Case from "LOW" to "HIGH"
Speed. This shift may be accomplished at any time, regardless of
vehicle speed.
(1) Release accelerator, depress clutch pedal, and move shift
lever to neutral position.
(2) Release clutch pedal, and accelerate engine to synchronize
engine speed with that of vehicle.
(3) Depress clutch pedal, and move shift lever toward rear into
"HIGH" speed position.
g. Shifting to Lower Speed in Transmission. The transmission
should always be shifted to the next lower speed before engine begins
to labor, or before vehicle speed is reduced appreciably. Shifting to
lower speed is accomplished as follows:
(1) Depress the clutch pedal quickly, maintaining the same pres-
sure on accelerator. Move gearshift lever to "NEUTRAL," and at
the same instant engage the clutch.
(2) Again depress the clutch pedal, and move the gearshift lever
to the next lower speed. Engage the clutch slowly, and at the same
time accelerate the engine speed to synchronize it with that of the
vehicle. NOTE: Use the same transmission gear going downhill as
would be required to climb the same hill. ^
h. Shifting into Reverse. Before attempting to shift into "RE-
VERSE", the truck must be brought to a complete stop.
(1) Push clutch pedal downward to disengage clutch.
(2) Shift the transmission to "NEUTRAL," raise latch on
gearshift lever, and move lever to left as far as possible, then toward
the rear (see shifting diagram plate).
(3) Engage clutch and accelerate the engine in the same manner
as previously explained.
i. Stopping the Truck.
(1) Remove foot from accelerator pedal, and apply brake by
pressing down on foot pedal.
(2) When speed of truck has been reduced to idling speed of
engine, disengage the clutch, and move transmission gearshift lever
into "NEUTRAL" position.
(3) When truck has come to a complete stop, release clutch pedal
and apply hand brake.
10. TOWING THE VEHICLE.
a. Towing to Start Vehicle. Perform the Before-operation Service
as instructed in paragraph 23; then place transfer case shifting lever
in "HIGH" gear, and the front axle control lever so that it is out of
22
TM 9-805
10
front axle drive. Place the transmission gearshift lever in either third
or high gear, then turn on the ignition switch, and hold the clutch
pedal all the way down against the floorboard. Start towing the
vehicle, and as soon as both vehicles attain a steady momentum of
about 10 to 12 miles per hour, let the clutch out slowly and use the
choke, if necessary, in the same manner as if starting the engine with
the cranking motor. As soon as the engine starts, push in the clutch
and place the transmission lever in "NEUTRAL", then stop both
vehicles, and uncouple the tow car.
b. Towing Disabled Vehicle. Place the front axle control lever
so that it is out of front axle drive. Then place the transfer case shift-
ing lever and the transmission gearshift lever in "NEUTRAL". Use
the brakes on the vehicle being towed to slow up or stop the vehicle
when towing it.
TM 9-805
11-14
1 Va -TON 4x4 TRUCK (Chevrolet)
Section IV
AUXILIARY EQUIPMENT CONTROLS AND OPERATION
Paragraph
General U
Fire extinguisher operation 12
Hoist operation 13
Front-mounted winch operation 14
Center-mounted winch operation 15
11. GENERAL.
a. The auxiliary equipment referred to in this section consists of
fire extinguisher, hoists, front-mounted winches, center-mounted
winches, and the different types of power take-offs required for
operation of this equipment. The operation of power take-offs will
not be treated separately, as the power take-off is only used as a
part of the operation of the other auxiliary equipment.
12. FIRE EXTINGUISHER OPERATION.
a. Release the spring-type lock, and remove extinguisher from the
mounting bracket. Turn handle to the left, and work it in and out like
a pump. Direct the stream of liquid at the base of flame unless used
on burning liquid. When extinguisher is used on burning liquid, direct
the stream against inside of liquid container above surface of liquid.
CAUTION: Refill or exchange extinguisher for one that has been
refilled at earliest possible moment after use, as this unit must be
kept in operating condition.
13. HOIST OPERATION.
a. Start the engine (par. 9 b). Disengage the clutch and shift the
hoist power take-off shift lever to the "IN GEAR" position as shown
on the shifting diagram plate located on the windshield header. En-
gage the clutch, and move the hoist valve control lever to the
"RAISE" position as shown on the shifting diagram plate. This starts
to raise dump body. Accelerate engine slightly to provide faster
action. When the body reaches the desired angle, shift the hoist valve
control lever to the "HOLD" position to hold the body in this posi-
tion, and to the "LOWER" position to lower the body. When the
body is firmly seated, shift the hoist valve control lever to the
"HOLD" position; disengage the clutch, and shift the hoist power
take-off shift lever to "NEUTRAL" position. The hoist may be oper-
ated by following the above instructions when the vehicle is in motion.
14. FRONT-MOUNTED WINCH OPERATION.
a. Vehicle Stationary (fig. 13). Disengage the jaw-type clutch on
the winch drum shaft by pushing clutch yoke toward center of vehicle
until poppet enters hole in support. Unreel sufficient cable from drum
24
TM 9-805
14-15
POPPET
FRONT END
FRAME
RA PD 33086
Figure 13Front-mounted Power Winch
to attach cable to load. Engage jaw clutch by pushing the clutch
yoke toward frame side rail until poppet drops in hole in support.
Place transmission in neutral; set the hand brake, and start the
engine. Disengage the clutch; shift the power take-off "WINCH"
shift lever to a forward speed (see shifting diagram plate on
windshield header); engage the clutch, and at the same time
accelerate engine as necessary to pull or lift load on winch. .NOTE:
Use "LOW" or "HIGH" gear depending on load to be handled; when
in doubt, use "LOW" gear. When load is to be stopped, depress clutch
pedal; shift power take-off to neutral; release jaw clutch; disconnect
cable from load, and carefully wind cable on drum by hand while
holding the cable tight. The operation in reverse is the same, except
that the engine is used to steadily release the cable from drum.
b. Vehicle in Gear. When the winch is being used to assist the
vehicle the instructions in subparagraph a above should be followed,
except that the transfer case and transmission should be in "LOW"
gear, the brakes released, and the power take-off in "LOW".
15. CENTER-MOUNTED WINCH OPERATION
(Telephone Service)
a. Controls. The power take-off and winch control levers on the
telephone service truck are not in the same positions as on the other
4x4 models. For location of these levers refer to figure 14.
25
TM 9-805
15
AWINCH CLUTCH AND BRAKE CONTROL LEVER
BTRANSMISSION GEARSHIFT LEVER
CHAND BRAKE LEVER
DTRANSFER CASE SHIR LEVER
EPOWER TAKE-OFF CONTROL LEVER
FFRONT AXLE SHIFT LEVER
RA PD 33087
Figure 14Cab Interior of Telephone Service Vehicles
b. Operation. Shift the transfer case to "NEUTRAL"; start the
engine; disengage the clutch, and shift the transmission to second
gear. Shift the power take-off lever to the forward ("REVERSE")
position as shown on the shifting diagram plate on windshield header
(fig. 11). During this shift the clutch pedal should be engaged and
disengaged slowly to properly mate the power take-off gears. With
the clutch pedal depressed, move the winch clutch and brake control
lever back into "CLUTCH" position to engage the winch clutch.
Engage the vehicle clutch pedal to unreel the cable, and pull it out
to attach it to load. The cable can also be unreeled by shifting the
winch clutch and brake lever forward to disengage the clutch, and
applying sufficient brake to prevent the cable from loosening on the
drum while the cable is unreeled by hand. Attach the cable to load;
depress the clutch pedal; shift the power take-off to forward gear,
and engage the clutch to lift or pull the load. When load is properly
26
TM 9-805
15
positioned, depress clutch pedal; shift winch clutch and brake control
lever to center (DECLUTCH) position; shift transmission to
"NEUTRAL," release clutch pedal, and shift power take-off to
"NEUTRAL." If the winch is not to be used again, shift transfer
case to "HIGH" gear; disconnect cable from load, and tightly wind
cable on drum (fig. 126). This winch is also used in connection with
the pole derrick for setting poles.
TM 9-805
16-18
1 y2-TON 4x4 TRUCK (Chevrolet)
Section V
OPERATION UNDER UNUSUAL CONDITIONS
Paragraph
Sand 16
Mud and water 17
Rough terrain 18
Snow and ice 19
Hot weather 20
Cold weather 21
16. SAND.
a. When operating in sandy or dusty localities, it is necessary to
clean the valve cover air cleaner and the carburetor air cleaner more
frequently than usual. Under extreme conditions, it may be necessary
to clean these air cleaners daily. This can be determined by removing
the covers and rubbing a finger through the oil in the air cleaners to
see if there is grit, sand, or dirt in the oil chamber. It will also be
necessary to clean the hydrovac air cleaner about once a month or
more often, depending on the conditions. This can be determined by
removing the air cleaner cover and examining the wire gauze, and if
dirty, remove, clean, and oil it.
17. MUD AND WATER.
a. Mud. When driving through mud it may be necessary to shift
the front axle control lever to engage the front axle drive. Under
extreme conditions it may also be necessary to use a lower transmis-
sion speed. Very often when driving through soft mud, the mud will
work its way into the brake drums, and get on the brake linings and
shoes. This condition causes excessive wear on the brake linings and
drums, and the mud should be removed as soon as conditions permit.
It will be necessary to remove the brake drums so that the dirt can
be washed out with water.
1). Water. When driving through water, it is necessary to reduce
the speed of the vehicle to as slow as 2 to 3 miles per hour under
extreme conditions. If the depth of the water is above the lowest point
of the flywheel housing underpan, the transmission should be shifted
to the low or first speed, and the clutch should not be released until
the vehicle is in shallower water, as water on the clutch facings will
cause the clutch to slip. After the vehicle has passed through the
water, the brakes should be tested by applying the brakes. If the
brakes do not take hold properly, it will be necessary to "ride" the
brake pedal a short distance to dry out the brake linings.
18. ROUGH TERRAIN.
a. When operating over rough terrain, the speed of the vehicle
should be governed by the condition of the terrain. Do not attempt
28
TM 9-805
18-20
OPERATION UNDER UNUSUAL CONDITIONS
to drive the vehicle so fast that it jumps over the rough spots. In
extreme cases it will be necessary to shift the transmission to a lower
speed so that the vehicle can follow the terrain without excessive
jarring.
19. SNOW AND ICE.
a. Snow. Driving through snow is similar to driving through sand
with two exceptions, one of which is the possibility of skidding, and
the other is the fact that snow will not cause excessive brake lining
wear. When stopping the vehicle in snow, do not apply the brakes
suddenly, as this is liable to lock the wheels and cause the vehicle
to skid. It will not be necessary to remove the drums to clean out
any snow that might get into the brake mechanism unless the brakes
get full of slush, which freezes and causes the brake shoes to become
inoperative.
b. Ice. Driving over ice is always hazardous, as too much power
or sudden brake application will cause the vehicle to skid. Never
drive the vehicle over ice at a speed that does not permit full control
of the vehicle at all times. When applying the brakes, depress the
brake pedal gradually, and do not release the clutch until the vehicle
is practically stopped.
20. HOT WEATHER.
a. Introduction. Operation of these vehicles in high temperatures
requires additional precautions, more frequent inspections, and closer
observance of the instruments and gages.
h. Cooling System. The formation of scale and rust occurs more
readily in high temperatures; therefore, the water should be drained
and the radiator and cooling system flushed, whenever the water be-
comes rusty. If a rust preventive is available, it should be added to
the water. Check the fan belt frequently to see that it is adjusted
properly. Check the water pump frequently to see that it is operating
properly and not leaking. Check the hose connections to see that they
do not leak, and that they do not show signs of deterioration; if so,
they should be replaced. Check the thermostat to see that it is open-
ing properly. Check the radiator core to see that the air passages in
the core are not congested with bugs, leaves, etc. If these passages
are congested, they should be cleaned out.
e. Battery. When the vehicle is being operated in extremely hot
climates the distilled water in the battery electrolyte evaporates very
rapidly. For this reason the battery should be checked daily, and
distilled water added to bring the electrolyte % mcn above the top
of plates. Battery electrolyte is much more active at high temperature
than at low temperature. This highly active electrolyte causes rapid
deterioration of the plates and separators, and more rapid "self-
discharge" of idle batteries. CAUTION: Idle batteries must be
stored in a cool place. Batteries can safely be used in hot climates
with a weaker electrolyte solution, which will prolong battery life.
When unusually short battery life is experienced in tropical climates,
29
TM 9-805
20-21
the batteries should be forwarded to a higher echelon for adjustment
of electrolyte as recommended for use in hot climates.
21. COLD WEATHER.
a. Introduction. The operation and maintenance of these vehicles
at low temperatures requires additional precautions and preparations
that are not necessary in temperate climates. Low temperature ranges
can generally be divided into three ranges, each requiring definite
preparations and precautions: +32F to 0F; 0F to 20F; below
-20F.
1>. +32F to 0F. The cooling system must be protected with
a sufficiently strong antifreeze solution to protect it against freezing
at the lowest probable temperature. The battery must be kept in a
fully charged condition. The fuel system must be kept free from
dirt or water, and the engine should be kept properly tuned. SAE 10
oil should be used in the engine.
c. 0F to 20F. The cooling system must be filled with a perma-
nent type antifreeze solution strong enough to protect the cooling
system against freezing in temperatures as low as 20F. A 166F
thermostat must be installed. The lower part of the radiator core, and
the hood and fender skirt louvers must be covered. When parking the
vehicle for any length of time, the front must be covered with a tar-
paulin. The vehicle should be stored inside when facilities are avail-
able. CAUTION: SAE 10 engine oil must be used. The battery must
be kept fully charged, and the ignition system in good condition. To
start the engine, the throttle should be from 1/3 to y2 open, the choke
valve fully closed, and the clutch pedal fully depressed. When the
engine starts, adjust the choke and throttle to obtain a smooth, fast
idle. Run the engine at this speed until it is thoroughly warmed up,
and the oil pressure drops to normal, before attempting to drive the
vehicle.
d. Below 20F. Special winterizing equipment must be installed
for satisfactory operation in these, temperatures. The operating in-
structions in the winterizing equipment manual must be adhered to
for satisfactory operation of the equipment and the vehicle.
30
TM 9-805
22
Section VI
FIRST ECHELON PREVENTIVE MAINTENANCE SERVICE
Paragraph
Purpose 22
Before-operation service -. 23
During-operation service 24
At-halt service 25
After-operation and weekly service 26
22. PURPOSE.
a. To insure mechanical efficiency, it is necessary that the vehicle
be systematically inspected at intervals each day it is operated and
weekly, so that defects may be discovered and corrected before they
result in serious damage or failure. Certain scheduled maintenance
services will be performed at these designated intervals. The services
set forth in this section are those performed by driver or crew, before
operation, during operation, at halt, and after operation and weekly.
b. Driver preventive maintenance services are listed on the back
of "Driver's Trip Ticket and Preventive Maintenance Service Record,"
W. D. Form No. 48, to cover vehicles of all types and models. Items
peculiar to specific vehicles, but not listed on W. D. Form No. 48, are
covered in manual procedures under items to which they are related.
Certain items listed on the form, that do not pertain to the vehicle
involved, are eliminated from the procedures as written into the
manual. Every organization must thoroughly school each driver in
performing the maintenance procedures set forth in manuals, whether
or not. they are listed specifically on W. D. Form No. 48.
c. The items listed on W. D. Form No. 48 that apply to this
vehicle are expanded in this manual to provide specific procedures
for accomplishment of the inspections and services. These services
are arranged to facilitate inspection and conserve the time of the
driver, and are not necessarily in the same numerical order as shown
on W. D. Form No. 48. The item numbers, however, are identical with
those shown on that form.
<1. The general inspection of each item applies also to any sup-
porting member or connection, and generally includes a check to see
if the item is in good condition, correctly assembled, secure, or ex-
cessively worn.
(1) The inspection for "good condition" is usually an external
visual inspection to determine if the unit is damaged beyond safe or
serviceable limits. The term "good condition" is explained further by
the following: not bent or twisted, not chafed or burned, not broken
or cracked, not bare or frayed, not dented or collapsed, not torn or cut.
(2) The inspection of a unit to see that it is "correctly assembled"
is usually an external visual inspection to see if it is in its correctly
assembled position in the vehicle.
(3) The inspection of a unit to determine if it is "secure" is
usually an external visual examination, wrench, hand-feel, or a pry-
31
TM 9-805
22-23
bar check for looseness. Such an inspection should include brackets,
lock washers, lock nuts, locking wires, or cotter pins used in assembly.
(4) "Excessively worn" will be understood to mean worn close to,
or beyond, serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
e. Any defects or unsatisfactory operating characteristics beyond
the scope of first echelon to correct must be reported at the earliest
opportunity to the designated individual in authority.
23. BEFORE-OPERATION SERVICE.
a. This inspection schedule is designed primarily as a check to
see that the vehicle has not been damaged, tampered with, or sabo-
taged since the After-operation Service was performed. Various com-
bat conditions may have rendered the vehicle unsafe for operation,
and it is the duty of the driver to determine if the vehicle is in con-
dition to carry out any mission to which it may be assigned. This
operation will not be entirely omitted, even in extreme tactical
situations.
b. Procedures. Before-operation Service consists of inspecting
items listed below according to the procedure described, and correct-
ing-or reporting any deficiencies. Upon completion of the service,
results should be reported promptly to the designated individual in
authority.
(1) ITEM 1, TAMPERING AND DAMAGE. Look for injury to vehicle
in general, its accessories or equipment, caused by tampering or
sabotage, collision, falling debris, or shell fire.
(2) ITEM 2, FIRE EXTINGUISHER. Inspect fire extinguisher for
corrosion, full charge, clean nozzle, and secure mounting.
(3) ITEM 3, FUEL, ENGINE OIL, AND WATER. Check amount of
fuel, oil, and coolant. Add as needed. NOTE: Any appreciable drop
in levels since After-operation Service should be investigated, and
cause corrected or reported. When antifreeze solution is in use, if any
appreciable addition of water is needed, have antifreeze value tested.
Be sure spare fuel and water cans are full and securely mounted.
(4) ITEM 4, ACCESSORIES AND DRIVES. Examine carburetor, gener-
ator, regulator, cranking motor, fuel pump, fuel filter, air cleaner, and
water pump for loose or damaged connections and loose mountings.
Be sure fan and generator drive belt is in good condition and adjusted
to have 34-inch finger pressure deflection.
(5) ITEM 6, LEAKS, GENERAL. Look under vehicle and in engine
compartment for fuel, coolant, and lubricant leaks; particularly at
carburetor, fuel pump, fuel filter, radiator, and water pump.
(6) ITEM 7, ENGINE WARM-UP. Start engine and observe if crank-
ing motor has adequate cranking speed and engages and disengages
properly without unusual noise. Note any tendency toward difficult
starting. If oil pressure gage does not register within 10 seconds, stop
engine, and correct trouble or report to designated authority. Set hand
throttle to fast idle speed, and during the warm-up period proceed
32
TM 9-805
23
with the following Before-operation Services (items 8 through 22).
Listen for unusual noises; watch instrument indications, and note
any unsatisfactory engine performance such as misfiring and rapid
temperature rise.
(7) ITEM 8, CHOKE. While starting engine, observe choke for
satisfactory operation. As engine warms up, reset choke as required
for smooth engine operation, and to prevent crankcase oil dilution.
(8) ITEM 9, INSTRUMENTS.
(a) OH Pressure Gage. Oil pressure gage should show normal
reading of 5 pounds at idle, or 12 to 17 pounds at running speeds.
(b) Ammeter. After engine starts and is running at fast idle,
ammeter should show a high positive ( + ) charge rate for a short
period until generator restores to battery the current used in starting.
After this period ammeter should register a zero or slight positive
( + ) charge with lights and accessories turned off.
(c) Fuel Gage. Fuel gage should register approximate amount of
fuel in tank.
(d) Temperature Gage. Engine temperature should increase grad-
ually during warm-up period. Temperature gage should register
140F to 170F. CAUTION: Do not move vehicle until engine tem-
perature reaches 135F.
(9) ITEM 10, HORN AND WINDSHIELD WIPERS. Test horn (tactical
situation permitting) for proper operation and tone. Inspect wipers,
arms, and blades for good condition. See if blades contact glass evenly
throughout full stroke.
(10) ITEM 11, GLASS AND REAR VIEW MIRRORS. Look for loose or
damaged frames, brackets, or regulators. Clean windshield and door
glass, and inspect for damage or discoloration. Clean mirror and aim
properly.
(11) ITEM 12, LAMPS (LIGHTS) AND REFLECTORS. Operate all
switches (tactical situation permitting) and see if all lights respond
properly. Be sure all lights and reflectors are secure, and lenses are
clean and undamaged.
(12) ITEM 13, WHEEL AND FLANGE NUTS. See that all wheel
mounting and axle flange nuts are secure.
(13) ITEM 14, TIRES. Inspect all tires for damage or low pres-
sure. Inflate to 55 pounds pressure (tires cool), if time is available.
Remove imbedded objects from treads and from between duals. Make
sure spare is secure in carrier.
(14) ITEM 15, SPRINGS AND SUSPENSION. Examine springs for
abnormal sag, broken or shifted leaves, and loose or missing rebound
clips. See that eyebolts, U-bolts, shackles, and shock absorbers are
in good condition and tight. Examine shocks for leaks.
(15) ITEM 16, STEERING LINKAGE. Examine steering gear, Pitman
arm, rods, rod ends, and steering arms for looseness or damage and
excessive lubricant leaks.
(16) ITEM 17, FENDERS AND BUMPERS. Inspect fenders and
bumpers for looseness and damage.
33
TM 9-805
23-24
1'/, -TON 4x4 TRUCK (Chevrolet)
(17) ITEM 18, TOWING CONNECTIONS. Inspect tow hooks and
pintle hook for looseness or damage, and see that pintle hook locking
device is operating satisfactorily.
(18) ITEM 19, BODY, LOAD, AND TARPAULINS. Inspect cab and
top tarpaulin for damage. See that doors and latches operate properly.
Inspect cab and body for looseness and damage. Inspect load for
damage and see that it is properly distributed. On cargo bodies be
sure tail gate is secure and tarpaulin (if used) is properly lashed to
body hooks or loops. On dump bodies be sure body is fully lowered
and alined on frame sill, and that tail gate is closed, and lever is
in locked position. On panel bodies be sure rear doors are secure.
On telephone maintenance or earth borer equipped vehicles, be
sure materials are properly stowed, and stowage compartment doors
are closed and secure.
(19) ITEM 20, DECONTAMINATOR. Examine decontaminator for
secure mounting, full charge, and closed valve.
(20) ITEM 21, TOOLS AND EQUIPMENT. See that tools and equip-
ment are present, serviceable, and properly mounted and stowed.
(21) ITEM 22, ENGINE OPERATION. Engine may be assumed to
be operating normally when it idles with choke button fully de-
pressed and oil pressure is indicated on oil pressure gage (5 pounds
at idle, 12 to 17 pounds at running speeds). Accelerate engine several
times after it has reached normal operating temperature, and listen
for any unusual noises, unsatisfactory operating characteristics, or
excessive exhaust smoke.
(22) ITEM 23, DRIVER'S PERMIT AND FORM No. 26. Make sure
Driver's Permit, vehicle manual, Lubrication Guide, and Standard
Accident Form No. 26 are present, legible, and safely stowed.
(23) ITEM 25, DURING-OPERATION SERVICE. The During-operation
Service should start as soon as vehicle is put in motion.
24. DURING-OPERATION SERVICE.
a. While vehicle is in motion, listen for such sounds as rattles,
knocks, squeals, or hums that may indicate trouble. Look for indica-
tions of trouble in cooling system, and smoke from any part of the
vehicle. Be on the alert to detect any odor of overheated components
or units such as generator, brakes, or clutch, fuel vapor from a leak
in fuel system, exhaust gas, or other signs of trouble. Any time the
brakes are used, gears shifted, or vehicle turned, consider this a test
and notice any unsatisfactory or unusual performance. Watch the
instruments constantly. Notice promptly unusual instrument indica-
tion that may signify possible trouble in system to which that instru-
ment pertains.
b. Procedures. During-operation Service consists of observing
items listed below according to the procedures following each item,
and investigating any indications of serious trouble. Notice minor
deficiencies to be corrected or reported at earliest opportunity, usually
at next scheduled halt.
34
TM 9-805
24
(1) ITEM 27, FOOT AND HAND BRAKES. The foot brake should
have 1^-inch free pedal travel, and should operate smoothly and
effectively without pulling vehicle to one side, leaving % reserve
pedal travel available. If trailer is connected, note if electric brake
controller action is satisfactory to operate trailer brakes effectively.
When vehicle is stopped on a reasonable incline, hand brake should
hold vehicle with 1/3 reserve lever travel available.
(2) ITEM 28, CLUTCH. Inspect clutch pedal to see that it has
1-inch to 1J4-inch free travel before it starts to disengage. Clutch
should not chatter, squeal, or grab on engagement, or slip when fully
engaged under load.
(3) ITEM 29, TRANSMISSION. As transmission (and power take-off,
if used) is operated, see that gears shift smoothly, operate quietly,
and do not creep or jump out of mesh.
(4) ITEM 30, TRANSFER. As transfer and declutching shift mecha-
nism (and power take-off, if used) are operated, see that gears shift
smoothly, operate quietly, and do not creep or jump out of mesh.
(5) ITEM 31, ENGINE AND CONTROLS. Be on the alert for de-
ficiencies in engine performance such as lack of usual power, mis-
firing, unusual noise, stalling, indications of overheating, or unusual
exhaust smoke. Note if engine responds to controls satisfactorily, and
if controls appear to be in proper adjustment, and are not excessively
loose or binding.
(6) ITEM 32, INSTRUMENTS. Observe readings of all instruments
frequently during operation to be sure units to which they pertain are
functioning satisfactorily.
(a) Temperature Gage. Temperature gage should read 140F to
170F after warm-up. Investigate and report excessive engine heat
over 190F.
(b) Oil Pressure Gage. Oil pressure gage should read 5 pounds
at idle, and 12 to 17 pounds at running speeds. If there is unusual
drop in pressure, or oil pressure is not registering, engine should be
stopped immediately.
(c) Ammeter. During operation, after battery has recovered from
discharge caused by starting, ammeter should indicate a zero or
slight positive (+ ) reading with needle steady.
(d) Fuel Gage. Fuel gage should continue to indicate approxi-
mate amount of fuel in tank.
(e) Speedometer and Odometer. Speedometer should indicate
vehicle speed. Odometer should record accumulating mileage.
(7) ITEM 33, STEERING GEAR. Note any indication of looseness
or binding, excessive pull to either side, shimmy, wheel tramp, or
unusual noise.
(8) ITEM 34, RUNNING GEAR. Listen for any unusual noises, such
as knocking, clicking, or bumping sounds from wheels, axles, or sus-
pension parts.
(9) ITEM 35, BODY. Note any noise or abnormal condition that
might indicate shifting, loose top tarpaulin or curtains, loose or dam-
35
TM 9-805
24-25
aged doors, hardware, floor or inspection plates, or mounted body
attachments.
25. AT-HALT SERVICE.
a. At-halt Service may be regarded as minimum maintenance
procedures and should be performed under all tactical conditions,
even though more extensive maintenance services must be slighted
or omitted altogether.
b. Procedures. At-halt Service consists of investigating any
deficiencies noted during operation, inspecting items listed below
according to the procedures following the items, and correcting any
deficiencies found. Deficiencies not corrected should be reported
promptly to the designated individual in authority.
(1) ITEM 38, FUEL, OIL, AND WATER. Check amount of fuel, oil,
and coolant. Add as necessary. CAUTION: Do not turn radiator
filler cap beyond safety stop until hissing has ceased.
(2) ITEM 39, TEMPERATURES: HUBS, BRAKE DRUMS, TRANSFER,
TRANSMISSION, AND AXLES. Place hand cautiously on each brake drum
and wheel hub to determine if abnormally hot. Inspect transmission,
transfer, and driving axles for overheating or excessive oil leaks.
(3) ITEM 40, AXLE AND TRANSFER VENTS. Wipe clean and inspect
vents for damage or clogging. Vents must be kept open.
(4) ITEM 41, PROPELLER SHAFTS. Inspect all propeller shafts and
universal joints for looseness, damage, or oil leaks. Remove any for-
eign material wound around shaft or joints.
(5) ITEM 42, SPRINGS AND SUSPENSION. Examine springs for
broken or shifted leaves, damaged or loose clips, U-bolts, eyebolts,
and shackles. See if shock absorbers and linkage are securely con-
nected and mounted.
(6) ITEM 43, STEERING LINKAGE. Examine steering control
mechanism, arms, and linkage frictional joints for damage or loose-
ness, and investigate any irregularities noted during operation.
(7) ITEM 44, WHEEL AND FLANGE NUTS. See that wheel mounting
and axle flange nuts are present and secure.
(8) ITEM 45, TIRES. Examine tires for underinflation or damage.
Remove imbedded objects from treads and from between duals. See
that spare is inflated and secure in carrier.
(9) ITEM 46, LEAKS, GENERAL. Look in engine compartment and
under vehicle for indications of fuel, oil, coolant, or brake fluid leaks.
Trace any found to their source and correct or report them to proper
authority.
(10) ITEM 47, ACCESSORIES AND BOLTS. Inspect fan and water
pump pulley, and generator pulley for looseness. Examine fan belt
for excessive wear or fraying and deflection of y$ inch midway be-
tween fan and generator pulleys.
(11) ITEM 48, AIR CLEANERS. When operating under extremely
dusty or sandy conditions, see that air cleaners and breather caps
are in condition to deliver clean air. Service as required.
36
TM 9-805
25-26
(12) ITEM 49, FENDERS AND BUMPERS. Inspect fenders or splash
guards, and bumpers for looseness or damage.
(13) ITEM 50, TOWING CONNECTIONS. See that tow hooks and
pintle hook and fifth wheel (if used) are in good condition and
securely mounted. See that pintle hook or fifth wheel is properly
latched. If towing load, make sure trailer electrical connections are
securely fastened.
(14) ITEM 51, BODY, LOAD, AND TARPAULIN. Examine cab, body,
equipment, or load for shifting. Be sure tarpaulin (if used) is properly
secured and in good condition.
(15) ITEM 52, GLASS. Clean windshield, door and window glass,
rear view mirror, and light lenses; inspect for damage.
26. AFTER-OPERATION AND WEEKLY SERVICE.
a. After-operation Service is particularly important because at
this time the driver inspects his vehicle to detect any deficiencies
that may have developed, and corrects those he is permitted to
handle. He should report promptly, to the designated individual in
authority, the results of his inspection. If this schedule is performed
thoroughly, the vehicle should be ready to roll again on a moment's
notice. The Before-operation Service, with a few exceptions, is then
necessary only to ascertain whether or not the vehicle is in the same
condition in which it was left upon completion of the After-operation
Service. The After-operation Service should never be entirely omitted,
even in extreme tactical situations, but may be reduced to the bare
fundamental services outlined for the At-halt Service, if necessary.
b. Procedures. When performing the After-operation Service the
driver must remember and consider any irregularities noticed during
the day in the Before-operation, During-operation, and At-halt
Services. The After-operation Service consists of inspecting and
servicing the following items. Those items of the After-operation
Service that are marked by an asterisk (*) require additional
Weekly services, the procedures for which are indicated in sub-
paragraph (b) of each applicable item.
(1) ITEM 55, ENGINE OPERATION. See that engine idles satisfac-
torily. Accelerate and decelerate engine and note any missing, back-
firing, unusual noises, vibration, or exhaust smoke. Investigate any
unusual condition noticed during operation.
(2) ITEM 56, INSTRUMENTS. Check all pertinent instruments to
be sure all are operating properly, and continue to register or indi-
cate correct performance of the units to which they apply.
(3) ITEM 54, FUEL, OIL, AND WATER. Check fuel, oil, and coolant
levels; replenish as required. Leave sufficient space for expansion.
Fill spare cans. When antifreeze is used and an appreciable amount
of water is added to coolant, have value of antifreeze tested.
CAUTION: Observe safety precautions for grounding static elec-
tricity when handling gasoline. Do not add coolant when engine is
too hot.
37
TM 9-805
26
(4) ITEM 57, HORN AND WINDSHIELD WIPERS. Inspect horn for
secure mounting and tight connections. See if wiper arms and blades
are in good condition; inspect wiper blades for even contact with
glass throughout full stroke.
(5) ITEM 58, GLASS AND REAR VIEW MIRROR. Clean rear view
mirror, windshield, and other glass. Be sure glass and mountings are
secure and undamaged.
(6) ITEM 59, LAMPS (LIGHTS) AND REFLECTORS. Operate switches
and see that lamps respond. During blackout, inspect lamps with
switch in blackout position only. Be sure all lamps are off after
completing inspection. Depress brake pedal and see that stop lights
burn. Clean all lenses and warning reflectors, and inspect for
damage.
(7) ITEM 60, FIRE EXTINGUISHER. Inspect fire extinguisher for
presence, full charge, proper mounting, and clear nozzle. Examine for
corrosion or damage. If extinguisher has been used, report it for
refill or replacement.
(8) ITEM 61, DECONTAMINATOR. Inspect decontaminator for good
condition, full charge, and secure mounting. If used, report for refill
or replacement.
(9) ITEM 62, *BATTERIES.
(a) Inspect batteries to see that they are clean, secure, and not
leaking or damaged. See that cell caps are finger-tight.
(b) Weekly. Clean dirt from top of battery. If terminal connec-
tions or posts are corroded, clean them thoroughly and apply fresh,
thin coating of grease. Tighten terminal bolts if loose. Remove vent
caps and check level of electrolyte. Add water if required, taking
precautions so that battery will not be damaged during freezing
temperatures. Battery should be secure, not bulging or cracked or
leaking electrolyte; battery carrier should be secure, clean, free of
rust, and well painted. If mountings are loose, tighten them cau-
tiously so as not to damage the battery case. Report any defects.
(10) ITEM 63, *ACCESSORIES AND BELTS.
(a) Inspect all accessories such as carburetor, generator and
regulator, cranking motor, and water pump for loose connections
and loose mountings. Inspect carburetor, water pump and fuel filter
for leaks. Inspect fan belt for good condition and deflection of
% inch midway between pulleys. Investigate and correct or report
any deficiencies of accessory units noticed during operation.
(b) Weekly. Tighten any loose connections, linkage, or mount-
ings.
(11) ITEM 64, ELECTRICAL WIRING. Inspect all ignition wiring
for looseness or damage; wipe off grease or moisture. Also make an
inspection of all accessible low voltage wiling and connections for
looseness or damage, and be sure all wiring is supported, so as not
to chafe against other vehicle parts.
(12) ITEM 65, *AiR CLEANERS AND BREATHER CAPS.
(a) Inspect for looseness or damage. Examine oil in reservoirs
38
TM 9-805
26
for correct level and excessive dirt. When operating in sandy or
dusty conditions, clean and service air cleaners and breather caps
as often as necessary.
(b) Weekly. Remove cleaner reservoirs and elements, wash in
dry-cleaning solvent, refill reservoirs with oil, and reinstall securely.
Be sure all gaskets seal properly, and that joints and connections
are secure.
(13) ITEM 66, *FUEL FILTERS.
(a) Examine fuel filters for leakage, damage, and loose mounting.
(b) Weekly. Remove drain plug; drain water and sediment from
bowl. If fuel pump sediment bowl shows excessive dirt, remove bowl
and clean element.
(14) ITEM 67, ENGINE CONTROLS. Inspect engine controls for
wear, damage, or disconnected linkage, and for adequate lubrication.
(15) ITEM 68, *TIRES.
(a) Examine all tires, including spares for damage and excessive
wear. Remove all imbedded foreign matter, such as nails, glass, or
stones, from treads and carcasses and from between duals. Check for
low pressures and proper position of valve stem and presence of
valve caps. Inflate to correct pressure, as needed (55 Ib maximum,
cool).
(b) Weekly. Replace badly worn or otherwise unserviceable tires.
Serviceable tires, which show abnormal wear, should be relocated to
other wheels to even the wear. Apparent mechanical deficiencies
causing such wear should be reported to higher echelon for attention.
(16) ITEM 69, SPRINGS AND SUSPENSION. Inspect springs for ab-
normal sag, broken or shifted leaves, and loose or missing rebound
clips. See that eyebolts, U-bolts, and shackles are tight, and that
shock absorbers are secure and not leaking. Investigate any unusual
noise or condition noticed during operation.
(17) ITEM 70, STEERING LINKAGE. Inspect steering linkage for
bent, loose, or inadequately lubricated parts. Investigate any unusual
condition noticed during operation.
(18) ITEM 71, PROPELLER SHAFTS. Inspect all drive shafts and
universal joints for looseness or damage, and excessive oil leaks.
Remove any foreign material wound around shafts or joints.
(19) ITEM 72, *AXLE AND TRANSFER VENTS.
(a) See that all axle housing and transfer vents are present, in
good condition, secure, and not clogged.
(b) Weekly. Remove and clean axle and transfer vents, and
reinstall securely.
(20) ITEM 73, LEAKS, GENERAL. Inspect around engine compart-
ment and beneath vehicle for indications of fuel, oil, coolant, or
brake fluid leaks.
(21) ITEM 74, GEAR OIL LEVELS. After units have cooled, check
lubricant level of differentials, transmission, and transfer; report if
low. NOTE: Proper level with units cool is */2 inch below filler plug
hole.
39
TM 9-805
26
1V2 -TON 4x4 TRUCK (Chevrolet)
(22) ITEM 74, FENDERS AND BUMPERS. Examine for looseness or
damage.
(23) ITEM 77, *TOWING CONNECTIONS.
(a) Inspect tow hooks (fifth wheel, if used) and pintle hool for
looseness or damage. Inspect towed load (if any) electrical connec-
tions for good condition and secure attachment.
(b) Weekly. Lower the trailer landing gear, observing whether
or not it operates properly, is adequately lubricated, not damaged,
and secure. Unhitch the trailer. Clean the contacting surfaces of the
fifth wheel, upper plate, and kingpin thoroughly. Inspect them for
wear and damage, and apply a fresh coating of clean grease. Tighten
all mounting bolts; rehitch the trailer, noticing if the hand lever
works easily, and if the latching mechanism closes completely and
latches securely. Tighten mounting bolts of tow hooks, pintle hook,
or fifth wheel (if used), as required.
(24) ITEM 78, BODY, LOAD, AND TARPAULIN, (HOIST, IF USED),
Inspect cab and body carefully for damaged, loose, or missing
parts. Make sure load is evenly distributed, and that load or equip-
ment is secure. See that tarpaulin and curtains (if used) are in good
condition, and that grommets and ropes are present and undamaged.
All ropes should be lashed securely to hooks or rings. Examine hoist
cylinder (where used) at pump and pump valve for leaks.
(25) ITEM 79, *WINCH.
(a) Examine winch assembly for looseness or damage, and ex-
cessive oil leaks at worm gear housing. See that winch drive shaft
shear pin is in good condition and secure. Be sure sliding clutch
operates freely and locks securely.
(b) Weekly. If vehicle has been operated in deep water, sample
lubricant for contamination. If water is present, report condition. If
winch cable was used recently, or is dry or wound unevenly, unwind
entire length and clean. Rewind evenly on winch drum, applying a
thin coat of engine oil while winding, and secure cable chain and
hook securely to front tow hooks. NOTE: Clean, used oil is satis-
factory. If winch is center-mounted, check drive chain adjustment.
Idler should be set so that chain is tight.
(26) ITEM 82, *TIGHTEN.
(a) Tighten any mounting or external assembly nuts or screws
where inspection of vehicle has indicated the necessity.
(b) Weekly. Tighten wheel mounting and axle flange nuts and
cap screws, spring U-bolts, eyebolts, shackles and rebound clips,
torque rods, shock links, U-joint companion flanges, body mount-
ings, engine mountings, accessories or special equipment mountings,
transfer case mountings, steering arms, towing connections, or any
other mountings or external assembly nuts or screws, where inspec-
tion or experience indicates the necessity, on a weekly or mileage
basis.
(27) ITEM 83, *LUBRICATE AS NEEDED.
(a) Lubricate all items such as shackles, hinges, latches, control
40
TM 9-805
26
linkage frictional joints, or any point where inspection has indicated
oilcan or hand greasing is needed.
(b) Weekly. Lubricate all points of the vehicle indicated on the
Lubrication Guide as needing lubrication on a weekly or a mileage
basis.
(28) ITEM 84, *CLEAN ENGINE AND VEHICLE.
(a) Clean dirt and grease or oil drippings from inside cab, and
from engine compartment and exterior of engine. Wipe off excess
dirt and grease from entire vehicle.
(b) Weekly. Wash vehicle when possible. If not possible, wipe
off thoroughly. Inspect paint or camouflage pattern for rust, or for
bright spots which might cause light reflections. See that vehicle
markings are legible, unless covered for tactical reasons. CAUTION:
// vehicle is driven into water for washing, care must be taken to
see that water or dirt does not get into wheel bearings, gear cases,
or brakes, or on electrical units or wiring,
(29) ITEM 85, *TOOLS AND EQUIPMENT.
(a) Check vehicle stowage and tool lists to see that all items are
present. Inspect items to see that they are in good condition, and
properly mounted or stowed.
(b) Weekly. Clean all tools and equipment of rust or dirt, and
apply preservative where necessary, when possible. See that tools
with cutting edge are sharp and properly protected, and that all
items are securely mounted or stowed. NOTE: When services are
completed, be sure all inspection plates are replaced securely.
41
TM 9-805
27-28
Section VII
LUBRICATION
Introduction 27
Lubrication Guide 28
Reports and records 29
27. INTRODUCTION.
a. Lubrication is an essential part of preventive maintenance, de-
termining to a great extent the serviceability of parts and assemblies.
28. LUBRICATION GUIDE.
a. General. Lubrication instructions for these vehicles are con-
solidated in a Lubrication Guide (figs. 15 and 16). These specify
the points to be lubricated, the periods of lubrication, and the lubri-
cant to be used. In addition to the items on the Lubrication Guide,
other small moving parts, such as hinges and latches, must be
lubricated at frequent intervals.
b. Supplies. In the field it may not be possible to supply a
complete assortment of lubricants called for by the Lubrication
Guide to meet the recommendations. It will be necessary to make
the best use of those available, subject to inspection by the officer
concerned, in consultation with responsible ordnance personnel.
c. Lubrication Notes. The following instructions supplement
and repeat for clarity those notes on the Lubrication Guide which
pertain to lubrication and service of individual units and parts. All
note references in the guide itself are to the subparagraphs below
having the corresponding number.
(1) FITTINGS. Clean before applying lubricant. Lubricate until
new lubricant is forced from the bearing, unless otherwise specified.
CAUTION: Lubricate chassis points after washing truck.
(2) INTERVALS. Intervals indicated are for normal service. For
extreme conditions of speed, heat, water, sand, mud, snow, rough
roads, dust, etc., reduce interval by 1/& or y2, or more if conditions
warrant.
(3) CLEANING. Use SOLVENT, dry-cleaning, or OIL, fuel, Diesel,
to clean or wash all parts. Use of gasoline for this purpose is pro-
hibited. Dry all parts thoroughly before lubricating.
(4) AIR CLEANERS. Daily, check engine air cleaner level and re-
fill oil reservoir to bead level with used crankcase oil or OIL, engine,
SAE 30 above + 32F; SAE 10 for +30F to 0F. From 0F to
40F, use FLUID, shock-absorber, light. Every 1,000 miles (daily
under extreme dust conditions) remove and wash all parts. Below
40F, remove oil and operate dry. Every 1,000 miles or more
frequently if required, remove hydrovac cylinder air cleaner, located
at rear of cylinder, wash all parts and reoil curled hair with used
crankcase oil or OIL, engine, SAE 30 above +32F; SAE 10 for
+ 32F to 0F. From 0F to -40F, use FLUID, shock-absorber,
42
TM 9-805
28
LUBRICATION
light. Below 40F, wash and replace dry. Every 1,000 miles, pr more
frequently if required, clean and oil crankcase breather on late
models. Breather is located on top of valve cover. Every 3,000 miles,
or more frequently if required, remove, clean, and reoil governor
cleaner with used crankcase oil or OIL, engine, SAE 30 above +32F;
SAE 10 for +32F to 0F. From 0F to -40F, use FLUID, shock-
absorber, light. Below 40F, wash and replace dry.
(5) CRANKCASE. Drain only when engine is hot. Refill to "FULL"
mark on gage. Run engine a few minutes and recheck oil level. CAU-
TION: Be sure pressure gage indicates oil is circulating.
(6) OIL FILTER. Every 1,000 miles, drain sediment. Every 6,000
miles, or more often if filter becomes clogged, drain filter, clean inside
and renew element. Run engine a few minutes, check crankcase level
and add OIL, engine, to "FULL" mark on gage. (SAE 30 above
+ 32F; SAE 10 +32F to 0F; and refer to OFSB 6-11, below
0F.)
(7) GEAR CASES. Weekly, check level with truck on level ground
and, if necessary, add lubricant to within y2 inch of plug level when
cold or to plug level when hot. Drain, and refill at inervals indicated
on guide. Drain only after operation. Fill differentials to level of lower
plug hole. Clean magnetic drain plug on transfer case before replac-
ing. Keep all gear case breathers clean.
(8) UNIVERSAL JOINTS AND SLIP JOINTS.
(a) Winch and Dump Body Hoist. Apply GREASE, general pur-
pose, No. 1, above +32F and No. 0 below +32F, to joint until
lubricant appears at cross, and to slip joint until lubricant is forced
from end of slip joint.
(b) Truck. Apply GREASE, general purpose, No. 1, above +32F
and No. 0 below +32F, to joint until it overflows at relief valve and
to slip joint until lubricant is forced from vent at universal joint
end of spline.
(9) WINCH PROPELLER SHAFT SHEAR PIN. Every 6,000 miles,
disconnect front universal joint, remove shear pin and universal joint
from shaft, clean and coat end of shaft and inside of universal joint
collar with GREASE, general purpose, No. 1 above +32F, and
No. 0 below +32F, to prevent rusting.
(10) FRONT WHEEL UNIVERSAL JOINTS. With vehicle on level
ground, remove inspection plug on top of steering knuckle housing
and add lubricant through fitting at bottom of steering knuckle hous-
ing until it comes out inspection hole. Replace plug. Every 6,000
miles, disassemble, clean, reassemble, and refill.
(11) HYDROVAC CYLINDER. Every 6,000 miles, remove pipe plug
from the cylinder at the relay valve end of the unit of single- and
double-piston types. Also remove pipe plug at the center plate of
double-piston type. Lubricate both types with about % ounce of
FLUID, shock-absorber, light, through each opening. Replace plugs.
(12) DISTRIBUTOR. Every 6,000 miles, wipe distributor breaker
cam lightly with GREASE, general purpose, No. 1 above +32F, and
No. 0 below +32F, and lubricate breaker arm pivot and wick under
43
UI
oc
28
TM 9-805
1i/2-TON 4x4 TRUCK (Chevrolet)
45
28
TM 9-805
LUBRICATION
TM 9-805
28
1 i/2-TON 4x4 TRUCK (Chevrolet)
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28
LUBRICATION
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TM 9-805
28
rotor with one to two drops of OIL, engine, SAE 30 above +32F;
SAE 10 for +32F to 0F; OIL, lubricating, preservative, special,
below 0F.
(13) ACCELERATING PUMP SHAFT. Remove air cleaner and car-
buretor accelerating pump dust cover. Saturate felt ring on carbure-
tor pump lever shaft with OIL, engine, SAE 30 above +32F; SAE
10 for +32F to 0F; OIL, lubricating preservative, special, below
0F.
(14) HYDRAULIC HOIST CYLINDERS.
(a) Hercules. Raise body to maximum lift, fill cylinder and
before replacing cover, lower body to bleed air and surplus oil.
Again raise body and replace fill hole cover and gasket.
(b) Perfection. Raise body to maximum lift, fill cylinder, replace
and tighten fill plug. Loosen, but do not remove, vent plug and lower
body completely to bleed air and surplus oil. Raise body and
tighten vent plug.
(c) Both Models. Every 6 months, disconnect oil line from pump,
drain and refill. Use OIL, engine, SAE 10, for all temperatures.
(15) TRACTOR MODEL FIFTH WHEELS. Every 1,000 miles, clean
and lubricate lower plate coupler pin, locking jaws and guide with
OIL, engine, SAE 30 above +32F; SAE 10 for +32F to 0F; and
OIL, lubricating, preservative, special, below 0F.
(16) WINCH CABLE. Coat winch cable with used crankcase oil
or OIL, engine, SAE 30 above + 32F; SAE 10 for +32F to
0F; and OIL, lubricating, preservative, special, below 0F after
each period of use. When not in use, coat outer coils weekly.
(17) CLUTCH PILOT BEARING. Whenever clutch is removed for
inspection or repair, and after cleaning parts, coat the shift fork ball
seat, pack recess inside clutch release bearing collar, pack pilot bear-
ing and fill cavity in crankshaft behind bearing, coat shaft splines
lightly and coat ball seat in shift fork with GREASE, general pur-
pose, No. 2. CAUTION: Do not wash clutch release bearing.
(18) OILCAN POINTS. Every 1,000 miles, lubricate pintle hook pins
and connections, control rod bushings, clevises, linkage, etc., with
OIL, engine, SAE 30 above +32F; SAE 10 for +32F to 0F;
OIL, lubricating, preservative, special, below 0F.
(19) RUBBER BUSHINGS. Every 1,000 miles, apply FLUID, brake,
hydraulic, to shock-absorber link rubber bushings. CAUTION: Do
not oil.
(20) POINTS REQUIRING No LUBRICATION SERVICE. These points
are the fan, water pump, clutch release bearing, generator (late
models), springs, propeller shaft center bearing (175-in. wheelbase
model), power take-off, clutch and brake pedals, front axle declutch,
dump hoist hydraulic pump, and governor.
(21) WHEEL BEARINGS. Remove bearing cone assemblies from
hub and wash spindle and inside of hub. Inspect bearing races and
replace if necessary. Wet the spindle and inside of hub and hub cap
48
TM 9-805
28-29
LUBRICATION
with GREASE, general purpose, No. 2, to a miximum thickness of Vig-
inch to retard rust. Wash bearing cones and grease seals and dry.
Inspect and replace if necessary. Lubricate bearings with GREASE,
general purpose, No. 2, with a packer or by hand, kneading lubricant
into all spaces in the bearing. Use extreme care to protect bearings
from dirt and immediately reassemble and replace wheel. The lubri-
cant in the bearings is sufficient to provide lubrication until the next
service period. Do not nil hub or hub cap. Any excess might result
in leakage into the brake drum.
29. REPORTS AND RECORDS.
a. Reports. If lubrication instructions are closely followed,
proper lubricants used, and satisfactory results are not obtained,
make a report to the ordnance officer responsible for the mainte-
nance of the materiel.
b. Records. A complete record of lubrication may be kept for
every vehicle in the Duty Roster (W.D. AGO Form 6).
49
TM 9-805
30
Section VIII
TOOLS AND EQUIPMENT STOWAGE ON VEHICLE
Vehicle tools 30
Vehicle equipment 31
Vehicle spare parts 32
30. VEHICLE TOOLS.
a. General. Each vehicle is equipped with the tools listed in sub-
paragraph c below so that minor repairs can be performed by the
driving personnel. The larger tools, and a tool bag containing small
