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TM 9-2320-302-34

1. 0017 00 0017 00 1 Bull Idler Gear Replacement 0037 00 0037 00 1 C Cab Anti lock Brake System ABS Wiring Harness Replacement 0065 00 0065 00 1 Body Repa aie se eae GERA ERSTE 0105 00 0105 00 1 Door Repair 0108 00 0108 00 1 Door Replacement cese rupe ew he 0107 00 0107 00 1 Main Wiring Harness Replacement 0057 00 0057 00 1 Mounts Replacement Front 0097 00 0097 00 1 Mounts Replacement Rear 0098 00 0098 00 1 Overhead Wiring Harness Replacement 0061 00 0061 00 1 Replacement syrene paa QE Y ts 0104 00 0104 00 1 Camshaft and Bearings Replacement 0026 00 0026 00 1 Drive Gear Maintenance 0034 00 0034 00 1 Characteristics Capabilities and Features Equipment 0002 00 0002 00 1 Chassis Wiring Harness Replacement 0062 00 0062 00 1 Gl tch Repair Fan Eae a a see ERO anne coe de Be 0050 00 0050 00 1 Collision Warning System CWS Theory of Operation 0003 00 0003 00 10 Wiring Harness
2. 0047 00 1 Radiator R pait ee RS Re Ta Eade Gade 0048 00 1 Water Pump Repair 0 0 6c RR 0049 00 1 Fan Clutch MOS 0050 00 1 Spindle and Housing 0051 00 1 Alternator Repair isses duoi oie e hie ehe e ER PENES TER AR FE 0052 00 1 Starter Solenoid Replacement 0053 00 1 Starter REPAM x2 usan UR S RR SI Ege OPER SORS 0054 00 1 Engine Power Wiring Harness 0055 00 1 Engine Wiring Harness Replacement 0056 00 1 Main Cab Wiring Harness Replacement 0057 00 1 Switch Panel Wiring Harness 0058 00 1 WP 0059 00 Turn Signal Marker Light Wiring Harness Replacement 0059 00 1 Page Number Turn Signal Thru deck Wiring Harness Replacement Overhead Cab Wiring Harness 0061 00 Chassis Wiring Harness Replacement 0062 00 Front Anti lock Brake System ABS Wiring Harness Replacement 0063 00 1 Rear Anti lock Brake System ABS Wiring Harness Replacement Cab Anti lock Brake System ABS Wiring Harness Replacement Collision Warning System CWS
3. 0085 00 1 Power Steering Pump 0086 00 1 Power Steering Pump 0087 00 1 Steering Gear Replacement 0088 00 1 Steering Gear Repair 0 ccc teen here 0089 00 1 Steering Column 1 0090 00 1 Fifth Wheel 0091 00 1 Slide Bracket and Plate 0092 00 1 Top Plate Replacement 0 0 0 cece Ih 0093 00 1 Top Plate Repais dedu rre PRSE aet Eme ea PARR ae RS 0094 00 1 Ramp Replacement ssc sr ereta err 0095 00 1 Crossmember Replacement 0096 00 1 Front Cab Mounts 0097 00 1 Rear Cab Mounts Replacement 0098 00 1 Front Spring 0099 00 1 Front Spring Hangers 0100 00 1 Rear Suspension Center Bearing 0101 00 1 Rear Spring Assembly 0102 00 1 Rear Suspension Control Rod and V Rod
4. 0003 00 0003 00 8 Window Replacement 0110 00 0110 00 1 Rear rear Axle Differential Carrier Flepaltz c erts ae Sam fo x ret barat ra c vb res ts 0082 00 0082 00 1 RHeplaceimernt e CR AR EH re eee 0081 00 0081 00 1 Receiver drier Replacement Air Conditioner 0118 00 0118 00 1 Refrigerant R 134a Maintenance Air Conditioning System 0112 00 0112 00 1 Reporting Equipment Improvement Recommendations EIRs 0001 00 0001 00 1 Retarder Maintenance Engine 0022 00 0022 00 1 Rocker Arm Assemblies Maintenance 0027 00 0027 00 1 Cover Replacement 2 cece eet eee 0016 00 0016 00 1 Rod Maintenance 0074 00 0074 00 1 S Slide Bracket and Plate 0092 00 0092 00 1 SMGC Repair HOOQ ease S 0106 00 0106 00 1 Index 7 TM 9 2320 302 34 INDEX Continued Subject Work Package Page S Continued Solenoid Replacement Fuel Injector ise RR ee Pe eee ed 0047 00 0047 00 1 Sire ha hoe erg ub pee es us Deco AUT abet whe AUR Sa enters ft ud 0053 00 0053 00 1 Spindle and Housing Repair 0051 00 0051 00 1 Spring Assembly Re
5. HAZARDOUS WASTE DISPOSAL When servicing this vehicle performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries and CARC paint consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 HEARING PROTECTION Hearing protecting is required when operating vehicle at more than 45 mph 72 kph with windows open for an extended period of time Hearing protection is also required when personnel are within 1 meter 3 1 ft of vehicle when operating at low engine idle 600 rpm and within 3 5 meters 11 ft of vehicle when operating at high idle 1600 rpm Failure to follow this warning may result in hearing damage TM 9 2320 302 34 pe WARNING VW NBC EXPOSURE If NBC exposure is suspected all air cleaner media should be handled by personnel wearing protective equipment Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PER SONNEL WEARING FULL NBC PROTEC TIVE EQUIPMENT SEE OPERATOR MAINTENANCE MANUAL 7690 01 114 3702 To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 WARNIN
6. 0011 00 1 WP 0012 00 Rear Engine Mounts 0012 00 1 TM 9 2320 302 34 Table of Contents Continued Page Number Fan Drive Support Replacement 0013 00 Air Intake Manifold Replacement 0014 00 1 Exhaust Manifold 1 0015 00 1 Rocker Arm Cover 0016 00 1 Breather Tube 0017 00 1 Cylinder Head 0018 00 1 Gear Case Cover 0019 00 1 Vibration Damper 1 0020 00 1 Accessory Drive 0021 00 1 Engine Retarder Maintenance 0 cece 0022 00 1 Crankshaft Rear Oil Seal 0023 00 1 Flywheel Housing 0024 00 1 Flex Plate Maintenance 0025 00 1 WP 0026 00 Camshaft and Bearings 0026 00 1 Rocker Arm Assemblies 0027 00 1 Oil Pan
7. 0066 00 0066 00 1 Column Replacement Steering 0090 00 0090 00 1 Compressor Repair Air 6 2 0084 00 0084 00 1 Compressor Air Conditioner Heplacement uestre Rete GWT Ree al Re ee dan ee 0117 00 0117 00 1 DEVICE ia IEEE 0116 00 0116 00 1 Condenser Replacement Air Conditioner 0119 00 0119 00 1 Cooling System Theory of 0003 00 0003 00 3 Corrosion Prevention and Control CPC 0001 00 0001 00 1 Cover Replacement Gear Case Media Nauta Seta eo i bes gu aie dem 0019 00 0019 00 1 poe lm CLIE 0016 00 0016 00 1 Index 2 TM 9 2320 302 34 INDEX Continued Subject Work Package Page C Continued Crankshaft Front Oil Seal Replacement 0031 00 0031 00 1 Rear Oil Seal Replacement 0023 00 0023 00 1 Replacement siio tn ete ina LEE VEU PUE 0033 00 0033 00 1 Cross Tube Arm Replacement Front 0075 00 0075 00 1 Crossmember Replacement 0096 00 0096 00 1 Cylinder Assembly and Piston Maintenance 0041 00 0041 00 1 Cylinder Block Assembly Repair 0036 00 0036 00 1 Cylinder Block Pressure Te
8. Flex Plate Maintenance 0 Flywheel Housing Replacement Foot Brake Valve Repair Forward rear Axle Differential Carrier Repa Maser ale ETT Replacement Wee EX Se RO ee a SERES Front Anti lock Brake System ABS Wiring Harness Replacement Axle Assembly Replacement Axle Caster Adjustment Cab Mounts Replacement Cross Tube Arm Replacement Engine Mount Adapter and Support Replacement Oil Seal Replacement Crankshaft Spring Hangers Replacement Index 4 Work Package 0069 00 0011 00 0012 00 0055 00 0022 00 0006 00 0056 00 0002 00 0002 00 0115 00 0015 00 0003 00 0114 00 0050 00 0120 00 0013 00 0091 00 0025 00 0024 00 0083 00 0080 00 0079 00 0063 00 0072 00 0073 00 0097 00 0075 00 0011 00 0031 00 00100 00 Page 0069 00 1 0011 00 1 0012 00 1 0055 00 1 0022 00 1 0006 00 1 0056 00 1 0002 00 1 0002 00 6 0115 00 1 0015 00 1 0003 00 2 0114 00 1 0050 00 1 0120 00 1 0013 00 1 0091 00 1 0025 00 1 0024 00 1 0083 00 1 0080 00 1 0079 00 1 0063 00 1 0072 00 1 0073 00 1 0097 00 1 0075 00 1 0011 00 1 0031 00 1 0100
9. dan Moers Sade dial Ake artes 0097 00 0097 00 1 Hear Cab cinta be Rh eae ce ee eee Ree 0098 00 0098 00 1 N Nomenclature Cross reference List 0001 00 0001 00 2 Oil Pan Maintenance s e bus ERE Um EL 0028 00 0028 00 1 Pressure Relief and Regulator Valves Replacement 0030 00 0030 00 1 Pump Maintenance 00 cee ett eee a 0029 00 0029 00 1 Seal Replacement Front Crankshaft 0031 00 0031 00 1 Seal Replacement Rear Crankshaft 0023 00 0023 00 1 Overhead Cab Wiring Harness 0061 00 0061 00 1 Ozone Depleting Substances ODS 0001 00 0001 00 1 Pack Power Replacement 0010 00 0010 00 1 Pan Oil Maintenance au ea Eb Er eh ee dee ea el AN 0028 00 0028 00 1 Piston and Cylinder Assembly Maintenance 0041 00 0041 00 1 Plate Tops cec gne dre antec Medea Bite tele can Bate 0094 00 0094 00 1 Replacements Be 0093 00 0093 00 1 Plate and Slide Bracket Repair 0092 00 0092 00 1 Plate Maintenance Flex 0 0 ccc eee eee ee 0025 00 0025 00 1 Power Pack Replacement 0010 00 0010