tools, are located on the several models as follows:
Model . Too) Location
G-7103Chassis with cab Under driver's seat
G-7105Panel In back of driver's seat back
G-7113Cab tractor Tool box on right running board
G-7106Dump less winch I TT
G-7116-Dump with winch f Under dnver s seat
G-7107Cargo less winch I In compartment under body tail
G-7117Cargo with winch f gate
G-7163Telephone earth borer I TT ,
G-7173-Telephone maintenance f Under dnvers seat
b. Special Tools. A list of special tools for second echelon use
will be found in section XI.
c. Vehicular Tool List. , . ,, . ,,
. . .. Federal Stock No.
Crank, engine starting
Hammer, machinist's, ball peen, 16-oz 41-H-523
Handle, wheel bearing nut
Handle, wheel wrench
Pliers, combination slip joint, 6-in 41-P-1650
Screwdriver, clutch head, %2-in 41-S-1117-4
Screwdriver, clutch head, %-in 41-S-1117-6
Screwdriver, clutch head, y16-in 41-S-1117-8
Screwdriver, common, 6-in. blade 41-S-1104
Wrench, adjustable, automobile type, 11-in 41-W-448
Wrench, adjustable, crescent type, 8-in 41-W-486
Wrench, engineer's, open-end, %- x 7/16-in 41-W-991
Wrench, engineer's, open-end, l/2- x !%2-in 41-W-1003
Wrench, engineer's, open-end, %6- x ] Vie-in 41-W-1005-5
Wrench, engineers, open-end, %- x 2%2-in 41-W-1008-10
Wrench, engineer's, open-end, %- x %-in 41-W-1012-5
Wrench, spark plug
Wrench, special hex socket (winch trucks only)
Wrench, wheel
Wrench, wheel bearing nut
Wrench, clutch feed shaft coupling (earth borer only)
Wrench, clutch shaft bearing nut lock (earth borer only)
50
TM 9-805
30-32
TOOLS AND EQUIPMENT STOWAGE ON VEHICLE
Wrench, idler gear adjusting nut (earth borer only)
Wrench, leveling ratchet (earth borer only)
Wrench, leveling worm shaft bushing (earth borer only)
31. VEHICLE EQUIPMENT.
a. The following items of equipment are included with each
vehicle, and are located on the various models as outlined in para-
graph 30 a.
Chains, tire, 7.50 x 20 single, 7.50 x 20 dual
Chain, utility tow (1)
Extension, lubricating gun
*Extinguisher, fire
Gage, tire pressure
Gun, lubrication
Handle, jack
Iron, tire changing
Jack, auto assembly
Oiler
Pump, tire
32. VEHICLE SPARE PARTS.
a. General. A number of vehicle spare parts are contained in
a kit attached to the dash above the fire extinguisher on the assistant
driver's side. Whenever spare parts are removed from the kit and put
into service, an equal quantity should be replaced in the kit at the
first opportunity so they will be available when needed.
b. Spare Parts Kit. The following parts are contained in the
vehicle spare parts kit:
Belt, fan and generator Pin, cotter (unit)
Cap, tire valve (unit) Pin, winch drive shaft shear
Lamp, incandescent, No. 63 type, Plug, spark (unit)
3-cp Tape, friction (54-in. wide 8-oz
Lamp-unit, taillight blackout tail roll)
Lamp-unit, taillight blackout stop Valve, tire (unit)
Lamp-unit, taillight service tail Wire, stove pipe
and stop (2 units)
*The fire extinguisher is installed on all models at the back of the dash on the
assistant driver's side.
51
TM 9-805
33
PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS
Section IX
RECORD OF MODIFICATIONS
Paragraph
FSMWO and major unit assembly replacement record 33
33. FSMWO AND MAJOR UNIT ASSEMBLY REPLACEMENT
RECORD.
a. Description. Every vehicle is supplied with a copy of AGO
Form No. 478, which provides a means of keeping a record of each
FSMWO completed, or major unit assembly replaced. This form
includes spaces for the 'vehicle name and U. S. A. Registration
Number, instructions for use, and information pertinent to the work
accomplished. It is very important that the form be used as directed,
and that it remain with the vehicle until the vehicle is removed from
service.
b. Instructions for Use. Personnel performing modifications or
major unit assembly replacements must record clearly on the form
a description of the work completed, and must initial the form in
the columns provided. When each modification is completed, record
the date, hours and/or mileage, and FSMWO number. When major
unit assemblies, such as engines, transmissions, transfer cases, are
replaced, record the date, hours and/or mileage, and nomenclature
of the unit assembly. Minor repairs, and minor parts and accessory
replacements, need not be recorded.
c. Early Modifications. Upon receipt by a third or fourth echelon
repair facility of a vehicle for modification or repair, maintenance
personnel will record the FSMWO numbers of modifications applied
prior to the date of AGO Form No. 478.
52
TM 9-805
34
Section X
SECOND ECHELON PREVENTIVE MAINTENANCE
Paragraph
Second echelon preventive maintenance services 34
34. SECOND ECHELON PREVENTIVE MAINTENANCE
SERVICES.
a. Regular scheduled maintenance inspections and services are a
preventive maintenance function of the using arms, and are the
responsibility of commanders of operating organizations.
(1) FREQUENCY. The frequency of the preventive maintenance
services outlined herein is considered a minimum requirement for
normal operation of vehicles. Under unusual operating conditions,
such as extreme temperatures, dusty or sandy terrain, it may be
necessary to perform certain maintenance services more frequently.
(2) FIRST ECHELON PARTICIPATION. The drivers should accom-
pany their vehicles and -assist the mechanics while periodic second
echelon preventive maintenance services are performed. Ordinarily
the driver should present the vehicle for a scheduled preventive
maintenance service in a reasonably clean condition; that is, it should
be dry, and not caked with mud or grease to such an extent that
inspection and servicing will be seriously hampered. However, the
vehicle should not be washed or wiped thoroughly clean, since cer-
tain types of defects, such as cracks, leaks, and loose or shifted parts
or assemblies are more evident if the surfaces are slightly soiled or
dusty.
(3) If instructions other than those contained in the general pro-
cedures in subparagraph (4), or the specific procedures in subpara-
graph (5) which follow, are required for the correct performance of
a preventive maintenance service, or for correction of a deficiency,
other sections of the vehicle operator's manual pertaining to the item
involved, or a designated individual in authority, should be consulted.
(4) GENERAL PROCEDURES. These general procedures are basic
instructions which are to be followed when performing the services
on the items listed in the specific procedures. NOTE: The second
echelon personnel must be thoroughly trained in these procedures so
that they will apply them automatically.
(a) When new or overhauled subassemblies are installed to cor-
rect deficiencies, care should be taken to see that they are clean,
correctly installed, properly lubricated, and adjusted.
(b) When installing new lubricant retainer seals, a coating of the
lubricant should be wiped over the sealing surface of the lip of the
seal. When the new seal is a leather seal, it should be soaked in SAE
10 engine oil (warm if possible) for at least 30 minutes. Then the
leather lip should be worked carefully by hand before installing the
seal. The lip must not be scratched or marred.
(c) The general inspection of each item applies also to any sup-
porting member or connection, and usually includes a check to see
53
TM 9-805
34
whether or not the item is in good condition, correctly assembled,
secure, or excessively worn. The mechanic must be thoroughly
trained in the following explanations of these terms:
1. The inspection for "good condition" is usually an external
visual inspection to determine if the unit is damaged beyond safe or
serviceable limits. The term "good condition" is explained further by
the following: not bent or twisted, not chafed or burned, not broken
or cracked, not bare or frayed, not dented or collapsed, not torn or cut.
2. The inspection of a unit to see that it is "correctly assembled"
is usually an external visual inspection to see whether or net it is in
its normal assembled position in the vehicle.
3. The inspection of a unit to determine if it is "secure" is usually
an external visual examination, a hand-feel, or a pry-bar check for
looseness. Such an inspection should include any brackets, lock wash-
ers, lock nuts, locking wires, or cotter pins used in assembly.
4. "Excessively worn" will be understood to mean worn close to,
or beyond, serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
(d) Special Services. These are indicated by repeating the item
numbers in the columns which show the interval at which the services
are to be performed, and show that the parts,, or assemblies, are to
receive certain mandatory services. For example, an item number in
one or both columns opposite a Tighten procedure, means that the
actual tightening of the object must be performed. The special serv-
ices include:
1. Adjust. Make all necessary adjustments in accordance with
the pertinent section of this manual, special bulletins, or other cur-
rent directives.
2. Clean. Clean units of the vehicle with dry-cleaning solvent to
remove excess lubricant, dirt, and other foreign material. After the
parts are cleaned, rinse them in clean fluid and dry them thoroughly.
Take care to keep the parts clean until reassembled, and be certain
to keep cleaning fluid away from rubber or other material that it
would damage. Clean the protective grease coating frorrj new parts,
since this material is usually not a good lubricant.
3. Special lubrication. This applies either to lubrication oper-
ations that do not appear on the vehicle Lubricat'on Guide, and to
items that do appear on such Guides, but should be performed in
connection with the maintenance operations, if parts have been dis-
assembled for inspection or service.
4. Serve. This usually consists of performing special operations,
such as replenishing battery water, draining and refilling units with
oil, and cleaning or changing the oil filter or cartridge.
5. Tighten. All tightening operations should be performed with
sufficient wrench-torque (force on the wrench handle) to tighten the
unit according to good mechanical practice. Use torque-indicating
wrench where specified. Do not overtighten, as this may strip threads
or cause distortion. Tightening will always be understood to include
the correct installation of lock washers, lock nuts, and cotter pins
provided to secure the tightening.
54
TM 9-805
34
(e) When conditions make it difficult to perform the complete
preventive maintenance procedures at one time, they can sometimes
be handled in sections, planning to complete all operations within
the week if possible. All available time at halts, and in bivouac areas,
must be utilized, if necessary, to assure that maintenance operations
are completed. When limited by the tactical situation, items with
special services in the columns should be given first consideration.
(f) The numbers of the preventive maintenance procedures that
follow are identical with those outlined on W.D. AGO Form No. 461,
which is the Preventive Maintenance Service Work Sheet for Wheeled
and Half-track Vehicles. Certain items on the work sheet that do
not apply to this vehicle, are not included in the procedures in this
manual. In general, the numerical sequence of items on the work
sheet is followed in the manual procedures, but in some instances
there is deviation for conservation of the mechanic's time and effort.
(5) SPECIFIC PROCEDURES. The procedures for performing each
item in the 1,000-mile (monthly) and 6,000-mile (6-month) mainte-
nance procedures are described in the following chart. Each page of
the chart has two columns at its left edge corresponding to the 6,000-
mile and the 1,000-mile maintenance respectively. Very often it will
be found that a particular procedure does not apply to both sched-
uled maintenances. In order to determine which procedure to follow,
look down the column corresponding to the maintenance due, and
wherever an item number appears, perform the operations indicated
opposite the number.
ROAD TEST
NOTE: When the tactical situation does not permit a
full road test, perform Jhose items which require little,
or no, movement of the vehicle. When a road test is
possible, it should be for 5 miles preferably, and not
over 10 miles.
Before-operation Service. Perform the Before-oper-
ation Service described in paragraph 23.
Dash Instruments and Cages.
OIL PRESSURE GAGE. Normal oil pressure with engine
at idle is 5 pounds, at running speeds, 12 to 17 pounds
(engine warm). CAUTION: When gage indicates zero
or excessively low pressure, stop engine immediately and
investigate.
AMMETER. Ammeter should show high charge for
short time after starting, and then return to zero or
slightly above zero with all lights and accessories
switched off. When battery is low, or electrical load
heavy, high reading will continue for a longer time.
Ammeter hand should be steady.
SPEEDOMETER AND ODOMETER. Speedometer should
indicate road speed correctly, and operate without ex-
cessive fluctuation and noise. Odometer should register
total accumulating mileage.
MAINTENANCE
6.000
Mill
(si
ninth)
1.000
Mile
(mon-
thly)
55
TM 9-805
34
MAINTENANCE
1,000
Mile
(mn-
TEMPERATURE GAGE. Under normal conditions the
temperature gage should show 140 to 170F after
warm-up. Maximum safe operating temperature 190F.
FUEL GAGE. Fuel gage should register approximate
amount of fuel in tank at all times.
Horn, Mirror, and Windshield Wipers. Test horn for
proper operation and tone (tactical situation permit-
ting). Observe wiper for full contact with glass through-
out complete stroke.
Brakes (Service and Parking, Braking Effect, Feel,
Side Pull, Noise, Chatter, and Pedal Travel). Operate
brakes at various speeds during road test.
SERVICE BRAKES. Apply foot pedal sufficiently to
stop vehicle within minimum distance and observe their
effectiveness, any pull of vehicle to one side, unusual
noise, or chatter. Pedal should depress with little effort,
and should return to off position when released.
PARKING BRAKE. Stop vehicle on reasonable incline;
apply parking brake, and observe if it holds vehicle
effectively; make sure that lever has at least 1/3 travel
in reserve, and that ratchet and pawl latch the applied
brake securely.
Clutch. Clutch pedal must have free travel of 1 inch to
1% inches. Clutch must operate smoothly without
squealing, chattering, or grabbing on engagement, or
slipping when fully engaged under load.
Transmission and Transfer (Lever Action, Declutch-
ing, Vibration, and Noise). Levers should move into
each gear range position easily and quietly. Test de-
clutching lever to see that front axle engages properly.
Note any vibration that may indicate loose mountings
or noise that may indicate damaged, execessively worn,
or inadequately lubricated parts.
Steering (Free Play, Bind, Wander, Shimmy, Side
Pull, Column, and Wheel). With vehicle in motion
move steering wheel fully in both directions, and ob-
serve whether or not there is any indication of looseness
or binding. Note any tendency of vehicle to wander,
shimmy, or pull to one side. See that steering column
and wheel are in good condition and secure.
Engine (Idle, Acceleration, Power, Noise, and Gov-
erned Speed). Observe engine operating characteristics
as follows:
UNUSUAL NOISES. Listen for knocks and rattles as the
engine is accelerated and decelerated, under both light
and heavy loads.
ACCELERATION AND POWER. Operate the engine at
various speeds in all gear ratios, noting if the vehicle
56
TM 9-805
MAINTENANCE
MM
1.000
Mill
(KM-
tMy)
Mill
<a
Hit)
10
10
11
11
13
13
14
14
16
16
17
17
34
has normal pulling power and acceleration. Note any
tendency to stall while shifting. NOTE: A slight ping
during fast acceleration is normal.
GOVERNED SPEED. With the vehicle in a low gear,
slowly depress the accelerator to the toeboard, and by
observing the speedometer reading, see if the vehicle
reaches, but does not exceed, the governed speed speci-
fied on the caution plate.
Unusual Noises (Attachments, Cab, and Wheels). Be
on the alert during road test for any noise that may
indicate loose or damaged attachments mounted on ve-
hicle, loose cab or body mountings, floor plates, doors,
windshield, or hardware. Listen particularly for indica-
tions of loose wheel mountings.
Brake Booster Operation, Hydrovac. Whenever brakes
are applied, observe if the hydrovac unit appears to
assist in the application satisfactorily. After stopping
vehicle operate pedal and listen at hydrovac air cleaner
unit for air movement, indicating unit is operating.
Temperatures (Brake Drums, Hubs, Axles, Trans-
mission, and Transfer). Place hand cautiously on all
brake drums and wheel hubs to see if they are abnorm-
ally hot. Inspect axle housing, transmission, and trans-
fer case for indications of overheating.
Leaks. Look for engine oil, coolant, and fuel leaks
within engine section and underneath the vehicle. Trace
any leaks found to their source and correct or report
them to designated authority.
MAINTENANCE OPERATIONS
Raise Vehicle-Block Safely
CAUTION: Use necessary precautions to block vehicle
so it may be operated safely in gear at reasonable speeds.
Gear Oil Level and Leaks (Axles, Transmission, and
Transfer). Remove filler plugs in front and rear axles,
transmission, and transfer case, and check lubricant
levels. Proper level is from lower edge of filler hole
when hot, to y2 inch below when cold. Allow sufficient
time for foaming to subside before checking levels. Note
condition of lubricant. If an oil change is due in any of
these units, or condition of lubricant indicates an oil
change is necessary, drain and refill with specified oil.
Note any indications of excessive lubricant leaks at oil
seals or gaskets.
Unusual Noises (Engine, Belts, Accessories, Trans-
mission, Transfer, Shafts and Joints, Axles, and
Wheel Bearings). With engine running observe as
TM 9-805
34
MAINTENANCE
6,000
Mita
(til
Htk}
I.MI
Mile
(me-
Ikly)
22
22
22
18
18
19
19
1'/a-TON 4x4 TRUCK (Chevrolet)
ENGINE, BELT AND ACCESSORIES. Accelerate and de-
celerate the engine momentarily, and listen for any
unusual noise in these units that might indicate dam-
aged, loose, or excessively worn engine parts, drive belt,
or accessories. Locate and correct or report any unusual
engine noise heard during the road test.
TRANSMISSION, TRANSFER, PROPELLER SHAFTS AND
JOINTS, AXLES, AND WHEEL BEARINGS. With the trans-
mission in an intermedia'te gear, and front driving axles
engaged, operate these units at a constant, moderate
speed by use of the hand throttle, and listen for any
unusual noise that might indicate damaged, loose, or
excessively worn unit parts. Observe all propeller shafts
and wheels for vibrations and runout. Locate, correct,
or report any noise noted during road test.
Battery. Inspect battery case for cracks and leaks. Clean
top of battery. Inspect cables, terminals, bolts, posts,
straps, and hold-downs for good condit'on. Test specific
gravity and voltage, and record on W.D. AGO Form
No. 461. Specific gravity readings below 1.225 indicate
battery should be recharged or replaced. Electrolyte
level should be above top of plates, and may extend l/4
inch above plates. Replenish by adding distilled or
clean water.
CONDITION TEST. Perform high-rate discharge test
according to instructions for "condition" test which
accompany test instrument, and record voltage on
W.D. AGO Form No. 461. Cell variation should not be
more than 30 percent. NOTE: Specific gravity must be
above 1.225 to make this test. Clean entire battery and
carrier, repaint carrier if corroded. Clean battery cable
terminals, terminal bolts and nuts, and battery posts;
and grease lightly. Inspect bolts for serviceability.
Tighten terminals and hold-down bolts carefully to
avoid damage to battery.
Cylinder Head and Gasket. Examine cylinder head for
cracks, and cylinder head and gaskets for indica-
tions of oil, coolant, or compression leaks. If head bolts
are loose, or leaks are evident, tighten to 75 to 80 foot-
pounds torque and in proper sequence, according to
figure 24.
Valve Mechanism. Look for broken valve springs and
proper oil delivery, and see that valve mechanism parts
are correctly assembled, and not excessively worn. Ad-
just valves only if noisy.
ADJUST. Adjust valve clearance to specifications.
Normal operation: intake valve, 0.006 to 0.008 inch;
exhaust valve, 0.013 to 0.015 inch. Heavy duty oper-
58
TM 9-805
MAINTENANCE
MM
1.0M
Mill
Mik
(sl
Htk)
(me-
l)
20
20
20
21
23
23
24
24
24
25
25
25
26
26
34
ation: intake valve, 0.010 inch; exhaust valve, 0.020
inch. CAUTION: Before adjusting valves, engine
should run idle for at least 30 minutes until thoroughly
warmed up.
Spark Plugs. Inspect around insulators or gaskets for
leaks. When operating conditions require, plugs may be
removed for service.
SERVE. Remove plugs, clean deposits from electrodes
and insulators; inspect for cracks. Adjust gaps to 0.040
inch by bending grounded electrodes only. Use torque-
indicating wrench (15 ft-lb maximum) for installing
plugs. NOTE: Replace plugs after completing item 21.
Compression. Perform compression test on all cylinders
with spark plugs removed and throttle wide open.
Minimum compression is 110 pounds, with 5 to 10
pounds variation allowed between cylinders. Record
results on W.D. AGO Form No. 461.
Crankcase. With engine idling, look for oil leaks
around crankcase, at timing-gear cover, valve cover,
and clutch housing. With engine stopped, check oil
level. If an oil change is due or condition of oil warrants
a change, drain crankcase and refill to correct level
with specified oil. Do not start engine again until item
24 is completed.
Oil Filter and Lines. See if oil filter, and all exterior oil
lines and connections are in good condition, secure, and
not leaking. Remove filter drain plug and drain water
and dirt.
SERVE. When cartridge replacement is due, or when
filter is clogged, remove cover and oil filter cartridge.
Clean filter case and install new cartridge, using new
gaskets.
Radiator (Core, Shell, Mountings, Hose, Cap and
Gasket, Antifreeze Record, and Steam Relief Tube).
Inspect all applicable items to see that they are in good
condition, secure, and not leaking. Examine condition
of coolant to see if it is so contaminated that cooling
system should be cleaned. Clean all insects, dirt, or
grease deposits from core air passages and inspect for
bent cooling fins. CAUTION: Use only a suitably
shaped piece of wood or blunt instrument to straighten
fins. If antifreeze is in use, test its protective value, and
record in space provided on back of work sheet Form
No. 461.
TM 9-805
34
MAINTENANCE
MM
1,000
Mile
Mill
(til
Nik)
(Ml-
27
III))
29
29
31
31
31
32
32
1%-TON 4x4 TRUCK (Chevrolet)
blades for cracks and looseness at hub; and shroud for
security and alinement with fan. Correct or report if
water leaks continuously at drain hole.
Generator, Cranking Motor, and Switch. Inspect for
good condition, secure mounting, and clean, secure
wiring connections; see that cranking motor linkage
and retracting spring are correctly assembled, in good
condition, and not excessively worn.
SERVE. Remove generator and cranking motor inspec-
tion covers; see that commutators and brushes are not
excessively worn, that brushes are free in holders, have
sufficient spring tension to hold them in contact with
commutator, and that brush connecting wires are secure
and not chafing. Clean commutator end of generator
and cranking motor with compressed air. If commuta-
tor is dirty, clean with flint paper 2/0 and blow out dust
with compressed air. Tighten generator and cranking
motor mounting bolts securely.
Drive Belt and Pulleys. Inspect drive belt for evidence
of excessive wear, cracks, or deterioration. Inspect all
drive pulleys and hubs for good condition, alinement,
and secure mountings. Adjust fan and generator drive
belt to 54-inch finger-pressure deflection.
Distributor. Inspect distributor assembly externally for
secure mounting, cleanliness, condition of attachments,
and tight connections. Examine cap and rotor for cracks
or signs of electrical leakage; cap terminals and rotor
conductor strap for corroded or burned condition. See
that cap vent hole is open. Inspect breaker points for
alinement, burning, or pitting, and proper gap adjust-
ment (0.018 in.); check condenser lead for chafing, and
breaker arm block for security. NOTE: // breaker points
are badly pitted, install new set of points and con-
denser. Check shaft for side-play looseness, to deter-
mine amount of bushing wear. Test centrifugal-advance
mechanism for normal range of movement by finger
force against rotor. When finger is removed, shaft
should return to original position without binding or
sticking.
SPECIAL LUBRICATION. Apply a small amount of
grease to cam surfaces and movable breaker arm pin.
CAUTION: Keep lubricant away from breaker points.
Wipe cam clean before applying lubricant.
ADJUST. Adjust breaker point gap (0.018 in.).
Coil and Wiring. See that coil mounting is tight, and
coil is clean and not damaged. Inspect high and low
6O
TM 9-805
34
MAINTENANCE
UN
Mb
(six
Kith)
MM
Mill
(UN-
tun)
33
33
34
34
36
36
37
37
37
37
38
38
39
38
39
tension wiring in engine compartment for indications
of chafing, cracking, swelling, or loose support mount-
ing. If necessary, tighten connections.
Manifolds and Heat Control. Inspect intake and
exhaust manifolds for cracks, mounting nuts for pres-
ence and security, and gaskets for good condition and
indications of leaks. Tighten all manifold-assembly,
mounting, exhaust pipe, and carburetor flange nuts
evenly and securely. Inspect bimetal heat valve con-
trol spring for correct assembly to heat control valve
shaft, and shaft for freedom to operate. CAUTION:
Bimetal spring should be wound only y2 turn at 70F.
Air Cleaner. Inspect carburetor air cleaner to see that
it is in good condition, securely mounted and connected,
and not leaking. Remove reservoir and element, clean
in dry-cleaning solvent, fill reservoir to proper level
with clean engine oil, and reassemble. Be sure gaskets
are in place and all joints and air horn connections are
tight.
Carburetor (Choke, Throttle, Linkage, and Gover-
nor). See that these items are in good condition, cor-
rectly assembled, and securely installed; that the carbu-
retor does not leak; that the control linkage, including
the choke and throttle shaft, is not excessively worn;
that the choke valve opens- fully when the control is
in its released position; that the throttle valve opens
fully when the accelerator is fully depressed; and that
the governor is secure and properly sealed.
Fuel Filter and Lines. Inspect fuel filter and lines
for leakage, looseness, and damage.
CLEAN. Close fuel shut-off valve, drain sediment from
filter bowl, and flush out bowl by opening shut-off valve
briefly. Replace drain plug. Clean fuel pump filter bowl
and screen, and open shut-off valve.
CLEAN. Remove fuel filter bowl and element. Wash
parts in dry-cleaning solvent. Reassemble filter, making
sure gaskets are in good condition. NOTE: // element
is damaged, replace.
Fuel Pump (Pressure). Inspect pump to see that it is
in good condition, securely mounted, and. not leaking.
Remove sediment bowl, and wash bowl and screen in
dry-cleaning solvent. NOTE: Be sure gasket is in place
and serviceable when bowl is reinstalled.
TM 9-805
34
MAINTENANCE
UM 1.M
Mile Milt
(sii (
Mik) tkly)
40
41
41
42
43
43
47
40
41
42
43
47
gages and operates properly without excessive noise,
and has adequate speed; and if the engine starts readily.
As soon as the engine starts, note if the oil pressure gage
and ammeter indications are satisfactory.
Leaks (Engine Oil, Fuel, and Water). With engine
running recheck all points of oil, fuel, and cooling sys-
tem for leaks. Trace any found to source and correct
or report them to proper authority.
Ignition Timing. With octane selector set at zero,
neon light connected, start engine and run at slow idle
speed. Check ignition timing. Observe whether auto-
matic control advances timing as engine is gradually
accelerated.
ADJUST. Adjust ignition timing (par. 86).
Engine Idle and Vacuum Test. Inspect as follows:
ADJUST. Connect a vacuum gage to the intake mani-
fold at wiper connection, adjust the engine idle speed
and idle mixture until the vacuum gage indicates a
steady maximum reading.
Regulator Unit (Connections, Voltage, Current, and
Cut-out). Inspect regulator unit to see that it is in good
condition, securely mounted and connected, and clean.
TEST. Connect the low-voltage circuit tester and
observe if the voltage regulator, current regulator, and
cut-out, control the generator output properly. Replace
if test shows faulty operation. CAUTION: This test
should be made only after the regulator unit has reached
normal operating temperatures.
Tires and Rims (Valve Stems and Caps, Condition,
Direction, Matching, Spare Carrier). Inspect and
service as follows:
VALVE STEMS AND CAPS. Observe if all valve stems are
in good condition and in correct position, and make sure
that all valve caps are present and finger-tight.
CONDITION. Examine all tires for cuts, bruises, breaks,
and blisters. Remove imbedded glass, nails, and stones.
Look for irregular tread wear, watching for any sign of
flat spots, cupping, feather edges, and one-sided wear.
Correct mechanical deficiencies causing such conditions.
Remove tires worn thin at center of tread (or other
unserviceable tires) and exchange for new or retreaded
tires. Front tires, worn irregularly, should be moved to
rear-wheel positions.
DIRECTION. Directional tires and non-directional tires
should not be installed on the same vehicle. Directional
tires on rear wheels should be mounted so that the "V"
of the chevron will point down when viewed from the
front. Directional tires on front wheels will ordinarily
62
TM 9-805
34
MAINTENANCE
UN
1.100
Mik
(Mr
IW)
Mik
(Hi
Hit)
47
47
48
49
49
be mounted so that the "V" of the chevrons will point
up when viewed from the front.
MATCHING. With the tires properly inflated, inspect
them to see if they are matched according to over-all
circumference and type of tread.
SPARE-TIRE CARRIERS. See if spare-tire carriers are
in good condition and secure.
RIMS. All rims and their clamp rings or flanges should
be in good condition and secure.
TIGHTEN. Tighten all wheel nuts securely.
SERVE. With the tires properly inflated, measure the
over-all circumference of all tires, including spares.
Select the tires to be mounted on duals or on driving
axles, so that they will not have differences in over-all
circumference exceeding ^4 inch. Mount all dual tires
with the larger tire outside. The valve stem on the inner
wheel should point out and the valve stem on the
outer wheel should point in, and should be opposite
each other. NOTE: The spares must be matched prop-
erly and mounted for use on one of the road wheels at
intervals not exceeding 90 days. A convenient time to
do this is during these maintenance services. CAU-
TION: After performing the tire-matching service, do
not reinstall the wheels until the wheel-bearing services
are completed.
Rear Brakes (Drums, Supports, Cylinders). Remove
rear wheels, and inspect and service as follows: On
6,000-mile maintenance several wheel bearing and brake
items up to 52 are group services and overlap. Perform
in best order for economy of time and orderly re-
assembly.
DRUM AND SUPPORTS. Clean dirt and grease from
drums and supports (dust shields), keeping dry-clean-
ing solvent away from linings. Examine drums and
supports to see that they are in good condition, securely
mounted, and if drums are excessively worn or scored.
WHEEL CYLINDERS. Observe if wheel cylinders are in
good condition and securely mounted. Examine for
fluid leaks. If leaks are evident, replace wheel cylinder.
TIGHTEN. Tighten brake support cap screws and hub
to drum nuts securely.
Rear Brake Shoes (Linings, Anchors, Springs). If
vehicle has been operated in deep water, mud, or loose
sand, remove right rear wheel and brake drum, and
examine lining for damage. If this lm;ng must be re-
placed, remove all wheels, check their brakes, and
service as necessary.
INSPECTION. Remove rear wheels and check linings
to see if they are in good condition, tightly secured to
63
TM 9-805
34
MAINTENANCE
6,000
Mild
(si
ninth)
1,000
Mile
(m-
lhl)
49
49
52
52
52
52
53
53
54
54
brake shoes, in good wearing contact with drums, free
of dirt or lubricant, and not excessively worn. Also see
that shoes are in good condition, properly secured to
anchors, guides, and retracting springs and that springs
have sufficient tension to return shoes properly to re-
leased position. Thickness of linings at most worn point
should be enough for at least 1,000 miles of service
before rivet heads are likely to contact drums.
CLEAN. Clean all dirt and grease from linings with
wire brush, cloth, or compressed air.
ADJUST. Perform rear brake shoe adjustment. Adjust
to slight drag, back off adjusting pinion % turn or four
sides of hex head of adjusting pinion. Adjust at each
end of cylinder.
Rear Wheels (Bearings, Seals, Drive Flanges, and
Nuts). Inspect and service as follows:
WHEELS. Inspect wheels to see that they are in good
condition and secure.
BEARINGS AND SEALS. Check for looseness of wheel
bearing adjustment. Revolve wheels and listen for evi-
dence of dry or damaged bearings. Inspect around
flanges and brake supports for lubricant leaks.
DRIVE FLANGES AND NUTS. Note if these are in good
condition, and if nuts are tightened securely.
CLEAN. Disassemble rear wheel bearings and oil seals.
Clean thoroughly in dry-cleaning solvent, and examine
bearing cups and cones to see that they are in good
condition; determine if machined surfaces they contact
are in good condition, and that there is no excessive
wear.
SPECIAL LUBRICATION. When all of the related items
are to the point where the wheel bearings are to be
reinstalled, lubricate the bearings according to Lubrica-
tion Guide (par. 28).
ADJUST. After lubricating the wheel bearings, reassem-
ble the hub and drum assemblies into place, and adjust
the wheel bearings (par. 133).
Front Brakes (Hose, Drums, Supports, and Cylin-
ders). Inspect front brake hose and drums to see that
they are in good condition, that hose is properly sup-
ported, securely connected, and not chafing or leaking.
Remove front wheels and inspect and service as follows:
DRUMS AND SUPPORTS. Clean and inspect in same
manner as in item 48.
CYLINDERS. Inspect in sarm manner as in item 48.
Front Brake Shoes (Linings, Anchors, and Springs).
Inspect in same manner as in item 49.
INSPECTION. Remove front wheels and brake drums
TM 9-805
34
MAINTENANCE
E.100
Mill
(sii
milk)
1.080
Mile
(men
IH)
54
54
55
55
55
55
56
56
57
57
57
and inspect shoes, linings, anchors, and springs in same
manner as in item 49 for 6,000-mile service.
CLEAN. Clean in same manner as in item 49.
ADJUST. Perform front brake shoe adjustment as
described in paragraph 122 after subsequent related
items to 60 inclusive, are completed.
Steering Knuckles (Joints, Bearings, and Seals).
Inspect to see that knuckle housings are in good condi-
tion. Look particularly for cracks around steering arms.
See that outside knuckle felt seals and seal flanges are
in good condition and secure. Remove lubrication plug
and examine sample of lubricant to see if it appears
to be contaminated.
CLEAN. Remove constant velocity universal joint
assembly. Wash thoroughly in dry-cleaning solvent and,
without disassembly, inspect parts to see that they are
in good condition and not excessively worn. Pay par-
ticular attention to universal joint washers, balls and
races, axle splines, flanges, and pivot bearings, or bush-
ings.
SPECIAL LUBRICATION. Pack new lubricant well into
constant velocity universal joint until it fills all space
between balls, cages, and races. Reassemble steering
knuckle, taking care to replace any unserviceable lubri-
cant retainer seals or gaskets.
Front Springs (Clips, Leaves, U-bolts, Hangers, and
Shackles). See that they are in good condition, cor-
rectly assembled, and secure. Spring clips and bolts
should be in place; spring leaves should not be shifted
out of their correct position. NOTE: This may be an
indication of a sheared center bolt. Note if the deflec-
tion of both springs is normal and approximately the
same. Test the hangers and bolts for excessive wear by
means of a pry bar.
TIGHTEN. Tighten all spring U-bolts securely and
uniformly.
Steering (Arms, Tie Rods, Drag Link, Seals and
Boots, Pitman Arm, Gear, Column, and Wheel). See
that these items are in good condition, correctly and
securely assembled and mounted, whether or not the
steering gear case is leaking lubricant, and that the
lubricant is at the proper level. Pay particular attention
to the Pitman arm to see that it is securely mounted
and not bent out of its normal shape. Also observe if
the steering system is in good adjustment.
TIGHTEN. Tighten the Pitman arm shaft nut securely.
Also tighten the steering gear case assembly and mount-
TM 9-805
34
MAINTENANCE
6,000
Mile
(six
mint*)
1,000
Mill
(mo-
IhlO
58
58
58
60
60
60
60
60
61
61
62
62
62
63
63
TVa-TON 4x4 TRUCK (Chevrolet)
ing nuts or screws, taking care not to disturb the adjust-
ing screws and lock nuts. CAUTION: Loosen the steer-
ing column bracket when tightening the steering case
mounting nuts, so as not to distort the column.
Front Shock Absorbers and Links. See that shock
absorber bodies are securely mounted to frame. Ex-
amine links and bushings for wear or loose connections.
Look for fluid leaks.
SERVE. Disconnect link from axle. Fill body with
fluid. Work arm several times, allowing any excess fluid
to run out. NOTE: // arm comes down easily part way,
then comes to a stop and moves down slowly rest of
way, not enough fluid has been added. Too much re-
sistance or no resistance may indicate broken or inoper-
ative units.
Front Wheels (Bearings, Seals, Flanges, Axle End
Play, and Nuts). Inspect front wheels, bearings, seals,
drive flanges, and nuts in same manner as in item 52
for similar rear wheel items.
CLEAN. Disassemble, clean, and inspect the front
wheel bearings and oil seals in the same manner as
described in item 52.
SPECIAL LUBRICATION. Apply in same manner as
described in item 52.
ADJUST. Adjust wheel bearings in same manner as
described in item 52, and adjust brake shoes as described
in paragraph 122.
Front Axle (Pinion End Play, Seal, Vent, and Aline-
ment). Examine housing for cracks, leaks, and bent or
sprung condition. Make sure that differential carrier
cap screws are tight. Test pinion shaft for end play, and
see that seal is not leaking. Inspect front axle alinement
by comparing measurements from front spring eyebolt
to center of axle spring pad, on each side.
CLEAN. Remove and clean axle vent.
Front Propeller Shafts (Joints, Alinement, Seals,
and Yokes). Examine lock rings and U-bolts for pres-
ence, security, and good condition. See that yoke is
securely mounted and is not excessively worn at sleeve
yoke. Look for indication of leaks at trunnion bearing
seals and at sleeve yoke cap and gasket.
TIGHTEN. Tighten all U-bolts and yoke nuts securely.
Engine (Mountings, Ground Strap, and Side Pans).
TM 9-805
MAINTENANCE
up
1,000
Mik
Mill
(M
(iflM-
ninth)
IN
64
64
64
65
65
65
66
66
67
67
68
68
68
71
71
71
72
72
34
or damage. Examine side pans and ground strap for
good condition and secure mounting. See if engine brace
rod is in good condition and secure.
Hand Brake (Ratchet and Pawl, Linkage, Drum, and
Lining). Inspect hand brake for worn ratchet, pawl, or
linkage; scored or oily drum; thin or oily shoe lining.
See that all parts are securely mounted.
ADJUST. Adjust hand brake lining clearance to 0.010
to 0.012 inch between lining and drum at anchor; 0.010
inch between upper and lower ends of lining and drum.
Clutch Pedal (Free Travel, Linkage, and Return
Spring). Inspect shaft mounting and operating linkage
for wear and free operation; see that adjustment locking
devices are secure. Make sure pedal return spring brings
pedal to correct released position.
ADJUST. Adjust clutch pedal free travel to 1 to 1%
inches.
Brake Pedal (Free Travel, Linkage, and Return
Spring). Check toeboard and brake pedal arm clear-
ance; normal clearance is % mh between brake pedal
arm and underside of toeboard. Examine pedal oper-
ating linkage for wear and secure connections. See that
pedal retracting spring returns pedal against its stop.
Brake Master Cylinder (Vent, Fluid Level, Leaks,
and Switch). See that filler plug vent is open, that boot
is properly installed, and that unit is securely mounted.
Look for indications of leaks, and see that stop light
switch is securely installed and terminals secure. Fill
master cylinder reservoir to within % mch f top. Clean
vent hole and replace gasket when needed.
Brake, Hydrovac Unit (Air Cleaner and Hose, Cylin-
der). Look for fluid leaks. Test unit for secure mount-
ing, and see that cylinder clamps, plugs, vents, hose,
and connections are secure. Remove, disassemble, clean,
and reoil air cleaner.
SPECIAL LUBRICATION. Lubricate according to Lubri-
cation Guide.
Transmission (Mountings, Linkage, Seals, and Power
Take-off). Examine transmission and power take-off
unit (when so equipped), its controls and drives, for
TM 9-805
34
MAINTENANCE
UN
1,609
Mill
(n-
*)
Mile
(sli
month)
72
73
73
73
75
75
77
77
78
78
78
79
79
if so equipped, for indications of cracks, leaks at seals
and gaskets, misalinement, and insecure mounting.
Clean vent and inspect for good condition. See that
vent is securely mounted. Inspect linkage for wear and
secure connections. Tighten all mounting bolts.
TIGHTEN. Tighten all external case assembly cap
screws and lock screws.
Rear Propeller Shaft (Joints, Alinement, Seals, and
Yokes). Examine lock rings and U-joint bolts for
presence, security, and good condition. See that yoke
is securely mounted, and is not excessively worn at
sleeve yoke. Look for indication of leaks at trunnion
bearing seals, and at sleeve yoke cap and gasket.
TIGHTEN. Tighten all U-joint bolts, and yoke nuts
securely.
Rear Axle (Pinion End Play, Seals, Vent, and Aline-
ment). Examine rear axle housing for cracks, leaks, and
bent or sprung condition. Test pinion shaft for end play,
and check to see that seal is not leaking. Make sure
differential carrier mounting cap screws are tight.
Observe whether or not rear axle appears to be in
alinement. Clean housing vent.
Rear Springs (Clips, Leaves, U-bolls, Hangers, and
Shackles). See that spring clips and bolts are in place,
and spring leaves not shifted out of position. See that
deflection of both springs is normal and approximately
the same. Using a pry bar, test hangers, shackles, and
bolts for excessive wear and looseness. Tighten all spring
U-bolts uniformly and securely.
Rear Shock Absorbers and Links. See that shock
absorber bodies are securely mounted to frame. Ex-
amine links and bushings for wear or loose connections.
Look for fluid leaks.
SERVE. Disconnect link from axle. Fill body with
fluid. Work arm several times, allowing any excess
fluid to run out. NOTE: // arm comes down easily
part way, then comes to a stop and moves down slowly
rest of way, not enough fluid has been added. Too much
resistance or no resistance may indicate broken or
inoperative units.
Cab and Body Mountings. Examine cab three-point
mountings. Inspect cab right and left front mountings
for deteriorated, loose, or missing fabric rubber cush-
ions; lock nuts for security on mounting bolts; cab rear
mounting for cracked, broken, or loose U-springs; center
TM 9-805
MAINTENANCE
LM
Ull
Mite
(Kl-
MiU)
wy>
80
80
81
81
82
82
83
83
83
84
84
85
85
86
86
87
87
34
bolts and cab mounting bolts securely, and adjust cab
rear center mounting bolt. CAUTION: Loosen steering
column bracket before alining cab, or tightening cab
bolts; otherwise, column may become distorted.
Frame (Rails and Cross Members). Examine side
rails, cross members, and brackets for evidence of bent,
cracked, or damaged condition. Look for loose rivets
and apparent misalinement.
Wiring, Conduits, and Crommets. Examine wiring and
conduits under vehicle for loose supports, chafed or
worn-through insulation, pinched or damaged wiring
harness, or loose connections. Check grommets for pres-
ence and good condition. Inspect trailer connection
socket and connections for good condition.
Fuel Tank, Fittings, and Lines. Examine fuel tank for
secure mounting, and indications of leaks; see that filler
neck is secure and not leaking, and that cap seals
properly. Inspect fuel lines for loose connections, loose
mountings, and for leaks.
SERVE. Remove plug from bottom of fuel tank to
drain water and sediment. Drain only until fuel starts to
run clear. Use necessary precautions against fire.
Brake Lines (Fittings and Hose). Examine brake
lines, fittings, and hose under the vehicle and at axle
housings for leaks, secure mounting, and good condition.
Exhaust Pipe and Muffler. Inspect exhaust pipe for
Secure attachment to exhaust manifold and muffler.
Look for exhaust leaks; see that muffler clamps are
secure, muffler body is not cracked, dented, or leaking;
and that tail pipe is unobstructed.
VEHICLE LUBRICATION. If due, lubricate in accord-
ance with Lubrication Guide, section VII, and current
lubrication directives, using only clean lubricant and
omitting items that have had special lubrication during
this service. Replace damaged or missing fittings, vents,
flexible lines, or plugs.
LOWER VEHICLE TO GROUND
Toe-in and Turning Stops. Use the toe-in gage to
determine if toe-in is V16 inch. See that wheel turning
stops are present and secure. Turn front wheels fully
in both directions, and see if turn is limited by stops
TM 9-805
34
MAINTENANCE
1,000
Mite
(*
1,000
Mil
(wt-
tkly)
Nik)
87
87
87
87
88
88
89
89
90
90
90
1 V2 -TON 4x4 TRUCK (Chevrolet)
cable from unreeling. Inspect worm gear case for secure
mounting; assembly bolts, cap screws, and plugs for
tightness. Inspect for leaks. Replace any improvised
shear pins. Inspect cable for frayed ends, sharp kinks,
or other damage, and see that it is evenly wound. Check
guide roller for freedom to roll, cleanliness, and secure
shaft. Lubricate sliding jaw clutch, shaft, and operating
arm with engine oil.
SERVE. Check winch worm gear case oil level, and add
or drain lubricant as necessary to bring to correct level.
ADJUST. Adjust center-mounted winch drive chain
idler until any perceptible slack is eliminated.
SERVE. Check winch worm gear case oil level and add
as necessary to bring to correct level. If an oil change is
due, or condition of lubricant warrants, drain and refill
winch worm gear case with specified oil.
CLEAN. Unwind winch cable and clean entire length.
As cable is rewound evenly and tightly, apply a coating
of engine oil.
Fifth Wheel (On Vehicles So Equipped). Inspect
fifth-wheel rocker plate and bed plate for good condi-
tion, proper assembly, and secure mounting. Inspect
kingpin lock to see that it operates properly and locks
securely. Inspect kingpin for excessive wear. Tighten
all assembly and mounting bolts. Clean fifth-wheel
plate and lubricate with chassis lubricant. Lubricate
grease fittings and hand-pack lubricant into latching
mechanism.
Tractor-to-Trailer Brake Wiring and Connections
(On Vehicles So Equipped). Inspect wiring for good
condition and secure fastening so it will not chafe or
interfere with working parts. Inspect connecting fittings
to see that they are in good condition, securely mounted,
and are not excessively worn.
Hoist (Mounting, Drive, Controls, Pump, Lines, and
Cylinder) (On Vehicles So Equipped). Raise body
and inspect sills, subsills, hoist, pump, lines, drive
shafts, and universal joints to see that they are in good
condition, correctly assembled, and securely mounted.
Inspect drive shaft joints, controls, and linkage for
excessive wear. Look for oil leaks at cylinder, pump,
and lines. Observe for cylinder piston leaks by noting
whether or not body tends to drop. Fill cylinder with
prescribed lubricant in manner indicated for specific
make of hoist in section XXXIII. Lubricate grease
fittings, and apply few drops of oil to pin joints of lift-
ing and pump control mechanism.
TM 9-805
34
MAINTENANCE
Lin
Mll
"
Mt)
91
91
91
92
92
93
93
94
94
95
95
96
96
98
98
99
99
100
100
nuts securely. Tighten piston rod packing nut and any
pump or control valve gland nuts, taking care not to
overtighten them as this may score shafts and cause
leaks.
Lamps (Lights) (Head, Tail, Body, Stop, and Black-
out). Inspect the head, tail, body, stop, and blackout
lights for broken lenses and secure mounting. Tactical
situation permitting, operate switches, and see that
lights respond. Test foot switch high and low beam
control. Test blackout Hghts to make sure they do not
illuminate any part of the vehicle. See that stop light
burns when brake pedal is depressed.
ADJUST. Aim headlight beams. Adjust blackout lamp-
units so that their light does not shine on any part of
vehicle.
Safety Reflectors. Inspect for proper position, cleanli-
ness, good condition, and secure mounting.
Front Bumper, Tow Hooks, Brush Guards, and
Grilles. Inspect for presence, good condition, and secure
mounting.
Hood, Hinges and Fasteners. See that hood is alined
and secure when fastened, and is not bent or kinked.
Make sure fasteners are present, secure, in good condi-
tion, and properly lubricated.
Front Fenders and Running Boards. Inspect for loose
mounting, cracks, and dents.
Cab (Doors, Hardware, Glass, Seat and Trim, Floor-
boards, Ventilator, and Map Compartment). Inspect
these items to see that they are in good condition and
secure; that ventilator door and windshield hardware
operates properly; that doors are alined in their open-
ings; engage the bumpers and strikers, and latch prop-
erly in closed position.
Circuit Breaker. Examine thermal circuit breaker (30
amp) located on main light switch to see that connec-
tions are tight. Inspect the horn circuit breaker located
between ignition switch and horn; gas gage circuit
breaker located between ignition and gas gage instru-
ment for any damage and for tight connections.
Rear Fenders and Splash Guards. Inspect for secure
mounting and good condition.
TM 9-805
34
MAINTENANCE
1,000
Mile
(i
mulk)
1,000
Mile
(DIM-
My)
101
101
103
103
104
104
131
131
1 '/a-TON 4x4 TRUCK (Chevrolet)
Compartments). Inspect all applicable above items on
vehicle to see if they are in good condition, correctly
assembled, and secure.
CARGO BODIES. On cargo bodies be sure that tail gate
closes and latches properly, that chains are intact, that
top bows are secure and not damaged, and that tarpau-
li-s and end curtains are properly installed and lashed
to body hooks or rings.
PANEL BODIES. On panel bodies be sure that doors fit
openings, that they close and latch properly; that locks
and strikers are adequately lubricated, and not exces-
sively worn.
TELEPHONE MAINTENANCE AND EARTH BORER
VEHICLES. On telephone maintenance and earth borer
vehicles see that all panels and stowage bins are secure
and not damaged; that compartment doors fit, close,
and latch properly; and that any special equipment
and mounting brackets are in good condition and se-
curely mounted.
DUMP BODIES. On dump bodies see that tail gate
closes and latches properly, that locking lever operates
satisfactorily, and that body is properly alined on sills.
Rear Bumper and Pintle Hook. Inspect these units for
good condition and security. Examine pintle and latch
for proper operation and adequate lubrication. See that
spring is not broken, and that draw bar is not exces-
sively worn.
Paint and Markings. Examine the paint of entire ve-
hicle to see that it is in good condition, paying par-
ticular attention to any bright spots in finish that might
cause glare or reflection. Inspect vehicle markings and
identification for legibility. Include identification plates
and their mountings, if furnished.
Radio Bonding. Examine suppressors, filters, con-
densers, shielding, and bonding for proper position, good
condition, security, and cleanliness. NOTE: Report any
irregularities, except cleaning and tightening, to signal
corps personnel.
TOOLS AND EQUIPMENT
Tools (Vehicle and Pioneer). Inspect all the standard
vehicle and Pioneer tools to see that they are all present
(pars. 30 and 31), in good condition, clean, and properly
stowed or securely mounted. Also examine the tools
which have cutting edges to see that they are sharp.
72
TM 9-805
34
MAINTENANCE
MM
ulk)
1,001
tw
132
133
134
135
136
137
132
133
134
135
136
137
139
141
142
139
141
142
Any tools mounted on the outside of the vehicle which
have bright or polished surfaces, should be painted or
otherwise treated to prevent rust, glare, or reflection.
Fire Extinguisher. See that they are in good condition,
securely mounted, and fully charged. Also be sure the
nozzles are free from corrosion.
Decontaminator. See that decontaminator is in good
condition, and securely mounted. Make the check for
full charge by removing the filler plug.
First Aid Kit (if Specified). See that it is in good con-
dition, and that all of its items are present and properly
packed. Report any deficiencies immediately.
Publications and Form No. 26. The vehicle and equip-
ment manuals, Lubrication Guide, and Standard Form
No. 26 (Accident Report Form), should be present,
legible, and properly stowed.
Traction Devices (Chains). Examine tire chains to be
sure they are in good condition, clean (if not in use),
not excessively worn, protected against rust, and prop-
erly mounted or stowed.
Tow (Chains, Cables, Rope, and Snatch Blocks). See
that the provided towing devices are in good condition,
clean, and properly stowed. Tow chains or cables should
be properly protected against rust when not in use. If
snatch blocks are furnished, check to see that they
operate freely.
Fuel and Water Cans and Brackets. Observe whether
or not fuel, water cans, and brackets are in good condi-
tion and secure; see that caps fit tightly and are secured
to can with a chain; and determine if the cans are
leaking.
Modifications (FSMWO's) Completed. Inspect the
vehicle to determine whether or not all Field Service
Modification Work Orders have been completed.
Final Road Test. Recheck items 2 to 15-inclusive. Con-
fine this test to minimum distance necessary to make
satisfactory observations. Recheck transmission, trans-
fer, and front and rear axles for lubricant level and for
leaks.
NOTE: Correct, or report all deficiencies found during
final road test, to the proper authority.
73
TM 9-805
35-36
Section XI
ORGANIZATION TOOLS AND EQUIPMENT
Special tool sets ..., 35
Special tool set 36
35. STANDARD TOOL SETS.
a. The tool sets available to individuals (specialists) and organiza-
tions, dependent upon the allocation in the tables of equipment are
listed in SNL N-19. The components of these tool sets are also listed
and illustrated.
36. SPECIAL TOOL SET.
a. The following special tools are allocated one each to a regi-
mental or battalion maintenance platoon.
Manufacturer's Federal
Number Stock No.
Flaring tool, brake tube KM-J-1280 14-T-3076-35
Wrench, socket, cylinder head
bolt (wide sweep) 54 m- hex,
1/1. in. square drive KM-KMO-187-10 41-W-2965
74
TM 9-805
37-38
Section XII
TROUBLE SHOOTING
General 37
Engine 38
Clutch 39
Fuel system 40
Cooling system 41
Electrical system 42
Transmission 43
Transfer case 44
Propeller shafts 45
Front axle 46
Rear axle 47
Brake system 48
Wheels, wheel bearings, hubs, and tires 49
Springs and shock absorbers 50
Steering arm 51
Cab, body, and frame 52
Power take-off 53
Winch ,. 54
Hydraulic hoist 55
37. GENERAL.
a. The trouble shooting information given in this section will aid
in determining the cause of troubles that may develop in the units
or systems of the vehicle. A separate paragraph is used for trouble
shooting on each vehicle unit or system. Each trouble symptom
carries a subparagraph heading followed by itemized possible causes
of the trouble and the tests or correction procedures. If it is not prac-
tical to give the diagnosis or correction procedure under the specific
symptom, a paragraph reference where complete information can
be found, will be shown.
38. ENGINE.
a. Engine Will Not Turn.
(1) ENGINE SEIZURE. Place transmission gearshift lever in neutral
and attempt to turn the engine with the hand crank. If the engine
cannot be turned with the hand crank, seizure is indicated. Notify
higher authority.
(2) STARTING SYSTEM INOPERATIVE. See paragraph 42 b.
(3) INCORRECT OIL VISCOSITY. Drain and fill with proper grade
(par. 28 c (4)).
73
TM 9-805
38
b. Engine Turns but Will Not Start.
(1) FUEL NOT REACHING COMBUSTION CHAMBERS. Disconnect
fuel line from carburetor bowl, turn ignition switch off, and work
fuel pump priming lever up and down several strokes. If fuel does
not flow from fuel line, check for fuel supply in main tank, and see
that valve at fuel filter is open. Refer to paragraph 40 for further
checks.
(2) INOPERATIVE IGNITION SYSTEM. Make sure ignition switch is
turned on. Crank engine and watch ammeter hand; if ammeter hand
does not move, there is trouble in the ignition system. See paragraph
42 a. If ammeter hand moves, make further check by removing spark
plug wire from one spark plug, holding wire terminal % mch from
engine, and cranking engine. If spark does not jump gap, spark is
probably inadequate. See paragraph 42 a (3) for further checks.
(3) SLOW CRANKING SPEED. See paragraph 42 b (1).
c. Engine Does Not Develop Full Power.
(1) FAULTY IGNITION SYSTEM. See paragraph 42 a.
(2) IMPROPER FUEL MIXTURE. See paragraph 40.
(3) INCORRECT VALVE ADJUSTMENT. Adjust valves (par. 61).
(4) LEAKING CYLINDER HEAD GASKET. Replace gasket (par. 60).
(5) EXHAUST SYSTEM PARTLY RESTRICTED. Replace or clean
restricted parts (par. 78).
(6) AIR LEAKS AT CARBURETOR OR MANIFOLD GASKETS. With
engine running, apply a small amount of oil to gaskets and note any
change in engine speed, or any indication of the oil being drawn into
manifold. Tighten attaching bolts, or replace leaking gaskets (par.
62).
(7) ENGINE OVERHEATING. Note temperature indicator for oper-
ating temperature. Check cooling cystem (par. 41). Check for correct
. grade of oil and fuel.
(8) PREIGNITION. Check for correct grade of fuel. Check ignition
timing (par.-57 k). Check cooling system (par. 57 n). Check spark
plugs (par. 42 a (3)). If the above items are found satisfactory, it
may be necessary to clean carbon (par. 59) and exchange the cylinder
head, to assure satisfactory valve operation (par. 58).
(9) INCORRECT GOVERNOR OPERATION. Remove carburetor air
cleaner, and open carburetor throttle valve. Look down through the
carburetor to check the position of the governor throttle valve, which
should be 10 degrees from vertical. If in any other position, replace
the governor (par. 76).
(10) TRANSFER CASE IN FOUR-WHEEL DRIVE ON HARD SURFACE
ROADS. Shift transfer case to two-wheel drive (par. 5 k).
(11) POOR ENGINE COMPRESSION OR IMPROPER VALVE TIMING.
Test compression (par. 57 b). If poor compression is caused by
cylinder head gasket leak, replace the gasket. Report valve trouble
to higher authority, or replace cylinder head with one having con-
ditioned valves. Report other compression troubles, or improper
valve timing, to higher authority.
76
TM 9-805
38
TROUBLE SHOOTING
il. Engine Misfires.
(1) FAULTY IGNITION SYSTEM. See paragraph 42 a.
(2) Low ENGINE COMPRESSION. See subparagraph c (11) above.
(3) INCORRECT FUEL MIXTURE. Check for air leaks. See sub-
paragraph ( (3) below. Adjust carburetor idling (par. 72 b). Car-
buretor not functioning properly. Notify higher authority.
(4) LEAKING CYLINDER HEAD GASKET. Replace head gasket
(par. 60).
e. Popping, Spitting, or Spark Knock.
(1) OVERHEATED INTAKE MANIFOLD. Make sure manifold heat
control valve shaft is free in manifold. Disconnect control valve
thermostatic spring and check its tension. Spring must be wound up
only y2 turn to hook over anchor pin at 70F. Replace thermostatic
spring or manifold if spring is damaged or valve shaft frozen in
manifold.
(2) FAULTY INGITION SYSTEM. See paragraph 42 a.
(3) POOR CARBURETION. See paragraph 40.
(4) VALVES NOT SEATING PROPERLY. Adjust valves (par. 61).
Test engine compression (par 57 b).
(5) ENGINE OVERHEATING. Thoroughly flush cooling system.
Adjust fan belt. Tune engine (par. 57).
(6) FAULTY SPARK PLUGS. Remove, inspect, clean, and adjust
spark plugs (par. 42 a (3)).
(7) Low OCTANE FUEL. Low octane fuel will cause spark knock.
It is normal to get a slight knock on acceleration. If higher octane
fuel is not available, excessive spark knock may be decreased by
setting the distributor octane selector back a few degrees.
(8) EXCESSIVE CARBON IN COMBUSTION CHAMBERS. Remove
cylinder head. Clean carbon (par. 59), and inspect valve condition.
f. Rough Engine Idling.
(1) IMPROPER IDLING ADJUSTMENT. Adjust carburetor idling
(par. 72 b).
(2) CARBURETOR NEEDLE VALVE NOT SEATING. This condition
usually causes fuel to leak out on body of carburetor. Notify higher
authority, or replace carburetor.
(3) AIR LEAKING INTO MANIFOLD. Disconnect hydrovac and
windshield wiper vacuum lines, and plug manifold fittings. If engine
idle is improved, a leak in one of these systems is indicated. Dis-
connect line from crankcase ventilator metering valve, and plug end
of valve. Improvement in engine idling indicates leak in crankcase
ventilator line, or a sticking metering valve. Check carburetor and
manifold gaskets for leak (subpar. c (6) above).
(4) VALVES NOT SEATING PROPERLY. Adjust valves (par. 61).
Check compression (par. 57 b).
(5) CYLINDER HEAD GASKET LEAK. Test compression (par. 57 b).
If necessary, replace gasket (par. 58).
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g. Excessive Oil Consumption.
(1) EXTERNAL OIL LEAKS. Check oil pan drain plug for leaks. If
necessary drain oil, replace plug gasket, and refill crankcase. Check
for leaks along oil pan. Tighten oil pan bolts (par. 63) and replace
gaskets if necessary. Check for leaks at timing gear cover. If leaks
are detected, notify higher authority. Check for leaks at fuel pump
gasket; tighten bolts, or replace gasket. Check for leaks at rocker
arm cover and push rod cover. Replace gaskets if necessary. Check
for leaks at oil lines or oil filter, and make necessary repairs. Check
for oil leak at rear main bearing, which is indicated by engine oil
running out of clutch housing. Notify higher authority.
(2) BURNING OIL. Check by running engine at about % throttle
opening and watch for excessive blue smoke in exhaust. Report to
higher authority.
li. Abnormal Oil Pressure.
(1) Low OIL PRESSURE. Light oil at high operating temperatures
will produce a rather low pressure. If pressure is too low, check for
sufficient oil of good quality in crankcase, and check for oil leaks.
If trouble cannot be located, notify higher authority.
(2) No OIL PRESSURE. Stop engine and check for oil in crankcase.
Disconnect oil line to oil gage, start engine, and check for oil being
forced out of fitting on engine. If oil is not forced out of fitting, oil
pump failure is indicated. Do not run engine. Notify higher authority.
(3) HIGH OIL PRESSURE. Heavy or cold oil produces high oil
pressure. Make sure correct grade of oil is being used. Run engine
just above idling speed until oil is warmed up. If pressure still is
abnormally high, oil lines are probably restricted. Notify higher
authority.
i. Engine Noises. It is often very difficult to determine the exact
cause of engine noises. If unusual noises develop which the driver
is unable to definitely locate and correct, the vehicle should not be
driven until the engine has been inspected by higher authority, and
instructions given regarding its use and repair. When unusual engine
noises develop, check for low or no oil pressure, and abnormally high
temperature reading. Check for sufficient oil in the crankcase and
sufficient solution in the cooling system.
j. Engine Tune-up. Many of the troubles referred to under
trouble snooting can be corrected with a good engine tune-up. See
paragraph 57.
39. CLUTCH.
a. Clutch Drag. With vehicle parked and engine idling, push
clutch pedal clear down, hesitate slightly, and shift transmission into
gear. If the gears clash, a "draggy" clutch is indicated.,Adjust clutch
pedal to obtain 1% inches of free pedal travel (par. 69*). If this does
not correct trouble, the clutch will have to be removed and inspected
(par. 70). Replace damaged parts.
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1>. Clutch Slipping. This can be detected by placing the vehicle
on a hard pull in high gear. Adjust clutch pedal to 1% inches free
travel. If clutch pedal adjustment does not correct trouble, clutch
must be disassembled (par. 70) to check for worn, oil-soaked, or
loose facings. Also check for weak -clutch spring, damaged clutch
pressure plate, or pressure plate lugs binding in cover. Replace
damaged parts.
c. Clutch Grabbing. It will be necessary to disassemble clutch
(par. 70) and inspect the clutch facings for excessive wear, also for
glazed or oil-soaked condition. Replace damaged parts.
d. Clutch Chatter. Clutch chatter on engagement may be caused
by loose engine mountings. Check engine mounting bolts. Dis-
assemble clutch (par. 70), and inspect the disk facings for being
glazed, worn, or oil-soaked. Check pressure plate lug fit in cover.
Replace all damaged parts.
e. Clutch Rattle.
(1) WEAK RETRACTOR SPRINGS. Remove flywheel underpan, and
replace the three retractor springs.
(2) THROWOUT FORK LOOSE ON BALL, CLUTCH DISK CUSHION
SPRINGS BROKEN, OR PRESSURE PLATE LUGS LOOSE IN CLUTCH
COVER. Disassemble clutch and make necessary replacements (par.
70).
40. FUEL SYSTEM.
a. Fuel Does Not Reach Carburetor. Disconnect fuel line from
fitting on carburetor bowl, and crank engine or pump lever on fuel
pump. If fuel is not forced out of fuel line, fuel is not being delivered
to carburetor.
(1) LACK OF FUEL. Check fuel supply in main tank.
(2) VALVE TURNED OFF. Turn on fuel line valve at fuel filter on
right side of frame.
(3) GAS TANK CAP VENT PLUGGED. Clean vent or replace cap.
(4) FUEL FILTER PLUGGED. Remove and clean filter (par. 74).
(5) PLUGGED FUEL LINE. Remove fuel line and blow out with
compressed air.
(6) FUEL PUMP INOPERATIVE. Remove sediment bowl, clean
thoroughly, and install bowl, using a new gasket. Work the fuel
pump priming lever several strokes, which should fill the fuel
pump. If fuel pump fails to operate, replace pump (par. 73), or notify
higher authority.
b. Excessive Fuel in Carburetor. This is caused by leaking
needle valve in carburetor. Replace carburetor or notify higher
authority.
c. Fast Idling.
(1) CARBURETOR CONTROLS STICKING. Check to see that throttle
valve closes until stop screw rests on stop. Lubricate and free-up
controls if necessary.
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(par. 72 b).
d. Will Not Idle.
(par. 72 b).
(2) Low SPEED JET PLUGGED. Notify higher authority, or replace
carburetor (par. 72).
e. Rough Idling. See paragraph 38 f.
f. Engine Misses or Cuts Out on Acceleration. Remove car-
buretor air cleaner, look down into carburetor air horn, and open
and close throttle valve. If accelerating pump is working, a small
stream of fuel will be injected into carburetor from accelerating
pump jet. If pump is not working, replace carburetor or notify
higher authority.
g. Hard Starting.
(1) CHOKE VALVE NOT CLOSING. Remove air cleaner, and pull
choke button on dash all the way out. If valve does not close, adjust
by pushing choke button in, loosening choke lever to control screw,
opening choke valve, and tightening screw. Recheck in choke position.
(2) CHOKE VALVE SPRING BROKEN. Pull choke button all the
way out, and check opening and closing of choke valve by pushing
down on free side of choke valve. Replace carburetor, or notify higher
authority, if the choke valve spring is broken.
41. COOLING SYSTEM.
a. Overheating. This condition is indicated by high temperature
indicator reading, excessive spark knock, loss of power, or boiling of
coolant.
(1) LACK OF COOLANT. Fill cooling system (par. 80 e).
(2) LOOSEN FAN BELT. Adjust fan belt (par. 82).
(3) FAN BELT DAMAGED. Replace fan belt (par. 82).
(4) THERMOSTAT NOT OPENING. Replace thermostat (par. 83).
(5) COOLING SYSTEM CLOGGED. Thoroughly flush cooling system
following instructions furnished with the flushing solution.
(6) FAULTY IGNITION. See paragraph 42 a.
(7) FAULTY WATER PUMP. Replace water pump (par. 81).
b. Overcooling. Indicated by low temperature indicator reading
and time required for engine to warm up.
(1) THERMOSTAT FAILURE. Replace thermostat (par. 83).
(2) WATER BYPASS SHUT-OFF COCK OPEN. Close shut-off cock
on left side of cylinder head. See instructions on metal tag attached
to shut-off cock (par. 6 m).
c. Loss of Coolant.
(1) LEAKING RADIATOR. Replace radiator (par. 80) or notify
higher authority.
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(2) LOOSE OR DAMAGED HOSE CONNECTIONS. Tighten or replace
hose connections.
(3) LEAKY WATER PUMP. Replace pump (par. 81).
(4) PRESSURE RADIATOR CAP NOT SEALING PROPERLY. Replace
cap gasket.
(5) LEAKS AT CYLINDER HEAD GASKET. Replace gasket (par. 58).
(6) LEAKY CYLINDER EXPANSION PLUGS OR CRACKED CYLINDER
BLOCK. Notify higher authority.
(7) CRACKED CYLINDER HEAD. Replace cylinder head (par. 60).
(8) OVERHEATING. See subparagraph a above.
42. ELECTRICAL SYSTEM.
a. Ignition System.
(1) HARD STARTING.
(a) Distributor Points Faulty. Remove distributor cap, clean
points, replacing if badly pitted, and adjust gap to 0.018 inch (par.
87 c).
(b) Spark Plugs Faulty. Remove, clean, inspect, and adjust spark
plugs (par. 42 a (3)).
(c) High Tension Wires Faulty. Inspect high tension wires for
poor insulation, shorting, and corroded terminals. Replace if neces-
sary.
(d) Loose Terminals in Primary Circuit. Clean and tighten all
terminals in the primary ignition circuit between battery and dis-
tributor.
(e) Low Capacity Condenser. Test by trying a condenser that
is known to be of standard capacity.
(f) Battery Not Fully Charged or Faulty. This can usually be
detected by slow cranking speed. Install fully charged battery (par.
94).
(g) Low Capacity Coil. Test by installing a coil that is known
to be up to specifications.
(h) Carburetor or Fuel System Faulty. See paragraph 40.
(2) ENGINE FAILS TO START.
(a) Starting System Trouble. Trouble in the starting system is
usually detected by slow cranking speed (subpar. b below).
(b) Fuel System Trouble. See paragraph 40.
(c) Loose Connections in Primary Circuit. Clean and tighten all
connections in the primary circuit between battery and distributor.
(d) High Tension Wires Shorting. Check high tension wiring for
damaged insulation. Replace damaged wires.
(e) Distributor Faulty. Clean and adjust distributor points and
time engine (par. 86). Check distributor cap and rotor for cracks
or damage. Replace damaged parts.
(f) Coil or Condenser Faulty. If facilities for testing are not
available, replace these units (one at a time) with units known to
be satisfactory (par. 87 d and 88 a).
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1 y2-TON 4x4 TRUCK (Chevrolet)
(6) Ignition System Shorted. Check for wet high-tension wires,
spark plugs, and distributor; if wet, dry them thoroughly. With igni-
tion switch turned on, note the ammeter reading. If it is high, a short
in the primary circuit is indicated. Check primary circuit wiring
carefully to locate short circuit.
(3) ENGINE MISFIRES. See paragraph 38 d.
(a) Spark Plugs Faulty. Test by shorting spark plugs one by
one to determine the cylinder that is misfiring. Remove spark plugs
and check for cracked porcelains, badly burned electrodes, excessive
deposits, or being fouled. Replace plugs if found in bad condition.
Clean, adjust, and install spark plugs (par. 88 c).
(b) High Tension Wires Faulty. Check condition of high tension
wires. Replace all wires that have poor insulation.
(c) Distributor Cap Faulty. Check distributor cap for cracks and
damaged terminals. Replace distributor cap if damage is found.
b. Battery and Starting System.
(1) SLOW CRANKING SPEED.
(a) Partially Discharged Battery. Check with hydrometer. If
reading is below 1.250, charge or exchange battery (par. 94).
(b) Low Capacity Battery. Test each cell with a high-discharge
cell-testing voltmeter. If low capacity or shorted cell is found, replace
battery (par. 94).
(c) Loose or Corroded Terminals in Starting Circuit (fig. 48).
Thoroughly clean and tighten all connections and terminals in the
starting system.
(d) Burned Cranking Motor Switch Contacts. Remove cranking
motor switch and examine contacts; if they are burned, replace switch
(par. 90).
(e) Heavy Oil in Engine. Change to proper grade (par. 28 c (4)).
(f) Cranking Motor Faulty. If the above checks did not reveal
the trouble, the cranking motor is evidently at fault. Notify higher
authority, or replace cranking motor (par. 90).
(2) CRANKING MOTOR WILL NOT OPERATE.
(a) Discharged Battery. Test with hydrometer; if below 1.250,
replace or charge battery.
(b) Battery Cables or Terminals Faulty. Inspect, clean, and
tighten terminals. Replace damaged cables.
(c) Faulty or Damaged Cranking Motor or Cranking Motor
Drive. Notify higher authority, or replace cranking motor (par. 90).
(3) STARTING SYSTEM TESTS OK BUT ENGINE DOES NOT TURN.
(a) Transmission in Gear. Shift transmission to neutral.
(b) Engine Seized. Attempt to turn engine with starting crank;
if it will not turn, try turning water pump by fan blades. If pump
will not turn, replace pump (par. 81). Remove pistons, and again
try to turn engine with starting crank. If engine cannot be turned
with spark plugs removed, notify higher authority.
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TROUBLE SHOOTING
(4) BATTERY DISCHARGED. Test with battery hydrometer. The
following items may cause a discharged battery.
(a) Discharged Through Equipment. Check to see that the igni-
tion, light, heater, or other accessory switches have not been left
turned on. Install a fully charged battery. After connecting the posi-
tive cable, touch ground strap to negative terminal of battery, and
note carefully for any spark that would indicate a short or complete
circuit in the system. Connect ground strap and watch ammeter for
any signs of discharge. If any discharge is noted, a thorough check
of the circuits must be made.
(b) Low or No Charging Rate. See subparagraph c (4) below.
(c) Generator-regulator Cutout Relay Points Sticking. This can
be detected by a high rate discharge with engine idling or turned off.
Replace regulator (par. 89 c).
c. Generator and Regulator.
(1) GENERAL. As the charging rate of the generator is governed
by the state of charge of the battery, it is important that the battery
be tested and the terminals checked (par. 94), before condemning
the generator or the regulator. The following paragraphs outline
several tests that will assist in determining whether the trouble is
in the generator, the regulator, or the wiring.
(2) FULLY CHARGED BATTERY AND A Low CHARGING RATE. This
indicates normal voltage regulator operation. To check the current
regulator, remove the battery wire from the battery ("BAT")
terminal of the regulator. Connect the positive lead of an ammeter
to the battery terminal of the regulator, and the negative lead to
the battery wire. With the ignition switch in the "OFF" position,
step on the starting switch, and crank the engine for about 15
seconds. Then start the engine and, with it running at medium
speed, turn on lights, radio, and other electrical accessories; note
quickly the generator output, which should be approximately 40
amperes. Now turn off the lights, radio, and other accessories, and
allow the engine to continue running. As soon as the generator has
replaced in the battery the current used in cranking, the voltage
regulator, if operating properly, will taper the output down to a
few amperes.
(3) FULLY CHARGED BATTERY AND A HIGH CHARGING RATE.
Disconnect the field wire from the field ("F") terminal of the
regulator. This opens the generator field circuit, and the output
should immediately drop off. If it does not, the generator and field
wires are shorted together in the wiring harness. If the output drops
off to "ZERO" with the field lead disconnected, the trouble has been
isolated in the regulator. Notify higher authority, or replace the regu-
lator (par. 89 c).
(4) Low BATTERY AND A Low OR No CHARGING RATE. Check
the circuit for loose connections, corroded battery terminals, loose
or corroded ground strap, and frayed or damaged wires. The high
resistance resulting from these conditions will prevent normal charge
from reaching the battery. If the entire charging circuit is in good
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TM 9-805
42
condition, then either the regulator or generator is at fault. With a
jumper wire connect the field and armature terminals together.
Increase the generator speed, and check the output. If the output
increases, the regulator requires attention and must be replaced
(par. 89 c). If the output does not increase, the generator is not
functioning properly. Check the fan belt for proper adjustment.
Remove the cover band, and inspect the commutator for dirt, which
can be cleaned with No. 00 flint paper, and the dirt blown out. If
the output still does not increase, flash the armature terminal to
ground with a screwdriver, with the generator operating at medium
speed. If a spark does not occur, the trouble is in the generator.
Notify higher authority, or replace generator (par. 89 h).
(1. Temperature Indicator.
(1) INDICATOR HAND STAYS IN "HOT" RANGE. This indicates
damaged indicator caused by overheating. Replace indicator (par.
91 b).
(2) INDICATOR HAND STAYS IN "COLD" RANGE. If hand stays in
"COLD" position it may indicate a damaged thermostat; remove
thermostat and see if it is holding open (par. 83). If hand does not
move on gage, check for a leak in the indicator line. Replace indi-
cator (par. 91 b).
e. Fuel Cage. The ignition switch must be turned on to provide
a circuit for the fuel gage. The gage consists of a tank unit, dash unit,
and the wiring. These three items must be taken into consideration
when trouble shooting the fuel gage.
(1) GAGE SHOWS EMPTY AT ALL TIMES. Check for loose con-
nections at ignition switch and dash unit. Disconnect tank unit wire
from dash unit; if gage shows full, dash unit is OK. If gage con-
tinues to show empty, replace dash unit (par. 91 c (2)). Connect wire
to dash unit, and disconnect wire from tank unit; if gage shows full,
the tank unit is shorted and must be replaced (par. 91 c (3)). If
gage does not show full, the wire is shorted.
(2) GAGE SHOWS FULL AT ALL TIMES. Check for loose connec-
tions or high resistance at the tank terminal of dash unit, at the
tank unit terminal, and tank unit ground wire. If gage continues to
show full, disconnect wire from tank unit, and ground end of wire
to frame. If gage still shows full, there is an open circuit in the
wiring. Repair or replace dash unit to tank wire. If gage shows
empty with end of wire grounded, there is an open circuit in the
tank unit and it must be replaced (par. 91 c (3)).
f. Speedometer.
(1) DOES NOT REGISTER SPEED OR MILEAGE. Disconnect cable
from speedometer head, and drive vehicle or jack up rear wheels;
start engine, and place controls in position for two-wheel drive.
Check to see if end of speedometer cable is turning. If cable turns,
speedometer head must be replaced (par. 91 f). If cable does not
turn, disconnect cable from transfer case. If end of speedometer
driven gear shaft in transfer case turns, cable is broken and should
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TM 9-805
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TROUBLE SHOOTING
be replaced. If speedometer gear shaft in transfer case does not turn,
the speedometer drive and driven gear must be replaced. Notify
higher authority.
(2) DOES NOT REGISTER SPEED. Replace speedometer (par.
91 f).
(3) DOES NOT REGISTER MILEAGE. Replace speedometer (par.
91 fV
(4) REGISTERS MILEAGE ACCURATELY BUT SPEED NOT ACCURATE.
Replace speedometer, or notify higher authority.
(5) SPEEDOMETER NOISE. Disconnect cable from speedometer
head; if noise stops, replace speedometer head. If noise does not stop,
. disconnect cable from fitting on transfer case; if noise stops, replace or
lubricate cable. If noise does not stop, notify higher authority.
g. Oil Pressure Gage.
(1) GAGE SHOWS PRESSURE WITH ENGINE NOT RUNNING. Dis-
connect line from back of gage; if gage does not return to zero, re-
place gage (par. 91 g). If gage returns to zero, the line is restricted.
Clean out line, or notify higher authority.
(2) GAGE WILL NOT SHOW PRESSURE. This is an indication of
engine trouble. Do not run engine. Check oil level in crankcase. Dis-
connect pressure gage line from fitting on left side of engine; crank
engine several revolutions. If oil is not forced out of fitting, notify
higher authority. If oil is forced out of fitting, replace gage (par.
91 g).
h. Ammeter. If the ammeter is thought to be faulty, the simplest
method of checking is to install an ammeter that is known to be
satisfactory, and compare the reading under the same operating con-
ditions.
i. Lighting.
(1) ALL LIGHTS BURN DIM.
(a) Discharged Battery. Test battery with hydrometer, and if
necessary test with voltmeter (par. 94 b). Replace or recharge low
battery.
(b) Loose or Corroded Connections. Check, tighten, and clean
all connections between battery and lighting switch.
(2) INDIVIDUAL LIGHT OR LIGHTS BURN DIM. Check the indi-
vidual light circuit for loose or corroded connections. Check the light
for poor ground connections. Make necessary corrections.
(3) ALL LIGHTS Do NOT BURN. Check for discharged battery
and poor connections between battery and lighting switch. With
lighting switch turned on, check for open-circuited lighting switch
circuit breaker by connecting the two terminals on circuit breaker
with a jumper wire. If the lamps light with the jumper in place, the
lighting switch assembly should be replaced. Check individual cir-
cuits for short circuit.
(4) INDIVIDUAL LIGHTS Do NOT BURN. Check for burned out
lamp or lamps, loose connections in the individual circuit, and poor
ground at the individual light.
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TM 9-805
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(5) CIRCUIT BREAKER CLICKS ON AND OFF. This indicates a
short circuit in the lighting system. Check the light switch in each
position to isolate the short in an individual circuit. If necessary,
disconnect the wires one-by-one from the switch until the short is
traced to an individual circuit. Trace the wire, and insulate or
replace the damaged wire or unit.
j. Radio Suppression.
(1) The radio suppression equipment is installed to control the
radiation of radio interference by the electrical equipment of the
truck. It is very important that the equipment have tight, clean
connections. Periodically tighten all bond straps, filter, and con-
denser connections. Tighten the plated bolts in front end sheet
metal assembly.
(2) RADIO INTERFERENCE.
(a) Poor Bond Strap Connections. Tighten all bond strap attach-
ing bolts or remove bolts; clean surfaces and reinstall bolts, using
plated toothed lock washers.
(b) Poor Bonds at Sheet Metal. Tighten all sheet metal attach-
ing bolts, making sure that the toothed lock washers are used on all
plated bolts.
(c) Test for Continued Interference. Start the engine, and run
at a fast idle to see if the above repairs corrected the trouble. If
trouble still exists, speed up engine and turn off ignition switch. If
noise continues, it is in generator and regulator system; however,
if noise stops as soon as ignition is turned off, the noise is in the
ignition system.
(d) Noise in Generator-regulator System. Check the mounting
and connections of the three filters at regulator, and the filter and
condenser at the generator. Remove the generator band; inspect and
clean the commutator. If commutator is badly burned or worn,
replace the generator. Test the circuit as instructed in subparagraph
(c) above. If noise still exists, change the filters and condenser one-
by-one, testing after each installation until the faulty unit is located.
(e) Noise in Ignition System. If the test in subparagraph (c)
above indicated that the trouble was in the ignition system, check
all electrical connections in the primary and secondary circuits to
see that they are tight and clean. Check, clean, and adjust or replace
distributor points (par. 87). Check, clean, and adjust or replace
spark plugs (par. 88). Check for oil-soaked or damaged high ten-
sion wires. Check for cracked or damaged distributor cap. Replace
damaged parts. Check distributor and ignition coil filters for good
connections and tight mounting. Start engine and test for radio
interference. If interference exists, replace the two filters and seven
suppressors one-by-one, testing between replacements until inter-
ference is eliminated.
43. TRANSMISSION (sec. XX).
a. Slips Out of High Gear.
(1) TRANSMISSION MOUNTING BOLTS LOOSE. Tighten the four
bolts attaching the transmission to clutch housing.
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TROUBLE SHOOTING
(2) SHIFT LOCK SPRING WEAK OR BROKEN. Disengage clutch and
move shifting lever slowly between high gear, neutral, and third
gear to check for lock ball dropping in shaft groove. If a pronounced
locking action is not detected, the spring is weak or broken. Notify
higher authority or replace transmission (pars. 97 and 98).
(3) DAMAGED MAIN SHAFT PILOT BEARING. This can usually be
detected by idling engine with clutch engaged, or driving in third
gear and listening for bearing noise. Notify higher authority, or
replace transmission.
b. Slips Out of Low Gear.
(1) SHIFT LOCK SPRING WEAK OR BROKEN. Test by shifting
slowly between low gear, neutral, and second gear. If a pronounced
locking action is not noted in the three positions, the spring is
evidently weak or broken. Notify higher authority or replace trans-
mission (pars. 97 and 98).
(2) WORN Low SPEED GEARS. Usually results in gear noise as
well as jumping out of gear. Notify higher authority, or replace trans-
mission (pars. 97 and 98).
c. Noisy Gears. Notify higher authority, or replace transmission
(pars. 97 and 98).
d. Difficulty in Shifting into Low Gear. When shifting into low
or second gear, pull the lever to left as far as it will go, and attempt
to-shift into low and second; if shifts cannot be made, move lever
. slightly to right and try again; if shift can be made, the reverse
latch on lower end of shift lever or interlock guide plate is worn.
Notify higher authority, or replace transmission (pars. 97 and 98).
e. Lubricant Leaks into Clutch Housing.
(1) TRANSMISSION LUBRICANT LEVEL HIGH. Drain down to cor-
rect level.
(2) CLUTCH GEAR BEARING RETAINER LOOSE. Remove trans-
mission, tighten retainer screws, and install transmission (par. 98).
f. Lubricant Leaks at Rear of Transmission.
(1) BEARING RETAINER LOOSE. Tighten bearing retainer screws.
(2) BEARING RETAINER GASKET DAMAGED. Notify higher author-
ity, or replace transmission (pars. 97 and 98).
(3) IDLER GEAR SHAFT LOOSE. Notify higher authority, or replace
transmission (pars. 97 and 98).
44. TRANSFER CASE (sec. XXI).
a. Lubricant Leaks.
(1) BEARING RETAINERS LOOSE. Tighten bearing retainer cap
screws.
(2) BEARING RETAINER GASKETS DAMAGED. Replace gaskets or
notify higher authority.
(3) OIL SEALS DAMAGED. Notify higher authority, or replace
transfer case (pars. 101 and 102).
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11/2-TON 4x4 TRUCK (Chevrolet)
(4) CASE CRACKED. Notify higher authority, or replace transfer
case (pars. 101 and 102).
b. Slips Out of Gear.
(1) SHIFT LOCK SPRING WEAK OR BROKEN. Notify higher author-
ity, or replace transfer case (pars. 101 and 102).
(2) MISALINEMENT OF MAIN SHAFT EXTENSION. Notify higher
authority, or replace transfer case (pars. 101 and 102).
(3) IMPROPER ADJUSTMENT OF SHIFTER SHAFT CONTROL RODS.
Adjust control rods (par. 100).
45. PROPELLER SHAFTS (sec. XXII).
a. Vibration.
(1) BENT PROPELLER SHAFT. Replace shaft (pars. 104 and 105).
(2) SHAFT IMPROPERLY ASSEMBLED. Check to see that the slip
joint is installed on the shaft with the sleeve yoke in the same plane
as the yoke welded to the opposite end of shaft.
(3) UNIVERSAL JOINTS BADLY WORN. Replace worn joint or
propeller shaft (pars. 104 and 105).
b. Excessive Backlash.
(1) WORN UNIVERSAL JOINTS. Replace propeller shaft (pars.
104 and 105).
(2) UNIVERSAL JOINT U-CLAMPS LOOSE. Tighten U-clamps.
c. Noisy Universal Joints.
(1) LACK OF LUBRICANT. Lubricate joints.
(2) WORN UNIVERSAL JOINT. Replace joint or propeller shaft
(pars. 104 and 105).
46. FRONT AXLE.
a. Hard Steering.
(1) STEERING GEAR TROUBLE. See paragraph 51.
(2) LACK OF LUBRICANT. Lubricate tie rod ends and steering con-
necting rod.
(3) Low TIRE PRESSURE. Inflate front tires to 55 pounds.
(4) TIE ROD BOLTS TIGHT. Adjust tie rod bolts by removing
cotter pins, tightening nuts just wrench-tight, and backing them off
y2 turn. Install cotter pins.
(5) STEERING KNUCKLE BEARINGS DRY OR Too TIGHT. Notify
higher authority.
(6) IMPROPER TOE-IN. Adjust toe-in (par. 108).
b. Lubricant Leaks.
(1) LEAKS AT STEERING KNUCKLE SUPPORT. Replace seal and
gasket (par. 110).
(2) LEAKS AT AXLE HOUSING COVER GASKET. Tighten attaching
screws; or, drain lubricant, remove cover, and replace gasket.
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TROUBLE SHOOTING
(3) LEAKS AT DIFFERENTIAL CARRIER GASKET. Tighten carrier
attaching bolts or replace gasket. See third member replacement
(par. 112).
c. Shimmy.
(1) STEERING GEAR TROUBLE. See paragraph 51.
(2) TIE ROD BUSHINGS WORN. Notify higher authority.
(3) IMPROPER TIRE INFLATION. Inflate front tires to 55 pounds.
(4) LOOSE FRONT WHEEL BEARINGS. Adjust front wheel bearings
(par. 133).
(5) STEERING KNUCKLE BEARINGS LOOSE. Notify higher
authority.
(6) IMPROPER CASTER. Notify higher authority.
(7) WHEELS LOOSE ON HUBS. Tighten wheel attaching nuts.
d. Wandering.
(1) FRONT WHEEL BEARINGS OUT OF ADJUSTMENT. Adjust front
wheel bearings (par. 133).
(2) SPRING CENTER BOLT SHEARED AND AXLE SHIFTED. Replace
center bolt and tighten U-bolts securely.
e. Noisy Differential.
(1) LACK OF LUBRICANT. Fill differential to correct level.
(2) FAULTY GEARS OR BEARINGS. Report to higher authority.
47. REAR AXLE.
a. Lubricant Leaks.
(1) LEAKS AT AXLE HOUSING COVER. Tighten cover retaining
bolts; or, drain lubricant, remove cover, install new gasket, and
install cover.
(2) LEAKS AT DIFFERENTIAL CARRIER GASKET. Tighten carrier
attaching bolts, or replace gasket. See third member assembly re-
placement (par. 116).
(3) LEAKS AT AXLE FLANGE. Install new gaskets and tighten
bolts securely.
b. Noisy Differential.
(1) LACK OF LUBRICANT. Fill differential to correct level.
(2) FAULTY GEARS OR BEARINGS. Report to higher authority.
c. Excessive Backlash.
(1) AXLE SHAFT FLANGES LOOSE. Install new terne plate gasket
and tighten bolts securely.
(2) WORN DIFFERENTIAL AND SIDE GEAR SPACERS. Notify higher
authority.
(3) WORN UNIVERSAL JOINTS. Replace propeller shaft, (par. 104).
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TM 9-805
48
48. BRAKE SYSTEM.
a. Brake Pedal "Spongy." "Spongy" brake pedal action indi-
cates air in hydraulic system. Bleed brakes (par. 123).
b. AH Brakes Drag.
(1) IMPROPER PEDAL TOEBOARD CLEARANCE. Adjust pedal toe-
board clearance (par. 122 b).
(2) DIRT IN MASTER CYLINDER COMPENSATING PORT. Replace
master cylinder (par. 124).
(3) MINERAL OIL IN SYSTEM. Replace master and wheel cylin-
ders, flush system, and refill with correct fluid (pars. 124 and 125).
c. One Brake Drags.
(1) LOOSE WHEEL BEARINGS. Adjust wheel bearings (par. 133).
(2) WEAK OR BROKEN RETRACTOR SPRING. Replace retractor
spring (par. 126).
(3) IMPROPER BRAKE SHOE ADJUSTMENT. Readjust brake shoes.
d. Excessive Pedal Travel.
(1) NORMAL LINING WEAR. Adjust brake (par. 122).
(2) FLUID Low IN MASTER CYLINDER. Fill master cylinder and
bleed all brakes (par. 123).
e. Brake Pedal Applies Brakes but Pedal Gradually Goes to
Floor.
(1) EXTERNAL LEAKS. Apply brakes, force pedal on down to
floor two or three times, and check for external leaks at master cylin-
der, wheel cylinders, and all lines. Make necessary repairs or replace-
ments.
(2) MASTER CYLINDER LEAK PAST PRIMARY CUP. If external
leaks were not found in the above test, it is evident that the master
cylinder primary cup is leaking. Replace master cylinder (par. 124).
f. Brakes Uneven.
(1) OIL ON LININGS. Thoroughly clean brake mechanism and
install new linings (par. 126). Correct cause of oil leaking on brake
lining.
(2) TIRES IMPROPERLY INFLATED. Inflate tires according to
specifications (par. 131).
(3) SPRING CENTER BOLT SHEARED AND SPRING SHIFTED ON
AXLE. Replace center bolt and tighten U-bolts securely.
g. Excessive Pedal Pressure Required, Poor Brakes.
(1) GREASE, MUD OR WATER ON LININGS. Remove drums and
clean linings.
(2) FULL AREA OF LININGS NOT CONTACTING DRUMS. Free-up
shoe linkage, sand lining, or replace shoes or drums if damaged.
(3) SCORED BRAKE DRUMS. Replace drums (par. 126).
(4) HYDROVAC SYSTEM NOT OPERATING PROPERLY. See sub-
paragraph h below.
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TROUBLE SHOOTING
h. Hydrovac System Fails to Operate.
(1) RESTRICTED HYDROVAC AIR CLEANER. Clean and lubricate
air cleaner (par. 28 c (3)).
(2) VACUUM LINE LEAKS. This generally produces a rough idling
engine as well as hydrovac trouble. Correct air leaks.
(3) HYDROVAC LINE CHECK VALVE STICKING. Remove valve,
disassemble, and clean thoroughly.
(4) LACK OF LUBRICANT IN HYDROVAC CYLINDER. Lubricate
cylinder (par. 28 c (11)).
(5) WORN OR DAMAGED PARTS IN HYDROVAC. Replace hydrovac
(par. 128).
49. WHEELS, WHEEL BEARINGS, HUBS, AND TIRES.
a. Hard Steering.
(1) TIRES UNDERINFLATED. Inflate tires to recommended pres-
sure (par. 131 b (4)).
(2) STEERING GEAR OR FRONT AXLE TROUBLES (pars. 46 and 51).
b. Tires Leak Air.
(1) VALVE CORE LEAKS. Tighten or replace valve core.
(2) TUBE LEAKS. Remove tire and check tube for leaks (par.
132). Patch or vulcanize tube.
c. Uneven or Excessive Tire Wear.
(2) IMPROPER TIRE PRESSURE. Maintain correct tire pressure.
(3) IMPROPER CASTER OR CAMBER. If the caster or camber are
thought to be incorrect, notify higher authority.
(4) EXCESSIVE USE OF FOUR-WHEEL DRIVE. Use four-wheel drive
only where additional traction is required.
(5) SPRUNG WHEELS. Check wheels by jacking up vehicle and
turning wheels. Replace wheels having excessive run-out.
(6) AXLE SHIFTED ON SPRING SEAT. Replace spring center bolt if
necessary, and tighten U-bolts.
d. Wheels Loose on Hub Bolts. Improperly tightened or elon-
gated holes in hub, due to running with loose wheel nuts. Tighten
nuts, and if holes are elongated, replace wheel.
e. Wheel Bearings Loose.
(1) IMPROPERLY ADJUSTED. Adjust according to instructions in
paragraph 133.
(2) BEARINGS WORN OR DAMAGED. Replace bearings (par. 134).
50. SPRINGS AND SHOCK ABSORBERS.
a. Hard Riding.
(1) INSUFFICIENT LUBRICATION. Lubricate chassis (par. 28).
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TM 9-805
50-51
(2) BROKEN SPRING HANGER, SHACKLE PIN, OR SPRING EYE.
Replace broken part or notify higher authority.
(3) No SHOCK ABSORBER ACTION. Disconnect shock absorber
link and move arm up and down. If movement is not controlled, fill
shock absorber (par. 138 b), and recheck. If condition is not corrected,
replace shock absorber (par. 138 a). If shock absorber arm catches or
binds, replace shock absorber.
b. Excessive Flexibility.
(1) BROKEN SPRING LEAVES. Replace spring (par. 137).
(2) SHOCK ABSORBER FLUID Low. Fill shock absorber (par.
138 b).
(3) BROKEN SHOCK ABSORBER. Disconnect shock absorber link,
and check absorber action. If shock absorber arm binds or moves
without shock control, replace assembly (par. 138 a).
c. Excessive Noise.
(1) WORN SHACKLE PINS AND BUSHINGS. Replace worn parts
(par. 136), or notify higher authority.
(2) DRY SPRING LEAVES. Lubricate spring, or notify higher
authority.
(3) LOOSE SPRING CLIPS. Tighten spring clips.
(4) LOOSE SPRING SHACKLES. Notify higher authority.
(5) BROKEN SHOCK ABSORBER. Disconnect shock absorber link
and work arm up and down; if there is free movement for a short
distance, and the arm then comes to a definite stop, replace shock
absorber.
51. STEERING ARM.
a. Hard Steering.
(1) LACK OF LUBRICATION. Lubricate steering gear, tie rod ends,
and steering connecting rod.
(2) TIE ROD ADJUSTED Too TIGHT. Remove tie rod bolt cotter
pin, tighten nut wrench-tight, and back off % turn. Install cotter pin.
(3) UNDERINFLATED TIRES. Innate front tires to 55 pounds.
(4) IMPROPER STEERING GEAR ADJUSTMENT. Adjust steering gear
(par. 143).
(5) TIGHT, DRY OR DAMAGED STEERING KNUCKLE BEARINGS.
Notify higher authority.
(6) IMPROPER FRONT AXLE ALINEMENT. See paragraph 106 b.
b. Loose Steering.
(1) IMPROPER STEERING GEAR ADJUSTMENT. Adjust steering gear
(par. 143).
(2) LOOSE STEERING CONNECTING ROD JOINTS. Adjust steering
connecting rod ends (par. 141), or replace worn parts.
(3) WORN TIE ROD BOLT BUSHINGS. Notify higher authority.
c. Vehicle Pulls to One Side.
(1) UNEQUAL TIRE PRESSURE. Innate front tires to 55 pounds.
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TROUBLE SHOOTING
(2) DRAGGING BRAKES. Adjust brakes (par. 122).
(3) TIGHT OR DAMAGED WHEEL BEARINGS. Adjust or replace
wheel bearings (par. 133).
(4) IMPROPER CASTER OR CAMBER. Notify higher authority.
d. Wander or Weaving.
(1) TIGHT STEERING GEAR. Adjust steering gear (par. 143).
(2) LOOSE STEERING GEAR. Adjust steering gear (par. 143).
(3) TIGHT, DRY, OR DAMAGED STEERING KNUCKLE BEARINGS.
Notify higher authority.
(4) IMPROPER FRONT END ALINEMENT. Notify higher authority.
e. Road Shocks Transferred to Steering Wheel.
(1) STEERING CONNECTING ROD ASSEMBLED WRONG OR IM-
PROPERLY ADJUSTED. See paragraph 141.
(2) STEERING GEAR IMPROPERLY ADJUSTED. Adjust steering
gear (par. 143).
52. CAB, BODY, AND FRAME.
a. - Windshield Leaks.
(1) TEST FOR LEAKS. Force the windshield adjusting arms all the
way down to close windshield, and lock the center of windshield with
clamp lock. Sit in cab and watch for leaks while an assistant sprays
water on windshield and front of cab. Leaks may occur between
weatherstrip and cab windshield frame, between windshield glass and
windshield frame or at windshield center channel.
(2) LEAKS AT WINDSHIELD DIVISION CHANNEL. Remove the
center division channel attachings screws and inner channel. Seal with
a suitable waterproof sealing compound.
(3) LEAKS BETWEEN WINDSHIELD WEATHERSTRIP AND CAB
OPENING. Adjust hinge mounting to center windshield in opening.
Replace rubber weatherstrip if it is damaged (par. 146 c). When the
weatherstrip is in good condition, and the windshield has been ad-
justed to the opening, a slight leak at one or two points can be cor-
rected by opening the windshield, pushing the lip of weatherstrip
toward windshield opening, and working a strip of friction tape
folded to four thicknesses in between the outer edge of weatherstrip
and outer flange of windshield frame. In some cases it may be neces-
sary to shim between the hinges and windshield frame to increase the
weatherstrip tension at the top.
b. Doors Close Hard.
(1) LACK OF LUBRICATION. Lubricate door hinges, door check
strap, door lock bolt, door lock striker plate, door dovetail plate, and
door dovetail.
(2) DOOR HINGES SPRUNG. Replace door hinges.
c. Door Windows Will Not Raise. Check for damaged run
channels, or obstructions in window opening. Notify higher authority.
93
TM 9-805
52-55
(1. Windshield Wipers Will Not Operate.
(1) LEAK OR OBSTRUCTION IN VACUUM LINE. Disconnect vacuum
line from wiper, and check for normal vacuum. Make necessary
repairs.
(2) WIPER WILL NOT OPERATE. Notify higher authority, or
replace wiper (par. 146 d).
e. Frame Bent or Sagged. Notify higher authority.
f. Frame Rivets Loose. Notify higher authority.
53. POWER TAKE-OFF.
a. Leaks Lubricant.
(1) LEAKS AT MOUNTING. Tighten mounting bolts, or replace
gasket between power take-off and transmission (par. 155 c).
(2) LEAKS AT POWER TAKE-OFF COVER GASKET. Tighten cover
bolts, or replace gasket.
(3) LEAKS AT CAPS OR SEALS. Tighten cap retaining screws,
replace gaskets, or notify higher authority.
b. Will Not Stay in Gear. Disconnect shift pull rod, shift gear
into position until lock ball drops into groove, and adjust pull rod to
correct length with lever in position. If this does not correct trouble,
notify higher authority, or replace power take-off.
c. Gears Noisy. Check lubricant level in power take-off. Notify
higher authority.
54. WINCH.
a. Winch Drum Brake Will Not Hold. If the winch cable loosens
up on drum when poppet is in position in hole in cross member, the
brake should be adjusted (par. 161 c (1)).
b. Winch Will Not Drive.
(1) SHEAR PIN IN DRIVE SHAFT JOINT BROKEN. Replace shear
pin (par. 161 c (3)).
(2) JAW CLUTCH NOT ENGAGED. Engage jaw clutch.
(3); POWER TAKE-OFF NOT OPERATING. Check to see that power
take-off is shifted into gear. If power take-off output shaft does hot
turn, notify higher authority or replace power take-off.
c. Worm Brake Will Not Hold. If the winch will not hold a
normal load with the power cut off, the worm brake should be
adjusted (par. 161 c (2)).
55. HYDRAULIC HOIST.
a. Leaks Oil. Check for oil leaks at all flange, plate, cover, and
fitting gaskets. Tighten attaching screws, bolts, or nuts. Check for
leaks at packing glands; tighten if necessary. Check for leaks at pipe
fittings or manifold studs; tighten if necessary. If the above checks
or corrections fail to stop the leaks, notify higher authority, replace
gaskets or packings if advisable, or replace hoist assembly.
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TM 9-805
55
TROUBLE SHOOTING
b. Will Not Raise Body Clear Up. Check for lack of oil in
system and fill system (pars. 164 b, 165 b, or 166 b).
c. Will Not Hold in Desired Position.
(1) CONTROL VALVE LINKAGE NOT ADJUSTED PROPERLY. Adjust
control valve control rod length, and recheck until correct operation
is obtained.
(2) OIL LEAK PAST PISTON. Notify higher authority, or replace
hoist assembly. ,
d. Will Not Raise Body.
(1) LACK OF OIL. Fill system (pars. 164 b, 165 b, or 166 b).
(2) PUMP GEARS NOT TURNING. Check for disconnected drive
line or loose drive yoke on pump drive shaft. Make necessary repairs
or replacement.
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TM 9-805
56
TVa-TON 4x4 TRUCK (Chevrolet)
Section XIII
ENGINE-DESCRIPTION, DATA, MAINTENANCE,
AND ADJUSTMENT IN VEHICLE
Description and tabulated data 56
Tune-up 57
Cylinder head and gasket removal 58
Carbon removal 59
Cylinder head and gasket installation 60
Valve tappet adjustment 61
Intake and exhaust manifolds and gaskets 62
Oil pan 63
Oil filter ,... 64
Crankcase ventilator 65
56. DESCRIPTION AND TABULATED DATA.
a. Description. The engine is a 4-cycle, gasoline, 6-cylinder, in-
line, valve-in-head type. The engine number is stamped on a ma-
chined surface in the right side of the block just back of the
distributor. The cylinders are numbered consecutively from the fan,
or front end of the engine. The engine runs in a clockwise direction,
as viewed from the front.
b. Data.
Model Chevrolet BV 1001 up
Number of cylinders 6
Firing order 1-5-3-6-2-4
Bore and stroke 3%6 in. x 3l%6 in.
Piston displacement 235.5 cu in.
Compression ratio 6.62 to 1
Maximum brake horsepowerat
3,100 rpm 93
Rated horsepower (SAE) 30.4
Weight of engine and clutch 574 Ib
Torque, ft-lb 182
Oil capacity 5 qt
Oil filler location Right side
Oil gage rod Right side, back of
distributor
Oil drain location Bottom, rear of pan
96
TM 9-805
57
AROCKER ARM COVER AIR CLEANER
BCARBURETOR AIR CLEANER
CGENERATOR REGULATOR UNIT
DHORN
ECARBURETOR
FWATER BY-PASS SHUT-OFF COCK
GENGINE GOVERNOR
HWINDSHIELD WIPER VACUUM LINE
IHYDROVAC VACUUM CHECK VALVE
LINE
JMANIFOLD HEAT CONTROL VALVE
KCRANKCASE VENTILATION VACUUM
LINE
LACCELERATOR LEVER (BELL CRANK
TO CARBURETOR)
MACCELERATOR LEVER (BELL CRANK
TO ACCELERATOR PEDAL)
NIDLE ADJUSTMENT -SCREW
OTHROTTLE STOP SCREW
RA PD 33073
Figure 1 7Engine in Chassis, Left Side
57. TUNE-UP.
a. General. One of the most important operations in the main-
tenance of the engine is proper engine tune-up. This operation, more
than any other, will determine whether or not the engine delivers
the maximum in performance and economy.
h. Compression Test (fig. 19).
(1) Before making any checks on an engine, run it for several
minutes to warm it up and lubricate the valve mechanism. The com-
pression of the engine must be checked first when tuning an engine,
because an engine with uneven compression cannot be tuned
successfully.
97
TM 9-805
57
AOIL FILTER
BROCKER ARM COVER AIR CLEANER
CPRIMARY LEADIGNITION SWITCH
TO COIL
DIGNITION COIL
EOIL FILLER TUBE
FCRANKCASE VENTILATOR VACUUM
LINE
GTHERMOSTAT HOUSING
HFUEL PUMP TO CARBURETOR LINE
IWATER PUMP
JAMMETER TO CRANKING MOTOR
'SWITCH WIRE
KCRANKING MOTOR SWITCH
WSPARK PLUG
LBATTERY POSITIVE CABLE
MCRANKING MOTOR CONDENSER
NCRANKING MOTOR
OOIL LEVEL GAGE ROD
PDISTRIBUTOR
QDISTRIBUTOR FILTER
R_PRIMARY LEADFILTER TO IGNITION
POINTS
SPRIMARY LEADCOIL TO
DISTRIBUTOR FILTER
TSECONDARY LEADCOIL TO
DISTRIBUTOR
USPARK PLUG WIRES
VFUEL PUMP
SUPPRESSORS RA pD 33074
Figure 18Engine in Chassis, Right Side
(2) Remove all spark plugs. Be sure the ignition is turned off,
and the throttle valve is in the open position.
(3) Insert the compression gage (41-G-124) in a spark plug
hole, and hold it tightly. Crank the engine with the cranking motor
until the gage reaches its highest reading. This requires only a few
turns of the engine. Repeat the same test on all cylinders, and make
a note of the compression on each cylinder.
98
TM 9-805
57
COMPRESSION GAUGE
RA PD 32290
Figure 19Checking Engine Compression, Using Gage
(41-9-194}
(4) The compression on all cylinders should be 110 pounds or
better, and all cylinders should read alike, within 5 to 10 pounds,
for satisfactory engine performance.
(5) Should there be a low compression reading on two adjacent
cylinders, it indicates a possible intercylinder leak, usually caused
by a leak at a cylinder head gasket.
(6) If the compression readings are low or vary widely, the
cause of the trouble may be determined by injecting a liberal supply
of engine oil on top of the pistons of the low-reading cylinders.
(7) Crank the engine over several times, and then take a second
compression test. If there is practically no difference in the readings
when compared with the first test, it indicates sticky or poorly seat-
ing valves. However, if the compression reading on the low-reading
cylinders is about uniform with the other cylinders, it indicates
compression loss past the pistons and rings.
(8) The cause of low or uneven compression must be corrected
before proceeding with an engine tune-up job.
c. Spark Plugs (fig. 20).
(1) Clean the spark plugs thoroughly, using an abrasive-type
cleaner. If the porcelains are badly glazed or blistered, the spark
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TM 9-805
57
.040
RA PD 32272
Figure 20Setting Spark Plug Gap
plugs should be replaced. All spark plugs must be of the same make
and heat range.
(2) Adjust the spark plug gaps to 0.040 inch, using a round
feeler gage. CAUTION: Do not bend the center electrode.
(3) Care must be used when installing the 10-millimeter spark
plugs, or the gap setting may be changed. If a torque wrench is
used when installing the plugs, the proper torque is 15 foot-pounds.
tl. Battery Test. Connect the negative terminal of a voltmeter
to the starting switch terminal, and the positive terminal of the
voltmeter to a good ground. Close the cranking motor switch, and
crank the engine for 15 seconds. If the cranking motor turns the
engine over at a good rate of speed with the voltmeter reading 5 volts
or better, it indicates a satisfactory starting circuit. This includes
the condition of the battery, terminals, and cables. However, if the
cranking speed is slow, or the voltmeter reading is under 5 volts,
the cranking motor, battery, and battery cable terminals should be
checked individually to locate the source of the trouble (par. 42 !>)
e. Distributor (fig. 18).
(1) Remove the spark plug wires from the distributor cap, and
examine the terminals for corrosion. The wires must also be checked
for damaged insulation, and for being oil-soaked.
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TM 9-805
57
(2) Remove the distributor cap, and check the cap and dis-
tributor rotor for cracks or burned contacts.
(3) Check the automatic advance mechanism by turning the