10. pem em c e we Main 29500963 Lt Blue 2 87 22 00 98 5 54 6 305 Regulator 0 113 0 866 3 88 2 15 68 6 Control 23049325 Orange 10 1 83 14 8 44 6 24 0 131 we OU ems ex e e e C2 Latch 29501071 Lt Green 1 32 11 43 41 3 19 0 71 0 rr poema ee a em ae Exh Back 23049391 No Code 0 XS 7 80 29 2 18 2 0 024 0 307 1 14 0 72 5 C1 Latch 6885065 Blue 12 1 37 16 26 46 2 29 2 18 D Lu me es ex em d Converter 29507456 Pink 10 2 1 53 11 00 30 3 22 8 ndividual springs For complete spring assembly v c0 0c c 6 INL TM 9 2320 302 34 FRONT AXLE ASSEMBLY REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Jack hydraulic Item 73 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Wrench torque 100 600 Ib ft Item 140 0126 00 Wrench set socket 3 4 in drive Item 141 Wwy 0126 00 0072 00 Materials Parts Pin cotter P N MS24665 357 3 Compound adhesive Item 10 WP 0125 00 Compound sealing Item 15 WP 0125 00 Personnel Required Two Equipment Condition Front brake spider and brake chamber bracket removed TM 9 2320 302 20 ABS sensors removed TM 9 2320 302 20 Front shock absorbers removed TM 9 2320 302 20 N WARNING Use extreme caution when han
11. Cab Replacement onc aden Sale ae ne EE HRS X 0104 00 1 0105 00 Cab Body Repair 0 RH HI tenes 0105 00 1 Hood SMC Repair soos E EDERE DUREE DP ERE 0106 00 1 Cab Door Replacement 0107 00 1 TM 9 2320 302 34 Table of Contents Continued TM 9 2320 302 34 Table of Contents Continued Page Number Cab Door cscnit reserves Heads 0108 00 1 Windshield 1 0109 00 1 Rear Window 0110 00 1 WP 0111 00 Air Ducts Replacement 0111 00 1 Air Conditioning System Refrigerant R 134a 0112 00 1 HVAC Unit 0113 00 1 Air Conditioner Expansion Valve Replacement 0114 00 1 Air Conditioner Evaporator Coil 0115 00 1 Air Conditioner Compressor 0116 00 1 Air Conditioner Compressor Replacement 0117 00 1 Air Conditioner Receiver drier Replacement 0118 00 1 Air Conditioner Condenser Replacement 0119 00 1 Air Conditioner Fan Cycling Switch Replacement 0
12. NOTE If there is a problem performing step 37 tighten four cap screws to 10 20 lb ft 14 27 Nm Install two adjusting rings 9 in differential carrier 1 Tighten four cap screws 7 to 347 431 Ib ft 471 584 Nm Install dial indicator on flange of differential carrier 1 with plunger against back surface of ring gear 2 342 1220 0082 00 18 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 40 Loosen adjusting ring 9 on gear side of ring gear 2 so small amount of end play shows on dial indicator when ring gear is moved left and right 342 1221 41 Tighten adjusting ring 9 loosened in step 40 so no end play shows on dial indicator 42 Tighten two adjusting rings 9 one notch from zero end play measured in step 40 Bearing preload is now set 43 Adjust dial indicator to zero 342 1222 0082 00 19 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 44 45 46 47 48 49 50 51 52 Rotate ring gear 2 while reading dial indicator runout must not exceed 0 008 in 0 200 mm If runout is exceeded perform disassembly steps 9 through 11 Inspect all ring gear subassembly 10 parts and differential carrier 1 for possible excessive runout caused Replace defective part s 342 1223 Repeat steps 36 through 46 Attach dial indicator on mounting flange of differ
13. Ensure all cup plugs and pipe plugs are in place Ensure all cylinder liners cylinder liner seal rings and crevice seals are in place 2 From cylinder block pressure test kit position six test rings 2 on top of cylinder liner flanges Install two test ring retaining strips 3 3 Install 14 bolts 4 and tighten to 170 175 Ib ft 231 237 Nm 4 Position two outside sealing strips 5 on cylinder block 6 with rubber surface against cylinder block Install 20 bolts 7 and tighten to 120 Ib in 14 Nm 342 904 5 Install water manifold cover 8 in oil cooler neck opening 9 Use bolt 10 supplied to secure water manifold cover 6 Attach air line to fitting 11 on upper manifold cover 0040 00 2 TM 9 2320 302 34 CYLINDER BLOCK PRESSURE TESTING CONTINUED 0040 00 TESTING CONTINUED 9 10 11 12 13 342 905 a n WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel Apply 20 psi 138 kPa air pressure to cylinder block using attached air line Spray cylinder block with detergent and water solution and observe solution for bubbles indicating cracks or leaks If cracks are detected replace cylinder block Remove air supply line Remove 20 bolts 7 and two outside sealing strips 5 Remove 14 bolts 4 two