distributor cam in a clockwise direction as far as possible; then
release the cam, and see if the springs return it to its retarded posi-
tion. If the cam does not return readily, the distributor must be
replaced.
(4) Examine the distributor points. Dirty points should be
cleaned, and pitted or worn points should be replaced. Check the
points for alinement, and aline them if necessary.
CONDENSER
K4H
DISTRIBUTOR CAM
BREAKER ARM
IS"
ECCENTRIC
SCREW
RA PD 33057
Figure 21 Distributor Point Adjustment
(5) Hand-crank the engine until the cam follower rests on the
peak of the cam. Adjust the point gap to 0.018 inch, using a feeler
gage (fig. 21). This operation must be performed very accurately,
as it affects point-dwell, or length of time points stay together.
Hand-crank the engine until the cam follower is located between
the cam peaks. Hook the end of a point scale over the movable
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TM 9-805
57
point, and pull steadily on the spring scale until the points just
start to open. At this point the reading on the scale should be
between 17 and 21 ounces.
(6) Set the octane selector at "0" on the scale. Reassemble dis-
tributor cap and spark plug wires. Make sure that the terminals of
the primary wire from thf ignition coil to the distributor are clean
and tight.
f. Coil and Condenser (figs. 18 and 21). Check ignition coil and
condenser (pars. 87 d and 88 a).
g. Fuel Pump (fig. 17). Remove the filter bowl and screen, and
wash them thoroughly in dry-cleaning solvent. When reassembling,
make sure _ that the cork gasket is in good condition and properly
seated. Tighten all fuel pump connections.
ROCKER ARM
COVER
AIR CLEANER
RA PD 33066
Figure 22-FiHing Oil Bath Air Cleaners
h. Carburetor and Rocker Arm Cover Air Cleaners (fig. 17).
(1) Remove the air cleaners from the carburetor and rocker arm
cover. Remove the wing nut from the top, and remove the cover.
Remove the filter element assembly. CAUTION: Do not pry the
element loose if it sticks. The element must be removed by hand to
avoid damaging the filter element flange, which must lie flat against
1O2
TM 9-805
57
the body to insure a tight seat, and prevent air leaks when the cover
is assembled.
(2) Empty the oil out of the cleaner, and clean out all oil and
accumulated dirt. Wash body with dry-cleaning solvent and wipe
dry. Wash filter element by slushing up and down in dry-cleaning
solvent. Dry thoroughly, either with an air hose, or by letting it
stand until dry. Fill the body of the cleaner with engine oil, crank-
case grade (fig. 22).
(3) It is not necessary to reoil the filter element, as this is done
automatically when the vehicle is driven.
(4) Reassemble the filter element in the body of the cleaner,
being sure that the flange sits flat against the top flange of the body.
(5) Reassemble the cover, making sure that the gasket is clean
and in good condition over its entire surface, so that a tight seal is
obtained at this point. Install wing nut.
(6) Reassemble the cleaners to the carburetor and rocker arm
cover. The carburetor cleaner must be put on so that it rests against
the carburetor to assure a good seat at this point; then tighten clamp.
i. Carburetor (fig. 17). The only adjustments that should be
attempted by the using arms are the throttle stop screw and idling
adjusting screw (par. 72 !)
j. Manifold Heal Control Valve (fig. 17). Unhook the thermo-
static spring from its anchor pin, and check for correct installation.
When properly installed it requires only % turn of the spring to
slip it over its anchor pin. Should the thermostatic spring be dis-
torted in any way it should be replaced.
k. Ignition Timing. With the octane selector set at "0" attach
one wire of the neon timing light to No. 1 spark plug, and the other
wire to the No. 1 spark plug wire. Mark the steel ball imbedded in
the flywheel with a piece of chalk. Start the engine and run it at
idling speed. Loosen distributor clamp, and rotate distributor body
clockwise or counterclockwise until the steel ball in the flywheel lines
up with the pointer on the flywheel housing (fig. 49). Tighten the
distributor clamp screw.
1. Valve Adjustment.
(1) Start the engine and while it is warming up, tighten the
cylinder head bolts, rocker arm shaft support bolts and nuts, and
the manifold bolts and nuts. Where torque wrenches are available,
the cylinder head bolts should be tightened to 75 or 80 foot-pounds,
and the rocker arm shaft support bolts to 25 to 30 foot-pounds.
(2) Normalize the engine and adjust the valves (par. 61).
(3) Install the rocker arm cover, using a new gasket, and check
for oil leaks.
m. Idling Adjustment (fig. 17). Adjust the carburetor idle and
throttle stop screws in combinations with each other to secure the
best idling performance. Idling speed should be set at 500 to 550
revolutions per minute.
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TM 9-805
57-58
n. Cooling System. Tighten all hose connections, and examine
for any indications of water leaks. Check the fan belt for cracks,
being oil-soaked, and for proper tension; and adjust it if necessary
(par. 82).
o. Road Test. After the completion of the above operations, the
vehicle should be road-tested for performance. During this time the
octane selector should be adjusted for the grade of fuel being used.
For best performance and maximum gasoline economy, the octane
selector should be set to produce a slight ping when accelerating at
wide-open throttle.
GUIDE PINS
Figure 23Cylinder Head Installation
RA PD 32287
58. CYLINDER HEAD AND GASKET REMOVAL.
a. Disconnect Manifolds. Remove the carburetor air cleaner.
Disconnect lower end of throttle rod. Disconnect the manifold from
the engine. Pull the manifold and carburetor assembly to the left
until it clears the cylinder head, and wire it to the radiator brace
rod or block it up to support its weight. Remove fuel pump to
carburetor line and the crankcase ventilator to manifold line.
b. Remove Push Rod Cover. Drain cooling system. Remove
rocker arm cover. Remove spark plugs. Remove push rod cover.
c. Remove Rocker Arms. Disconnect steam relief tube hose and
remove tube. Remove thermostat housing. Disconnect temperature
indicator and oil line to rocker arm. Remove the two rocker arm
""rnblies by removing the four bolts and two nuts.
104
eo
58
CO
1O5
TM 9-805
TM 9-805
58-60
(I. Remove Cylinder Head and Casket. Lift out the push rods,
and remove the cylinder head bolts. Lift off the cylinder head and
remove gasket. Remove temperature indicator fitting.
59. CARBON REMOVAL.
a. With an electric drill and carbon brush, remove all carbon
from the combustion chambers and valve ports every time the head
is removed. Scrape the carbon from the heads of the pistons and
the top of the cylinder wall. Remove any sludge and gum forma-
tions from the rocker arms and shafts. Clean all oil holes and pas-
sages in the rocker arms and shafts.
ROCKER ARM SHAFT ASSEMBLIES
CONNECTOR ASSEMBLY
RA PD 32289
Figure 25 Installing Rocker Arms and Shafts
60. CYLINDER HEAD AND GASKET INSTALLATION.
a. Install Cylinder Head (fig. 23). Place the head gasket on the
block with the markings "THIS SIDE UP," up and on the camshaft
side of the engine. Install two cylinder head guide pins in the block,
one in the front, and the other in the rear holes on the manifold side,
to maintain alinement of the gasket while the head is being set in
place. Install the cylinder head and tighten the 15 head bolts finger-
tight. Then use a torque wrench and tighten all head bolts to
between 75 and 80 foot-pounds, following the sequence shown in
figure 24. It is important to follow this sequence when tightening
head bolts to prevent water leaks into the cylinders, or compression
leaks between cylinders, or into the water jacket.
b. Install Push Rod Cover. Install rocker arm shafts with con-
nector assembly between them (fig. 25), and tighten retaining bolts
1O6
TM 9-805
60-61
and nuts. Attach and tighten rocker arm oil line to connector
assembly. Install temperature indicator fitting. Install steam relief
tube. Connect temperature indicator. Install thermostat housing.
Install push rod cover.
<. Connec! Manifolds. Install spark plugs. Install rocker arm
cover. Fill cooling systems. Connect manifold assembly and tighten
securely. Install fuel pump to carburetor line and crankcase venti-
lator to manifold line.
RA PD 32257
Figure 26"Valve Adjustment
61. VALVE TAPPET ADJUSTMENT.
a. Normalize Engine. To normalize the expansion of all parts
and stabilize oil temperature, run the engine at a fast idle (approxi-
mately 600 rpm) and check the oil temperature with a thermometer
at the overflow pipe on the valve rocker shaft connector. When a
constant oil temperature is reached for a period of 5 minutes, the
engine is normalized and ready for valve adjustment. If a ther-
mometer is not available for checking the oil temperature, the engine
should be run at a fast idle for 30 minutes before making'the
adjustment.
107
TM 9-805
61-62
b. Adjustment (fig. 26). Lubricate valve stems to insure free
movement of the valves in their guides. Adjust the clearance between
the rocker arms and the valve stems as follows:
Normal Operation
Intake 0.006 to 0.008 in.
Exhaust 0.013 to 0.015 in.
Heavy-Duly Operation
0.010 in.
0.020 in.
INTAKE
MANIFOLD
HEAT CONTROL
VALVE
EXHAUST
MANIFOLD
RA PD 32283
Figure 2/-Manifold Heat Control Valve
62. INTAKE AND EXHAUST MANIFOLDS AND GASKETS.
a. General. The intake and exhaust manifolds are bolted together
with a gasket between them, and should not be disassembled unless
one of the manifolds or the gasket requires replacement. The thermo-
statically controlled valve located in the exhaust manifold (fig. 27)
controls the amount of hot exhaust gases to be directed into the
intake heat chamber. This valve aids in "warming up" the engine,
yet prevents overheating of the fuel mixture. The tension of the
thermostatic spring is very important for proper engine operation.
The spring should be wound up just enough for the end to slip over
the pin in the manifold. This is approximately y2 turn of the spring
at 70F.
b. Manifold Removal (fig. 28). Remove the two nuts attaching
the exhaust pipe to the manifold. Remove air cleaner, carburetor,
governor, and gaskets. Disconnect wires, and remove horn with
-*cket. Disconnect hydrovac vacuum line, windshield wiper line,
1O8
TM 9-805
62
RA PD 33060
Figure 28Manifold Replacement
and crankcase ventilator line from four-way fitting on manifold.
Remove crankcase ventilator line. Remove the two nuts and six cap
screws attaching the manifolds to the cylinder head. Remove the
manifolds and gaskets. Remove four-way fitting and metering valve
from manifold.
c. Manifold Installation. Place new gaskets in position, and
install the manifolds. Tighten all nuts and cap screws evenly and
securely to avoid possible gasket leaks. Install the governor and
carburetor, using new gaskets. Install air cleaner. Fit exhaust pipe
to manifold, using new packing if necessary. Install and tighten re-
taining nuts. Install four-way fitting and metering valve in manifold.
Connect ventilator pipe, windshield wiper line, and hydrovac vacuum
line. Install horn and connect wires.
109
TM 9-805
63-64
1 1/2 -TON 4x4 TRUCK (Chevrolet)
63. OIL PAN.
a. General. The oil troughs in the oil pan are adjusted to the
proper height so that the connecting rod dippers will dip into the
oil, and supply lubrication at low engine speeds. As the engine
speed is increased and the oil pressure builds up, the oil streams
from the nozzles rise and are intercepted by the dippers, forcing the
oil into the connecting rod bearings under high pressure. CAUTION:
Care should be taken not to bend the oil nozzles so that the oil
stream is directed into the connecting rod dippers.
h. Removal. Drain oil from pan. Remove oil gage rod and
guide tube. Remove oil pan cap screws. Bump the oil pan to loosen
it from the gaskets and lower it to the floor, being careful not to
damage the oil screen or oil troughs in the pan.
RA PD 33065
Figure 29Oil Filter Element Replacement
e. Installation. Tie or shellac new gaskets to the block. Install
the new end seals. Work the oil pan up into position, being careful
not to damage the suction screen. Install and tighten retaining cap
screws. Install the oil gage tube and oil gage rod. Install the drain
plug, and refill oil pan with seasonal grade engine oil.
64. OIL FILTER.
a. General. A replaceable-element type oil filter is used to re-
move foreign matter from the oil. The element should be inspected
and replaced periodically, depending on how frequently the oil is
changed, type and quality oil used, severity of service, climatic con-
ditions, etc.
110
TM 9-805
64-65
b. Element Replacement (fig 29). Remove drain plug and drain
oil. Remove cover and gasket. Lift out the element. Clean the oil
filter body and cover with a clean rag. Install drain plug. Place new
element into position in the body, and install gasket and cover.
c. Filter Replacement. Disconnect oil lines. Remove upper and
lower clamp to bracket bolts on one side of clamps, and loosen
clamps sufficiently to permit withdrawal of filter. To install oil filter,
slide it into position between the clamps and tighten the clamps.
Reconnect oil lines.
65. CRANKCASE VENTILATOR.
a. Description. The crankcase and rocker arm cover are venti-
lated by a positive suction through the crankcase, provided by con-
necting a pipe from the oil filler tube to the intake manifold. Fresh
air is drawn through an oil bath air cleaner mounted on the valve
rocker cover, around the top of the engine, and down past the valve
push rods into the crankcase. Air and any fumes in the crankcase are
then drawn by suction up the oil filler tube through the connecting
pipe and metering valve into the intake manifold.
b. Maintenance.
(1) The crankcase breather air cleaner on the valve rocker arm
cover should be serviced periodically at the same time as the car-
buretor air cleaner (par. 77 b). Both air cleaners use the same type
oil as used in the engine.
(2) Remove the crankcase breather air cleaner from the valve
rocker arm cover, empty out the old oil, and clean out any accumu-
lated dirt. Wash the cleaner body with dry-cleaning solvent and,
wipe dry.
(3) Wash the cleaner filter element in dry-cleaning solvent and
wipe dry.
(4) Fill the body of the crankcase breather air cleaner with
engine oil of the viscosity used in the engine to the level indicated on
the side of the cleaner body (fig. 22). The capacity of the crankcase
breather air cleaner is % pint.
(5) Approximately every 5,000 miles, remove the crankcase
ventilator to metering valve pipe assembly, and the metering valve
assembly. Disassemble the meterine; valve, and clean all parts thor-
oughly in dry-cleaning solvent. Wipe all parts dry, and reassemble
the valve assembly. Blow out the crankcase ventilator to metering
valve pipe assembly with compressed air, or clean out with dry-
cleaning solvent. Dry thoroughly.
(6) Reinstall the crankcase ventilator to metering valve pipe
assembly and the metering valve on engine, being sure that all pipe
connections are tight. Any air leak in the passage from the oil filler
111
TM 9-805
65
lVa-TON 4x4 TRUCK (Chevrolet)
tube to the inlet manifold will reduce the efficiency of the ventilating
system.
(7) Under extreme conditions of operation such as unusual
amount of dust and dirt in the air, or where there are other types
than heavy-duty oils being used, it may be necessary to clean the
metering valve and pipe assembly more often.
112
TM 9-805
66
Section XIV
ENGINE-REMOVAL AND INSTALLATION
Paragraph
Removal 66
Installation 67
66. REMOVAL.
a. Remove Sheet Metal. Drain both the radiator and the cylinder
block. Remove hood and side panels. Remove the radiator, front end
sheet metal, and fenders as a unit (par. 150).
b. Disconnect Wires and Lines. Remove battery cable and am-
meter wire from cranking motor switch terminal. Tape end of
battery cable wire, or disconnect the negative cable, to prevent shorts.
Remove ignition wire from top of coil. Drain the oil filter, and dis-
connect the two oil filter lines at connectors. Turn off valve at fuel
filter and disconnect the fuel feed line at the fuel pump. Remove
right engine side pan. Disconnect the radio suppression ground straps
from the rocker arm cover and side of clutch housing. Disconnect
wiring from horn and remove horn. Disconnect carburetor end of
choke and throttle cables. Remove carburetor air cleaner. Discon-
nect oil pressure, temperature indicator, windshield wiper, and
hydrovac booster lines from engine assembly.
c. Disconnect and Remove Brace Rods and Levers. Disconnect
exhaust pipe from the manifolds. Remove left engine side pan and
disconnect the two radio suppression ground straps from the left
side of the engine. Remove floor and toeboards. Split the universal
joint back of the transmission. Remove transfer case control levers
and emergency brake lever attaching bolts on right side of trans-
mission. Disconnect power plant brace rod to transmission bracket
from transmission and pull back spring at left rear corner of trans-
mission. Disconnect propeller shaft (or shafts) and shift linkage
from transmission power take-off, if vehicle is so equipped.
d. Remove Transmission Cover. Disconnect accelerator rod
from the bell crank on left side of engine. Remove the three cap
screws attaching clutch and brake pedal shaft assembly to clutch
housing and disconnect clutch pull-back spring. Disconnect clutch
pedal from clutch adjusting eye and brake pull rod link from lever.
Remove pedal and shaft assembly. Remove cranking motor cross
shaft and disconnect the link and spring from ^cranking motor gear-
shift lever. Remove the transmission cover and cover top of trans-
mission with a rag.
e. Remove Engine (fig. 32). Disconnect the front and rear
engine mountings. If vehicle is equipped with transmission power
take-off, remove left engine mounting. Remove steam relief tube
and temperature indicator fitting. Remove the third cylinder head
bolt from the rear on the left side, and install the engine lifting eye-
bolt. Connect a chain fall to the eyebolt and raise the engine, clutch,
and transmission from the chassis as a unit. If this engine is to be
113
01
66
114
TM 9-805
66
115
TM 9-805
TM 9-805
66-67
RA PD 33072
Figure 32Engine Assembly Removal
replaced with a new or rebuilt engine, transfer all accessories, fit-
tings, and equipment (which are not furnished) from the old to the
new engine.
67. INSTALLATION.
a. Install Engine in Vehicle. Install a lifting eyebolt in the
third cylinder head bolt hole from the rear on the left side of the
engine, and raise the engine with a hoist. Swing it over the chassis
and guide the assembly into place. Install left rear engine mounting
if it was removed for engine removal. Install engine mounting bolts
and nuts; tighten, and lock. Install transmission cover, placing the
power plant brace rod bracket in position under the left rear two
cover bolts. If these bolts will not drop through bracket and enter
holes in cover, adjust length of brace rod so that they will enter
without shifting the power plant. Install the two bolts that attach
transfer case control levers and emergency brake lever mounting
bracket to right side of transmission. Remove lifting eyebolt.
Install cylinder head bolt temperature indicator fitting, temperature
indicator, and steam relief tube.
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TM 9-805
67
b. Connect Shafts and Rods. Install cranking motor cross shaft
and bolt the brackets securely. Hook up the cranking motor gearshift
link. Place the clutch and brake pedal shaft with pedals in position,
install the three retaining bolts, connect clutch pedal to adjusting
eye, hook up clutch pull-back spring and brake pull rod. Hook the
brake pedal pull-back spring to clip at left rear transmission cover
bolt. Install the accelerator rod and attach it to bell crank on left
side of engine.
c. Connect Propeller Shaft. Place the universal joint in position
and install the U-clamps, lock washers, and nuts. Connect drive
shaft (or shafts) and shift linkage to transmission power take-off,
if vehicle is so equipped. Install the floor and toe boards. Install left
engine side pan, and attach the two radio suppression ground straps
to left side of engine. Connect the exhaust pipe to exhaust manifold.
Connect the hydrovac booster vacuum line and windshield wiper line.
d. Connect Cages and Lines. Connect oil pressure gage and oil
filter lines to connector on left side of engine. Connect choke and
throttle cables. Install horn and attach horn wires. Connect the radio
suppression ground straps to rocker arm cover stud and clutch hous-
ing. Install right engine side pan and tighten screws. Attach gasoline
supply line to fuel pump, and turn on valve at fuel filter. Attach the
ignition wire to top of coil. Attach the battery cable and ammeter wire
to cranking motor terminal.
e. Install Sheet Metal. Install the radiator front end sheet metal
and fenders as a unit (par. 151). Install air cleaner. Install hood and
side panels. Fill crankcase and transmission. Lubricate the universal
joint that was disassembled. Tune engine; test lights, horn, and gen-
erator charging rate. Recheck oil level.
117
TM 9-805
68
Section XV
CLUTCH
Paragraph
Adjustment '69
Clutch replacement 70
CLUTCH
PEDAL
THROW
OUT
FORK
CLUTCH PEDAL
ADJUSTING LINK
ADJUSTING
NUT
LOCK
NUT
PULL
BACK
SPRING
^^^^^1
RA PD 32247
Figure 33Clutch Free Pedal Travel Adjustment
a. Description. The clutch is a single-plate, dry-disk type, incor-
porating a spring-mounted hub. The engagement pressure is supplied
by a single diaphragm spring. The clutch is controlled by the clutch
pedal, connecting link, throwout fork, and throwout bearing.
b. Data.
Type Single dry plate
Facings:
Outside diameter 10^4 in.
Thickness 0.137 in. to 0.143 in.
118
68
119
CLUTCH
TM 9-805
TM 9-805
68-70
1'/2-TON 4x4 TRUCK (Chevrolet)
Spring:
Type Single diaphragm
Diameter 9 in.
Throwout Bearing:
Type Sealed ball bearing
Manufacturer's number New Departure CT-22
Service Data:
Clutch pedal adjustment 1 in. to 1% in.
Clearance between:
Driving lugs and cover 0.002 in. to 0.006 in.
Splined hub and shaft '. 0.005 in to 0.0055 in.
RETRACTING
SPRING
DRIVING
LUGS
SPECIAL
CAP SCREW
ALIGNMENT MARKS ^ RA PO 32248
Figure 35Retracting Spring Removal
69. ADJUSTMENT.
a. The free pedal travel before the throwout bearing contacts the
diaphragm spring should be between 1 inch and 1% inches. To make
this adjustment, loosen the adjusting lock nut (fig. 33), and turn
the adjusting nut until 1%-inch free travel of the pedal is obtained.
Tighten the lock nut.
70. CLUTCH REPLACEMENT (fig. 34).
a. Removal.
(1) REMOVE TRANSMISSION ASSEMBLY (par. 97).
12O
TM 9-805
70
CLUTCH
(2) REMOVE CLUTCH FORK. Remove throwout bearing from the
fork. Disconnect pull-back spring, and remove adjusting link from
the clutch fork. Remove the clutch fork by pressing it away from
its mounting with a screwdriver until the fork snaps loose from the
ball. The spring retainer may be removed from the fork by prying
it out of the groove, one end at a time. Remove the throwout fork
mounting ball stud from the clutch housing.
(3) REMOVE COVER ASSEMBLY AND DISK. Loosen the nine clutch
to flywheel bolts one turn at a time (to prevent cover distortion),
until the diaphragm spring pressure is released. Remove the clutch
cover assembly and disk from the clutch housing.
THROW OUT
FORK
RA PO 32249
Figure 36Cheeking Fit of Ball In Throwout Fork
(4) DISASSEMBLE COVER (fig. 35). Remove the three clutch pres-
sure plate retracting springs, and remove the pressure plate from the
clutch cover assembly. The clutch cover, diaphragm spring, and two
pivot rings are riveted together and serviced as an assembly.
b. Inspection.
(1) Wash all parts (except the throwout bearing and disk) in
dry-cleaning solvent.
(2) Inspect the pressure plate and flywheel for scores or cracks
that would affect normal clutch operation.
121
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70
lVa -TON 4x4 TRUCK (Chevrolet)
(3) Check the three pressure plate drive lugs for excessive wear
or burs. Check their fit in the cover. They should have from 0.002-
inch to 0.009-inch clearance (fig. 35).
(4) Check the throwout bearing for roughness and free fit on the
extension of the transmission main drive gear bearing retainer.
CAUTION: This is a permanently lubricated bearing, and must not
be washed in dry-cleaning solvent.
RA PD 32250
Figure 37Alining Cover Assembly with Flywheel
(5) Check fit of the ball stud in the throwout fork (fig. 36).
NOTE: This should be snug without side play.
(6) Inspect the clutch disk for worn, loose, or oil-soaked facings,
for broken disk springs, or loose hub rivets. Check to see that the
splines are not excessively worn, and that they move freely on the
splines of the clutch gear. If the splines are worn, the disk should be
replaced.
122
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CLUTCH
(7) Place clutch disk on clutch shaft, and turn shaft to check for
sprung clutch disk.
c. Clutch Reassembly.
(1) ASSEMBLE CLUTCH COVER. Install the pressure plate in the
cover assembly, making sure to mate the "O" mark on the pressure
plate lug with the "O" mark on the cover (fig. 35). This is necessary
to maintain proper balance. Install the three pressure plate retracting
springs. The clutch is now ready to be reassembled to the engine.
COAT THIS GROOVE
PACK THIS RECESS .
Figure 38Throwout Bearing Collar Lubrication
(2) INSTALL COVER AND DISK. Hand-crank the engine until the
"X" mark on the flywheel is at the bottom. Install the clutch disk,
pressure plate, and cover assembly. Turn the clutch assembly until
the "X" mark on the cover lines up with the "X" mark on the fly-
wheel (fig. 37). Install the nine bolts, and tighten them each a turn
at a time to prevent distorting the cover as the spring pressure is
being taken up.
123
TM 9-805
70
(3) INSTALL CLUTCH FORK. Install the throwout fork mounting
ball in the clutch housing. Pack the ball seat in the fork with a small
amount of ball and roller bearing grease. Install a new spring re-
tainer in the groove in the clutch fork if the old retainer is worn or
damaged. Make certain the retainer is installed with the high side
of the retainer up, away from the ball bearing, and the open end of
the retainer on the horizontal. Replace the fork in position in the
clutch housing, and snap the fork onto the ball.
(4) INSTALL THROWOUT BEARING. Lubricate the recess on inside
of throwout bearing collar, and coat the throwout fork groove with
a small amount of ball and roller bearing grease (fig. 38). Then
install throwout bearing on the throwout fork. CAUTION: Be care-
ful not to use too much lubricant. Install the adjustment link and
pull-back spring.
(5) INSTALL TRANSMISSION. Install the transmission (par. 98).
(6) ADJUST CLUTCH PEDAL. Adjust the clutch pedal (par. 69).
124
TM 9-805
71-72
Section XVI
FUEL SYSTEM
Paragraph
Description 71
Carburetor 72
Fuel pump 73
Fuel filter 74
Fuel tank 75
Governor 76
71. DESCRIPTION.
a. The fuel system consists of a large fuel supply tank, a fuel
filter, a cam-operated fuel pump, carburetor, air cleaner, and the
necessary pipes and fittings.
72. CARBURETOR.
a. Description and Tabulated Data.
(1) DESCRIPTION. The carburetor used is of the Carter down-
draft design. It is mounted at the top center of the intake manifold.
(2) DATA.
Type Downdraft
Make Carter
Model W1-515-S
Metering rod (marked) 67-46
Float level % in.
b. Adjustments. The only adjustments on this carburetor are
throttle opening (idling speed) and idling mixture. Before attempting
to adjust the carburetor, make sure the carburetor to manifold and
manifold to cylinder head bolts are tight to prevent air leaks. Make
sure the air cleaner is properly cleaned, and that the valves are prop-
erly adjusted. Adjust the idle and throttle stop screws (fig. 17) in
combination with each other to secure the best idling performance.
The correct idling speed is 500 to 550 revolutions per minute.
c. Removal (fig. 17). Remove air cleaner, disconnect choke and
throttle controls, and disconnect the fuel line from float chamber
cover fitting. Remove the two nuts that attach the carburetor and
governor to manifold, and remove the carburetor assembly.
d. Installation. Install a new gasket, place the carburetor in
position, and install the retaining nuts. Connect the throttle and
choke controls and check their operation. Open the idle adjusting
screw \Y2 turns. Connect the fuel line, and install the air cleaner. Fill
the carburetor float chamber by working lever on fuel pump. Start
the engine, and adjust the throttle and idle adjusting screws in com-
bination with each other to obtain a smooth idle at between 500 and
550 revolutions per minute.
125
TM 9-805
72
BOWL
RETAINER
FILTER
SCREEN
INLET
INLET
VALVE
DIAPHRAGM
BOWL
RETAINER
NUT
SEDIMENT
OUTLET
VALVE
OUTLET
RA PD 32296
Figure 39Fuel Pump
126
TM 9-805
73
FUEL SYSTEM
73. FUEL PUMP.
(1) DESCRIPTION (fig. 18). The diaphragm-type fuel pump is
mounted on the right side of the engine crankcase, and is operated
by an eccentric on the camshaft. The float controlled needle valve
in the carburetor controls the amount of fuel flow, and a coil spring
in fuel pump maintains constant pressure in pump to carburetor fuel
line. A lever on the pump provides a means of priming the pump and
filling the carburetor bowl.
Figure 40Filling Carburetor Bowl
(2) DATA.
Type . Diaphragm
Make AC No. 1537272
Model AF
Pressure 3^4 lb maximum
127
TM 9-805
73-74
1'/j-TON 4x4 TRUCK (Chevrolet)
h. Maintenance. Keep the attaching cap screws and fuel line
connections tight. Remove and clean glass sediment bowl on top of
pump when presence of water or.sediment is noticed.
c. Removal. Disconnect the fuel pump inlet and outlet lines.
Disconnect the pump primer spring, remove the retaining cap screws,
and remove fuel pump and gasket (fig. 39).
d. Installation. Place a new gasket on the flange of fuel pump,
place the pump in position against the engine crankcase, and install
the attaching cap screws. Connect the inlet and outlet fuel lines
securely, and attach the primer spring. Fill the fuel pump and lines
with the primer lever (fig. 40).
SHUT-OFF
VALVE
II DISC TYPE STRAINS!
p MOOtt I.,
DRAIN
PLUG
RA PD 32298
Figure 41-Fuel Filter
74. FUEL FILTER.
(1) DESCRIPTION (fig. 41). The multiple-disk type fuel filter is
mounted on the outside of the right frame side rail. It is connected
in the fuel line between the fuel tank and fuel pump. A shut-off
valve is located on the tank side of filter, and a drain plug is in the
bottom of filter bowl. The fuel enters the filter, is filtered between
the closely spaced disks of the filter element, and then passes to the
fuel pump. Water and dirt that accumulate in the filter can be
drained off by removing the drain plug.
128
TM 9-805
74
FUEL SYSTEM
(2) DATA.
Type Multiple-disk
Make AC No. 1595134
Model T-2
1>. Maintenance (fig. 42). Make sure that all connections are
kept tight to prevent fuel or air leaks. Drain and flush out the filter
bowl regularly by closing the shut-off cock and removing the drain
plug. After draining, flush bowl by opening valve and admitting a
small amount of fuel. Install the drain plug and open shut-off valve.
To clean the filter element close the shut-off valve, remove the cover
bolt, bowl, and filter element. Wash all parts of the filter in dry-
cleaning solvent. Slush the filter element back and forth in clean
gasoline to remove all particles of dirt. Assemble the filter element,
bowl, and cover bolt, using new gaskets. Open the shut-off valve.
i RA PD 33067
Figure 42Fuel Filter Clement Replacement
e. Removal. Drain fuel from main tank until fuel level is below
outlet pipe. Disconnect the fuel inlet and outlet lines, and remove
the two filter to frame attaching bolts.
d. Installation. Place the filter assembly in position against the
frame, and install the retaining bolts. Connect the fuel lines to the
filter, open the shut-off valve, fill fuel tank, and check for fuel leaks.
129
TM 9-805
75-76
75. FUEL TANK.
a. Description. The heavy steel seam-welded tank is fitted
with baffle plates to prevent surging of the fuel and to give additional
strength to the tank. It is mounted on two support brackets extend-
ing to the left from the frame right side rail. The tank is held in place
by two steel straps that go over the tank and attach to the support
brackets. An L-section brace is attached to the two steel straps at
the left side of tank. A heavy bracket extends from the frame left
side rail and is attached to the center of the L-brace by one bolt.
The capacity of the fuel tank is 30 gallons.
b. Removal. Drain the fuel from tank and install drain plug.
Disconnect the filler neck coupling hose, the tank to filter fuel line,
and the fuel gage lead wire. Remove the support bracket to frame
right side rail bolts, and the bolt that attaches the side support at
left side of tank to support bracket. Lower the tank and bracket
assembly until it rests on the propeller shaft, then tip outer edge of
tank down to clear the frame side rail. Remove the nuts from strap
to bracket anchor bolts, and swing the straps up away from tank.
Lift tank off brackets.
c. Installation. Place the tank in position on the brackets with
the fuel line outlet on the side toward frame end of bracket. Securely
tighten the anchor strap to support bracket nuts. Place the tank
assembly in position, install the support bracket to frame bolts, and
the left support bracket to tank side support bolt. Connect the filler
neck hose, and tighten the clamp. Connect the fuel line to tank and
the fuel gage lead to fuel gage tank unit. Fill the fuel tank, and
check for leaks.
76. GOVERNOR.
(1) DESCRIPTION (fig. 17). The adjustable governor is designed
to provide control of the engine and vehicle speed. It is mounted
between the carburetor and intake manifold. The governor throttle
valve is opened by spring tension and closed by manifold vacuum
and flow of fuel mixture, thus controlling the volume of fuel mixture
admitted to the engine.
(2) DATA.
Type Velocity
Make Handy
Model V5-160
b. Removal. Remove carburetor (par. 72). Lift the governor and
gasket off manifold flange studs.
c. Installation. Place a new gasket in position on the manifold
flange studs and place the governor in position. Install the carburetor
(par. 72).
130
TM 9-805
77-78
Section XVII
INTAKE AND EXHAUST SYSTEM
Paragraph
Air cleaner 77
Exhaust system 78
77. AIR CLEANER,
(1) DESCRIPTION (fig. 17). The oil-bath type air cleaner mounts
on the top of the carburetor, and filters dirt from the air before it
enters the carburetor.
(2) DATA.
Make A.C.
Type Oil-bath
Part number 1542078
h. Air Cleaner Maintenance (fig. 22). Loosen the clamp screw
and remove air cleaner. Remove the wing nut from top of cleaner,
and remove cover. Remove the filter element assembly. NOTE: Do
not pry on filter element, or damage will result. Empty the oil out
of the cleaner body and wash it thoroughly with dry-cleaning solvent.
Wash filter element by slushing it up and down in dry-cleaning
solvent. Dry the filter element with an air hose. Fill the cleaner
with two pints of crankcase oil. Install the filter element, making
sure that the flange seats on the top of the cleaner body. Install the
gasket, cover, and wing nut, making sure that the gasket makes a
good seal between cover and body. Install cleaner on carburetor and
tighten clamp nut.
78. EXHAUST SYSTEM.
a. Description. The exhaust system consists of the exhaust pipe,
muffler, and tail pipe. This system carries the exhaust gases from
the manifold along the chassis frame, and out frpm under the left
side or rear of body. The muffler employs the reverse-flow and
diffusion principles to silence the exhaust.
b. Exhaust Pipe Replacement (fig. 43).
(1) REMOVAL. Disconnect the muffler suoport spring from ex-
haust pipe clamp and remove clamp. Loosen the exhaust pipe clamp,
remove the exhaust pipe to manifold stud nuts, and remove the
exhaust pipe.
(2) INSTALLATION. Install muffler support spring anchor clamp.
Place the exhaust pipe with packing flange in position, and hook the
muffler support spring to exhaust pipe. Place a new exhaust pipe
packing in position, and install the exhaust pipe to manifold stud
nuts. Tighten the exhaust pipe clamp at muffler, and the exhaust
pipe to manifold stud nuts securely.
131
78
132
TM 9-805
TM 9-805
78
INTAKE AND EXHAUST SYSTEM
r. Tail Pipe Replacement. Disconnect the tail pipe support at
rear of tail pipe, and the two brackets at frame side rail. Loosen the
tail pipe clamp at muffler, and pull the pipe off muffler. Place the
new pipe in position, and install the tail pipe clamp brackets and
support.
d. Muffler Replacement. Remove the tail pipe (subpar. c above).
Loosen the exhaust pipe clamp, and disconnect the muffler strap.
Pull the muffler off the exhaust pipe. Place the new muffler in position
and attach the muffler strap, but do not tighten it. Connect the
exhaust and tail pipes. Rotate the muffler slightly, if necessary, to
correctly position the inlet and outlet tubes. Tighten the muffler
strap, exhaust pipe clamp, tail pipe clamp, tail pipe brackets, and
tail pipe support.
133
TM 9-805
79
Section XVIII
COOLING SYSTEM
Radiator core 80
Water pump 81
Fan belt 82
Thermostat replacement 83
Steam relief tube 84
a. Description (fig. 44). The cooling system consists of a radi-
ator, fan shroud, fan, thermostat, centrifugal water pump, fan belt,
hose, and connections.
RADIATOR CORE
THERMOSTAT
RA PD 33092
Figure 44Cooling System
b. Data.
Cooling system capacity 17/4 ^
Water pump type Centrifugal
Water pump drive Belt
Water pump bearings Permanently sealed and lubricated
134
TM 9-805
79
COOLING SYSTEM
Fan belt deflection 3/$ in.
Adjustment Moving generator
Thermostat Starts to open at 140 to 147F
Fully opened, 170F
Number of fan blades 4
RA PD 33068
Figure 45Radiator Core Removal
Clearance fan to radiator Approximately ly^ in.
Radiator type Fin and tube
Frontal area 403.75 sq in.
Core thickness 3y8 in.
135
79
136
TM 9-805
RA PD 32256
FAN ASSEMBLY I WATER PUMP
Figure 46Water Pump Removal
TM 9-805
80-81
COOLING SYSTEM
80. RADIATOR CORE.
a. Description. The radiator core is of the tube and fin construc-
tion and is made of copper. The core is supported in a steel anchor-
age and bolted in a support. The support is bolted to the front cross
member through a rubber cushion.
b. Radiator Core Removal (fig. 45). Remove radiator cap, drain
the radiator, and remove all hose connections. Disconnect the steam
relief tube from radiator. Remove the two bolts that attach radiator
brace to the radiator support, loosen brace rod nuts at the dash, and
tie front end of brace rod to hood. Remove the fan blades. Disconnect
headlight wiring loom from the clips along the top and sides of
radiator. Remove the six cap screws (three on each side) that hold
fan shroud and radiator to the support. Push the fan shroud to one
side, slipping it past bolt that attaches radiator support, and lift fan
shroud up and out. Lift radiator core up and out, being careful not
to damage pore.
c. Radiator Core Installation. Lower the radiator core into place,
and work fan shroud into position back of radiator. Install the six
cap screws through fan shroud and radiator core to the support.
Install headlight wiring loom in clips along top and sides of radiator.
Install fan blades, and connect radiator brace to radiator support.
Install all hose connections and clamps. Connect steam relief tube
to radiator. Tighten nuts on brace rods at dash. Refill cooling system,
and check to make sure there are no water leaks.
d. Draining Cooling System. To drain the radiator, remove
filler cap and open the valve located at bottom of radiator on the
right side. To drain the cylinder block, open the valve located on
left side of engine at the rear cylinder (fig. 30).
e. Filling Cooling System. When cooling system has been
drained, run engine at idling speed while filling radiator to prevent
air pockets from forming in the cooling system. CAUTION: Never
pour cold water into radiator when engine is unusually hot, as the
cold water may crack the cylinder head. When using antifreeze,
never fill the radiator full. Leave about 1 inch of air space between
top of water and top of radiator to allow for expansion of the anti-
freeze. This will prevent loss of antifreeze.
81. WATER PUMP.
a. Description (fig. 44). The centrifugal-type water pump is
mounted on the front of the cylinder block, and is belt-driven from
the crankshaft. The pump shaft is ball-bearing mounted. The bear-
ings are packed with a high melting point lubricant and require no
additional lubrication.
b. Water Pump Removal (fig. 46). Remove radiator cap and
drain the radiator. Loosen hose clamps that secure hose to water
pump and elbow. Slide hose away from water pump. Loosen bolt
in slotted end of generator brace and mounting bracket, and loosen
fan belt. Remove belt from water pump pulley. Remove the four cap
137
TM 9-805
81-82
screws that attach pump to cylinder block, and remove pump and
fan blades as an assembly by turning it as it is removed.
c. Installation. Place pump and fan blade assembly in position,
using a new gasket. Install the four cap screws that hold the pump
to cylinder block. Install fan belt over the three pulleys, and adjust
to proper tension. Slide hose connection over water pump opening,
and tighten hose clamps. Close both drain cocks, fill the radiator,
and make sure there are no water leaks.
WATER
PUMP
FAN
BELT
CORRECT 3,"
TENSION *
FAN BELT
ADJUSTMENT
BOLT
GENERATOR
BRACE
GENERATOR
RA PD 32255
Figure 47Fan Belt Adjustment
82. FAN BELT.
a. Description. The fan belt is of the V-type and drives the fan,
water pump, and generator.
b. Fan Belt Adjustment (fig. 47). Loosen bolt at generator
mounting bracket and end of slotted brace. Rock the generator on
its mounting bracket. Moving generator away from engine tightens
the belt. Moving generator toward engine loosens the belt. The
138
TM 9-805
82-84
COOLING SYSTEM
correct adjustment is obtained when the belt can be depressed ^ inch
from normal. Tighten the bolt at generator mounting bracket and
end of slotted brace, and recheck for proper tension.
83. THERMOSTAT REPLACEMENT.
a. Remove radiator cap, drain radiator, and loosen upper hose
clamps. Remove cap screws that attach water outlet connection to
thermostat housing (fig. 44). Remove water outlet connection and
remove thermostat. Install thermostat, making sure exposed parts
of bellows are to front and rear. Install new gasket and water outlet
connection. Install hose connection and hose clamps. Fill cooling
system.
84. STEAM RELIEF TUBE (fig. 30).
a. The steam relief tube is connected to the top of the radiator
at the front and to the left side of cylinder head at the rear. It is for
the purpose of relieving any air pockets that may be caused by steam
or surging of water when the vehicle is descending steep grades. The
steam relief tube requires no attention other than keeping it from
leaking. If leaks occur at front end of tube, tighten or replace hose
connection. If leak occurs at rear of tube, tighten packing nut to
shut-off valve. Keep shut-off valve closed except when operating
on extreme grades when the temperature is above 60F.
139
TM 9-805
85-87
I'/,-TON 4x4 TRUCK (Chevrolet)
Section XIX
ELECTRICAL SYSTEM, INSTRUMENTS AND GAGES
Description 85
Ignition timing 86
Distributor 87
Ignition coil, ignition switch, and spark plugs 88
Generator and regulator 89
Cranking motor and switch 90
Instruments and gages 91
Wiring 92
Lighting 93
Battery 94
Radio suppression equipment 95
85. DESCRIPTION.
a. The electrical system consists of the ignition system, gener-
ator and regulator, cranking motor and switch, instruments and gages,
lights, battery, radio suppression, and the necessary battery cables
and wiring (fig. 48).
86. IGNITION TIMING.
a. Set Octane Selector. Set the octane selector so that center
calibration mark on rear of distributor clamp is in line with the mark
on machined surface of block.
b. Set Timing (fig. 49). Connect a timing light to the No. 1
spark plug, then start the engine and run it at idling speed. Loosen
the distributor clamp, and turn the distributor body either in a
clockwise or counterclockwise direction, until steel ball in flywheel
lines up with pointer in flywheel housing. Tighten the distributor
clamp.
87. DISTRIBUTOR.
a. Description (fig. 18). The distributor directs the high tension
current to the various cylinders at exactly the proper time.
b. Data.
Make Delco-Remy
Model 1110136
Type of advance Centrifugal
Firing order: 1-5-3-6-2-4
Breaker point gap 0.018 in.
Breaker arm spring tension 17-21 oz
Spark advance starts at 800 rpm
140
TM 9-805
87
c. Breaker Points. .
(1) CLEANING. Remove the distributor cap and rotor, and insert
a fine-cut ignition point file between the points. File with a straight
steady motion to keep the points flat.
(2) ADJUSTMENT (fig. 21). Remove the distributor cap and rotor.
Hand-crank the engine until the breaker arm cam follower is on
the peak of one of the lobes. Loosen the stationary mount lock screw
(the screw nearest the point), and turn the eccentric adjusting screw
to the right or left until an 0.018-inch feeler gage just fits in the gap.
Tighten the lock screw, and recheck the gap clearance.
(3) REMOVAL (fig. 21). Remove the distributor cap and lift off
the rotor. Loosen the nut that retains the movable arm spring to the
terminal on the side of the distributor, and lift out the movable
arm. Remove the stationary point lock screw and lift out the sta-
tionary point.
(4) INSTALLATION. Place stationary point in position in distrib-
utor, and install the lock screw, but do not tighten it. Place the mov-
able point in position, with the spring in place on the terminal on
side of distributor. Tighten the terminal nut securely. Hand-crank
the engine until the breaker arm cam follower is on the peak of one
of the lobes, then turn the eccentric adjusting screw to the right or
left until an 0.018-inch feeler gage just fits in the gap. Tighten the
lock screw, and recheck the gap.
d. Condenser.
(1) REMOVAL. Remove the distributor cap and lift off the rotor.
Loosen the nut that retains the condenser pigtail to the terminal,
and lift the pigtail off the terminal. Remove the screw that retains
the condenser to the distributor, and lift out the condenser.
(2) INSTALLATION. Place the condenser in position in the dis-
tributor and install the retaining screw and lock washer. Connect the
pigtail to the terminal and tighten the nut securely.
e. Distributor Replacement.
(1) REMOVAL (fig. 18).
(a) Mark Distributor for Installation. Remove the valve cover
air cleaner and valve cover; then hand-crank the engine until No. 6
cylinder exhaust valve opens, and continue to hand-crank the engine
until the exhaust valve just closes. Remove the cap from the dis-
tributor, and scratch a mark on the distributor housing in line with
the contact tip on the distributor rotor. NOTE: This procedure
locates No. 1 cylinder firing position to insure that the timing will
be correct when the distributor is installed.
(b) Remove Distributor. Remove the nut and washer that
attaches the primary lead to the primary terminal, and remove the
wire. Loosen the distributor clamp screw, and then work the dis-
tributor assembly up and out of the cylinder block.
(2) INSTALLATION (fig. 50).
(a) Install Spark Plug Wires. Obtain a new or rebuilt distributor
assembly, and scratch a mark on the housing in the same location
141
TM 9-805
87
1 '/, -TO
N 4 x 4 TRUCK (Chevrolet)
*.!?* DOTTED LINES S
1 . ADDITIONAL CK
i USED ON
IX G-7113 MODELS
HOW CHASSIS
CUITS REAR HARNESS CHAS
G-7H3 MODELS REA
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TRAILER
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K-OUT x-x
-ia
3 LIGHT- ( 3:
ITCH ^ ^
FUEL GAGE
TANK UNIT
V / SWITCH
6 '-^>-
12
LOAD REGULATOR
DOME LIGHT
SWITCH
- ye:
J HORN BUTTON -(JD 3
. TRAILER
BRAKE
CONTROLLER
DOME LIGHT-
B.O.T.[V 1 ,
*p S
^,8"l
"asUr-^ o 8
FUEL GAGE "\J (,
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U-10-
TM 9-805
87
B. O. DRIVING LIGHT.
GENERATOR
VOLTAGE WIRING HARNESS
CURRENT
REGULATOR
SUPPRESORS
DISTRIBUTOR FILTER
-CRANKING MOTOR
CONDENSER
CRANKING MOTOR
RA PD 33091
Wiring Diagram
143
TM 9-805
87
TIMING TIMING
POINTER LIGHT
NO. 1 SPARK NO. 1 SPARK
PLUG WIRE PLUG
RA PD 32269
Figure 49Setting Engine Timing
DISTRIBUTOR LOCK |
RA PD 33058
Figure SODistributor Installation
144
TM 9-805
87-88
as the one placed on the distributor just removed. Remove the cap
from the new distributor, and transfer the spark plug wires from the
old cap to the new one, one at a time, to make sure the firing order
will be correct.
(b) Set Distributor for Installation. If the engine crankshaft has
been turned, since the distributor was removed, hand-crank the
engine to place the engine in No. 1 cylinder firing position. Turn the
distributor shaft by the rotor in a clockwise direction until the con-
tact tip on the rotor lines up with the scratch mark made on the
housing, and then about y$ inch further. This is necessary to com-
pensate for the angle of the distributor gear when it engages the
gear on the camshaft.
(c) Install Distributor. Install distributor through distributor
clamp, and into opening in block with grease cup on distributor at
right angles to cylinder block; continue to push distributor down
until the gears are engaged. If the distributor bottoms before it is
pushed all the way down, it will be necessary to crank the engine
slowly, while at-the same time pressing down lightly on the dis-
tributor, until the distributor moves all the way down. This is neces-
sary in order to pick up the drive tang on the oil pump shaft. Tighten
distributor clamp screw just snug while making sure that grease cup
is at right angles to the cylinder block.
(d) Install Distributor Cap. Install cap on distributor and clamp
in place. Set octane selector so that center calibration mark on rear
of distributor clamp is in line with mark on machined surface of the
block.
(e) Time Engine. Connect a timing light to the No. 1 spark plug;
then start the engine and run it at idling speed. Loosen the distrib-
utor clamp, and turn the distributor body either in a clockwise or
counterclockwise direction, until steel ball in flywheel lines up with
pointer in flywheel housing (fig. 49). Tighten the distributor clamp,
and replace the valve cover and valve cover air cleaner.
88. IGNITION COIL, IGNITION SWITCH, AND SPARK
PLUGS.
a. Ignition Coil.
(1) REMOVAL (fig. 18). Remove the two nuts and lock washers
from the two terminals on top of the coil. Tag the wires "positive"
(+) and "negative" ( ) so they can be installed on the proper
terminals. Pull the high tension wire out of terminal at bottom of
coil. Remove the two screws that retain coil to side of engine, and
lift off the coil.
(2) INSTALLATION. Place coil in position on engine, and install
the two retaining screws and lock washers. Push the high tension
wire in place in the lower terminal. Install positive wire on positive
terminal, and negative wire on negative terminal on top of coil, and
install the retaining nuts and lock washers. Tighten the nuts and
mounting screws securely.
145
TM 9-805
88-89
z-TON 4x4 TRUCK (Chevrolet)
b. Ignition Switch Replacement. Unscrew the ignition switch
retaining ring on face of instrument panel, and push the switch out
of hole in panel. Reach under panel and bring the switch down as
far as it will go, so that it will be accessible. Obtain a new switch, and
change the wires from the old switch to the new switch. Place switch
in panel, and install the retaining ring.
c. Spark Plug Adjustment (fig. 20). Remove spark plugs, and
use a round feeler gage to set the gap at 0.040 inch. Place a new
gasket on plug and screw plug in finger-tight; then tighten % to ^
turn with a wrench. NOTE: // it is necessary fo use the old gasket,
tighten Ye to y4 turn with a wrench.
FAN BELT
ADJUSTMENT
BRACKET
COMMUTATOR
COVER BAND
Figure 51 Generator Assembly
89. GENERATOR AND REGULATOR,
(1) DESCRIPTION (fig. 51). The generator is mounted on a bracket
at the left side of the engine near the front, and is driven by the fan
belt. The function of the generator is to convert a small amount of
mechanical energy from the engine into electrical energy which is
stored in the battery. The output of the generator is controlled by
a combination voltage and current regulator mounted on the dash.
This regulator is adjusted to prevent the voltage rising above 7.5
146
TM 9-805
89
AAMMETER FILTER
BCUT-OUT RELAY
CCURRENT REGULATOR
DVOLTAGE REGULATOR
EGENERATOR FIELD FILTER
FARMATURE FILTER
GVACUUM LINE TO HYDROVAC
HLINE TO OIL PRESSURE GAGE
IOIL FILTER INLET LINE
JOIL FILTER OUTLET LINE
KWINDSHIELD WIPER VACUUM LINE
LHYDROVAC VACUUM CHECK VALVE
MVACUUM LINE TO CHECK VALVE
NWIRING HARNESS JUNCTION BLOCK
RA PD 33070
Figure 52Voltage Regulator (Cover Removed)
volts, and the current from rising above 40 amperes, thereby pre-
venting damage to either the battery or generator.
(2) DATA.
(a) Generator.
Make Delco-Remy
Model 1105860
Voltage 6
147
TM 9-805
89
Ty2-TON 4x4 TRUCK (Chevrolet)
(b) Regulator.
Make Delco-Remy
Model 1118468
Voltage setting 7.5 volts (hot)
Current setting 40 amps (hot)
b. Generator.
(1) REMOVAL. Disconnect the three wires from terminals on top
of generator. Identify each wire with a tag. Remove the cap screw
from slotted brace on top of generator. Push generator toward engine,
and lift the fan belt off generator pulley. Remove the two bolts and
nuts at bottom of generator that retain generator to mounting
bracket, and lift off the generator.
COMMUTATOR
COVER BAND
RA PD 33O813
Figure S3Cranking Motor and Pedal Linkage
(2) INSTALLATION. Place the generator in position on the mount-
ing bracket and install the two retaining bolts, nuts, and lock
washers. Install the bolt, flat washer, lock washer, and slotted brace,
but do not tighten the bolt and nut. Place fan belt on generator pulley
and adjust the fan belt (par. 82). Install the three wires on the same
"rminals on generator from which they were removed.
148
TM 9-805
89-90
c. Regulator (fig. 52).
(1) REMOVAL. Disconnect the four wires from the regulator.
Identify each wire with a tag and tape end of wire that was removed
from battery terminal to prevent it from touching metal, causing
a short circuit. Remove the four nuts and lock washers attaching
regulator to dash, and lift off the regulator.
(2) INSTALLATION. Check and make sure the dash is clean at
regulator mounting holes, and also that the four mounting legs on
regulator are clean. Then place regulator in position on dash and
install the four mounting bolts with a lock washer on each side of
mounting legs. Connect the four wires on the same terminals from
which they were removed. Start engine and check the operation by
noting reading of ammeter.
PEDAL LINK
AMMETER WIRE r-BATTERY CABLE
RA PD 330814
Figure 54Cranking Motor Removal
90. CRANKING MOTOR AND SWITCH.
(1) DESCRIPTION (fig. 53). The starting system consists of the
battery, cranking motor, cranking motor switch, battery cable, and
ground strap. The battery supplies the electrical energy to turn the
149
TM 9-805
90
1Va-TON 4x4 TRUCK (Chevrolet)
cranking motor when the switch is closed, and the cranking motor
converts the electrical energy into mechanical energy which does the
actual work of cranking the engine.
(2) DATA.
Cranking motor make Delco-Remy
Model 1107055
Voltage 6
b. Cranking Motor.
(1) REMOVAL (fig. 54). Remove the nut and lock washer that
retain the battery cable and ammeter wire to the cranking motor
ATEMPERATURE INDICATOR
BINSTRUMENT PANEL LIGHTS
CAMMETER
DFUEL GAGE
ESPEEDOMETER
FOIL PRESSURE GAGE
HLIGHT SWITCH
IBLACKOUT LIGHT BUTTON
JCARBURETOR CHOKE CONTROL
KIGNITION SWITCH
LCOWL VENTILATOR CONTROL LEVER
MHAND THROTTLE
GBLACKOUT DRIVING LIGHT SWITCH NINSTRUMENT PANEL LIGHT SWITCH
RA PD 33076
Figure 55Instruments and Switches
switch, and lift off the cable and ammeter wire. Wrap tape around
end of battery cable so that the terminal does not contact any metal.
Disconnect the lever linkage pull-back spring. Then remove the
cotter pin, and disconnect pedal link from top of drive mechanism
shift lever. Remove the two nuts and lock washers that retain crank-
ing motor assembly to clutch housing, and lift out the assembly.
150
TM 9-805
90-91
(2) INSTALLATION. Place the cranking motor in position in clutch
housing and install the two retaining nuts and lock washers. Connect
the pedal link to drive mechanism lever, and install the spring clip
and cotter pin. Install the pull-back spring. Place the battery cable
and ammeter wire on the cranking motor switch post, and install the
retaining nut and lock washer.
d. Cranking Motor Switch.
(1) REMOVAL. Remove the nut and lock washer that retain the
battery cable to the switch terminal and lift the cable, ammeter
wire, and condenser wire off the switch. Tape end of cable to prevent
shorts. Remove the two screws that retain switch to cranking motor,
and lift off the switch assembly.
(2) INSTALLATION. Make sure that the two bakelite insulators are
in place on each side of inside of switch, then place the switch in
position on cranking motor, and install the condenser and two
mounting screws and lock washers. Place the condenser lead, battery
cable, and ammeter wire on the switch terminal,'and install the
retaining nut and lock washer.
91. INSTRUMENTS AND GAGES.
a. Description (fig. 55). The instruments and gages are located
on the left side of the instrument panel, and consist of a temperature
indicator graduated in degrees Fahrenheit, fuel gage, speedometer,
oil pressure gage, ammeter, and light switches.
b. Temperature Indicator Replacement. Drain the radiator and
remove the heat unit from adapter at left rear of cylinder head.
Remove bolt and clip attaching temperature indicator lead to bond
strap. Remove the two nuts and lock washers that retain indicator
unit to clamp in back of instrument panel, and pull indicator unit
out of face of instrument panel, at the same time pulling the heat
unit through the dash. Install a new assembly in the reverse manner.
c. Fuel Gage.
(1) INTRODUCTION. The fuel gage is composed of two units: the
indicating unit on the instrument panel, and the unit in the fuel tank.
(2) INDICATOR UNIT REPLACEMENT. Disconnect the two wires
from back of indicator unit. Remove the two nuts from back of unit,
and lift out unit. Install a new unit in the reverse manner, making
sure to install the insulators over posts and in holes in clamp.
(3) TANK UNIT REPLACEMENT (fig. 56). Remove the wire from
terminal on tank unit and the ground wire from under one of the
mounting screws. Remove the screws that attach tank unit to top
of tank, and remove the unit. Install a new tank unit in the reverse
manner.
d. Light Switch Replacement. Loosen the-set screw in side of
knob, and unscrew knob until it comes off the shaft. Remove the
151
TM 9-805
91
Figure 56Fuel Gage Tank Unit Replacement
cap screw from left side of release button housing, and lift off the
housing. Unscrew nut that retains the switch to the panel. Push
switch through panel, remove one wire at a time, and install it on the
new switch. Install the switch in the reverse manner.
e. Blackout Driving Light Switch Replacement. Loosen the set
screw in the knob and unscrew the knob. Remove nut that retains
switch to panel, and push switch out of panel. Remove one wire at
a time, and install it on the new switch. Install the switch in the
reverse manner.
f. Speedometer.
(1) DESCRIPTION. The speedometer is driven by a flexible shaft
which in turn is driven by gears in the transfer case. The flexible
shaft is housed in a cable.
(2) REPLACEMENT. Disconnect the flexible cable from the head,
remove the two wing nuts that retain head to clamp bracket, and
lift head out of face of instrument panel. Install a new speedometer
head in the reverse manner.
152
TM 9-805
91-92
g. Oil Pressure Gage Replacement. Disconnect the oil line from
the back of gage at rear of instrument panel, and remove gage from
back of instrument panel. Install a new gage in the reverse manner.
h. Ammeter Replacement. Disconnect wires from back of alti-
meter, being careful not to let the positive wire touch any metal.
Remove the two nuts that retain ammeter to clamp bracket, and pull
BODY HARNESS
GENERATOR HARNESS
JUNCTION BLOCK
immgmm
CHASSIS FRONT HARNESS
BMMM
CHASSIS REAR HARNESS
RA PD 33069
Figure 57Wiring Harness Connections to Junction Block
ammeter out of face of instrument panel. Install a new ammeter in
the reverse manner, making sure to install insulators over terminal
posts.
92. WIRING (fig. 48).
a. Introduction. The wiring system that connects the various
units of the vehicle with the battery consists of a battery cable, indi-
vidual wires, and wiring harnesses which consist of several wires in
153
TM 9-805
92
a loom. There are four main harnesses (fig. 57); namely, the front
harness, rear harness, body harness, and the generator-to-regulator
wiring harness. To assist in understanding the various electrical cir-
ctiits, the major harnesses and junction block are explained and
illustrated, giving the name of the circuit and color of the wire.
(1) BODY HARNESS. The body harness leads from the switches,
instrument panel lights, and instruments on the instrument panel
to the junction block on the left side of the dash.
(2) FRONT HARNESS. The front harness leads from the junction
block on the left side of the dash to the headlight junction blocks on
the lower hood side panels with leads taken off for the horn.
14
RA PD 33093
Figure 58Chassis Front Wiring Harness Connections
to Junction Block
(3) REAR HARNESS. The rear harness leads from the junction
block on the left side of the dash to the taillight junctions at the left
rear corner of the frame. A lead is also taken off for the fuel gage
tank unit.
(4) GENERATOR-TO-REGULATOR HARNESS. The generator-to-
regulator harness contains three wires, connecting the armature,
field, and ground terminals of the generator to the regulator on the
dash.
(5) CRANKING MOTOR TO AMMETER AND COIL WIRING. The
cranking motor to ammeter and coil wires lead from the cranking
motor switch to the ammeter, and also from the ignition switch to
154
TM 9-805
92
the coil, with a jumper wire to the fuel gage circuit breaker. The
wire that leads from the cranking motor switch to the ammeter
supplies the current to all of the instrument panel connections.
(6) JUNCTION BLOCK (figs. 58, 59, and 60). The front and rear
harnesses are connected to the body harness at the junction block
on left side of dash under the hood. The terminals are not numbered,
but for explanatory purposes, the terminals in the illustrations are
numbered, and cross-referenced to the wiring diagram (fig. 48). In
addition, the name of the circuit, and the color and size of the wires
are given. These illustrations and explanations will simplify the
replacement of the wiring harnesses, and checking the various circuits
for short or open circuits.
b. Front Wiring Harness Connection Table (fig. 58).
Wir. Wire
Sin No. Color
16 Natural with red tracer
16 Natural with green tracer
12 Natural with black cross
tracer
14 Natural with black tracer
Tormina! Connoctt
No. lo
1 Blackout driving light
2 Blackout headlights
4 Headlight upper beam
5 Horn
6 Horn
7 Headlight lower beam
II 12 13 14
RA PD 33094
figure 59Chassis Rear Wiring Harness Connections
to Junction Block
155
TM 9-805
92
c. Rear Wiring Harness Connection Table (fig. 59).
Terminal Connects
No. lo
2 Blackout taillights
3 Trailer connector BK ter-
minal (G-7113 models
only)
Fuel gage
Trailer connection taillight
Service taillight
Service stop light
Blackout stop light
10
11
12
13
14
Wire Wire
Sixe No. Color
16
16
14
16
16
16
14
Stop light switch
Stop light switch and stop
light terminal on trailer
connection 14
I23
Natural with green tracer
Natural with black tracer
Black
Natural with black cross
tracer
Natural
Natural with green cross
tracer
Natural
Natural with black tracer
RA PD 33095
Figure 60Chassis Body Wiring Harness Connections
to Junction Block
d. Body Wiring Harness Connection Table (fig. 60).
Tormina! Connoctt
No. to
1 Blackout driving light
Wire
Sixe No.
16
Wir.
Color
Natural with red tracer
156
TM 9-805
92
Wire
Sixe No.
Wire
Color
Terminal Connects
No. to
2 Lighting switch blackout
headlight terminal
"BHT" 16 Natural with green tracer
3 Trailer brake controller BK
terminal (G-7113 models
only)
4 Dimmer switch bright
(upper beam) terminal 12 Natural with black cross
tracer
5 Horn button
6 Horn circuit breaker
7 Dimmer switch dim (lower
beam) terminal
8 Fuel gage
9 Lighting switch trailer tail-
light terminal "TT"
10 Lighting switch terminal
"HT," also center termi-
nal on dimmer switch
and instrument panel
light switch
11 "S" terminal on light
switch
12 "BS" terminal on light
switch
13 "SW" terminal on light
switch
14 "SS" terminal on light
switch
14 Black
12 Natural with black and
red cross tracers
16 Natural
16 Natural with green cross
tracer
14 Natural
e. Light Switch (fig. 61). The light switch has four positions.
When the button is pushed in all the way, the switch is in the "OFF"
position. Pulling the knob out to the first position turns on the black-
out marker lights, the blackout taillights, and also provides a circuit
for the blackout stop light and blackout driving light. Pulling the
knob to the next position turns on the main driving lights and service
tail and stop light. When the switch is all the way out, the service
stop light is connected for use in daylight driving. The terminals are
marked as shown in figure 61, and the connections to the junction
block and ammeter are shown in the following table.
157
TM 9-805
92
BHT B
Figure 6 J-Main tight Switch
MAIN LIGHT SWITCH CONNECTION TABLE
Terminal
Marking
BS
HT
Connection
Service stop light
Blackout stop light
Head and taillight
Connects lo
No. 10 terminal on junction
block
block
block
SEALED BEAM
UNIT
CONNECTOR
RA PD 32278
Figure 62Headlight Construction
158
TM 9-805
92-93
Terminal
Marking Connection Connects to
BHT Blackout head and taillights No. 1 terminal on junction
block
B Light switch supply Ammeter
SS Stop light switch and stop No. 3 terminal on junction
light wire to trailer con- block
nector
TT Trailer taillight No. 8 terminal on junction
block
SW Stop light-switch feed No. 12 terminal on junction
block
A No connections
93. LIGHTING,
a. Description.
(1) HEADLIGHTS (fig. 62). The headlights are the "sealed beam"
type; the reflector, lamp, and lens are a complete unit, and can only
be replaced as a unit. The lower beam filament is positioned slightly
to one side of the focal point in the reflector. This results in deflect-
ing the lower beam to the right side of the road when approaching
other vehicles going in the opposite direction. The headlights use
a 6- to 8-volt, 45- to 35-watt triple-contact lamp.
(2) BLACKOUT DRIVING LIGHT (fig. 9). The blackout driving
light is mounted on the left front fender alongside the headlight. It
is used when driving in a blackout. The diffused beam pattern does
not have a hot spot concentrated on the road; it casts illumination
from 30 to 100 feet in front of the vehicle. The blackout driving light
is equipped with a "sealed" unit that has a 6-volt, 10-candlepower
lamp, and a hood and mask that diffuse the beam and prevent
detection from overhead.
(3) BLACKOUT MARKER LIGHTS (fig. 9). The blackout marker
lights are mounted on the front fenders; a dowel in the fender assures
proper positioning of the light. These lights use a 6- to 8-volt, 3-
candlepower, single-contact, bayonet-base lamp.
(4) BLACKOUT TAIL AND STOP LIGHT. The blackout tail and
stop light is mounted en the rear of chassis at the right side, and
contains two sealed units; one for the taillight, and the other for the
stop light. Each unit consists of a housing, a lamp soldered to the
housing, a filter, and lens. Both units use a 6- to 8-volt, 3-candle-
power, single-contact lamp.
(5) BLACKOUT TAIL, SERVICE TAIL AND STOP LIGHT. The black-
out tail, service tail, and stop light is mounted at the rear of the
chassis on the left side. It is constructed similar to the blackout tail
and stop light, the difference being in the service tail and stoo light
unit that contains a double-filament lamp, 3-candlepower for the
taillight, and 21-candlepower for the stop light, and a lens made of
ruby glass.
159
TM 9-805
93
CENTER LINE AHEAD-
Lr I nftlNU tMr v
^CENTER LINE
]/ OF TRUCK
SPOT SHOULD BE^
rEREDUPAND
N ON LINE A-A
^-CENTER LIN
/ OF RIGHT HX
^-HOT SPOT SHOULD
/ BE CENTERED SIDEWAYS
ON LINE B-B
I/
,^-HEADLAMP
/I
f////////,/fr,
- ^,"//i
>\
\S//////////<
s//, /'/'///,//
V| ,
3 FOR ALL
AIM RIGHT Ht
SAME AS LEF
CENTER HOT
LHOTSPO'
- OF HEADLAMP
SIDEWAYS O
UPPER E
EAM
NO FURTHER ADJU
STMENT IS
NEEDED FOR LOW,ER BEAM
RA PD 32279
Figure 63Headlight Aiming Diagram
b. Headlight Aiming.
(1) INTRODUCTION (fig. 63). Headlights may be aimed by the use
of a portable aiming screen which can be constructed very easily.
Construct a frame approximately 5 feet high and 8 feet long. The
frame can be constructed of common lumber approximately 1 inch
x 3 inches. Cover the frame with a piece of light-colored cloth; make
a narrow, dark, vertical stripe down the center, and two stripes, 18
inches from each side of the center stripe and parallel to it, as shown
by lines "B" and "C" in the illustration. Then place nails on the end
upright of the frame so that the nails are 1 inch apart, beginning at
about 2 feet from the bottom of the screen and continuing upward
about 2 feet. Then secure a piece of black tape about yz- or 3^-inch
wide and about 6 inches longer than screen is wide. Fasten a weight
on each end of the tape to keep the tape stretched when laid across
the nails as shown by line "A" in the illustration.
(2) AIMING HEADLIGHTS. Place the screen against a wall in a
fairly dark corner of room that is fairly level. Run the vehicle directly
in front of the screen so that the headlights are 25 feet from the
screen. Measure from the floor to the center of the headlights, and
place the black tape across the screen so that it is 3 inches below
the center of the headlights. Turn on the upper beam of the head-
lights, and cover one of the lights. Check the location of the beam
on the screen. The center of the hot spot should be centered on the
intersection of the vertical and horizontal lines as shown in figure 63.
If the aim is incorrect, loosen the nut on the headlight mounting
bolt, and move the headlight body on its ball and socket joint until
TM 9-805
93
c. Headlight Replacement. Remove the two headlight harness
leads and the ground lead from terminal block ort inside of hood side
panel, and pull the three wires through hole in side of vehicle in
under the front fender. Remove the nut and washer that retain light
to mounting bracket; then lift off the light, and pull the wire harness
through hole in fender. Install a new light in the reverse manner,
and aim.
d. Blackout Driving Light Replacement. Pull the sleeve con-
nector apart on wire that leads from driving light to front wiring
harness just inside of hood side panel. Pull the wire through hole
in side of vehicle in under the front fender. Remove nut from bottom
of light that secures light to fender, lift off the light, and pull the
wire through hole in fender. Install a new light jn the reverse manner.
e. Blackout Marker Light Replacement. The blackout marker
lights are replaced in the same manner as the blackout driving light.
f. Blackout Tail and Stop Light Replacement. Push the bayonet
connections in the light, at the same time turning them counter-
clockwise about l/$ of an inch; then pull the connection out of the
lights. Remove the two nuts and lock washers that retain light to
mounting bracket, and lift off the light. Install a new light in the
reverse manner.
g. Blackout Tail, Service Tail, and Stop Light Replacement.
The blackout tail, service tail, and stop light is replaced in the same
manner as the blackout tail and stop light.
h. Headlight Sealed Beam Unit Replacement. Remove the three
bolts that retain headlight mounting bracket to fender, and turn
light away from the vehicle. Loosen the lens rim clamp screw, and
lift off the rim. Remove the three screws that secure retainer ring to
light body, and remove the ring. Pull the sealed beam unit out of the
light body, and disconnect wiring connector from rear of the unit.
Install a new sealed beam unit in the reverse manner. NOTE: By
removing the three bracket mounting bolts to turn the headlight,
it will not be necessary to reaim the headlight after replacing a
sealed beam unit.
i. Blackout Marker Light Lamp Replacement. Remove the
light rim retaining screw, and pull the rim out at the bottom; then
raise it upward to release the stamped catch in cover from slot in
top of light body. Push in the lamp and at the same time turn it
counterclockwise about % f an inch; then pull out the lamp. Install
a new lamp in the reverse manner.
j. Blackout Driving Light Unit Replacement. Remove rim
retaining screw at bottom of rim, and pull out rim and light unit.
Disconnect the two wires from the light. Release the spring retainers
and remove the lamp-unit retainer and lamp unit. Install* a new
sealed unit in the reverse manner.
k. Blackout Tail and Stop Light Unit Replacement. Push in
bayonet connection at rear of light, turn it counterclockwise about
% of an inch, and pull out the bayonet connection. Remove the two
screws that retain rim to light body, and lift off the light rim. Pull
161
TM 9-805
93-94
HYDROMETER
GROUND
STRAP
CABLE
BATTERY RA PD 32259
Figure 64Specific Gravity Test of Battery
the lamp unit out of the socket and light body. Install a new lamp
unit in the reverse manner.
1. Blackout Tail, Service Tail, and Stop Light Unit Replace-
ment. The blackout tail, service tail, and stop light units are replaced
in the same manner as the blackout tail and stop light units.
94. BATTERY.
(1) DESCRIPTION (fig. 64). The battery is mounted in a hanger
located outside of the frame side rail to the rear of cab step on the
right side of the truck. It is protected by a removable cover, attached
by two thumb screws, that provides access for testing and filling the
battery.
162
TM 9-805
94-95
(2) DATA.
Make -. Delco
Model 19C1
Number of plates 19
Ampere hour capacity at 20-hour rate 150
b. Inspection and Maintenance. Operation of the vehicle in zero
or subzero temperatures makes frequent checking of the specific
gravity of the electrolyte imperative, as a discharged or partially
discharged battery will freeze at a higher temperature than a fully
charged battery. The temperatures at which electrolyte will freeze
are as follows:
Specific Gravity Temperature (Fahrenheit)
1.180 -6
1.200 -17
1.220 -31
1.240 51
After testing and filling the battery, install the three filler plugs, then
check the terminals to see that they are tight and free of corrosion.
If corrosion exists, scrape the terminal, and apply a coating of grease
to the terminals. Check to see that the battery is tight in the hanger
to prevent physical damage to the battery. Install the battery cover,
and tighten the two wing nuts securely.
c. Removal. Unscrew the two thumb screws, and lift off the
terminal cover. Loosen nuts on cable clamp bolts several turns, and
spread ends of clamps to loosen them; then lift the cables with
clamps off the battery posts. Remove the two nuts and lock washers
that retain the battery retainer, and lift off the retainer. Lift the
battery out of the hanger.
d. Installation. Place battery in hanger with positive or largest
terminal post to the front. Place retainer on battery, install the two
nuts and lock washers, and tighten them alternately until they are
quite snug. Clean the terminal posts and cable terminals, and tap
the cable clamps in position on the posts. Tighten the clamp bolts
and nuts securely. Apply a coating of grease on the terminals; then
install the terminal cover, and tighten the thumb screws securely.
95. RADIO SUPPRESSION EQUIPMENT,
a. Introduction.
(1) Radio suppression equipment is installed to control the
radiation of radio interference by the electrical equipment of a
vehicle, and also to control noise in the vehicle radio receiving set.
It is important that the suppression system be maintained in perfect
condition, as vehicles that radiate interference can be easily located
by the use of short wave listening devices in the hands of the enemy.
(2) Radio suppression is accomplished on these vehicles by the
use of two systems: one using resistor suppressors, filters, condensers,
and bonding; and the other using suppressors, shielding and con-
densers. The first system is used on earlier production vehicles, and
the second on later models.
163
TM 9-805
95
[SUPPRESSORS!
| CONDENSER I
î RA PD 33096
Figure 65Suppressors, Distributor Filter, and Cranking
Motor Condenser
RA PD 33097
Figure 66-Generator FHter and Condenser
164
TM 9-805
95
I BONDS
RA PD 33096
^^MBHM^mMM
Figure 67Armature, Ammeter, and Field Filters
b. Early Production System.
(1) GENERAL. Many early production models included radio sup-
pression equipment of the first type mentioned in subparagraph a (2)
above, consisting of 7 suppressors, 6 filters, 2 condensers, 13 flexible
metal bond straps, a metal screen, and a number of plated bolts,
nuts, and toothed lock washers.
(2) SUPPRESSORS (fig. 65). Suppressors are used on each high
tension lead to the spark plugs, and also on the high tension lead
from the coil to the center of the distributor cap. When installing
a suppressor on a high tension wire, the wire and insulation should
be cut flush and the suppressor screwed on to the wire, making sure
the screw enters in the center of the wire strands. The snap-on ter-
minal^ must make a good contact with the spark plug. The resistance
of the'se suppressors is approximately 10,000 ohms.
(3) FILTERS (figs. 65, 66, 67, and 68). Six filters are used to pre-
vent the continued transmission of any disturbance along the wires
by bypassing it to ground. Four are used in the generator circuit,
and two in the ignition circuit. When replacing a filter it is important
that the terminal screws and mounting bolts be tightened securely.
(4) CONDENSERS. Two condensers are used; one on the generator
(fig. 66), and the other on the cranking motor (fig. 65), to accomplish
165
TM 9-805
95
"A PD 33099
Figure 68-fgnif/on Coil Filter
LOCKWASHERS
BOND STRAP
METAL PANEL
BOLT
METAL PARTS
LOCKWASHERS
BOND STRAP
INSTALLATION
BONDING TWO METAL
PARTS TOGETHER
RA PO 33100
Figure 69Methods Used in Bonding
166
TM 9-805
95
RA PD 33101
Figure 70Front-end Bond Locations
PD 33102
Figure 71Bonding at Fender and Hood
the same purpose as the filters mentioned in subparagraph (3) above.
The condenser retaining screws and terminals must be kept tight.
(5) BONDING. Bonding is accomplished by the use of 13 flexible
metal straps, a metal screen welded at the hood side panel louvers,
and numerous plated bolts, nuts, and toothed lock washers. The
purpose of bonding is to keep all metal parts at a common potential.
The method used to install the flexible metal straps is illustrated in
figure 69. The bond straps are located at the following points:
167
TM 9-805
95
RA PD 33103
Figure 72Generator Condenser
(a) Two bonds between the dash and hood.
(b) One bond connecting speedometer cable, throttle control, and
oil gage line to dash.
(c) Two bonds, one between rear bolt on rocker arm cover and
dash; the other connects the choke control and temperature indicator
line to the dash.
(d) Two bonds between radiator support bracket and radiator
lower baffle. On trucks equipped with front winch, the lower ends
of the bond straps are attached to the front cross member.
(e) Two bonds, one on each side between the fender lower skirt
and frame side rail. '.
(f) Two bonds, one on each side between cab side sill and frame
side rail.
() One bond between clutch housing and left side pan rear
bracket.
(h) One bond between front of oil pan and frame front cross
member left side.
(i) The hood side panel louvers are shielded by welding a piece
of metal screen to the inside of the side panel. It will be noted that
toothed lock washers are placed under the head of the bolt and also
the nut.
(j) Whenever any of the bonded parts are removed, make sure
that the metal surfaces are clean at the bolt locations before install-
he bolts and toothed lock washers; also tighten the bolts and
168
TM 9-805
95
CONDENSER
^M
CONDENSER
GROUND WIRE
Figure 73Regulator Condensers
UPPER SHIELD ASSEMBLY
PRIMARY LEAD
CONDENSER
TERMINAL POST
LOWER SHIELD ASSEMBLY
RA PD 33105
Figure 74Layout of Shielding Parts
169
TM 9-805
95
I1/a-TON 4x4 TRUCK (Chevrolet)
A-SPECIAL STUD PART NO. 3679110 ELOWER SHIELD ASSEMBLY
BBREATHER TUBE BRACKET FNO. 1 SPARK PLUG WIRE
CSPECIAL STUD PART NO. 3679109 GCRANKING MOTOR CONDENSER
DPRIMARY WIRE FROM IGNITION SWITCH
Figure 75Upper Shield Removed for Servicing
nuts securely. Figures 70 and 71 show the locations at which plated
bolts, nuts, and toothed lock washers are used.
c. Late Production System.
(1) GENERAL. The later production models are equipped with
a radio suppression system consisting of seven suppressors, five con-
densers, and a two-piece metal shield which encloses the ignition
system.
(2) SUPPRESSORS. Suppressors are used as outlined in subpara-
graph b (2) above.
(3) CONDENSERS. The five condensers used on this system are
installed at the following points: a generator condenser mounted on
the outside of the generator housing (fig. 72), two regulator con-
densers located just below the generator regulator (fig. 73), an igni-
tion condenser mounted on the lower half of the ignition shielding
(fig. 74), and a starter condenser attached to the cranking motor
housing (fig. 75).
(4) SHIELDING (fig. 74). A two-piece metal shield is used to
enclose the sp3rk plugs, distributor, coil, and wiring. The lower
shield assembly is attached to the engine side cover by four bolts and
eight lock washers, with a lock washer on each side of the bolting
brackets. The primary ignition wire from the ignition switch is
attached to the insulated terminal post, and the ignition primary
circuit is completed to the coil by a lead from the terminal post to
170
TM 9-805
95
AUPPER SHIELD
BTHUMB SCREWS
CWING NUTS
DLOWER. SHIELD
EBREATHER TUBE
BRACKET
RA PD 33107
Figure 76-Upper Shield Installed
the primary lead terminal on top of the coil (fig. 75). The circuit
completed in this manner permits the removal of the upper shield
assembly for service inspection and adjustments, without disturbing
the ignition primary circuit. The upper shield assembly is attached
to the engine with two special studs (fig. 75) in the side cover attach-
ing holes and two thumb screws (fig. 76). The upper shield is retained
to the lower shield by three wing nuts and lock washers.
171
TM 9-805
96-97
Section XX
TRANSMISSION
Removal 97
Installation 98
a. Description (figs. 30 and 31). The selective sliding-gear type
transmission incorporates four forward speeds and one reverse speed.
Provision is made on the left side of the case for mounting a power
take-off when the vehicle is equipped with a winch or hoist. The
transmission assembly is bolted to the clutch housing, and becomes
a part of the unit power plant assembly.
b. Data.
Type Selective sliding gear
Make Chevrolet
Speeds 4 forward, 1 reverse
Mounting Unit power plant
Gear ratio:
First speed 7.06 to 1
Second speed 3.48 to 1
Third speed 1.71 to 1
Fourth speed 1.00 to 1
Reverse speed 6.98 to 1
97. REMOVAL (fig. 77).
a. Disconnect Controls and Drain Lubricant. Remove the floor
and toeboards. Drain the lubricant, and reinstall the drain plug.
Remove the two right rear transmission cover bolts. Remove transfer
case control lever and emergency brake bracket bolts from right side
of transmission, and push control levers away from transmission.
Install two cover bolts. Disconnect pull-back spring from transmis-
sion. NOTE: // the transmission is equipped with a power take-off,
disconnect the propeller shaft (or shafts) and controls, and remove
power take-off (par. 155).
b. Disconnect Propeller Shaft. Remove the U-clamps from the
transmission to transfer case propeller shaft front universal joint.
Hold the trunnion bearings in place and slide the .joint back on splines
of shaft. Leave the bearings on the trunnions, holding them in place
with a piece of tape wrapped endwise over the bearings.
c. Remove Transmission. Remove the flywheel underpan. Re-
move the transmission to clutch housing attaching bolts. Slide the
transmission back to clear the splines in the clutch disk, and lower
the transmission to the floor. NOTE: It is very important that the
weight of the transmission be supported until the end of the clutch
gear splines are out of the splines in the clutch disk.
172
97
173
TM 9-805
RA PD 32322
TRANSMISSION
Figure 77Transmission Removal
TM 9-805
98
98. INSTALLATION.
a. Install Transmission. Clean the mating surfaces of the trans-
mission and clutch housing. Raise the transmission until the main
drive gear shaft lines up with the splines in clutch disk, and work
the transmission forward until the case contacts clutch housing.
NOTE: Do not release the weight of transmission until the main
drive gear bearing retainer pilots into clutch housing, or the clutch
disk will be damaged. Install the four transmission to clutch housing
bolts and tighten securely. Install the flywheel underpan.
b. Connect Propeller Shaft. Remove tape from trunnion bear-
ings, and place the propeller shaft slip joint in position against the
flange. Install the U-clamp and tighten securely.
c. Connect Controls and Fill with Lubricant. Hook up the
brake pedal pull-back spring. Remove the two right rear transmis-
sion cover bolts. Place the emergency brake lever and transfer case
shift levers with bracket in position on right side of transmission, and
install the four attaching bolts. If vehicle is equipped with a power
take-off, bolt it to transmission and connect propeller shaft (or
shafts) and controls. Fill the transmission case to correct level (par.
28 c (6)), lubricate the universal joint, and install the floorboards.
Test the transmission for correct operation.
174
TM 9-805
99-101
Section XXI
TRANSFER CASE
Paragraph
Shifter shaft control rod adjustment 100
Removal 101
Installation 102
a. Description. The transfer case is a two-speed gear box mounted
on the frame between the transmission and rear axle. It provides a
drive for the front and rear axles.
b. Data.
Type Two speed with front axle
declutching
Gear ratio:
High speed 1 to 1
Low speed 1.9411 to 1
100. SHIFTER SHAFT CONTROL ROD ADJUSTMENT.
a. Remove the clevis pins from the adjusting eyes of both the
front axle and low speed shifter shaft pull rods at the transfer case
end. Loosen the adjusting eye lock nuts. With a punch, installed
through the eye of the shifter shaft, force both transfer case shifter
shafts in toward the case until the lock balls seat in the shafts in the
last position. In this position the upper shaft will place the transfer
case in the "HIGH" gear range, and the lower shaft will be in the
"FRONT AXLE DRIVE" range. Next, position the shifter levers
in the cab so that the front axle drive lever is in the "DRIVE" posi-
tion (all the way forward), and the low speed shifter lever is in the
"HIGH" position (all the way back). Center the two levers in the
space in the floorboard to provide end clearance. Holding the two
levers in this position, turn the adjusting eye on the low speed pull
rod until the clevis pin will drop through the adjusting eye and the
shifter shaft. With the low speed pull rod clevis pin in place, hold
the front axle drive shift lever forward, and adjust the pull rod until
the clevis pin will drop through adjusting eye and shifter shaft.
Lengthen the shaft one turn from this position for normal clearance,
and install clevis pin. Check the movement of both shifter levers to
make certain the detent ball locks in place in the shifter shafts in all
positions. Tighten the adjusting eye lock nuts and install cotter pins.
101. REMOVAL.
a. Drain the lubricant from the transfer case. Disconnect all
three propeller shafts and the shifter pull rods from the transfer case.
Disconnect the speedometer cable from the speedometer driven gear.
Place a roller jack under the transfer case from the right side of the
truck, and raise the jack to support the unit (fig. 78). Remove the
locking wire and eight cap screws that attach the transfer case to the
frame brackets. Support the transfer case while the jack is being
lowered and pull the jack and case out from under the truck.
175
TM 9-805
102
TRANSFER CASE
{ATTACHING BOLTS!
Figure 78Transfer Case Removal
RA PD 32320
102. INSTALLATION.
a. Place the transfer case on a roller jack. Move the jack and
transfer case under the truck from the right side. Raise the jack
until the transfer case is in position. Using a taper punch, line up the
holes, and install eight transfer case to frame bracket bolts. Tighten
the bolts and install locking wire in bolts. Connect speedometer cable
to speedometer driven gear in transfer case idler shaft front retainer.
Connect the shifter shaft pull rods to the shifter shafts, and install
clevis pins and cotter pins. Connect the three universal joints to the
transfer case. Remove filler plug, and fill transfer case to correct level
(par. 28 c (6)). Install filler plug, and tighten the filler and drain
plugs.
176
Is
0)
V)
177
103
TM 9-805
PROPELLER SHAFTS
TM 9-805
103-105
1'/,-TON 4x4 TRUCK (Chevrolet)
Section XXII
PROPELLER SHAFTS
Propeller shaft assembly removal 104
Propeller shaft assembly installation 105
a. Description (fig. 79). The propeller shafts are of tubular con-
struction, and are used to transmit the power from the transmission
to the transfer case, and from the transfer case to the front and rear
axles. Needle bearing universal joints are used at each end of the
propeller shafts.
b. Tabulated Data.
PROPELLER SHAFTS. UNIVERSAL JOINTS.
Number used3 TypeNeedle bearing
Shaft diameter3 in. Number used6
104. PROPELLER SHAFT ASSEMBLY REMOVAL (fig. 80).
a. Remove the U-bolts holding the universal joint to the yoke
at each end of the shaft, and tape the trunnions to the yokes so that
the bearings will not fall off. Remove the shaft with joints.
105. PROPELLER SHAFT ASSEMBLY INSTALLATION.
a. Place the shaft in position, install the U-bolts, and tighten
the nuts securely. Lubricate the joints (par. 28 c).
FRONT
YOKE
TRUNNION
BEARING
"U" BOLT
SLEEVE
YOKE
RA PD 55828
Figure 80Disconnecting Universal Joint
178
TM 9-805
106-107
Section XXIII
FRONT AXLE
Paragraph
Tie rod replacement 107
Toe-in adjustment 108
Steering arm replacement 109
Axle housing outer end seal replacement: 110
Axle shaft replacement Ill
Third member assembly replacement 112
Axle assembly removal 113
Axle assembly installation 114
a. Description. The front axle assembly is a front wheel driving
unit, consisting of a banjo-type housing, on which there is provision
for mounting the steering knuckle, and a conventional type differ-
ential. The front wheels are driven by axle shafts equipped with
constant-velocity type universal joints that are enclosed in the steer-
ing knuckle support housing.
b. Data.
Housing type Banjo
Drive Through springs
Drive type Hypoid
Gear ratio 6.67 to 1
Front wheel camber J4 to 1 degree
Front wheel caster 1 degree, 30 min. to
2 degrees
Front wheel toe-in 0 in. to y% in.
107. TIE ROD REPLACEMENT.
a. Removal. Remove the two tie rod bolts, and remove the tie
rod assembly with yokes. Remove the left tie rod yoke clamp bolt
retaining the tie rod lock, and remove the lock. Loosen the three
remaining tie rod yoke clamp bolts, and remove both tie rod yokes.
b. Installation. Install the tie rod yokes on ends of tie rod, and
turn them on an equal amount until tie rod -is 54% inches long
(center to center of tie rod bolt holes). Place the tie rod in position
with the end with coarse threads to the right, and install the tie rod
bolts. Install the two tie rod yoke clamp bolts loosely in each yoke,
placing the tie rod lock on the inner bolt at left yoke. Turn the front
wheels first to left, and then to right, until they hit the stops; and
check clearance between tie rod and lower rib of differential at each
side. If tie rod comes within *4 mcn of differential when wheels are
turned to left, turn left tie rod yoke onto tie rod, and right yoke off
an equal distance. If tie rod comes within l/s inch of the differential
when wheels are turned to right, turn right tie rod end on further,
and lift tie rod off an equal distance. Tighten tie rod yoke clamp bolts
at right side and adjust toe-in (par. 108 b).
179
TM 9-805
108-109
TIE ROD YOKE LOCK TIE ROD BOLT YOKE CLAMP BOLT
Figure 81 Tie Rod Adjustment
108. TOE-IN ADJUSTMENT.
a. Checking Toe-In. To check toe-in, mark a fine chalk line at
the center of the tread of both front tires. Set the two tires so that
the chalk mark is toward the front of the vehicle on a line with the
center of the wheel. Then carefully measure the distance from the
center of one chalk line to the other. Now revolve the wheels so that
the chalk lines are facing the back of the car and on center with the
wheel. Again measure the distance between the chalk marks. For
the correct toe-in setting the difference between the measurements
obtained should be between 0 inch and y8 inch, with the shorter
distance, if any, at the front.
b. Adjusting Toe-In (fig. 81). Remove tie rod bolt. Remove the
left tie rod yoke inner clamp bolt and washer, and loosen the outer
clamp bolt. Turn the tie rod yoke onto rod to decrease toe-in, and
off the rod to increase toe-in. If difficulty is experienced in securing
proper toe-in, it may be necessary to disconnect the tie rod from
the right steering arm and screw the end either on or off the tie rod
one turn. Then screw the left tie rod end on or off the rod to secure
the proper toe-in. Install the one tie rod and clamp bolt, and lock
and tighten all clamp bolts. Install the nuts on the tie rod bolts.
Tighten nuts wrench-tight, and back off 1/3 to 1/2 turn. Lock the
nut with a cotter pin.
109. STEERING ARM REPLACEMENT (fig. 82).
a. Remove steering connecting rod end at arm by removing cot-
ter pin and end plug. Then remove safety plug, tension spring, and
ball seat. Lift steering connecting rod off arm ball. Remove the four
nuts attaching arm to knuckle support. Remove the two studs near-
est the brake drum, and remove steering arm. Install new arm, the
two studs, four nuts and lock washers, and securely place the steer-
180
TM 9-805
109-110
FRONT AXLE
RA PD 33053
Figure 82Steering Knuckle Arm Removal
ing connecting rod on arm ball. When assembling the parts in the
rod ends, make sure they are assembled in the order they were re-
moved, as this method of assembly relieves steering gear from road
shocks in both directions. To adjust the ball joint, screw end plug in
tight, then back off % to one full turn. Lock the adjusting plugs
with a new cotter pin.
110. AXLE HOUSING OUTER END SEAL REPLACEMENT
(fig. 83).
a. Removal. Remove the 12 cap screws attaching inner retainer
to steering knuckle support, and remove inner retainer. Slide the
spring-loaded seal retainer and seal back on housing as the spring-
loaded seal cannot be replaced without removing steering knuckle.
Work the outer end seal (felt and rubber) out of the seal retainer,
and remove it from housing, as this seal is split. Remove the seal
retainer and gasket.
181
TM 9-805
110-111
TA|NERGASKET
OUTER Eh
OUTER END SEAL (FELT AND RUBBER))
OUTER END SEAL (SPRIN< LOADED)]
'SPRING LOADED SEAL RETAINER}
OUTER END SEAL INNER RETAINER ^^^^ RA PD 33046
Figure 83Outer Seal Replacement
b. Installation. Place a new seal retainer gasket on knuckle sup-
port with the diagonal cut as close to top as possible, and make sure
bolt holes line up. Install the seal retainer. Place the new outer end
seal (felt and rubber) in the retainer so that the taper of seal fits
the curvature of the axle outer end ball, and the diagonal cut will
be at the top. Place the spring-loaded seal and seal retainer against
the felt and rubber seal, and install the lower half of the inner
retainer, holding it in place with two or three cap screws installed
loosely. Position the spring-loaded seal uniformly around the
spherical bolt with a small screwdriver, and install the upper half
of the inner retainer. Install and tighten all of the retainer cap
screws.
111. AXLE SHAFT REPLACEMENT (EITHER SHAFT).
a. Removal (fig. 84).
(1) REMOVE WHEELS. Loosen the six wheel stud nuts on front
wheel two turns. Raise front of vehicle until the wheel clears the
ground, and support axle housing on jack stand or suitable blocks.
Remove the six wheel stud nuts that were previously loosened, and
remove the wheel.
(2) REMOVE HUB. Remove the eight bolts and lock washers
attaching drive flange to hub. Install two bolts in the tapped holes
of flange; screw them in alternately to remove flange. Raise the tangs
182
TM 9-805
111
FRONT AXLE
BRAKE BACKING PLATE
AXLE SHAFT
RA PD 55803
Figure 84Front Axle Shaft Removal
that lock the wheel bearing outer lock nut and remove the nut, lock
the inner lock nut, spacer washer, roller bearing assembly, and wheel
hub. Install brake wheel cylinder clamp.
(3) REMOVE FLANGE PLATE. Remove brake retracting spring.
Remove the six cap screws that attach the brake shoe anchor plate to
the steering knuckle, and remove anchor plate. Remove the 12 cap
screws that attach brake shoe anchor plate spacer, inner oil deflector,
brake flange plate, and steering knuckle to the steering knuckle
support. Remove the spacer and oil deflector. Slide brake flange plate
off the steering knuckle and support it with a piece of wire. This
procedure saves removing the brake line hose and bleeding brakes
after performing the repairs.
(4) REMOVE AXLE SHAFT. Remove steering knuckle from support
and pull the axle shaft from the housing, supporting it throughout
its full length to prevent damaging oil seal in the end of housing.
b. Installation.
(1) INSTALL AXLE SHAFT. Pack axle shaft universal joint with
general purpose grease No. 0, and rub a thin layer of grease on the
surfaces that contact the bushing and thrust washer. CAUTION:
When entering the axle shaft, care must be taken not to damage the
183
TM 9-805
111-113
1 Vj-TON 4x4 TRUCK (Chevrolet)
axle shaft oil seal. The universal joint should be supported from
below when entering the shaft in the differential gear.
(2) INSTALL BRAKE FLANGE PLATE. Place new gasket in position
on support, and place steering knuckle in position over axle shaft
with keyway at top. Place brake flange plate and oil deflector in
position on the steering knuckle, with the wheel cylinder at top.
Then place the anchor plate spacer in position so that two bosses
are spaced equally with reference to the wheel cylinder, and install
the 12 cap screws and tighten. Place anchor plate with brake shoes
attached in position and install cap screws; tighten them securely.
(3) INSTALL HUB AND BEARINGS. Hook one end of brake spring
in sec.ond hole of right-hand brake shoe, and stretch spring to fit in
second hole of left-hand shoe. Hand-pack the inner and outer bear-
ings with general purpose grease No. 2. Place hub assembly in posi-
tion on steering knuckle and install the outer bearing, washer, and
adjusting nut. Tighten the adjusting nut snugly, wrench-tight, then
back the nut off a distance equal to that between two adjacent flange
bolt holes, which is equal to 45 degrees. Place nut lock in position,
and aline nearest slot in nut with a short tang on nut lock. Bend
tang of lock down in slot of nut. Install locking nut and tighten
securely. Bend one of the tangs to fit in slot of lock nut.
(4) INSTALL DRIVE FLANGE (fig. 84). Place a new drive flange
gasket over the drive flange and install the flange, making sure to
line up the holes in the flange with those in the gasket. Install the
eight cap screws with lock washers and tighten securely. Fill uni-
versal joint to level of filter plug hole with general purpose grease
No. 0. Install wheel and remove blocking.
112. -THIRD MEMBER ASSEMBLY REPLACEMENT.
a. Removal. Remove tie rod bolt at left end of tie rod and swing
tie rod around out of the way. Pull both front axle shafts back to
clear differential (par. 111). Jack up front end of frame to provide
clearance at the oil pan. Follow instructions in paragraph 116 a,
except that pertaining to axle shafts.
b. Installation. Follow instructions in paragraph 116 b, except
that pertaining to axle shafts. Install axle shafts (par. 111). Place
tie rod in position, install tie rod bolt and nut; tighten nut wrench-
tight and back off from l/3 to l/z turn. Install cotter pin. Lubricate
tie rod and fill differential to correct level (par. 28 c (6)). Remove
jack from front end of frame.
113. AXLE ASSEMBLY REMOVAL (fig. 85).
a. Jack up front of vehicle and support the frame on suitable
stands. Split universal joint and tape trunnion bearings to prevent
them from falling off trunnion yoke. Disconnect steering connecting
rod and lift connecting rod off the knuckle arm ball. Disconnect
brake hose and shock absorber Hnks. Support the axle with a roller
jack. Remove the four nuts from the two front spring U-bolts on
each side, and remove the U-bolts and bumper retainer. Remove
184
TM 9-805
113-114
FRONT AXLE
RA PD 33108
Figure 85Front Axle Assembly Removal
axle assembly by lowering jack carefully, and roll the entire front
axle assembly out from under vehicle. Block up axle and remove
the six wheel nuts from each wheel and remove wheels.
114. AXLE ASSEMBLY INSTALLATION.
a. Install wheels, and roll front axle assembly under vehicle and
raise to proper position with suitable jack. Place U-bolts in position
around axle housing and front springs, and install bumper retainer,
lock washers, and nuts. Tighten nuts securely. Connect shock absorber
links and brake connections, and install steering connecting rod.
Remove tape from universal joint trunnion bearings and install
U-bolts, lock washers, and nuts. Tighten nuts. Lubricate grease fit-
ting, and check differential for lubricant. Remove jack stands and
tighten wheel nuts; adjust toe-in (par. 108), and bleed brake system
(par. 123).
185
TM 9-805
115-116
Section XXIV
REAR AXLE
Paragraph
Third member assembly replacement 116
Axle shaft replacement 117
Axle assembly removal 118
Axle assembly installation 119
a. General. The rear axle is of the single-reduction, full-floating,
hypoid type with a straddle-mounted pinion gear, and a high-
traction type differential. Being of the full-floating type, the axle
shafts can be removed with the weight of the vehicle on its wheels.
h. Data.
Housing type Banjo
Drive ~. Through springs
Gear ratio 6.67 to 1
Drive type Hypoid
116. THIRD MEMBER ASSEMBLY REPLACEMENT.
a. Removal (fig. 86). Drain the differential, remove the axle
shaft cap screws, and pull both axle shafts out far enough to clear
the differential. Remove rear universal joint U-clamps, tape the
trunnion bearings to the trunnions, and tie the propeller shaft to a
frame side rail. Remove the cap screws that retain third member
assembly to axle housing. Before the last cap screw is removed, place
a long drift punch through upper bolt hole in third member and
housing to support third member. Place a roller jack under third
member, and block it to support the assembly. Work the assembly
forward until it clears the axle housing, steady third member on
jack, remove drift, and lower the third member to floor.
b. Installation. Place third member on jack and block it in posi-
tion. Install a new gasket. Roll the assembly under vehicle, raise it
in line with axle housing, and place a long drift punch through upper
hole in third member and axle housing. Work the assembly into axle
housing, being careful not to damage gasket. Install the cap screws,
and tighten them securely. Remove tape from universal joint trun-
nion bearings, place the propeller shaft in position, and install the
U-clamps. Install the axle shafts and retaining cap screws. Fill dif-
ferential to correct level (par. 28 c (6)).
186
'5
0)
01
<o
o>
CO
3.
187
116
TM 9-805
REAR AXLE
TM 9-805
117-118
Figure 87-Pulling Axle Shaft from Hub
117. AXLE SHAFT REPLACEMENT.
a. Removal (fig. 87). Remove cap screws and lock washers.
Install two of the cap screws in the threaded holes provided in axle
shaft flange, and by turning these cap screws alternately, remove
the axle shaft.
b. Installation (fig. 88). Place a new terne plate gasket on axle
shaft and push the shaft into place, turning it slightly to engage the
splines in differential side gears. Install the cap screws in the flange
and, tightening them alternately, draw them up tight.
118. AXLE ASSEMBLY REMOVAL (fig. 89).
a. Raise rear end of vehicle, and support the frame on suitable
stands. Remove both wheels to provide clearance at the fenders.
Disconnect rear universal joint, and lower the shaft to floor. Tape
188
TM 9-805
118-119
REAR AXLE
PD 33048
Figure 88Replacing Axle Shaft
trunnion bearings in place to keep them from falling off. Disconnect
brake line from master cylinder where it joins the line running across
the axle to wheel cylinders. Place a jack under differential to sup-
port the axle, and remove the eight (four on each side) spring U-bolt
attaching nuts. Move shock absorber link and bracket up out of the
way, and remove anchor plate. Steady the assembly, and pull it out
from under the vehicle.
119. AXLE ASSEMBLY INSTALLATION.
a. Place the axle assembly on a roller jack, and move the jack
and axle into position under the vehicle. Raise the axle up against
the springs and install the anchor plate, shock absorbers, anchor
plates, U-bolt nuts and washers. Connect the brake hose to axle
brake connector "T." Connect the universal joint to pinion shaft
joint flange, and lubricate the joint. Install the wheels. Check the
differential lubricant level, and add lubricant if necessary (par. 28
c (6)). Bleed the brakes (par. 123).
189
os
01
<x
119
19O
TM 9-805
TM 9-805
120
Section XXV
BRAKE SYSTEM
Paragraph
Parking brake adjustment 121
Service brake adjustment 122
Bleeding brake system 123
Master, cylinder replacement 124
Wheel cylinder replacement 125
Brake shoe replacement 126
Parking brake band replacement 127
Hydrovac replacement 128
Trailer electric brake control 129
Brake line flaring 130
a. Description. The braking system combines hydraulically oper-
ated service brakes, a hydrovac booster system, and mechanically
operated parking brakes. Electrically controlled trailer brakes are
used in conjunction with the above on certain models.
b. Data.
Service brake type 4-wheel hydraulic
Parking brake type Drive shaft
Master cylinder size 1% m-
Wheel cylinder size:
Front 1% in-
Rear \y2 in.
Brake shoe size:
Front 14 x 2 in.
Rear 16 x 2 in.
Hand brake lining:
Length 29l/2 in.
Width 3 in.
Thickness 5/16 in.
Adjustments:
Front shoe From slight drag on drum, back
off adjusting screw 4 notches
Rear shoe : From slight drag on drum, back
off adjusting bolt % turn or 4 sides of hex head
Foot pedal to toeboard clearance % "*
Hydrovac model:
Double-piston type H-66-3.3
Single-piston type HS25-22P-51
191
TM 9-805
121
A-REAR ANCHOR SCREW
BBRAKE ANCHOR
CBRAKE BAND WITH LINING
D-BRAKE DRUM
EBRAKE PULL ROD
FADJUSTING BOLT
GOPERATING CAM
HADJUSTING SCREW LOCK NUTS
(LOWER SHOE)
IADJUSTING SCREW (LOWER SHOE)
JSPRINGS (SHOE RELEASE)
KSPRING (UPPER SHOE ADJUSTING)
LADJUSTING BOLT NUTS (UPPER
SHOE) RA pD 33,09
Figure 90Parking Brake Adjustment
121. PARKING BRAKE ADJUSTMENT (fig. 90).
a. The parking brake adjustment should be checked each time
the hydraulic service brakes are adjusted. Set hand brake lever in
fully released position, then detach pull rod. Remove rear anchor
screw lock wire, and turn the adjusting screw to secure 0.010-inch to
0.015-inch clearance between the brake band and drum underneath
brake anchor. Lock the anchor adjusting screw with a lock wire.
Loosen lower shoe adjustment lock nut, and turn the adjusting
screw to secure 0.020-inch clearance between the lower end of the
band and drum. Tighten adjusting screw lock nut. Loosen lock nut
on large adjusting bolt, and back it off until it is free of the adjust-
ing nut. Turn adjusting nut on adjusting bolt to secure 0.020-inch
clearance between upper end of band and the drum. Then tighten
the lock nut securely while holding the adjusting nut. Check the
pull rod adjustment by moving the operating cams forward until
they contact the pad on brake band bracket. Set the brake pedal in
the first notch from the fully released position. The pin hole in the