14. Remove three solenoid retention pins 32 from bottom of solenoid body 14 Remove three solenoids 33 six o rings 34 three solenoid regulator valves 35 and three springs 36 Check resistances of solenoids Resistance must be 2 5 ohms Remove valve retention pin 37 stop 38 spring 39 and valve 40 0071 00 43 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Disassembly Continued 20 21 22 23 24 25 26 27 28 29 30 31 Remove solenoid separator plate 41 NOTE Main valve body disassembly procedures are steps 21 through 34 If damaged remove retention pin 42 from main valve body 16 NOTE Solenoid retention pins must be removed from bottom of valve body Note grooved end of pin for positive retention Remove solenoid retention pin 43 from bottom of valve body 16 Remove solenoid 44 small o ring 45 and large o ring 46 Check resistances of solenoids Resistance must be 2 5 ohms Remove valve retention pin 47 Remove stop 48 spring 49 and converter flow valve 50 Remove valve retention pin 51 stop 52 spring 53 and lubrication regulator valve 54 WARNING Spring 55 is highly compressed Be extremely careful during disassembly Personal injury can occur if spring force is not controlled Install spring compressor tool J35924 Compress spring 55 then remove valve re
15. 0026 00 24 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE 0027 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Installation Adjustment INITIAL SETUP Maintenance Level Materials Parts Direct Support Plug cup P N 9421745 2 Tools and Special Tools Detergent Item 19 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Oil lubricating Item 25 WP 0125 00 0125 00 Caliper vernier Item 16 WP 0126 00 p Gage profile Item 39 WP 0126 00 Rags wiping Item 31 WP 0125 00 Installer cup plug Item 58 WP 0126 00 Tags marker Item 35 WP 0125 00 Lifter rocker arm Item 76 WP 0126 00 Wipes lint free Item 40 WP 0125 00 Pliers retaining ring Item 86 WP 0126 00 Socket socket wrench Item 116 WP 0126 00 Equipment Condition Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Engine retarder removed WP 0022 00 REMOVAL CAUTION Failure to follow procedures below could result in damage to rocker arm shaft 1 In one turn increments remove six retaining bolts 1 and saddle spacers 2 2 Remove two nuts 3 and saddle spacers 4 9 18 gi Fan D D Jj z 342 703 0027 00 1 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 REMOVAL CONTINUED NOTE Tag rocker arm assemblies by cylinder position prior to removal as an aid in installation Position lifter fin gers under cross arch of exhaust rocker arm
16. INSPECTION 1 Examine adjustable idler gear teeth for scoring pitting and wear If damaged or worn replace adjustable idler gear Inspect other gear train gears 2 Inspect contact surface of hub for scoring or evidence of overheating blue discoloration Replace hub if it has been overheated Check lubrication hole and gear gallery for blockage Slight irregularities in hub contact surface may be removed with fine stone or emery cloth 3 Inspect bushing contact surface for signs of scoring discoloration due to overheating or excessive wear Allowable clearance between bushing and hub is 0 0013 0 0030 in 0 035 0 078 mm Replace gear and bushing as an assembly if clearance is more than allowable or if surface of bushing is scored or has been overheated INSTALLATION 1 Install hub 4 on three studs 6 in gear housing assembly 5 Word OUT stamped on hub must be at top and facing forward Lubricate hub and adjustable idler gear bushing 7 with clean engine lubricating oil 342 1094 CAUTION Two timing marks are on adjustable idler gear Diamond shaped mark must align with diamond mark on camshaft drive gear Other mark should be between 5 and 6 o clock to prevent damage to equipment 0038 00 2 TM 9 2320 302 34 ADJUSTABLE IDLER GEAR REPLACEMENT CONTINUED 0038 00 INSTALLATION CONTINUED NOTE Ensure timing marks on adjustable idler gear are facing outward 2 Align adjustable idler gear diamond timing
17. POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 43 Connect electronic control module harness connectors 32 and 33 to connectors located at rear of ECM 34 44 Install wire 30 washer 29 and nut 28 on fuel pressure sending unit 31 45 Install bracket 24 on cable harness 27 Install spacer 25 bracket and screw 23 in engine block 26 Install new tiedown straps as required to secure harness 35 mem 342 930 0010 00 29 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 46 Install plate 19 and bracket 22 with washer 21 and screw 20 47 Install two wires 18 and cable 17 on plate 19 with washer 16 and nut 15 48 Connect two wires 14 to starter solenoid 11 with washer 13 and nut 12 49 Connect four wires 10 and cable 9 to starter solenoid 11 with washer 8 and nut 7 50 Connect three wires 5 ground strap 4 and cable 3 to starter 6 with washer 2 and nut 1 342 929 5 Install transmission rear mount WP 0070 00 52 Connect driveline TM 9 2320 302 20 53 Install transmission oil fill tube 54 Connect transmission wiring harness 55 Connect transmission oil cooler lines TM 9 2320 302 20 56 Install oil sampling valves 57 Install fender extensions 58 Install alternator and alternator adjusting rod 59 Install air conditioner compressor WP 0117 00 60 Install alternator
18. TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED c Disconnect release handle rod retainer 33 from release handle rod 34 and remove sill 30 34 342 602 33 30 14 Remove four screws 35 from window regulator 36 15 Disengage window regulator roller 37 from one end of window lift channel 38 16 Remove window regulator 36 from inside door panel 24 342 603 0108 00 6 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED WARNING Wear protective gloves when handling glass Failure to do so could result in injury to personnel 17 Tilt window guide 39 toward hinge side of door 2 and carefully pull window glass 3 toward top of door At the same time lift window glass toward inside door panel 24 until window glass is completely removed from door 18 342 605 0108 00 7 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED 19 Disconnect release handle retainer 42 and remove release handle rod 34 20 Disconnect door lock retainer 43 and remove door lock rod 44 21 Disconnect door latch retainer 45 and remove door latch rod 46 from exterior handle assembly 47 22 Remove stud 48 from exterior handle assembly 47 23 Remove fastening clip 49 and exterior handle assembly 47 from door 2 49 342 606 24 Remove four nuts 50 washers 51 cap screws
19. YW 48 47 0 040 0 080 in X 45 1 0 2 0 mm x 48 342 1018 NOTE If cylinder head fire deck has been resurfaced valves must be seated deeper to restore valve head recess depth to specification limits Do not grind new valve seat inserts for this purpose Reduced thickness valve seat inserts are available 0 010 0 020 and 0 030 in 0 254 0 508 and 0 762 mm shallower than standard 0032 00 12 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 CLEANING AND INSPECTION CONTINUED 15 Ensure valve heads 49 are recessed from cylinder head 2 fire deck surface by 0 055 0 071 in 1 4 1 8 mm minimum If not install reduced thickness valve seat inserts 342 1019 NOTE Replace rotator whenever spring is replaced 16 Inspect valve springs and replace any that are pitted or cracked 17 Use valve spring tester 50 to test valve springs 11 Replace spring if spring load is less than 63 Ib 280 at com pressed length of 2 648 in 67 26 mm 342 1020 0032 00 13 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 CLEANING AND INSPECTION CONTINUED NOTE If suitable for reuse valve may be refaced as long as after refacing valve rim width is not less than 0 086 in 2 19 mm for intake valves and 0 094 in 2 39 mm for exhaust valves 18 Ensure valve stems are free from scratches or scuff marks Valve faces must be free from ridges cracks and pitting If necessary reface valves or ins
20. and two screws 31 Install capacitor 30 and two screws 29 Install two terminal screws 28 insulator bushings 27 and new tenz nuts 26 CAUTION Use caution to ensure stator leads are not damaged 342 533 Install stator 22 in slip ring end housing 23 Connect three leads 25 and install three tenz nuts 24 Install rotor and drive end housing 21 in stator 22 and slip ring end housing 23 Install three screws 20 and new lock nuts 19 Install two terminal studs 18 new lock washers 17 nuts 16 new lock washers 15 and nuts 14 0052 00 10 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED ASSEMBLY CONTINUED 27 28 29 30 31 Install new seal 13 brush holder 12 and four screws 11 Install two brushes 10 Install two jumpers 9 new gasket 8 cover 7 two guard washers 6 new lock washers 5 and nuts 4 Install spacer 3 woodruff key 2 and fan 1 Install alternator END OF WORK PACKAGE 0052 00 11 0052 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0052 00 12 TM 9 2320 302 34 STARTER SOLENOID REPLACEMENT 0053 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Washer lock P N MS35333 42 Tools and Special Tools Adhesive silicone Item Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Caps vise jaw Item 17 WP 0126 00 Starter
21. 2 Attach two pressure test kit strips 30 to cylinder head fire deck 20 Install 20 cylinder head bolts 31 through cylin der head and test kit strips Install and tighten 20 nuts 32 to 120 Ib in 14 Nm 342 1013 0032 00 9 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 CLEANING AND INSPECTION CONTINUED NOTE e Leaking injector tubes must be replaced Replace any pipe plug or cup plug where leakage is present e Cylinder head must be pressure tested following replacement of any injector tubes cup plugs or pipe plugs Install gasket 33 and pressure test kit thermostat cover plate 34 on cylinder head 2 with bolts 35 Using hardware provided install material lift clamp 1 Install pressure test kit dummy fuel injectors 36 in injector bores Install fuel injector hold down clamp 37 washer 38 and hold down bolt 39 Tighten bolt to 43 49 Ib ft 58 66 Nm LB 0 n Bow Remove cylinder head 2 from engine mounting bracket 5 27 Z WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 8 Apply 30 psi 207 kPa air pressure to thermostat cover plate fitting 40 342 1014 9 Install pipe plugs in temp port and in air compressor coolant port 10 Immerse cylinder head 2 in water heated to 180 F 200 F 8
22. 22 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel CAUTION Do not use solvents or petroleum distillates to clean components To do so could result in damage to equip ment 1 Clean bolt assemblies oil pan and oil pan gasket surfaces with detergent and water Dry with compressed air 2 Remove gasket forming compound from pan rail joint faces of flywheel housing 7 gear housing 8 gear case cover 9 and cylinder block 3 where contact is made with oil pan gasket 342 746 3 Ensure all old gasket forming compound is removed from sealing surfaces INSPECTION 1 Inspect bolt assembly isolators for dryness cracks or tears Replace as necessary 2 Check oil pan for damage Replace or repair as necessary 3 Ensure oil pump pickup tube and screen assembly are not damaged 0028 00 3 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 REPAIR CAUTION Hold insert to prevent scoring of plastic oil pan Failure to prevent insert from slipping during removal could cause damage and result in equipment failure 1 Hold flats of insert 10 to prevent slippage and remove pipe plug 11 2 Remove nut 12 insert 10 and o ring 13 from oil pan 2 Discard o ring 342 747 9 Install new o ring 13 on flange of i
23. 342 891 b Fabrication Notes 1 Cut two 7 in lengths 2 Remove all burrs and sharp edges END OF WORK PACKAGE 0122 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0122 00 4 TM 9 2320 302 34 TORQUE LIMITS 0123 00 SCOPE 1 This work package lists standard torque values as shown in Table 1 and provides general information for applying torque Special torque values and tightening sequences are indicated in the maintenance procedures for applicable com ponents 2 Air conditioner refrigerant line torque specifications are provided in Table 2 GENERAL 1 Always use the torque values listed in Table 1 when the