192
193
121
TM 9-805
RA PD 32226
RA PD 32225
BRAKE SYSTEM
Figure 91-Adjusting Brakes, Front Wheel
Figure 92Adjusting Brakes/ Rear Wheel
194
121
TM 9-805
1 i/2-TON 4x4 TRUCK (Chevrolet)
195
121
TM 9-805
BRAKE SYSTEM
TM 9-805
121-122
RA PD 32229
Figure 95-Master Cylinder Filler
pull rod should then line up with the holes in the operating cams
for proper adjustment. If they do not line up, loosen the lock nut
at the clevis on the brake pedal end of the pull rod, and turn the
rod in the clevis until the proper adjustment as mentioned above,
is obtained. Tighten lock nut at clevis, and install cotter pin in pull
rod pin. Lubricate all frictional surfaces of the brake control linkage
and anchor bolts with engine oil.
122. SERVICE BRAKE ADJUSTMENT.
a. Adjustment at Wheels. Raise the truck and place jack stands
front and rear so that all four wheels rotate freely. Remove the
adjusting hole covers from the front flange plates, insert a screw-
driver through the adjusting hole, and engage the teeth on the
adjusting cover of the wheel cylinder (fig. 91). Turn the adjusting
cover in a clockwise direction, looking at the end of the cylinder,
196
TM 9-805
122
BRAKE SYSTEM
RA PD 32230
figure 96-Bleedlng Wheel Cylinder
until the shoes cause a slight drag on the drum. Turn the adjusting
cover back four notches. Backing off the adjusting cover moves the
brake shoe away from the drum to insure proper running clearance
of the shoes in the drum. Replace the adjusting hole covers. To
adjust the rear brakes turn the adjusting pinion (fig. 92) in a clock-
wise direction until shoe causes a slight drag on the drum. Turn the
adjusting pinion back % of a turn, or four sides of the hexagon on
pinion shaft, to provide running clearance.
b. Toeboard Clearance (fig. 93). Toeboard clearance very seldom
needs to be adjusted. The pedal stop, which is located in the brake
main cylinder, is permanent. Before attempting to adjust toeboard
clearance, be certain that the pedal returns to the full-released posi-
tion freely, with no binding, and that the pedal retracting spring
has not lost its tension. Loosen the check nut on the rear of the
clevis on the master cylinder push rod. Remove clevis pin, and turn
the clevis attached to the master cylinder push rod in the proper
197
TM 9-805
122-123
direction to secure %-inch toeboard clearance, measurement being
taken between pedal arm and underside of toe-pan. Tighten the
check nut against the clevis.
123. BLEEDING BRAKE SYSTEM.
a. General. The hydraulic brake system must be bled whenever
a pipe line has been disconnected, or when a leak has allowed air to
enter the system. The hydrovac booster system should be bled first,
and then the wheel cylinders; follow the bleeding sequence shown in
figure 94.
b. Install Automatic Filler (fig. 95). Clean all dirt from around
the master cylinder filler plug. Remove the filler plug and install the
bleeder adapter and automatic filler (41-F-2982). Open the auto-
matic valve in the filler.
MASTER CYLINDER
PUSH ROD
SWITCH
WIRING
HARNESS
CONNECTIONS
Figure 97Brake Master Cylinder
RA PD 33110
c. Install Drain Tube (fig. 96). Remove the bleeder valve screw
and attach the bleeder drain tube (41-T-4170) to the bleeder valve
at the relay valve end of the hydrovac (No. 1, fig. 94). Place the
end of the drain hose below the surface of brake fluid in a jar.
d. Bleed System. Unscrew bleeder valve y2 to 54 turn. Depress
the foot pedal by hand, allowing it to return slowly. Continuing this
pumping action forces the fluid through the lines and out at the
bleeder drain, carrying with it any air in the system. When bubbles
198
TM 9-805
123-124
BRAKE SYSTEM
cease to appear at the end of the bleeder drain hose and the stream
is a solid mass of fluid, tighten the bleeder valve and remove the
drain hose. Replace and tighten the screw at the end of the bleeder
valve. In numerical sequence, proceed in the same manner with the
other bleeding points. After the bleeding operation has been com-
pleted at the hydrovac and wheel cylinders, start the engine, and
depress the brake pedal several times. Then bleed again at point
BRAKE DRUM
RETAINING SCREWS
Figure 98Brake Drum Replacement
No. 3. After bleeding at all points, fill the master cylinder reservoir
Y$ full and replace the filler plug. NQTE: Fluid withdrawn in the
bleeding operation should not be used again.
124. MASTER CYLINDER REPLACEMENT (fig. 97).
a. Remove the clevis pin from the master cylinder link to idler
lever. Disconnect the brake pipe from the master cylinder end plug.
Disconnect wires from stop light switch. Remove the four bolts
attaching the master cylinder and bracket to the frame, and lift off
the cylinder. Remove cylinder from bracket. When installing a new
cylinder, proceed in the reverse order of removal and fill the cylinder
with fluid. It is then necessary to bleed the entire system (par. 123).
199
TM 9-805
125-126
REVERSE ACTING BRAKE SHOE
WHEEL CYLINDER
BRAKE SHOE
RETRACTING SPRING
ANCHOR PLATE
BRAKE SHOE GUIDE
ARTICULATING LINK
LINK PIN AND LOCK
FORWARD ACTING
BRAKE SHOE
FRICTION PIN
AND SPRING
Figure 99Brake Construction, Front Wheel
125. WHEEL CYLINDER REPLACEMENT.
a. Place vehicle on a level spot and remove the wheel. Remove
the three brake drum attaching screws and brake drums (fig. 98).
Disconnect pipe or hose from the wheel cylinder. Disconnect the
brake shoe retracting spring with pliers (41-P-1579). Remove the two
cap screws holding the cylinder to the flange plate and remove cyl-
inder (figs. 99 and 100). Install a new wheel cylinder assembly in
the reverse order of removal, and bleed the entire system (par. 123).
126. BRAKE SHOE REPLACEMENT (figs. 99 and 100).
a. Removal. Place vehicle in jack stands and remove all wheels.
Remove the three screws that attach each brake drum (fig. 98),
and remove the drums. Install wheel cylinder clamps (fig. 101) to
prevent leakage of brake fluid. Using brake spring pliers (41-P-1579)
remove the brake shoe retracting springs. Remove the brake shoe
anchor pin lock and pin; one on front brakes, two on rear; and lift
off brake shoes. Remove the articulating link friction spring pin
lock, pin, and spring. Disassemble the articulating links from the
shoes by removing pin lock and pin.
200
TM 9-805
126
BRAKE SYSTEM
WHEEL CYLINDER BRAKE SHOE
RETRACTING SPRING
FORWARD ACTINGBRAKESHOE
GREASE DEFLECTOR
UUTING LINKS
BRAKE DRUM
BRAKE SHOE GUIDE
FRICTION PIN
AND SPRING
RA PD 33051
Figure I00Brake Construction, Rear Wheel
CLAMP
RA PD 32214
Figure 1OI-Brake Wheel Cylinder Clamp
2O1
202
176
TM 9-805
1 i/j-TON 4x4 TRUCK (Chevrolet)
TM 9-805
126-128
BRAKE SYSTEM
WHEEL CYLINDER
ADJUSTING SCREW
BRAKE SHOE
BRAKE SHOE
GUIDE
RETRACTING
SPRING
LINK FIN
FLANGE PLATE
FRICTION PIN
AND SPRING
ARTICULATING LINKS
ANCHOR PIN
RA PD 32224
Figure 103 Electric Trailer Brake Adjustment
b. Installation. Assemble articulating links, pins, friction springs,
and locks to the new brake shoes. Then assemble shoes to anchor
plate and check fit of shoe in guide riveted to anchor plate. NOTE:
The shoes should be free without excessive side movement. Install
the brake shoe retracting spring, and remove wheel cylinder clamp.
Install brake drums and wheels. Jack up vehicle and remove stands.
127. PARKING BRAKE BAND REPLACEMENT.
a. Remove lock nut, lock washer, adjusting nut, flat washer, and
spring from the large adjusting bolt (fig. 90). Remove clevis pin
from operating cam and adjusting bolt. Remove adjusting bolt and
shoe springs. Remove lower shoe adjusting screw, nut, and washer.
Remove the rear anchor screw lock wire and the screw. Then slide
the band assembly off the anchor, and catch the release spring at
anchor. Assemble the brake band to the drum, and form it as neces-
sary to conform to the shape of the drum. Adjust according to in-
structions given in paragraph 121.
128. HYDRO VAC REPLACEMENT (fig. 102).
a. Disconnect hydraulic brake lines from the hydrovac unit.
Remove the hose connections to the air cleaner and the vacuum
line. Remove the four bolts retaining the hydrovac unit to the frame
203
TM 9-805
129-130
side rail, and lift off the unit. Installation is the reverse of removal,
except that the entire brake system must be bled (par. 123).
129. TRAILER ELECTRIC BRAKE CONTROL.
a. General (fig. 103). On certain vehicles an electric control unit
for the trailer brakes is mounted under the driver compartment
floorboards. The control unit is connected by an adjustable rod
clamped to the foot brake pedal pull rod, so that when the truck
foot brakes are applied, the trailer brakes also are applied. A stop
light switch also is incorporated in this unit which controls both
truck and trailer stop lights, according to main light switch position.
b. Load Control. A load control unit mounted on the instrument
panel has four positions for light, medium, medium-heavy, and heavy
loads, designated by the numbers 1, 2, 3, and 4. If the load in the
trailer is light, the load control should be set at No. 1; if it is heavy,
it should be set at No. 4. In other words, the load control should be
set in accordance with the weight of the load in the trailer.
, CUTTER
KMO-3A(KM)
REAMER BLADE RAPO 32232
Figure 7 04-Broke Tube Cutting Tool KM-KMO-3A (41-C-2825)
c. Adjustment. Remove clevis pin from front clevis at clamp.
Place control unit operating arm in full "OFF" position (toward
rear). Adjust clevis so that with operating arm in full "OFF" posi-
tion and foot brake pedal in released position, clevis pjn can be
inserted without altering either the arm or pedal position. Install
the clevis pin and cotter pin. Tighten clevis lock nut. The switch
blade and contacts should be cleaned occasionally with No. 00 flint
paper.
130. BRAKE LINE FLARING.
a. Cut Tube. Cut the tubing to the desired length, using tube
cutter to prevent flattening the tubing (fig. 104). Square-off the end
2O4
TM 9-805
130
BRAKE SYSTEM
with a fine-cut mill file, then ream the sharp edges with the reamer
blade provided on the tube cutter.
b. Install Tube in Die. Place new inverted flared tube nuts on
the tubing. Dip end of tubing to be flared in hydraulic brake fluid.
NOTE: This lubrication results in a better formation of the flare.
Loosen the clamping nuts on the flaring tool (41-T-3076-35), and
insert finished end of the tubing in the channel of the die until it
bears against the stop pin (fig. 105).
BRAKE
TUBE
STOP
PIN
M28O-KKM)
RA PD 32233
Figure 1 OS-Installing Tube In Tool KM-J-1280 (41-T-3076-35)
J-1280-2(KM)
RA PD 32234
Figure 106First Flare-forming Operation, Using Special
Flaring Tool KM-J-1280 (41-T-3076-35)
c. Install Tool in Vise. Tighten the clamping nuts by hand, and
place the fixture in a bench vise. Then tighten down the clamping
nuts firmly with a wrench, and remove the stop pin from the die.
The tubing is now firmly gripped in the die, and ready for the first
flare-forming operation.
205
TM 9-805
130
d. First Flare-forming Operation. Using the flare-forming tool
(41-T-3076-35) having the concave die, insert the forming tool in
the die and strike firm blows, using a 1-pound hammer, until the
shoulder of the tool contacts the top of the die. The cross-section
drawing (fig. 106) shows the first step in forming the double-flap
flare.
e. Second Flare-forming Operation. Next, using the flare-
forming tool (41-T-3076-35) having the 46-degree die at its lower
end, insert the tool in the die and strike firm blows, using a 1-pound
hammer, until the shoulder of the tool contacts the top of the die.
The cross-section drawing (fig. 107) shows the second and final
forming operation in making a double-lap flare.
;,
M280-3(KM)
RA PD 32235
Figure 107Final Flare-forming Operation, Using Special
Flaring Tool KM-J-1280 (41-T-3076-35)
2O6
TM 9-805
131
Section XXVI
WHEELS, WHEEL BEARINGS, HUBS, AND TIRES
Wheel and tire replacement 132
Wheel bearing adjustment 133
Wheel bearing replacement 134
a. Description.
(1) WHEELS. Interchangeable pierced-steel disk-type wheels are
used both front and rear. The wheel is attached to the hub with six
stud nuts. Dual wheels are used at the rear, and the construction is
such that duals can be attached at the front for severe operating
conditions.
(2) WHEEL BEARINGS. Timken tapered roller bearings are used
in the front wheel hubs, while Hyatt roller bearings are used in the
rear wheel hubs.
(3) HUBS. Each hub is fitted with an external flange for attaching
the brake drum and wheel. These are machined to take the inner
and outer wheel bearing cups and oil seal. The outer end of hub has
eight tapped holes for bolting the axle flange or drive flange.
(4) TIRES. Heavy-duty mud- and snow-type tires are used on all
wheels. A removable clamp ring holds the tire on the wheel.
b. Data.
(1) WHEELS.
Wheel size 20 x 7
Rim size 20 x 5.005 (7 in.)
Wheel offset 5% in.
(2) WHEEL BEARINGS (FRONT).
Inner cone and roller assembly Timken 33275
Inner cup Timken 33472
Outer cone and roller assembly Timken 399A
Outer cup Timken 394A
"(3) WHEEL BEARINGS (REAR).
Inner assembly Hyatt KD-12051Z
Outer assembly , Hyatt KB-11786Y
(4) TIRES.
Size 7.50 x 20
Number plies , 8
Inflation:
Frontwith single wheels 55 Ib
Frontwith dual wheels 27% Ib
Rearwith single wheels 55 Ib
Rearwith dual wheels 40 Ib
207
TM 9-805
132-133
LOCK NUT
W/OIL SEAL
LOCK NUT
LOCK
BEARING
ADJUSTING NUT
RA PD 55816
Figure 1 08 Wheel Bearing Adjustment Parts
132. WHEEL AND TIRE REPLACEMENT.
a. Removal. Set truck in level place, loosen wheel to hub retain-
ing nuts one turn, and block wheel at opposite end of vehicle. NOTK:
The wheel nuts on left side of vehicle have left-hand threads. Those
on right side have right-hand threads. Raise axle until wheel is free;
remove wheel nuts, and wheel and tire assembly. Deflate tire com-
pletely. Force clamp ring in until it drops into groove in wheel.
Insert a heavy screwdriver into the recess in the clamp ring, and
pry this side of the ring out over the edge of wheel. Work the ring
off wheel with tire irons, and remove the tire and tube assembly.
b. Installation. Place the tube in tire, place the tire on wheel,
and install clamp ring. NOTE: Make sure the clamp ring is seated
against the rim of the wheel throughout its entire circumference
before inflating the tire. Inflate tire slowly and watch to see that the
ring stays in place. Install wheel, tighten nuts, and remove jack and
wheel blocking.
133. WHEEL BEARING ADJUSTMENT (front or rear wheels) .
a. Remove Wheel and Axle Flange. Set emergency brake or
block a wheel. Loosen the wheel stud nuts one turn on the wheel to
208
TM 9-805
133-134
WHEEL BEARING
NUT WRENCH
RA PD 55802
Figure 109Wheel Bearing Adjustment
be adjusted. Raise axle until wheel is free, remove wheel stud nuts
and wheel assembly. Remove the rear axle shaft bolts or front axle
drive flange bolts and axle shaft or flange.
b. Adjust Bearing. Raise the tang of the lock nut lock (fig. 108),
and remove lock nut and seal assembly and lock nut lock. Tighten
the bearing adjusting nut wrench-tight (fig. 109). Then back the
adjusting nut off 45 degrees, which is equal to the distance between
two adjacent flange bolt holes. Install lock nut lock and aline
nearest slot in adjusting nut with short tang on lock nut lock, and
bend tang into slot. Install lock nut and seal, and tighten securely.
Bend one long tang on lock into slot in nut.
c. Install Flange or Axle and Wheel. Place a new terne plate
gasket on the drive flange (fig. 110), or axle shaft (fig. 88), and
install the shaft or flange. Install the lock washers and flange bolts.
Install wheel assembly, and remove blocking and jack. Tighten axle
flange bolts to a torque-load of 95 to 115 foot-pounds.
134. WHEEL BEARING REPLACEMENT,
a. Front Wheels.
(1) REMOVAL. Remove the wheel and axle flange (par. Ill a).
Remove the bearing adjusting lock nut and lock. Remove the bearing
2O9
TM 9-805
134
TERNE PLATE
GASKET
-^J RA PD 32324
Figure 110Installing Drive Flange
adjusting nut (fig. 108), spacer washer, roller bearing, and wheel
hub. Pull the bearing and oil seal. Drive the outer bearing cup out
of hub working from inner end of hub. Wash the bearings and inside
of hub with dry-cleaning solvent and inspect the bearings for being
worn, chipped, or cracked. Replace all damaged parts.
(2) INSTALLATION. Start the bearing cups into hub with the bear-
ing surface of cups facing away from center of hub. Drive or press
the bearing cups into hub. Hand-pack the inner bearing roller as-
sembly with grease (par. 28 c (10)). Install the bearing, coat the
outside of oil seal lightly with sealing compound, and drive it into
place against bearing cup. Coat the oil seal lightly with engine oil
to lubricate it. Install the hub, hand-pack the outer bearing roller
assembly, and place it over end of steering knuckle and into hub.
Install spacer washer and adjusting nut. Adjust bearing and re-
assemble (par. 133).
b. Rear Wheels.
(1) REMOVAL. Remove the wheel and axle shaft (par. 117 a and
132). Remove the bea'ring adjusting lock nut and lock. Remove the
bearing adjusting nut, spacer washer, and roller bearing and wheel
hub assembly. Pull the bearing and oil seal. Tap the outer bearing
cup away trom snap ring (fig. Ill), remove ring, and press or drive
the cup out of hub; wash the bearings, inside of hub, and end of
axle housing with dry-cleaning solvent, and inspect the bearings for
wear, chips, and cracks. Replace all damaged parts.
21O
4)
0)
01
0>
211
134
TM 9-805
TM 9-805
134
(2) INSTALLATION. Install the snap ring and press both bearing
cups into the hub, with the thick edge of cups toward center of hub.
Hand-pack the inner bearing with grease (par. 28 c 10). Install the
bearing, coat the outside of oil seal lightly with sealing compound,
and drive it into place against bearing cup. Lock the seal in place
by prick-punching end of hub in three equally spaced places. Coat
the oil seal lightly with engine oil to lubricate it. Install the hub,
hand-pack the outer bearing roller assembly, and place it over end
of steering knuckle and into hub. Install spacer washer and adjusting
nut. Adjust bearings and reassemble (par. 133).
212
TM 9-805
135
Section XXVII
SPRINGS AND SHOCK ABSORBERS
Paragraph
Shackle and hanger pin replacement 136
Spring replacement 137
Shock absorber 138
a. Description.
(1) SPRINGS. The springs are the semielliptic type. Bronze bush-
ings are pressed into the eyes at the ends of the springs. A Berlin
eye is formed on the rear of the second leaf of the front spring as
a. safety measure in case the main leaf should break. The front
springs are shackled at the front end of the spring, and the rear
springs are shackled at the rear end. On some models an auxiliary
spring having six leaves is used in conjunction with the rear spring.
(2) SHOCK ABSORBERS. The shock absorbers are the hydraulic
double-acting, opposed-cylinder type, and are used to provide a
smoother ride by dampening the spring vibration as the truck
passes over irregularities in the road.
b. Data.
(1) FRONT SPRINGS.
Length 40 in.
Center of rear eye to seat center 2(% in.
Width 2 in.
Number of leaves 9
(2) REAR SPRINGS.
Length 45is/16 in.
Front eye to center bolt 22!%2 in.
Width :2% in.
Number of leaves 10
(3) AUXILIARY SPRINGS.
Length (between frame brackets) 31 in.
Width 2^ in.
Number of leaves 6
(4) SHACKLE PIN.
Diameter 0.874 in. to 0.875 in.
Bushing diameter (I.D.) 0.876 in. to 0.880 in.
(5) SHOCK ABSORBERS.
Front Rear
Make Delco Delco
Type Hydraulic Hydraulic
Action Double Double
Rebound valve marking 2R 2J
Compression valve marking. . LO G2
213
TM 9-805
136-138
SHACKLE
SPRING EYE
LUBRICATION
FITTING
RA PD 32313
Figure 112Spring Shackle
136. SHACKLE AND HANGER PIN REPLACEMENT (fig. 112).
a. Raise the truck until the weight is off the springs, and support
the frame. Remove the bolt and nut that locks the shackle bolt in
the shackle, and drive the shackle pin(s) out from the inside. When
installing the shackle bolts, be sure to line up the groove in the bolt
with the lock bolt hole. Lubricate the shackle pins.
137. SPRING REPLACEMENT.
a. Remove the shackle and hanger pins (par. 136), and remove
the spring U-bolts. The spring can then be lifted from the axle.
When installing the springs, be sure to place the spring center bolt
in the hole in the spring seat, and the Berlin eye on the front spring
toward the rear of the vehicle. Lubricate the shackle pins.
138. SHOCK ABSORBER (figs. 82 and 113).
a. Replacement. Disconnect the link from the shock absorber
arm, and remove the four frame mounting bolts. Lift the shock
214
TM 9-805
138
SPRINGS AND SHOCK ABSORBERS
SHOCK ABSORBER ARM -
SHOCK ABSORBER
ATTACHING BOLTS
ABSORBER LINK!ANCHOR BOLT PLATE
RA PD 32314
Figure 113-Sfiock Absorber, Rear
215
TM 9-805
138
absorber from the frame. Install the shock absorber in the reverse
manner.
b. Filling. Clean all dirt from around filler plug, and remove the
plug. With a fluid injector, fill shock absorber full of fluid. Work
shock absorber arm up and down while filling to eliminate trapped
air. Withdraw a small quantity (about 2 tablespoonfuls) of fluid
from the shock absorber after it is full to provide expansion space.
216
TM 9-805
139
Section XXVIII
STEERING GEAR
p______,__l.
>r $jro grci p n
Description 139
Pitman arm replacement 140
Steering connecting rod replacement 141
Steering wheel replacement 142
Steering gear adjustment 143
Steering gear removal 144
Steering gear installation 145
PULLER
STEERING
GEAR
MOUNTING
BOLTS
PITMAN
ARM
CONNECTING
ROD
RA PD 32319
Figure 114-Pitman Arm Removal, Using Puffer (4J-P-2952J
139. DESCRIPTION.
a. The steering gear is of the recirculating ball type, having a
reduction ratio of 23.6 to 1. When the steering wheel is turned, helical
grooves on the main shaft cause ball bearings to climb up or down
the path carrying with them the ball nut. The rack teeth on the ball
nut cause the sector teeth on the Pitman shaft to follow them, thus
turning the Pitman shaft and Pitman arm. The steering connecting
217
TM 9-805
139-142
11/,-TON 4x4 TRUCK (Chevrolet)
rod is of the ball-and-socket type, having identical ball seats, springs,
and adjusting plugs on the ends; but the safety plugs are of different
lengths. The 20-inch steering wheel is of the three-spoke type which
is serrated to the main shaft, and held in place with a retaining nut.
The horn blowing mechanism is built into the mast jacket and
steering wheel.
140. PITMAN ARM REPLACEMENT (fig. 114).
a. Remove the end plug from the rear end of the steering connect-
ing rod, and pull the rod off the ball on the Pitman arm. Remove
the nut and lock washer from the end of the Pitman shaft, and pull
the Pitman arm off the Pitman shaft with puller (41-P-2952). Install
the new Pitman arm, lock washer, and nut; and tighten the nut
securely. Install the steering connecting rod on the Pitman arm ball,
making sure that the ball seats are in the proper position around the
ball (fig. 115). Then tighten the end plug until it bottoms, back it
off y2 turn, and install a new cotter pin. Lubricate the fitting on the
steering connecting rod.
AXLE END
PITMAN ARM END
AB
AADJUSTING PLUG
BTENSION SPRING
CSAFETY PLUG (SHORT)
0BALL SEAT
ESTEERING CONNECTING ROD
FSAFETY PLUG (LONG)
RA PD 33111
Figure 115-Steering Connecting Rod
141.
STEERING CONNECTING ROD REPLACEMENT.
a. Remove the end plugs from each end of the connecting rod,
and pull the rod off the two ball ends. Install the steering connecting
rod on the steering arm and Pitman arm ball with the springs, safety
plugs, and ball seats in the correct position in the rod (fig. 115),
making sure that the ball seats fit properly around the balls. Tighten
the end plugs in tight, back them off */2 turn, and install a new cotter
pin. Lubricate the steering connecting rod.
142. STEERING WHEEL REPLACEMENT.
a. Remove the two screws that retain the horn button, and lift
out the button. Remove the nut from the upper end of the main shaft
and pull the steering wheel off the main shaft, using puller (41-P-
2954). Place the steering wheel on the main shaft, and install the
218
TM 9-805
142-143
STEERING GEAR
STEERING GEAR
MOUNTING BOLTS
RA PD 33056
Figure 116Steering Gear Adjustment
lock washer and nut. Tighten the nut securely. Install the horn button
spring, insulator, contact plate, horn button, retainer plate, and
screws.
143. STEERING GEAR ADJUSTMENT (fig. 116).
a. Remove Load from Worm Bearing. Disconnect the steering
connecting rod from the Pitman arm (par. 141). Loosen the mast
jacket to instrument panel clamp nuts at the instrument panel; then
loosen the lash adjuster lock nut, and turn the lash adjuster two or
three turns in a counterclockwise direction to remove any worm
bearing load caused by close meshing of the rack and sector teeth.
b. Adjust Worm Bearing Load. Turn the steering wheel slowly
to the right or left until it stops; then turn it back one complete turn.
CAUTION: Do not turn the wheel hard against the stop as damage
to the ball guides may result. Loosen the worm bearing thrust screw
lock nut at the bottom of the steering gear, and tighten the thrust
screw until it requires between 1- and 1^-pcnind pull to keep the
wheel in motion. After setting the thrust screw properly, tighten the
lock nut, and check again to see that it requires between 1- and
1%-pound pull to keep the wheel in motion. If there is a noticeable
roughness when turning steering wheel after adjusting the bearings,
the bearings are probably damaged, and the steering gear must be
replaced.
219
TM 9-805
143.144
c. Tighten Mast Jacket Clamp. Tighten the mast jacket to in-
strument panel clamp nuts, and again check the tension on the
steering wheel to see that the shaft is not binding, caused by tighten-
ing the clamp nuts. If it requires more than 1/^-pound pull to keep
the wheel in motion, loosen the clamp nuts again; then loosen the
four bolts that retain the steering gear to the frame side rail, and
shift the steering gear so that the clamp nuts at the instrument panel
will not cause the shaft to bind when the nuts are tightened. Then
tighten the clamp nuts and the four mounting bolts, and again check
the tension on the wheel.
d. Centralize Rack and Sector Teeth. Locate the center of the
sector shaft travel by turning the steering wheel gently from the left
stop to the right stop while counting the number of turns the steering
wheel travels. Then turn the wheel back % the number of turns; this
will place the steering gear in the center position. Mark the steering
wheel with a piece of tape.
e. Lash Adjustment. Turn the lash adjuster clockwise to take
out all of the lash in the gear teeth. Check the pull at the steering
wheel while the wheel is passing through the center position. NOTE:
It should now require between 2 and 2l/2 pounds to pull the wheel
through the center position. Adjust the lash adjuster until all the
lash in the gear teeth has been eliminated; then tighten the lock nut,
and recheck the pull.
f. Assemble Steering Connecting Rod. Install the steering con-
necting rod over the ball on the Pitman arm, making sure the parts
are assembled according to the sequence shown in figure 115. Then
tighten the adjusting plug until it bottoms, and back it off y2 turn
and install a new cotter pin. Lubricate the fitting on the steering
connecting rod.
144. STEERING GEAR REMOVAL.
a. Remove Steering Wheel and Disconnect Horn Wire. Re-
move the two screws that retain the horn button, and lift off the
button. Remove the nut and washer and pull off the steering wheel,
Woodruff key, and upper bearing tension spring. Remove the clamp
that retains the mast jacket to the instrument panel. Remove the
horn wire from the terminal on the mast jacket.
b. Disconnect Brake Pedal. Remove the floor and toeboards;
then remove the clevis pin from the brake pedal pull rod at the
master cylinder, arid pull the brake pedal back as far as it will go.
c. Remove Steering Gear. Disconnect steering connecting rod.
Remove the nut and lock washer from the Pitman shaft, and pull
off the Pitman arm. Remove the left engine side pan bolts. Remove
the four bolts that mount the steering gear to the frame side rail,
lift the assembly up and out through the left door opening.
22O
TM 9-805
145
STEERING GEAR
"145. STEERING GEAR INSTALLATION.
a. Install Steering Gear. Slide steering gear assembly in through
the left door opening, and position the housing in frame side rail.
Install the four bolts and two anchor plates, and start the four
mounting bolt nuts. Install and tighten the clamp bracket at the
instrument panel; then tighten the mounting bolt nuts securely, and
install the lock nuts.
b. Cheek Steering Gear Adjustment. Install the steering wheel
and check to see that it requires between 2- and 2%-pound pull to
pull the wheel through the center position. If not, it will be necessary
to adjust the steering gear (par. 143).
c. Install Steering Connecting Rod. Install the Pitman arm,
lock washer, and nut; and tighten securely. Install the steering con-
necting rod on the Pitman arm, making sure the ball seats fit around
the Pitman arm ball properly; then tighten the end plug until it
bottoms, and back it off % turn, and install a new cotter pin. Install
the left engine side pan bolts. Connect the brake pedal to the master
cylinder, and install the toeboard and floor board.
d. Install Horn Button. Connect the horn wire to the terminal,
and install the horn button. Lubricate the steering gear and steering
connecting rod.
221
TM 9-805
146
1 V2-TON 4 x 4 TRUCK (Chevrolet)
Section XXIX
CAB, BODY, AND FRAME
Cab 146
Body 147
Frame 148
146. CAB.
a. The cab is of all-steel construction fitted with a hinged V-type
windshield, a cowl ventilator, adjustable door windows, and a sta-
tionary back window. The three-point cab to frame mounting pro-
vides a secure, yet flexible, cab mounting.
b. Cushions, Seat and Seat Back.
(1) ADJUSTMENT. The cab seat and seat back cushions are adjust-
able to provide correct position for the individual driver. To adjust,
lift front of seat and move seat forward or back to line up one of the
four holes in the bottom of the seat frame with the pins (one on each
side) of the seat riser brackets. The seat cushion is hooked to the
seat back cushion; therefore, when the seat cushion is moved forward
or back to obtain correct adjustment, the back cushion moves with it.
(2) CUSHION REMOVAL. Raise the front edge of seat cushion and
pull the cushion forward. Unhook the seat cushion from back cushion,
and remove the cushion. Raise the seat back cushion to unhook it
from the cab brackets, and remove back cushion.
(3) CUSHION INSTALLATION. Place the seat cushion and seat back
cushion in the Cab and hook the brackets on the bottom of back
cushion to brackets at back edge of seat cushion. Raise the back
cushion, and hook the brackets at the top of cushion in the brackets
on cab. Slide the cushion assembly back to the desired position, and
enter the seat adjuster holes over the seat riser bracket pins.
c. Windshield Assembly and/or Weatherstrip Replacement.
(1) REMOVAL. Release the windshield clamp at center of wind-
shield. Remove the windshield adjusting arm bracket to windshield
frame screws on each side of windshield. Remove the two screws
attaching each hinge to windshield frame, and remove windshield
assembly. Work the weatherstrip out of the groove in the windshield
frame.
(2) INSTALLATION. Coat the weatherstrip groove in windshield
frame with liquid soap, place the outer (front) edge of weatherstrip
in groove, and push inside edge into place, using a putty knife. Care-
fully position the windshield assembly in the windshield opening,
line up the hinges with the windshield, and install the screws. Install
222
TM 9-805
146-147
the windshield adjusting arm bracket screws. Push both windshield
arms down to fully close the windshield, and hook the clamp at
center of windshield. Check to see that windshield is properly
centered in opening, and that the weatherstrip seals all the way
around the windshield.
d. Windshield Wiper Replacement.
(1) REMOVAL. To remove either the left or right windshield
wiper motor, remove the windshield header cover panel covering the
wiper motor to be removed. Disconnect the hose from motor, remove
the wiper blade and arm assembly, and remove the mounting nut on
the front of header panel.
(2) INSTALLATION. Place the wiper motor in position, and install
the retaining nut. Install the wiper arm and blade assembly. Connect
the hose to motor, start the engine, and check wiper operation. Install
the windshield header cover plate.
147. BODY.
a. Description.
(1) PANEL BODY (MODEL G-7105). The panel body is a single
Unit, providing driver and passenger space, as well as a fully enclosed
cargo space. The front end of the panel body is constructed like the
conventional cab; however, the roof and side panels extend back to
enclose the cargo space. The rear end of body is fitted with a large
double door to provide convenience in loading.
(2) CARGO BODY. The steel cargo body is fitted with five bows to
support the tarpaulin. The tarpaulin when completely installed fully
encloses the cargo space. Hooks are provided around the body for
tying the tarpaulin in place. The tail gate is hinged at the bottom and
can be held in any position with the end gate chains. The lower sec-
tion of each side panel can be lowered to provide troop seats. A tool
compartment is provided under the back end of body.
(3) DUMP BODY. The dump body construction is very similar to
the cargo body; however, it is mounted on a subframe above the
chassis frame. The subframe is fitted with a hydraulic hoist so con-
structed that the front end of body can be raised to automatically
dump bulk material. The tail gate is so hinged that it can be re-
leased and allowed to swing out as the body is raised.
(4) TELEPHONE EARTH BORER BODY (MODEL G-7163). This
special body is designed primarily for mounting an earth borer (for
drilling pole holes) and a rear-mounted winch to use in connection
with the earth borer derrick for setting poles. Special supports are
hinged at the rear corners of the body; these supports are to be
adjusted to support the rear end of body when earth borer is in use.
(5) TELEPHONE MAINTENANCE BODY (MODEL G-7173). This is
a special body designed to provide for use of a rear-mounted winch,
223
TM 9-805
147-148
pole derrick, and wire reels. Special lockers, compartments, and
brackets are provided for carrying standard lineman's supplies, tools,
and equipment.
1. Cargo or Dump Body Tarpaulin Replacement.
(1) REMOVAL. Untie the tarpaulin ropes from the hooks around
the body. Remove tarpaulin assembly. Untie the front and rear
curtains and remove them. Fold or roll the tarpaulin and end curtains.
Do not leave the tarpaulin folded or rolled unless thoroughly dry.
(2) INSTALLATION. Place the end curtains in position, and properly
fasten them to end bows and body. Place the tarpaulin in position
over top of body bows, and tie the ropes securely to hooks on body.
c. Cargo or Dump Body Bows Replacement. Remove tarpaulin
as explained in subparagrahp b above. Lift the complete top bow or
bows out of the stake assemblies. Remove the eight bolts to separate
the upper bow, side bows, and corner assemblies. Reverse this proce-
dure when installing.
d. Troop Seat Assembly Replacement. Remove the bolts that
attach the seat hinge to the body, and remove the seat. Place the seat
in position, and install the hinge bolts.
148. FRAME.
a. Description. The chassis frame is composed of heavy channel
steel side rails having heavy cross members and brackets riveted to
the side rails. A frame extension at the front end provides a mount-
ing for the front bumper as well as the winch, on some models. A
special reinforcement at the back end of frame provides for the
mounting of a pintle hook.
b. Towing Hook Replacement. Remove the three bolts that
attach either towing hook to frame and front bumper, and remove
hook. Place the new towing hook in position on frame and bumper,
and install the three bolts.
c. Front Bumper Replacement.
(1) WINCH EQUIPPED MODELS. Remove the three towing hook
bolts on each side and remove hooks. Remove the two winch support
to bumper bolts, and cut the head from the four bumper to frame
extension rivets on each side. Drive the rivets out and remove bumper.
Place the new bumper in position, and install the towing hooks
loosely. Start the two winch support to bumper bolts. Install bolts,
nuts, and lock washers where the eight rivets were removed. Tighten
all attaching bolt nuts securely.
(2) VEHICLES NOT EQUIPPED WITH WINCH. Remove the three
bolts attaching each towing hook and remove hooks. Cut the heads
from the six attaching rivets at each frame member, drive out the
rivets, and remove the bumper. Remove the two rivets that attach
224
TM 9-805
148
the starting crank support to center of bumper, and bolt the support
to new bumper. Place the new bumper in position, and install the
towing hooks loosely. Install ffc-inch bolts, nuts, and lock washers
in the 12 bumper to frame holes, and tighten all attaching bolts and
towing hook bolts securely.
d. Rear Bumper Replacement. Remove the six bolts attaching
each rear bumper to frame, and remove the bumpers. Place the
bumpers in position at the rear corners of frame, and install the six
bolts that attach each bumper.
tNliTWWASHER i
SPRING m BUSHING PINT
PINTLE HOOK
CROSS MEMBER
BRACE
RA PD 33064
Figure 117Pintle Hook Replacement
e. Pintle Hook Replacement (fig. 117). Remove the cotter pin,
nut, and washer from front end of pintle hook, and pull the pintle
hook out of bushings. Push the new pintle hook through the bush-
ings, and install the washer and nut. Tighten the nut until there is
just enough spring tension to hold the bushings tight in frame. In-
stall cotter pin.
f. Pintle Hook Spring and/or Bushings > Replacement.
(1) REMOVAL. Remove cotter pin from end of pintle hook, and
tighten nut to relieve spring tension from pintle hook cross member
brace. Remove the six cross member brace bolts. Remove pintle hook
nut, washer, pintle hook, brace, spring, and bushing.
(2) INSTALLATION. Place the short end of one bushing through
frame rear cross member with collar against front side of frame
member. Place the long end of other bushing through pintle hook
cross member brace so that the collar will be on rear side of brace.
Place the spring over collar on rear bushing, and put cross member
225
TM 9-805
148
brace in position with short end of bushing piloting into spring. Push
pintle hook through bushings, and install washer and nut. Tighten
nut until cross member brace bolt holes are in position. Install six
bolts and tighten securely. Loosen pintle nut until spring tension
just tightens bushings in frame to prevent rattle. Install cotter pin.
The position of the pintle hook can be extended back several inches
farther away from the rear cross member by reversing the position
of the two bushings.
226
TM 9-805
149-151
Section XXX
CHASSIS SHEET METAL
â
rarofrapn
Description 149
Front-end sheet metal removal 150
Front-end sheet metal installation 151
Front fender replacement 152
Running board replacement .' 153
149. DESCRIPTION.
a. The chassis sheet metal consists of front fenders, front fender
skirts, rear fenders (some models), running boards, hood, and hood
side panels. To facilitate manufacturing and service operations, the
radiator, radiator guard, radiator support, fan shroud, front fenders,
fender skirts, and headlights are assembled into a single unit known
as the front-end sheet metal assembly.
150. FRONT-END SHEET METAL REMOVAL.
a. Remove Hood. Release the hood catches, raise the hood, and
disconnect the radio suppression bond straps from the hood. Remove
the hood brace rod anchor screws, the hood hinge pins, and the hood
assembly. Remove the two hood side panels.
b. Disconnect Cooling System. Disconnect the radiator brace
rod from radiator support and cowl, and remove brace rod. Drain
the cooling system, and remove radiator drain cock. Disconnect the
top and bottom radiator hose, and the steam, relief tube.
c. Disconnect Electrical Connections. Disconnect the electrical
wiring at the junction block on each side, and the blackout wires at
bayonet connectors. Remove wiring harnesses from clips on left
fender skirt and radiator. Disconnect wiring harness from generator.
Disconnect the radio suppression bond straps from rear end of each
fender skirt, and the two from bottom of radiator support.
d. Remove Sheet Metal Assembly. Remove the fender to run-
ning board and fender to cowl bolts on each side. Remove the bolts
attaching rear end of radiator diagonal support to cab bracket. Re-
move the nuts from lower radiator anchorage to frame cross member
bolts and remove the washers, springs, and bolts. Remove the fan
blades if the vehicle is equipped with a front-mounted winch. Slide
the front end sheet metal assembly forward until the fan shroud
clears the fan or fan hub, and lift the assembly off chassis (fig. 118).
If any of the individual items of this assembly require repairs or
replacement they can be removed from the assembly very easily.
151. FRONT-END SHEET METAL INSTALLATION.
a. Install Sheet Metal Assembly. Make sure the lower nose is
securely clamped to radiator outlet. Place the sheet metal .issembly
on the frame, and slide it back into position. Make sure the shroud
clears the fan to prevent damage to the fan, shroud, or radiator. If
the vehicle is equipped with a front-mounted winch it ''ill be neces-
227
TM 9-805
151
RA PD 33112
Figure 118Front-end Sheet Metal Removal
sary to have the fan blades removed when installing sheet metal
assembly. Line up the holes in the radiator anchorage, insulator,
and frame cross member. Install the mounting bolts, shims, springs,
washers, nuts, and lock nuts. Install and tighten the fender to cowl
and fender to running board bolts. Install the bolts attaching the
diagonal brace to cab bracket, and tighten them securely. Install the
fan if it was removed for sheet metal replacement.
b. Connect Electrical Equipment. Connect the radio suppres-
sion bond straps to lower radiator anchorage and fender skirts.
Connect the wiring harness to generator. Place wiring harnesses in
the clips on left fender skirt and radiator. Connect the electrical
wiring at the junction blocks and the bayonet connectors.
c. Connect Cooling System. Connect and tighten both radiator
hoses and the steam relief tube. Fill the cooling system and check for
228
TM 9-805
151-153
CHASSIS SHEET METAL
leaks. Check the operation of front lights. Start the engine and check
the generator output. Install the radiator brace rod, but leave the
nuts at dash loose.
d. Install Hood. Install the hood side panels, and tighten the
radiator brace rod nuts at dash evenly. Place the hood in position,
and install the hood hinge pins. Install the hood brace rod anchor
screws, and connect the radio suppression bond straps.
152. FRONT FENDER REPLACEMENT.
a. Removal. Raise the hood and place pin through hole in hood
brace to lock the hood up. Disconnect electrical*wiring at junction
block, and blackout wires at bayonet connectors. Disconnect wiring
harnesses from clips on fender skirt if left fender is being removed.
Remove the front and rear hood side panels from side on which fender
is to be removed. Remove the fender to running board and fender
to cowl bolts. Remove radio suppression ground strap from fender
skirt. Remove the bolts attaching the fender to radiator guard. Re-
move the fender and skirt assembly. Remove the bolts that attach
fender skirt to fender. Remove lights from fender.
b. Installation. Install the lights on the fender. Place the fender
skirt in position on the fender, and install the attaching bolts. Place
the fender assembly in position, and install the fender to radiator
guard, fender to cowl, and fender to running board bolts. Connect the
radio suppression ground strap to fender skirt. Install the hood side
panels. Connect the electrical wiring, and place the harnesses in clips
on left fender skirt. Test the operation of all front lights. Remove pin
from hood brace and lower hood.
153. RUNNING BOARD REPLACEMENT.
a. Remove the five bolts attaching the running board to fender,
and the two bolts attaching it to each step hanger. Remove the run-
ning board. Place the new running board in position, and install the
nine attaching bolts.
229
TM 9-805
154-155
1 '/a -TON 4x4 TRUCK (Chevrolet)
Section XXXI
POWER TAKE-OFF
Description 154
Hoist drive power take-off 155
Winch drive power take-off 156
Winch and hoist drive power take-off 157
Telephone service winch drive 158
Telephone service winch and earth borer drive 159
154. DESCRIPTION.
a. The power take-off is an auxiliary gear case (fig. 30) driven by
the transmission or transfer case, and provides a means of using
engine power to operate winches, hoists, earth borers, and other
auxiliary equipment used on certain vehicles. Due to the require-
ments and mounting of certain auxiliary equipment, several different
types and makes of power take-offs are required.
155. HOIST DRIVE POWER TAKE-OFF (Central Fibre
Products Co.).
a. Description. This is a transmission-mounted, single-drive, one-
speed power take-off having the power output shaft at the rear of
case. The drive gear is shifted into or out of mesh with the transmis-
sion countershaft gear by the use of a shift lever located just in front
of the driver's seat on the left side of cab. A drive shaft connects
the output shaft to the hoist pump shaft.
b. Data.
Make Central Fibre Products Co.
Model 2-B-13
Type Single speed
Drive Sliding gear
Mounting Left side of transmission
Drive shaft mounting Bronze bushings
c. Removal. Remove the set screw that retains the universal
joint yoke on the power take-off output shaft, and slide the universal
yoke off of drive shaft. Remove cotter pin and clevis pin from control
lever link. Drain lubricant from transmission, remove the six power
take-off attaching screws, and remove power take-off and gasket.
d. Installation. Place a %2"mcn gasket between the power take-
off and transmission case, and install the six cap screws. Line up the
keyway in drive shaft front universal joint yoke with key in output
shaft, and slide the joint onto shaft. Install the set screw that retains
the joint to output shaft. Connect the control lever link to shifter
shaft. Fill the transmission to correct level (par. 28).
23O
TM 9-805
156-157
POWER TAKE-OFF
156. WINCH DRIVE POWER TAKE-OFF (Spicer or Gar Wood).
a. Description. These are transmission-mounted, single-drive,
two forward speeds and one reverse speed power take-offs having the
power output shaft at the front of case. Although the internal con-
struction of these two makes varies somewhat, the operating prin-
ciples are identical, and they are interchangeable. The intermediate
gear is constantly in mesh with a transmission countershaft gear
and the "LOW" and "HIGH" speed gears on the idler shaft (front
two gears). The winch drive sliding gear can be shifted to the differ-
ent gear and neutral positions by use of the power take-off control
lever in the cab. A drive shaft connects the output shaft to the winch
worm shaft.
b. Data.
(1) Make . Gar Wood
Model 69Y9000C-Rev.
Type Two-speed and reverse
Drive Constant mesh gear
Intermediate gear mounting Two roller bearings
Idler gear shaft mounting Two needle bearings
Low speed idler gear Roller bearing
Winch drive shaft mounting Two ball bearings
(2) Make Spicer Manufacturing Co.
Model YAC7
Type Two-speed and reverse
c. Removal. Loosen set screw in shaft collar, and slide collar
forward. Remove the set screw that holds the universal joint on the
front end of power take-off winch drive shaft, and slide the joint off
shaft. Remove the drive key from end of shaft. Remove the control
rod to shifter shaft arm cotter pin and clevis pin. Drain the trans-
mission lubricant, remove the six power take-off attaching cap screws,
and remove the power take-off.
d. Installation. Place two ':!L,-inch gaskets on the flange of power
take-off, place the power take-off in position, and install the six
retaining cap screws. Install the key in winch drive shaft keyway.
Line up the joint keyway with key, and push joint onto end of shaft.
Install and tighten the set screw that attaches joint to shaft. Slide
collar into position, and tighten set screw. Connect the control rod
to shifter shaft arm, and install clevis pin and cotter pin. Fill the
transmission to correct level (par. 28), and test power take-off
operation.
157. WINCH AND HOIST DRIVE POWER TAKE-OFF (Spicer
or Gar Wood).
a. Description. Both manufacturers use the winch drive power
take-off described in paragraph 156 a with a special cover to provide
231
TM 9-805
157
a hoist drive. This special cover incorporates a hoist drive shaft, hoist
drive sliding gear, and hoist shifter shaft in addition to the standard
shifter shaft. This provides an output shaft at the front for winch
drive, and an output shaft at the rear for hoist drive.
b. Data.
(1) Make Gar Wood
Model 69Y9000CD-Rev.
Type Two-speed and reverse, plus
one speed hoist drive
Intermediate gear mounting Two roller bearings
Idler gear shaft mounting Two needle bearings
Low speed idler gear mounting Roller bearing
Winch drive shaft mounting Two ball bearings
Hoist drive shaft mounting Two bushings in cover
(2) Make Spicer Manufacturing Co.
Model' YAC7M
Type Two-speed and reverse, plus
one speed hoist drive
Intermediate gear mounting One roller bearing
Idler gear shaft mounting . Two needle bearings
Low speed idler gear mounting Roller bearing
Winch'drive shaft mounting Two ball bearings
Hoist drive shaft mounting . . Two needle bearings in cover
c. Removal. Loosen collar set screw on winch drive shaft, and
move collar forward. Remove the universal joint yoke to power take-
off winch drive shaft set screw, slide the universal joint off shaft, and
remove drive key. Remove the universal joint yoke to power take-off
hoist drive shaft set screw. Slide the joint off shaft, and remove shaft
key. Remove the cotter pins and clevis pins that attach the control
rods to the shifter shafts. Drain the transmission and power take-off
lubricant, and remove the two cap screws that retain the power take-
off brace. Remove the six power take-off attaching cap screws, and
remove the power take-off and gasket.
d. Installation. Place a new gasket on the flange of power take-
off, place the power take-off in position, and install the six cap screws.
Place the power take-off brace in position, and install the two retain-
ing cap screws. Place the drive keys in the keyways in the winch and
hoist drive shafts. Line up the keyways in universal joint yokes with
keys in shafts, slide joints over shafts, and install set screws. Slide
winch drive shaft collar into position, and tighten set screw. Place the
winch and hoist control rods on their respective shifter shafts, and
install the clevis pins and cotter pins. Fill the transmission (par. 28)
and check the operation of power take-off.
232
TM 9-805
158-159
POWER TAKE-OFF
158. TELEPHONE SERVICE WINCH DRIVE.
a. Description. This is a frame-mounted, single-drive one-speed
and reverse power take-off having the output shaft at rear of case.
It is shaft driven from the transfer case main shaft. The input shaft
is fitted with a sliding gear that can be shifted along the shaft to
provide "NEUTRAL," "REVERSE," and "FORWARD" speed. The
shift is accomplished by use of a shift lever located in the cab to the
right of transfer case shift levers.
b. Data.
Make :American Coach and Body Co.
Model A-328
Type Single speed and reverse
Mounting Special frame brackets
Drive Transfer case main shaft through
double universal joint
Input shaft mounting 1 ball and 1 roller bearing
Power shaft mounting 2 ball bearings
Reverse idler gear mounting 2 roller bearings
c. Removal. Loosen the idler pulley adjusting bolt, and slide the
pulley away from chain. Remove the winch drive chain removable
link and remove chain. Remove the nuts and lock washers from the
U-clamps that retain the universal joint trunnion bearings in the
yoke attached to the power take-off input shaft. Remove the cotter
pin and clevis pin that attach the shifter shaft. Place a jack under
power take-off; remove the four bolts that attach the power take-off
support channels to the frame brackets; lower the jack, and remove
the power take-off with support channels attached. Mark the channels
so that they can be installed in their original positions. Remove the
four cap screws that attach the support channels to the power take-
off case.
d. Installation. Place the support channels on the power take-off
assembly according to the marks made when disassembling, and
install the four cap screws. Place the power take-off assembly in
position. Install the four bolts that attach the support channels to
the frame brackets. Connect the shift control rod to the shifter shaft.
Place the power take-off drive shaft in position and install the U-
clamps. Place the winch drive chain over sprockets, and install the
removable link. Move the idler firmly against the chain, and tighten
the idler lock bolt. Fill the unit with lubricant (par. 28), and test
the power take-off operation in all gears.
159. TELEPHONE SERVICE WINCH AND EARTH BORER
DRIVE.
a. Description. The regular shift positions for this winch are the
same as they are on the winch drive power take-off, but the shift
lever can be pulled farther back, engaging the clutch gear with the
gear on the output shaft. This drives the earth borer only. If the
lever is pulled still farther back, the external teeth on the sliding
gear engage the back gear on the power shaft, providing drive for
the winch as well as the earth borer.
233
TM 9-805
159
I i/2-TON 4x4 TRUCK (Chevrolet)
b. Data.
Make American Coach and Body Co.
Model A-332
Type Single speed, reverse, and earth borer drive
Mounting Special frame brackets
Drive Transfer case main shaft through
double universal joints
Input shaft mounting One ball, one roller bearing
Output shaft mounting One ball, one roller bearing
Power shaft mounting Two ball bearings
Reverse idler gear mounting Two roller bearings
c. Removal. Loosen the chain idler pulley adjusting bolt and
slide the pulley away from the chain. Remove the chain removable
link and chain. Remove the U-clamps that retain the universal joint
trunnion bearings in the joint yokes on the power take-off input and
output shafts. Disconnect the shifter control rod from the shifter
shaft. Support the power take-off with a roller jack, remove the four
support channel to frame bracket attaching screws, and remove
power take-off with support channels. Mark the support channels
so that they can be installed in their original positions. Remove the
four cap screws attaching the support channels to power take-off
case.
d. Installation. Place the support channels on the power take-off
assembly according to the markings made when disassembling, and
install the four cap screws. Place the power take-off assembly in
position in the frame, and install the four bolts that attach the sup-
port channels to the frame brackets. Connect the shift control rod
to the shifter shaft, and install the clevis pin and cotter pin. Place
the power take-off drive shaft and earth borer drive shaft universal
joint trunnion in their seats on the power take-off flanges, and install
the U-clamps. Place the winch drive chain over the sprockets, and
install the removable link. Move the idler firmly against the chain,
and tighten the idler adjustment lock bolt. Fill the power take-off
with lubricant (par. 28) and test the power take-off operation.
234
TM 9-805
160-161
Section XXXII
WINCH
Paragraph
Description 160
Front-mounted winch 161
Center-mounted winch 162
160. DESCRIPTION.
a. Both the front- and center-mounted winches are power driven.
The winch consists of the cable, drum, drum shaft, worm gear, worm,
worm case brake, clutch, and miscellaneous component parts.
161. FRONT-MOUNTED WINCH.
a. Description (fig. 13). The jaw-clutch type power winch is
mounted between the extended frame side rails in front of the front
cross member. The winch is driven from the power take-off by a
drive shaft.' The power take-off provides two speeds for pulling the
winch cable in, and one speed (reverse) for paying out cable. The
winch may be used when the vehicle is standing, or to assist the
vehicle when in motion. By disengaging the jaw clutch the cable can
be unreeled by hand.
b. Data.
Make Gar Wood
Make Heil*
Model 2-U-512
Part number 22Y6222
Drum drive Jaw clutch
Power source Engine through transmission power take-off
Mounting Frame extension
c. Maintenance.
(1) DRUM BRAKE ADJUSTMENT (fig. 119). The correct drum brake
adjustment exists when there is sufficient drag on the drum to pre-
vent the drum from spinning while the cable is being pulled out with
the clutch disengaged. If it is necessary to make this adjustment, shift
the clutch to the released position, and engage the poppet in the hole
in frame member. Loosen the brake adjusting screw check nut, and
turn the adjusting screw until the brake engages the drum flange with
sufficient tension to prevent the cable from loosening up on drum.
Tighten adjusting screw check nut.
(2) WORM BRAKE ADJUSTMENT (fig. 120). The worm brake is
located in a case at the front end of the winch worm. Adjustment
can be made by tightening or loosening the spring-loaded adjusting-
nut located at the bottom of the brake case. Loosen the worm brake
adjusting nut lock nut, and turn the adjusting nut % turn at a time
until the brake is sufficiently tight to hold the load. When adjust-
ment is completed, tighten adjusting nut lock nut. CAUTION: Avoid
excessively tight brake adjustment, or overheating will result. It is
Identical with Gar Wood. All parts interchangeable.
235
TM 9-805
161
1 i/a-TON 4x4 TRUCK (Chevrolet)
RA PD 331 13
Figure 119Drum Broke Adjustment
natural for the brake to heat up somewhat, especially in reverse
operation; however, a check should be made after adjustment. If
brake case gets so hot that the hand cannot be held on it, the brake
adjusting nut should be loosened y2 turn, and the operation re-
checked.
(3) SHEAR PIN REPLACEMENT (fig. 121). The winch drive pro-
peller shaft front universal joint is attached to the worm shaft by
a soft iron shear pin to prevent overloading of the winch and possible
breakage of the winch cable. When the winch is excessively over-
loaded the pin will shear off, allowing the joint yoke to turn on the
worm shaft, thereby releasing the load from the winch. The worm
brake will hold the drum and prevent the cable from unreeling. To
replace, drive the pieces of the old pin out of worm shaft and joint
yoke, line up the hole in the yoke with the hole in shaft, and install
a new shear pin and cotter pin. NOTE: Standard shear pins must
be used, as rivets or bolts do not have correct tensile strength to pro-
vide the required safety and efficiency.
(4) DRIVE SHAFT REPLACEMENT.
(a) Removal (fig. 121). Remove cotter pin and shear pin from
front universal joint front yoke, loosen socket head set screw in
thrust collar at power take-off end of shaft, and slide the drive shaft
236
TM 9-805
161
WINCH
BRAKE
BAND
BRAKE
DISK
BRAKE
LINING
WORM
BRAKE
CASE
BRAKE
ADJUSTING
NUT
LOCK
NUT
RA PD 33114
Figure 120Worm Broke Adjustment
back until front joint is off worm shaft. Remove the set screw that
attaches the rear universal joint rear yoke to the power take-off
winch drive shaft, and remove the drive shaft assembly.
(b) Installation. Place the rear yoke of the splined joint on the
end of power take-off winch drive shaft and install the set screw that
retains the joint to shaft. Place the drive shaft in position, and line
up the shear pin hole in front joint front yoke with the shear pin
hole in winch worm shaft. Install the shear pin and cotter pin. Posi-
tion the thrust collar on the drive shaft % mh from the front end
of rear universal joint sleeve, and tighten the set screw.
d. Winch Removal. Remove cotter pin and shear pin from front
universal joint front yoke. Loosen set screw in thrust collar on drive
shaft at rear universal joint, and slide the front universal joint off the
worm shaft. Place a sling around winch drum, attach sling to a chain
hoist or wrecker crane, and raise just enough to support the winch.
Remove winch to cross member cap screws and bolt at rear of winch.
Remove winch to frame side rail attaching bolts and nuts, remove
winch support bracket bolts at bumper, and remove brackets. Lower
hoist and remove winch from vehicle. Remove sling from winch.
237
TM 9-805
161
RA PD 33115
Figure 121Shear Pin Location
WORM HOUSING
DRUM DRUM SHAFT
TAKE-OFF RA PD 33116
ADJUSTABLE
IDLER
Figure 122-Center-ntounted Winch
238
TM 9-805
161-162
WINCH
RA PD 33117
Figure 123Adjusting Winch Brake Pressure Plate
e. Winch Installation. Place winch under front of frame, place
a sling around drum, attach a chain hoist or crane to sling, and raise
winch into position in frame. Install the cap screws and bolt that
attach winch to cross member at rear of winch, the bolts that attach
winch and winch support bracket to frame side rail, and the bolts
that attach winch support bracket to front bumper. Tighten all
attaching bolts securely. Disconnect the chain hoist from winch and
remove sling. Slide the winch drive shaft front universal on worm
shaft, line up the shear pin hole in universal yoke with the hole in
worm shaft, install the shear pin and cotter pin. Position the thrust
collar on drive shaft % inch from splined yoke of rear universal, and
tighten set screw. Fill the gear case to correct level with lubricant,
and lubricate the assembly according to lubrication instructions
(par. 28).
162. CENTER-MOUNTED WINCH.
a. Description (fig. 122). The center-mounted winch is used only
on vehicles equipped for telephone service. The winch assembly with
mounting sills is mounted on the frame just back of the cab. The
winch is chain-driven from a frame-mounted power take-off that is
driven by the transfer case through a short drive shaft. The power
take-off provides a forward and a reverse gear.
239
TM 9-805
162
RA PD 33118
Figure I 24-Worm Brake Nut Stop Pin
b.
Data.
Make American Coach
Model L-18
Part number 101W20
Drum drive Jaw clutch
Power source Engine through transfer case
power take-off and chain
Mounting Frame back of cab
c. Maintenance.
(1) WORM BRAKE ADJUSTMENT (fig. 123). The winch worm
brake is located at the front end of the worm shaft. Adjustment is
accomplished by loosening or tightening the six pressure plate adjust-
ing screws. The brake is applied by end movement of the worm brake
nut. Force the worm and worm brake nut forward (toward the pres-
sure and brake lining plates) as far as it will go. The worm has a
minimum of %G-inch and a maximum of %-inch end movement.
Screw worm brake nut toward winch until pin hits stop (fig. 124).
Adjust clearance between pressure plate and brake lining plate to
provide uniform clearance of from ^2 to l/lf, inch. This is accom-
plished by loosening the six adjusting bolt lock nuts, and turning
the adjusting bolts. When the adjustment is completed, tighten the
lock nuts.
(2) DRIVE CHAIN REPLACEMENT (fig. 125). Loosen the idler
pulley lock bolt, and slide the pulley away from chain. Remove
cotter pins from chain removable link pins, and remove link from
chain. Place the chain over the sprockets, install the removable link,
and install new cotter pins in the link pins. Push the idler firmly
against the chain, and tighten the lock bolt.
24O
TM 9-805
162
WINCH
RA PD 33119
Figure 125-Winch Drive Chain Adjustment
d. Winch Removal. Loosen the idler pulley adjusting bolt, and
slide the pulley away from the chain (fig. 125). Remove the cotter
pins from removable chain link, and remove the link. Disconnect the
winch clutch and brake control rod from clutch shifter yoke and
lever, and remove control' rod. Remove the four mounting sill to
frame attaching bolts. Place a sling around the winch drum, and
connect the sling to a chain hoist or crane; slide the hoist to the right
side of body; raise the left end of winch, and work it up and to the
left until end of shaft clears side of body. Lower the chain hoist,
disconnect it from sling, and remove sling from winch.
e. Winch Installation. Place a sling around the winch, and raise
it with a chain hoist. Lower shaft end of winch first, and thread end
of shaft through opening in side of body as winch is lowered into
position. Line up the four sill to frame mounting bolt holes; install
the bolts and tighten securely. Install cotter pins. Disconnect hoist
and sling from winch. Place winch clutch and brake control rod in
position; install the clevis pins and cotter pins. Place drive chain
over sprockets; install removable link, link plate, and cotter pins.
Move the idler firmly against the chain, and tighten the lock bolt.
Fill the worm housing to correct level with lubricant, and lubricate
the winch (par. 28).
241
TM 9-805
163-164
Section XXXIII
HYDRAULIC HOIST
Description 163
Hercules hoist 164
Heil hoist * 165
Perfection hoist 166
163. DESCRIPTION.
a. Description. The hydraulic hoist is used on trucks equipped
with a dump body. The body is mounted on a subframe, and hinged
at the back end. The hoist is mounted in the subframe and hydrau-
lically raises the front end of body so that the load can be dumped
from the body through the hinged tail gate at rear. The hydraulic
hoist pump is shaft driven from a transmission-mounted power take-
off. Two levers in the driver's compartment are required to operate
the hoist. One engages the power take-off to drive the hoist pump,
and the other controls the valve for raising, holding, or lowering the
dump body. By shifting the control valve the hydraulic fluid can
be directed into the cylinder, either in front of the piston, or back
of the piston. This provides a means of forcing the piston to travel
in either direction. The piston is connected to the dump body by
links and arms that raise or lower the body as the piston is forced
back and forth in the cylinder. Dump body trucks may be equipped
with Hercules, Heil, or Perfection hoists. The removal, installation,
and service instructions vary somewhat for the different makes;
however, their duty is identical.
164. HERCULES HOIST.
a. Data.
Make Hercules Steel Products
Model K.D.O.
Type Hydraulic
Mounting Subframe above chassis frame
Drive Transmission power take-off
Pump Gear type
b. Maintenance (fig. 126).
(1) ADD OIL TO HYDRAULIC SYSTEM. When the body fails to
raise to its maximum angle, it indicates lack of oil in the hydraulic
system. To add oil, run the pump slowly. Set the hoist valve control
lever in the center ("RAISE") position. Remove filler hole cover on
top of cylinder and fill with SAE 10 engine oil. Lower body slowly
to force out excessive oil, then raise body slowly to top of travel,
and install filler hole cover and gasket. Recheck the hoist operation.
NOTE: During extremely cold weather a small amount of kerosene
may be added to the oil to improve hydraulic operation. This should
be drained out, and new oil installed, when weather permits.
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HYDRAULIC HOIST
BODY BRACKET
LIFT
ARM
VALVE MANIFOLD
Figure 126-Hercules Hydraulic Hoist
PD 33120
(2) CORRECT OIL LEAKS. The hydraulic hoist cylinder and pump
system should be checked regularly for oil leaks. Oil leaks at the
cylinder cover, piston rod packing, valve piston packing, cylinder
to manifold studs, pump to manifold studs, pump shaft packing, or
pump cover are often caused by loose bolts or packing glands. If
proper tightening does not correct the leak, hew packings must be
installed, or the assembly replaced.
c. Removal. Raise the dump body and securely block it in the
raised position. Disconnect the valve control rod from the shifter
lever. Loosen the socket head set screw in rear yoke of rear universal
joint of the hoist pump drive shaft. Place a sling around the hoist
cylinder; attach it to a chain hoist, and raise the chain hoist enough
to support the unit. Remove cotter pin from hoist cross head shaft,
and drive out shaft. Raise hoist cylinder and pump assembly, and
remove it from chassis.
d. Installation. Place a sling around hoist and raise the assembly
with a chain hoist. Swing the assembly into position in the hoist
frame; install the hoist cylinder shaft, and lock it in place with a new
cotter pin. Install hoist cross head shaft, and lock it in place with the
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BODY HINGE
"U"
BOLT
VENT
AND
FILLER
PLUG
HOIST
LEVER
LUBRICATION
FITTINGS
CONTROL
VALVE
RA PD 33121
Figure 127-Hell Hydraulic Hoist
cotter pin. Install Woodruff key in pump drive shaft; push the drive
shaft universal joint yoke on pump drive shaft, and lock it in place
with the socket head set screw. Connect valve control rod to valve
shift lever by installing clevis pin and cotter pin. Remove chain hoist
and sling from cylinder. F;ll the hoist with oil following the instruc-
tions in subparagraph b above. NOTE: Do not remove the blocking
from dump body until the cylinder is filled, and the body is to be
'ered.
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HYDRAULIC HOIST
165. HEEL HOIST.
a. Data.
Make The Heil Co.
Model SL-1
Type Hydraulic
Mounting . Subframe above chassis frame
Pump Gear type
(1) ADD OIL TO HYDRAULIC SYSTEM. Run the body up halfway,
and remove the 54-inch vent and filler plug. Pour oil in through this
opening while the pump is running slowly and the valve is in the
"RAISE" position, until body raises to full height. Add about l/2
pint more oil, then lower body slowly with pump running. Raise
body again to full height, and install the special 54-inch vent and
filler plug. See lubrication section (par. 28) for correct grade of oil.
If the filler plug is installed before lowering and raising the hoist,
the body may not properly seat on the sills. The oil may be thinned
with a small amount of kerosene to provide better operation in ex-
tremely cold climates. Drain and refill with fresh oil again as soon
as weather permits.
(2) CORRECT OIL LEAKS. The hydraulic hoist cylinder and pump
system should be checked regularly for oil leaks. Oil leaks at the
cylinder head, piston rod packing, pump support bracket, control
valve packing, pump shaft packing, pump gear end plate, or pump
housing cover, are often caused by loose bolts or packing glands. If
proper tightening does not correct the leaks, new packings must be
installed, or the assembly replaced.
c. Removal. Remove the cotter pins from the hoist lifting link
to body pins, and drive out the pins. Remove the cotter pins from
the body to hoist frame hinge pins, and drive out the pins. Attach
two chain hoists to the body, and lift it off the hoist unit. Remove
the cotter pin and clevis pin attaching control rod to valve operating
bell crank. Remove set screw from drive shaft rear universal joint
rear yoke, and slide the universal joint off the pump drive shaft.
Place a sling around the hoist cylinder, and attach it to chain hoist
to support unit. Remove frame lever pin, cylinder pivot pin lock
bolts, and pivot pin. Lift the cylinder and pump assembly out of
hoist frame.
d. Installation. Place the cylinder and pump assembly in posi-
tion in the hoist frame with a chain hoist. Install cylinder pivot pin
and frame lever pin, and lock them securely. Install Woodruff key
in pump drive gear shaft; install the universal joint, and tighten the
socket head set screw. Connect valve control rod to valve control bell
crank. Remove %-inch vent plug from cylinder head; fill the cylinder
with engine oil, and install the plug loosely. Place the body in posi-
tion on the hoist frame; install body hinge pins; line up lifting link
pin holes with holes in body, and install the pins. Fill the hydraulic
system according to instructions in subparagraph b above.
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AIR VENT
PLUG
LIFT LINK
PIPE PLUG
TIE BAR
PUMP
RA PD 33122
Figure 128-Perfectlon Hydraulic Hoist
166. PERFECTION HOIST.
a. Data.
Make Perfection Steel Body Co.
Model : 615 Special
Type Hydraulic
Mounting Subframe above chassis frame
Pump Gear type
(1) ADD OIL TO HYDRAULIC SYSTEM. Remove filler plug; raise
body to maximum lift; fill cylinder full, and install filler plug. See
lubrication section (par. 28) for correct lubricants. Loosen (do not
remove) plug at front top of cylinder and lower body. This action
bleeds all air and surplus oil from the cylinder. After body is com-
pletely lowered, again raise body and tighten plug. Recheck hoist
operation. The oil may be thinned with kerosene to provide better
operation in extremely cold climates. Drain and refill with fresh oil
as soon as weather permits.
(2) CORRECT OIL LEAKS. The hoist hydraulic system should be
checked regularly for oil leaks. Oil leaks at the cylinder head, piston
rod packing, pipe fittings, control valve packings, or pump covers,
are often caused by loose bolts or packing glands. If proper tighten-
ing does not correct the leaks, new packings must be installed, or
he assembly replaced.
246
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HYDRAULIC HOIST
c. Removal. Remove the cotter pins from the two lift link to
body pins, and the two body hinge pins. Remove the four pins;
attach chain hoist to body, and lift body from hoist unit. Disconnect
valve control rod from control valve control lever. Remove set screw
from drive shaft rear universal joint rear yoke, and slide universal
joint off pump drive gear shaft. Remove the four hoist unit to chassis
frame U-bolts, and the two guide bolts. Lift the hoist unit from
chassis frame with chain hoist.
d. Installation. Place the hoist assembly on the chassis frame.
Install the two guide bolts and the four U-bolts. Place drive shaft
rear universal joint on pump drive gear shaft. Install and tighten
the set screw attaching universal joint to pump gear shaft. Place the
valve control rod on the control valve control lever, and install clevis
pin. Remove the filler plug and fill cylinder with engine oil; install
filler plug loosely. Place the body on the hoist frame, and install
the body hinge pins and lift to body pins. Fill and bleed the hydraulic
system according to instructions in subparagraph b above.
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Section XXXIV
NEW VEHICLE RUN-IN TEST
Paragraph
Purpose 167
Correction of deficiencies 168
Run-in test procedures '. 169
167. PURPOSE.
a. When a new or reconditioned vehicle is first received at the
using organization, it is necessary for second echelon personnel to
determine whether or not the vehicle will operate satisfactorily when
placed in service. For this purpose, inspect all accessories, sub-
assemblies, assemblies, tools, and equipment to see that they are in
place and correctly adjusted. In addition, they will perform a run-in
test of at least 50 miles as directed in AR 850-15, paragraph 25, table
III, according to procedure in paragraph 169 below.
168. CORRECTION OF DEFICIENCIES.
a. Deficiencies disclosed during the course of the run-in test will
be treated as follows:
(1) Correct any deficiencies within the scope of the maintenance
echelon of the using organization before the vehicle is placed in
service.
(2) Refer deficiencies beyond the scope of the maintenance
echelon of the using organization to a higher echelon for correction.
(3) Bring deficiencies of serious nature to the attention of the
supplying organization.
169. RUN-IN TEST PROCEDURES,
a. Preliminary Service.
(1) FIRE EXTINGUISHER. See that portable extinguisher is present
and in good condition. Test it momentarily for proper operation, and
mount it securely.
(2) FUEL, OIL, AND WATER. Fill fuel tank. Check crankcase oil
and coolant supply, add oil and coolant as necessary to bring to
correct levels. Allow room for expansion in fuel tank and radiator.
During freezing weather, test value of antifreeze and add as neces-
sary to protect cooling system against freezing. CAUTION: // there
is a tag attached to filler cap or steering wheel concerning engine oil
in crankcase, follow instructions on tag before driving the vehicle.
(3) FUEL FILTER. Inspect fuel filter for leaks, damage, and secure
mountings and connections. Drain filter sediment bowl. If any appre-
ciable amount of water or dirt is present, remove bowl, and clean
bowl and element in dry-cleaning solvent. Also drain accumulated
water or dirt from bottom of fuel tank. Drain only until fuel runs
clean.
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TM 9-805
169
(4) BATTERY. Make hydrometer and voltage test of battery, and
add clean water to bring electrolyte H mcr above plates.
(5) AIR CLEANER AND BREATHER CAP. Examine carburetor and
crankcase ventilator breather cap to see if they are in good condition
and secure. Remove elements from both units, and wash thoroughly
in dry-cleaning solvent. Fill reservoirs to bead level with fresh oil,
and reinstall securely. Be sure all gaskets are in good condition, and
that ducts and air horn connections are tight.
(6) ACCESSORIES AND BELT. See that accessories such as car-
buretor, generator, regulator, cranking motor, distributor, water
pump, fan, and oil filter, are securely mounted. Make sure that fan
and generator drive belt is in good condition, and adjusted to have
54-inch finger-pressure deflection.
(7) ELECTRICAL WIRING. Examine all accessible wiring and con-
duits to see if they are in good condition, securely connected, and
properly supported.
(8) TIRES. See that all tires, including spare, are properly inflated
to 55 pounds, cool; that stems are in correct position; all valve caps
present and finger-tight. Inspect for damage, and remove objects
lodged in treads and carcasses and between duals.
(9) WHEEL AND FLANGE NUTS. See that all wheel mounting and
axle flange nuts are present and secure.
(10) FENDERS AND BUMPER. Examine fenders and front bumper
for looseness and damage.
(11) TOWING CONNECTIONS. Inspect all towing shackles, pintle
hook, and fifth wheel (where used), for looseness or damage. See
that pintle, or fifth-wheel connecting mechanism operates properly,
and latches securely.
(12) BODY AND TARPAULINS. Inspect cab and body for looseness
and damage. See that all attachments and items of special equip-
ment are in good condition. On cargo bodies be sure tail gate oper-
ates and latches properly, and that tarpaulin is in good condition;
and if in use, securely lashed to body hooks. Inspect end curtains
for damage and loose fastenings. On dump bodies test hoist for
proper operation, and while raised examine mechanism for loose-
ness, damage, and oil leaks. Be sure body when lowered is guided
to a correct alinement with frame sill, and that tail gate latching
device locks securely. On panel bodies be sure rear doors fit, close,
and latch properly- On all body types examine door and windshield
glass for damage; see that lift mechanism and all hardware is in
good operating condition and secure. Inspect drivers' and/or troop
seats, safety straps, floors, skid strips, and stowage compartments,
for good condition, correct assembly, and secure mounting. On tele-
phone maintenance and earth-borer equipped vehicle see that
the special boring or crane equipment is in proper position in vehicle,
and securely assembled and attached, and that all loose items are
properly stowed.
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TM 9-805
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(13) WINCH. Inspect winch for damage, secure mounting, and oil
leaks. Test winch clutch mechanism for proper operation. Test drag
brake to see if it holds drum from spinning as cable is unwound;
inspect it for wear, damage, and adequate lubrication. Test winch
automatic brake by placing vehicle at top of steep incline and attach-
ing cable to another vehicle at bottom. While drawing towed vehicle
up hill, release engine clutch; if towed vehicle backs down hill, brake
needs adjustment. Start lowering vehicle down hill with winch; throw
out engine clutch; if towed vehicle does not stop or drifts more than
1 or 2 inches, brake needs adjustment. See paragraphs 161 and 162.
After test, rewind cable evenly and tightly on drum and as winding,
clean cable thoroughly, and apply a film of engine oil. If winch is
center-mounted, inspect drive chain and sprockets to see that they
are in good condition and not excessively worn. Chain idler should
be adjusted so chain has no slack.
(14) LUBRICATE. Perform a complete lubrication of the vehicle,
covering all intervals, according to the instructions on the Lubrica-
tion Guide, paragraph 28, except gear cases, wheel bearings, and
other units covered in preceding procedures. Check all gear case oil
levels, and add as necessary to bring to correct level. Change only
if condition of oil indicates the necessity, or if gear oil is not of
proper grade for existing atmospheric temperature. NOTE: Perform
items (15) to (18) during lubrication.
(15) SPRINGS AND SUSPENSIONS. Inspect front and rear springs
and "shocks" to see that they are in good condition, correctly assem-
bled, secure, and that bushings and shackle pins are not excessively
loose, or damaged.
(16) STEERING LINKAGE. See that all steering arms, rods, and
connections are in good condition and secure; and that gear case is
securely mounted and not leaking excessively.
(17) PROPELER SHAFTS. Inspect all shafts and universal joints to
see that they are in good condition, correctly assembled, alined,
secure, and not leaking excessively.
(18) AXLE AND TRANSFER VENTS. See that axle housing and
transfer case vents are present, in good condition, and not clogged.
(19) CHOKE. Examine choke to be sure it opens and closes fully
in response to operation of choke button.
(20) ENGINE WARM-UP. Start engine and note if cranking motor
action is satisfactory, and engine has any tendency toward difficult
starting. Set hand throttle to run engine at fast idle during warm-up.
During warm-up, reset choke button so that engine will run smoothly,
and to prevent overchoking and oil dilution.
(21) INSTRUMENTS.
(a) OH Pressure Gage. Immediately after engine starts, observe
if oil pressure is satisfactory. (Normal operating pressure, hot, at
runnning speeds is 12 to 17 Ib; at idle, 5 Ib). Stop engine if pressure
is not indicated in 30 seconds.
250
TM 9-805
169
(b) Ammeter. Ammeter should show slight positive ( + ) charge.
High charge may be indicated until generator restores to battery the
current used in starting.
(c) Temperature Gage. Engine temperature should rise gradu-
ally during warm-up period to normal operating range, 140F to
170F.
(d) Fuel Gage. Fuel gage should register "FULL" if tank has
been filled.
(22) ENGINE CONTROLS. Observe if engine responds properly to
controls, and if controls operate without excessive looseness or binding.
(23) HORN AND WINDSHIELD WIPERS. See that these items are in
good condition and secure. If tactical situation permits, test horn
for proper operation and tone. See if wiper arms will operate through
their full range, and that blade contacts glass evenly and firmly.
(24) GLASS AND REAR VIEW MIRRORS. Clean all body glass and
mirrors, and inspect for looseness and damage. Adjust rear view
mirrors for correct vision.
(25) LAMPS (LIGHTS) AND REFLECTORS. Clean lenses and inspect
all units for looseness and damage. If tactical situation permits, open
and close all light switches to see if lamps respond properly.
(26) LEAKS, GENERAL. Look under vehicle, and within engine
compartment, for indications of fuel, oil, coolant, and brake fluid
leaks. Trace any leaks found to source, and correct or report them
to designated authority.
(27) TOOLS AND EQUIPMENT. Check tools and on vehicle stow-
age lists, paragraphs 30 to 32, to be sure all items are present, and
see that they are serviceable, and properly mounted or stowed.
b. Run-in Test. Perform the following procedures, items (1) to
(11) inclusive, during the road test of the vehicle. On vehicles which
have been driven 50 miles or more in the course of delivery from the
supplying to the using organization, reduce the length of the road
test to the least mileage necessary to make observations listed below.
CAUTION: Continuous operation of the vehicle at speeds approach-
ing the maximums indicated on the caution plate should be avoided
during the test.
(1) DASH INSTRUMENTS AND GAGES. Do not move vehicle until
engine temperature reaches 135F. Maximum safe operating tem-
perature is 190F. Observe readings of ammeter, oil, temperature,
and fuel gages to be sure they are indicating the proper function
of the units to which they apply. Also see that speedometer registers
the vehicle speed, and that odometer registers accumulating mileage.
(2) BRAKES: FOOT AND HAND. Test service brakes to see if they
stop vehicle effectively, without side pull, chatter, or squealing; and
observe if pedal free travel before meeting resistance is \l/2 inches.
Parking brake should hold vehicle on a reasonable incline, with l/3
reserve lever travel available. Observe if hydrovac brake booster
operates properly to assist in service brake application. CAUTION:
Avoid long application of brakes until shoes become evenly seated
to drums.
251
TM 9-805
169
(3) CLUTCH. Observe if clutch operates smoothly without grab,
chatter, or squeal on engagement, or slippage (under load) when
fully engaged. See that pedal has l'-inch free travel before meeting
resistance. CAUTION: Do not ride clutch pedal at any time, and do
not engage and disengage new clutch severely or unnecessarily, until
driven and driving disks have become properly worn in.
(4) TRANSMISSION AND TRANSFER. Gearshift mechanism should
operate easily and smoothly, and gears should operate quietly, and
not slip out of mesh. Test front axle declutching, and power take-off
mechanism (on vehicles so equipped) for proper operation.
(5) STEERING. Observe steering action for binding or looseness;
and note any excessive pull to one side, wander, shimmy, or wheel
tramp. See that column, bracket, and wheel are secure.
(6) ENGINE. Be on the alert for any abnormal engine operating
characteristics or unusual noise, such as lack of pulling power or
acceleration, backfiring, misfiring, stalling, overheating, or excessive
exhaust smoke. Observe if engine responds properly to all controls.
(7) UNUSUAL NOISE. Be on the alert throughout road test for any
unusual noise from body and attachments, running gear, suspensions,
or wheels, that might indicate looseness, damage, wear, inadequate
lubrication, or under-inflated tires.
(8) ^HALT VEHICLE AT IO-MILE INTERVALS FOR SERVICES IN
ITEMS "(9) TO (11) BELOW.
(9) BRAKE BOOSTER OPERATION. Listen at the hydrovac air
cleaner for air movement as the brake pedal is applied and released
several times, as a quick test to determine if system is operating.
(10) TEMPERATURES. Cautiously hand-feel each brake drum and
wheel hub for abnormal temperatures. Examine transmission, trans-
fer case, and differential housings for indications of overheating and
excessive lubricant leaks at seals, gaskets, or vents. NOTE: Transfer
case temperatures are normally higher than other gear cases.
(11) LEAKS. With engine running, and fuel, engine oil, and cooling
systems under pressure, look within engine compartment and under
vehicle for indications of leaks.
c. Upon completion of run-in test, correct or report any deficien-
cies noted. Report general condition of vehicle to designated indi-
vidual in authority. i
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Section XXXV
SHIPMENT AND TEMPORARY STORAGE
General instructions 170
Preparation for temporary storage or domestic shipment 171
Loading and blocking for rail shipment 172
170. GENERAL INSTRUCTIONS.
a. Preparation for domestic shipment of the vehicle is the same
as preparation for temporary storage or bivouac. Preparation for
shipment by rail includes instructions for loading and unloading the
vehicle, blocking necessary to secure the vehicle on freight cars,
number of vehicles per freight car, clearance, weight, and other infor-
mation necessary to properly prepare the vehicle for rail shipment.
For more detailed information, and for preparation for indefinite
storage, refer to AR 850-18.
171. PREPARATION FOR TEMPORARY STORAGE OR
DOMESTIC SHIPMENT.
a. Vehicles to be prepared for temporary storage or domestic
shipment are those ready for immediate service, but not used for
less than 30 days. If vehicles are to be indefinitely stored after ship-
ment by rail, they will be prepared for such storage at their desti-
nation.
b. If the vehicles are to be temporarily stored or bivouacked,
take the following precautions:
(1) LUBRICATION. Lubricate the vehicle completely (par. 28).
(2) COOLING SYSTEM. If freezing temperature may normally be
expected during the limited storage or shipment period, test the
coolant with a hydrometer and add the proper quantity of anti-
freeze compound, to afford protection from freezing at the lowest
temperature anticipated during the storage or shipping period. Com-
pletely inspect the cooling system for leaks.
(3) BATTERY. Check battery and terminals for corrosion and if
necessary, clean and thoroughly service battery (par. 94).
(4) TIRES. Clean, inspect, and properly inflate all tires. Replace
with serviceable tires, all tires requiring retreading or repairing. Do
not store vehicles on floors, cinders, or other surfaces which are
soaked with oil or grease. Wash off immediately any oil, grease, gaso-
line, or kerosene which comes in contact with the tires under any
circumstances.
(5) ROAD TEST. The preparation for limited storage will include
a road test of at least 5 miles, after the battery, cooling system, lubri-
cation, and tire services, to check on general condition of the vehicle.
Correct any defects noted in the vehicle operation, before the vehicle
253
TM 9-805
171
T/2-TON 4x4 TRUCK (Chevrolet)
is stored, or note on a tag attached to the steering wheel, stating
the repairs needed, or describing the condition present. A written
report of these items will then be made to the officer in charge.
(6) FUEL IN TANKS. It is not necessary to remove the fuel from
the tanks for shipment within the United States, nor to label the
tanks under Interstate Commerce Commission Regulations. Leave
fuel in the tanks except when storing in locations where Fire Ordi-
nances, or other local regulations, require removal of all gasoline
before storage.
(7) EXTERIOR OF VEHICLE. Remove rust appearing on any part
of the vehicle exterior with flint paper. Repaint painted surfaces
whenever necessary to protect wood or metal from deterioration.
Exposed polished metal surfaces which are susceptible to rust, such
as winch cables, chains, and, in the case of track-laying vehicles,
metal tracks, should be coated with a protective, medium-grade
lubricating oil. Close firmly all cab doors, windows, and windshields.
Vehicles equipped with open-type cabs with collapsible tops will
have the tops raised, all curtains in place, and the windshield closed.
Make sure tarpaulins and window curtains are in place and firmly
secured. Leave rubber mats, such as floor mats, where provided, in
an unrolled position on the floor, and not rolled or curled up. Equip-
ment, such as Pioneer and truck tools, tire chains, and fire extin-
guishers, will remain in place in the vehicle.
(8) INSPECTION. Make a systematic inspection just before ship-
ment or temporary storage, to insure that all above steps have been
covered, and that the vehicle is ready for operation on call. Make
a list of all missing or damaged items, and attach it to the steering
wheel. Refer to Before-operation Service (par. 23).
(9) ENGINE. To prepare the engine for storage, remove the air
cleaner from the carburetor. Start the engine, and-set the throttle
to run the engine at a fast idle. Pour 1 pint of medium-grade, pre-
servative, lubricating oil, Ordnance Department Specification AXS-
674, of the latest issue in effect, into the carburetor throat, being
careful not to choke the engine. Turn off the ignition switch as
quickly as possible after the oil has been poured into the carburetor.
With the engine switch off, open the throttle wide, and turn the
engine five complete revolutions by means of the cranking motor.
If the engine cannot be turned by the cranking motor with the switch
off, turn it by hand, or disconnect the high-tension lead and ground
it before turning the engine by means of the cranking motor. Then
reinstall the air cleaner.
(10) BRAKES. Release brakes and chock the wheels or tracks.
c. Inspections in Limited Storage. Vehicles in limited storage
will be inspected weekly for condition of tires and battery. If water
is added when freezing weather is anticipated, recharge the battery
with a portable charger, or remove the battery for charging. Do not
attempt to charge the battery by running the engine.
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172. LOADING AND BLOCKING FOR RAIL SHIPMENT.
a. Preparation. In addition to the preparation described in para-
graph 171, when ordnance vehicles are prepared for domestic ship-
ment, the following preparations and precautions will be taken:
(1) EXTERIOR. Cover the body of the vehicle with a canvas cover
supplied as an accessory.
(2) TIRES. Innate pneumatic tires from 5 to 10 pounds above
normal pressure.
(3) BATTERY. Disconnect the battery to prevent its discharge
by vandalism or accident. This may be accomplished by disconnecting
the positive lead, taping the end of the lead, and tying it back away
from the battery.
(4) BRAKES. The brakes must be applied and the transmission
placed in low gear, after the vehicle has been placed in position with
a brake wheel clearance of at least 6 inches ("A", fig. 129). The
vehicles will be located on the car in such a manner as to prevent
the car from carrying an unbalanced load.
(5) All cars containing ordnance vehicles must be placarded
"DO NOT HUMP".
(6) Ordnance vehicles may be shipped on flat cars, end-door box
cars, side-door box cars, or drop-end gondola cars, whichever type
car is the most convenient.
b. Facilities for Loading. Whenever possible, load and unload
vehicles from open cars under their own power, using permanent end
ramps and spanning platforms. Movement from one flat car to
another along the length of the train is made possible by cross-over
plates or spanning platforms. If no permanent end ramp is available,
an improvised ramp can be made from railroad ties. Vehicles may
be loaded in gondola cars without drop ends by using a crane. In
case of shipment in side-door box cars, use a dolly-type jack to fit
the vehicles into position within the car.
c. Securing Vehicles. In securing or blocking a vehicle, three
motions (lengthwise, sidewise, and bouncing), must be prevented.
There are two approved methods of blocking the vehicles on freight
cars, as described below. When blocking dual wheels, all blocking
will be located against the outside wheel of the dual.
(1) METHOD 1 (fig. 129). Locate eight blocks "B", one to the
front, and one to the rear of each wheel. Nail the heel of each block
to the car floor, using five 40-penny nails to each block. That portion
of the block under the tread will be toe-nailed to the car floor with
two 40-penny nails to each block. Locate two blocks "D" against
the outside face of each wheel. Nail the lower block to the car floor
with three 40-penny nails, and the top block to the lower block with
three 40-penny nails. Pass four strands, two wrappings, of No. 8
gage, black annealed wire "C" through the holes in the wheels, and
then through the stake pockets. Tighten the wires enough to remove
slack. When a box car is used, this strapping must be applied in a
255
TM 9-805
172
1Va-TON 4x4 TRUCK (Chevrolet)
8DC6
BLOCK-F-
-Z" CHAMFER AT CONTACT POINT-
-LENGTH TO SUIT
BLOCK-G
BLOCK-H
RA PD 317186
Figure 129Blocking Requirements for Securing Wheeled
Vehicles on Railroad Cars
256
TM 9-805
172
similar fashion, and attached to the floor by the use of blocking or
anchor plates. This strapping is not required when gondola cars are
used.
(2) METHOD 2 (fig. 129). Place four blocks "G", one to the front
and one to the rear of each set of wheels. These blocks are to be at
least 8 inches wider than the over-all width of the vehicle at the car
floor. Using 16 blocks "F", locate two against blocks "G" to the
front of each wheel, and two against blocks "G" to the rear of each
wheel. Pass four strands, two wrappings, of No. 8 gage, black
annealed wire "C" through the holes in the wheels, and secure as
described in method 1 above.
257
TM 9-805
REFERENCES
STANDARD NOMENCLATURE LISTS.
Truck, li/2-ton, 4x4, (Chevrolet) SNL G-506
Cleaning, preserving, and lubricating materials, re-
coil fluids, special oils, and miscellaneous related
items SNL K-l
Soldering, brazing, and welding materials, gases,
and related items SNL K-2
Tool-sets-motor transport :. SNL N-19
Intel-changeability chart of organizational special
tools for combat vehicles SNL G-19
Current Standard Nomenclature Lists are listed
above. An up-to-date list of SNL's is maintained
in the "Index to Ordnance Publications" OFSB 1-1
EXPLANATORY PUBLICATIONS.
List of Publications for Training FM 21-6
Automotive Materiel.
Automotive brakes TM 10-565
Automotive electricity TM 10-580
Automotive power transmission units TM 10-585
Chassis, body, and trailer units TM 10-560
Camouflage FM 5-20
Driver's manual TM 10-460
Electrical fundamentals TM 1-455
Fuels and carburetion TM 10-550
Motor transport FM 25-10
Military motor vehicles AR 850-15
Ordnance maintenance: Electrical equipment
(Delco Remy) TM 9-1825A
Ordnance maintenance: Carburetors (Carter) TM 9-1826A
Ordnance maintenance: Vacuum power brake sys-
tems (Bendix BK) TM 9-1827B
Standard military motor vehicles TM 9-2800
The internal combustion engine TM 10-570
The motor vehicle TM 10-510
Care and Preservation.
Automotive lubrication TM 10-540
Cleaning, preserving, lubricating, and welding ma-
terials, and similar items issued by the Ordnance
Department TM 9-850
258
TM 9-805
REFERENCES
Detailed lubrication instructions for Ordnance
Materiel OFSB-series
Explosives and demolitions FM 5-25
Motor vehicle inspections and preventive mainte-
nance services TM 9-2810
Maintenance and care of pneumatic tires and
rubber treads TM 31-200
Decontamination.
Chemical decontamination materials and equip-
ment TM 3-220
Decontamination of armored force vehicles FM 17-59
Defense against chemical attack FM 21-40
Military chemistry and chemical agents TM 3-215
Storage and Shipment.
Registration of motor vehicles AR 850-10
Storage of motor vehicle equipment AR 850-18
Rules governing the loading of mechanized and
motorized army equipment; also, major caliber
guns, for the United States Army and Navy, on
open top equipment, published by Operations
and Maintenance Department of Association of
American Railroads.
259
TM 9-805
INDEX
A Page No.
Auxiliary equipment controls and
operation
center-mounted winch operation. 25
fire extinguisher operation 24
front-mounted winch operation. . 24
general 24
hoist operation 24
Brake system
bleeding brake system
bleed system 198
general 198
install automatic filler 198
install drain tube 198
brake line flaring 205
brake shoes
installation 203
removal 200
data, tabulated 191
description 191
hydrovac replacement 203
master cylinder replacement 199
parking brake adjustment 192
service brake adjustment 196
trailer electric brake control
adjustment 204
general 204
load control 204
wheel cylinder replacement 200
Poa No.
Cab, body and frame
body (description)
cargo body 223
dump body 223
panel body (Model G-710S). .. 223
telephone earth borer body
(Model G-7163) 223
telephone maintenance body
(Model G-7173) 223
cab 222
cargo or dump body tarpaulin
installation 224
removal 224
cushion, seat, and seat back
adjustment 222
installation 222
removal 222
frame
description 224
front bumper replacement 224
pintle hook replacement 225
pintle hook spring and bushing
replacement 225
rear bumper replacement 225
towing hook replacement 224
troop seat assembly replacement. 224
windshield assembly and/or
weatherstrip
installation 222
removal 222
windshield wiper
installation 223
removal 223
Chassis sheet metal
description 227
TM 9-805
INDEX
No.
11
13
13
13
13
15
13
15
13
Page No.
removal of regulator 149
ignition coil, switch, and spark
plugs
installation of coil 145
removal of coil 145
spark plug adjustment 146
switch replacement . . . 146
ignition timing 140
instruments and gages
ammeter 153
blackout driving light switch
replacement 152
description 151
fuel gage 151
light switch replacement 151
oil pressure gage 153
D Page
Description of vehicle and tabulated
data
data
description
differences among models
Driving controls and operation
accelerator
brake pedal
carburetor choke
clutch pedal
cranking motor switch pedal
front axle shifting lever. .
hand brake lever
hand throttle
hoist power take-off control lever.
hoist valve control lever.
ignition switch
introduction
transfer case shifting lever
transmission gearshift lever
winch power take-off control lever
Electrical system, instruments, and
gages
battery
data, tabulated
description
inspection and maintenance. . .
installation
removal
cranking motor and switch
data, tabulated
description
installation of cranking motor..
installation of switch
removal of cranking motor....
removal of switch
description
distributor
TM 9-805
1 '/2-TON 4x4 TRUCK (Chevrolet)
ECont'd
EngineCont'd
Pag. No.
oil filter
element replacement
filter replacement
general
oil pan
general
installation
removal
removal
tune-up
battery test
carburetor
carburetor and rocker arm cover
air cleaners
coil and condenser
compression test
cooling system
distributor
fuel pump
general
idling adjustment
ignition timing
manifold heat control valve. . .
road test
spark plugs
valve adjustment
valve tappet adjustment
First echelon preventive maintenance
service
after-operation and weekly service
at-halt service
before-operation service
during-operation service
purpose
Front axle
axle assembly
installation
removal
axle housing outer end seal
installation.
removal
axle shaft
installation
removal
data, tabulated
description
steering arm replacement
Ill
111
110
110
110
110
113
100
103
109
102
104
100
102
97
103
103
TM 9-805
INDEX
Pag. No.
fuel gage 16
glove compartment lock 17
instrument lights 17
oil pressure gage 16
speedometer 16
temperature indicator 15
water bypass shut-off cock ...... 17
windshield wiper switches 16
Intake and exhaust system
air cleaner
data, tabulated 131
description 131
maintenance 131
exhaust system s
description 131
exhaust pipe replacement 131
muffler replacement 133
tail pipe replacement 133
Lighting controls
blackout driving light switch.... 19
headlight dimmer switch 19
instrument panel light switch.... 19
light switch 17
Lubrication
introduction 42
Lubrication Guide
general 42
lubrication notes 42
supplies 42
reports and records 49
Manual, scope of 5
New vehicle run-in test
correction of deficiencies 248
purpose 248
run-in test 251
run-in test procedures
preliminary service 248
Operation of the vehicle
preliminary instructions
shifting gears in transfer case.. . .
shifting into reverse
shifting to lower speed in trans-
mission
HCont'd PoB. NO.
Hydraulic hoistCont'd
Perfection hoist
data 246
installation 247
maintenance 246
removal. 247
Installation
axle assembly 182, 189
axle shaft 182, 188
battery 163
brake shoes 203
carburetor 125
cargo or dump body tarpaulin. .. 224
clutch 123
cranking motor 151
cushion, seat, and seat back 222
cylinder head and gasket 106
engine 116
front axle tie rod 179
front end sheet metal 227
front fender 229
TM 9-805
No. R Page No.
Rear axle
21 axle assembly
22 installation 189
removal 188
30 axle shaft
29 installation 188
28 removal 188
28 data, tabulated 186
28 description 186
29 third member assembly
installation 186
74 removal 186
74 Record of modifications
FSMWO and major unit assembly
replacement record
description 52
230 early modifications 52
instructions for use 52
230 References
230 explanatory publications
230 automotive material 258
230 care and preservation 258
decontamination 259
storage and shipment 259
234 standard nomenclature lists 258
233 Removal
234 axle assembly 182, 188
23 axle shaft 182, 188
battery 163
233 brake shoes 200
233 carburetor 125
233 cargo or dump body tarpaulin... 224
233
232
231
231
178
clutch 120
cranking motor 150
cushion, seat, and seat back 222
cylinder head and gasket 104
engine 113
231 front axle tie rod 179
232 front-end sheet metal 227
232 front fender :229
fuel filter 129
231 fuel pump 128
fuel tank 130
231 generator 138
governor 130
hydraulic hoist 243-247
ignition coil 145
1 '/2-TON 4x4 TRUCK (Chevrolet)
O Cont'd Pag.
Operation of the vehicleCont'd
starting the vehicle
stopping the truck
Operation under unusual conditions
cold weather
hot weather
mud and water
rough terrain
sand
snow and ice
Organizational tools and equipment
special tool set :. . .
standard tool sets
Power take-off
TM 9-805
INDEX
RCont'd Page No.
RemovalCont 'd
radiator core 137
regulator 149
steering gear 220
transfer case 175
transmission 172
Second echelon preventive mainte-
nance
maintenance operations 57
road test chart 55
services 53
tools and equipment 72
Shipment and temporary storage
general instructions 253
loading and blocking for rail
shipment
facilities for loading 255
preparation 255
securing vehicles 255
preparation for temporary storage
or domestic shipment 253
inspections in limited storage. . 254
Specifications of vehicle 11
Springs and shock absorbers
data, tabulated 213
description 213
shackle and hanger pin replace-
ment 214
shock absorbers
filling.... 216
replacement 214
spring replacement 214
Steering gear
description 217
installation 221
Pitman arm replacement 218
removal 220
steering connecting rod replace-
ment 218
steering rear adjustment 219
steering wheel replacement 218
Tires, wheels, wheel bearings and
hubs 207
Tools and equipment stowage on
vehicle
vehicle equipment 51
Page No.
vehicle tools
general 50
special tools 50
vehicular tool list 50
vehicular spare parts 51
Towing the vehicle
disabled vehicle 23
to start 22
Transfer case
data, tabulated 175
description 175
installation 176
removal 175
shifter sh'aft control rod adjust-
ment 175
Transmission
data, tabulated 172
description 172
installation 174
removal 172
TM 9-805
T Cont'd Fog*
Trouble shootingCont'd
electrical system
ammeter
battery and starting system. . .
fuel gage
generator and regulator
ignition system
lighting
oil pressure gage
radio suppression
speedometer
temperature indicator
engine
abnormal oil pressure
does not develop full power....
engine will not turn
excessive oil consumption
misfires:
noises
popping, spitting, or spark
knock
rough idling
tune-up
turns, but will not start
front axle
hard steering
lubricant leaks
noisy differential
shimmy
wandering
fuel system
engine misses or cuts out on
acceleration
excessive fuel in carburetor....
fast idling
fuel does not reach carburetor.
hard starting
rough idling
will not idle
general
hydraulic hoist
leaks oil
will-not hold in desired position
will not raise body
power take-off
gears noisy
leaks lubricant
will not stay in gear
propeller shafts
excessive backlash
noisy universal joints
No. Page No.
vibration 88
rear axle
85 excessive backlash 89
82 lubricant leaks 89
g4 noisy differential 89
83 springs and shock absorbers
81 excessive flexibility 92
85 excessive noise 92
85 hard riding 91
86 steering arm
84 hard steering 92
84 loose steering 92
road shocks transferred to steer-
7g ing wheel 93
73 vehicle pulls to one side 92
TM 9-805
INDEX
V Cont'd Pago No.
Vehicle maintenance instructions
Cont'd
hoist 242
intake and exhaust system 131
new vehicle run-in test 248
organizational tools and equip-
ment 74
power take-off 230
propeller shafts 178
rear axle 186
record of modifications 52
second echelon preventive mainte-
nance 53
shipment and temporary storage. 253
springs and shock absorbers 213
steering gear 217
transfer case 175
transmission 172
trouble shooting 75
wheels, wheel bearings, hubs and
tires 207
winch 235
Vehicle operating instructions
auxiliary equipment controls and
operation 24
description and tabulated data... 9
driving controls and operation... 13
first echelon preventive mainte-
nance service 31
introduction 5
Page No.
lubrication 42
operation under unusual condi-
tions 28
tools and equipment stowage on
vehicle 50
Wheels, wheel bearings, hubs, and
tires
data, tabulated 207
description 207
wheel and tire
installation 208
removal 208
wheel bearing adjustment 208
wheel bearing replacement 209
Winch
center-mounted winch
data 240
description 239
installation 241
maintenance 240
removal 241
description 235
front-mounted winch
data 235
description 235
installation 239
maintenance 235
removal 237
RAPDI4MAY4S-UMR
267