maintenance procedure does not give a specific torque value 2 Unless otherwise indicated standard torque tolerance shall be 1046 3 Torque values listed are based on clean dry threads Reduce torque by 10 when engine oil is used as a lubricant Reduce torque by 2046 if new plated cap screws are used 4 Cap screws threaded into aluminum may require reductions in torque of 30 or more of Grade 5 cap screw torque Cap screw threaded into aluminum must also attain two cap screw diameters of thread engagement 5 If the maintenance procedures do not specify a tightening order use the following guides a Unless otherwise specified lubricate threads of fasteners with oil OE HDO 10 or OEA b When tightening fasteners above 30 lb ft 41 Nm use the torque pattern but only tighten to 70 percent
24. 4 Install new seal ring 20 in bull idler gear hub recess 21 using engine lubricating oil to hold seal ring in place 342 980 VA WARNING Gear case cover weighs 89 Ib 40 kg Attach suitable lifting device prior to removal to prevent possible injury to personnel NOTE Ensure guide studs are positioned in corresponding bolt holes of gear case cover and gear housing 5 Position gear case cover 4 on two guide studs 14 and remove lifting sling 6 Install gear case cover 4 against gear housing 5 7 Install ten short bolts 18 0019 00 4 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED INSTALLATION CONTINUED 8 9 10 11 12 Install four long bolts 19 Remove two guide studs 14 and install two bolts 13 Install standoff bracket 9 and bolt 8 to gear case cover 4 Install standoff bracket 12 bolt 11 and nut 10 on gear case cover 4 Secure fan clutch solenoid air line 7 to gear case cover 4 and gear housing 5 with new tiedown straps 6 0019 00 5 342 979 0019 00 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED 0019 00 INSTALLATION CONTINUED 13 14 15 16 17 18 19 20 Tighten bolts to 43 54 lb ft 58 73 Nm in sequence shown TIGHTENING SEQUENCE Position alternator mounting bracket 3 on gear case cover 4 and gear housing assembly 5 Secure with two bolts 2 and nuts 1 Tighten to 43 54 Ib ft 58 7
25. 49 79260 J35996 A 33287 J 24365 33287 27 FM W ACCE 89536 PD1201 92059 450 05463 J35906 33287 J36235 33287 J35651 33287 J35652 B 33287 J22405 02 33287 J36347 33287 0200 79136 4200 3174865PC4 80064 0300 79136 A A 51194 80244 J35597 A 33287 135994 33287 J24210 33287 J35791 33287 GGGP781 81348 J24171 A 33287 1178 45225 J35951 175 33287 0126 00 5 REFERENCE SC 4910 95 A31 SC 4910 95 A31 TM 9 2320 302 24P SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P SC 4910 95 A31 TM 9 2320 302 24P SC 4910 95 A31 TM 9 2320 302 24P TM 9 2320 302 34 TOOL IDENTIFICATION LIST CONTINUED 0126 00 Table 1 Tool Identification List Continued 2 3 4 5 NATIONAL PART NUMBER ITEM NAME STOCK NUMBER CAGEC REFERENCE Reclaimer Refrigerant R134A 4250 01 396 8928 EEEAC304A 55719 GSA Catalog Reconditioning Set 5120 01 322 3507 J33880 33287 Remover Seal 5120 01 322 1131 J35993 33287 Remover Valve Guide 5120 01 322 3506 J34696 B 33287 Remover Valve Seat 5120 00 494 1836 J23479 271 33287 Remover Valve Seat 5120 01 322 8883 J23479 460 A 33287 Remover Wheel Bearing Cup 5120 00 784 6482 J3940 33287 Remover Installer Main Pressure J35924 33287 TM 9 2320 302 24P Spring Replacing Tool Engine 51
26. CONTINUED NOTE Perform step 4 on left side 4 Remove lock nut 13 washer 14 and screw 15 Disconnect cable 16 and set aside Discard lock nut 5 Remove lock nut 17 washer 18 and resilient mount 19 Discard lock nut WARNING Cab assembly weighs 1100 1b 499 kg Use hoist with lifting capacity of 1400 Ib 636 kg to support cab assembly Failure to do so could result in injury to personnel and or damage to equipment 6 Using cab sling and hoist lift cab assembly 20 enough to remove all slack and not allow cab assembly to drop when front cab mounts 21 are removed 7 Remove screw 22 washer 24 and bushing 23 8 Remove four lock nuts 25 washers 26 screws 27 washers 28 and front cab mount 21 Discard lock nuts 20 342 190 25 26 27 28 0097 00 3 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 REMOVAL CONTINUED NOTE Perform step 9 on left side 9 Remove three lock nuts 29 washers 30 two brackets 31 three screws 32 washers 33 and plate 34 Discard lock nuts 342 191 NOTE Perform step 10 on right side 10 Remove three lock nuts 35 washers 36 screws 37 washers 38 and plate 39 Discard lock nuts 342 192 0097 00 4 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 INSTALLATION Nw FW Dm WA v WARNING Cab assembly weights 1100 Ib 499 kg Use hoist with lifting cap