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to

'^t abo patg^Ph"

WAR DEPARTMENT TECHNICAL MANUAL

Generated on 2013-06-13 17:14 GMT / http://hdl.handle.net/2027/uc1.b3243764 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google

WAR DEPARTMENT TECHNICAL MANUAL

For supersession of Quartermaster Corps 10series manuals, see paragraph 1 d

WAR DEPARTMENT 30 DECEMBER 1943

DISSEMINATION OF RESTRICTED MATTER

No person is entitled solely by virtue of his grade or position lo knowl-

edge or possession of classified matter. Such matter is entrusted only

to those individuals whose official duties require such knowledge or

possession. (See also paragraph 234, AR 380-5, 15 March 19+4.)

Generated on 2013-06-13 17:15 GMT / http://hdl.handle.net/2027/uc1.b3243764 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google

Washington 25, D. C., 30 December 1943

TM 9-805IVi-ton 4x4 Truck (Chevrolet), is published for the

information and guidance of all concerned.

[A. G. 300.7 (22Nov 43)]

BY ORDER OF THE SECRETARY OF WAR:

The Adjutant General.

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

Generated on 2013-06-13 17:16 GMT / http://hdl.handle.net/2027/uc1.b3243764 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google

U6-TON 4x4 TRUCK I <\ 4" 3

PART ONE-VEHICLE OPERATING INSTRUCTIONS

SECTION I Introduction ................... 1 5-8

II Description and tabulated data . 2-4 9-12

III Driving controls and operation. . . 5-10 13-23

IV Auxiliary equipment controls and

operation .................... 11-15 24-27

V Operation under unusual

conditions ................... 16-21 28-30

VI First echelon preventive mainte-

nance service ................ 22-26 31-41

VII Lubrication ................... 27-29 42-49

VIII Tools and equipment stowage on

vehicle ...................... 30-32 50-51

PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS

IX Record of modifications ......... 33 52

X Second echelon preventive

maintenance ................. 34 53-73

XI Organization tools and equipment 35-36 74

XII Trouble shooting ............... 37-55 75-95

XIII Engine Description, data, mainte-

nance, and adjustment in vehicle 56-65 96-112

XIV Engine-Removal and installation 66-67 113-117

XV Clutch ........................ 68-70 118-124

Generated on 2013-06-13 17:18 GMT / http://hdl.handle.net/2027/uc1.b3243764 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google

li/a-TON 4x4 TRUCK (Chevrolet)

PART TWO-VEHICLE MAINTENANCE INSTRUCTIONS (Cont'd)

SECTION XVI Fuel system 71-76 125-130

XVII Intake and exhaust system 77-78 131-133

XVIII Cooling system 79-84 134-139

XIX Electrical system, instruments,

and gages 85-95 140-171

XX Transmission 96-98 172-174

XXI Transfer case 99-102 175-177

XXII Propeller shafts 103-105 178

XXIII Front axle 106-114 179-185

XXIV Rear axle 115-119 186-190

XXV Brake system 120-130 191-206