27. CONTINUED 4 Repeat step 3 for right side NOTE Ensure spacers 23 installed during step 2 do not slip out of place If spacer is not present frame will not be in line to allow installation of front crossmember 5 Install screw 16 three washers 15 capscrews 14 four washers 13 and nuts 12 342 1138 Install front engine mount adapter 7 and four bolts 11 Install two isolators 10 and spacer 9 Lower engine 8 and remove engine support oe ND Install two sleeves 6 isolators 5 washers 4 screws 3 washers 2 and new lock nuts 1 342 1139 10 Install vibration dampet WP 0020 00 11 Install front crossmemberz WP 0096 00 12 Install front ABS quick release valve TM 9 2320 302 20 END OF WORK PACKAGE 0011 00 4 TM 9 2320 302 34 REAR ENGINE MOUNTS REPLACEMENT 0012 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Trestles Item 135 WP 0126 00 V WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVAL On left side remove t
28. square cut seals 4 and filters 5 Discard o rings seals and fil ters 2 Remove transmission breather vent 6 from torque converter housing 342 1144 0071 00 2 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Output Shaft and Oil Seal 1 Remove bolt 7 retainer plug 8 and o rings 9 and 10 from output shaft yoke 11 Discard o rings 2 Remove oil seal 12 using puller J24171 A Discard oil seal LEZ MY Ug LEE Bee MAL l 1i fe M the RN RII J SS 25 UUN cde AE Y 342 1145 0071 00 3 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Torque Converter Module 1 2 3 Remove bolts securing torque converter shipping brackets s Remove bracket s Remove retaining ring 13 securing torque converter plug 14 Using an M6x30 1 bolt threaded into torque converter plug 14 remove torque converter plug and o ring 15 Discard o ring Install two bolts 16 into flexplate adapter 17 Use two bars at an angle to prevent rotation of torque converter 18 NOTE While attempting to remove torque converter center bolt converter will rotate Follow procedure in step 5 to hold converter stationary Remove converter center bolt 19 using bolt tool 738564 Remove and tag shim s 20 Remove torque
29. 0062 00 0062 00 1 Collision Warning System 0066 00 0066 00 1 ain dacs Gaeta EG uh hae aud aen ead dci EA Re ea EAM A 0069 00 0069 00 1 nib Ape ime uei ue x Poe Re Ibi 0056 00 0056 00 1 Engine Injector 4x oe dec eue de dae Lace bee ENDE 0069 00 0069 00 1 Engine POWE eo arke duele iene ines SP xm es el E Bg lE Egon s 0055 00 0055 00 1 Main Cabs iiec ex exces Er gard n EE d 0057 00 0057 00 1 Overhead Cab uus eux ERR era ERA EE 0061 00 0061 00 1 Switch Panel eek e Re he eg km gn ee XR ee RO is 0058 00 0058 00 1 iis ERREUR RH er Rep nete YR dre dios 0067 00 0067 00 1 Turn Signal Thru deck sa sves e ee 0060 00 0060 00 1 Turn Signal Marker Light lille 0059 00 0059 00 1 Index 10 By Order of the Secretary of the Army ERIC SHINSEKI General United States Army Chief of Staff Official JOEL B HUDSON Administrative Assistant to the Secretary of the Army 13903 DISTRIBUTION To be distributed in accordance with the initial distribution number IDN 381095 requirements for TM 9 2320 302 34 This Page Intentionally Left Blank RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is ODISC4 1 Jul 01 TO Forward to prop
30. 0122 00 1 TM 9 2320 302 34 ILLUSTRATED LIST OF MANUFACTURED ITEMS CONTINUED 0122 00 FABRICATED TOOLS CONTINUED b Fabrication Notes 1 Drill and tap sleeve P N 166JX for 1 2 x 13 UNC thread 2 Extend length of thread to 2 1 2 in 3 Install screw in sleeve as shown 2 Item 2 a Materials 1 Cover Plate P N 5122281 2 Coupling P N 5141773 3 Bar Stock 3 4 x 1 2 x 4 in 2 4 Tubing Heavy Wall 1 2 in Inside Diameter 3 4 in Long 4 342 800 b Fabrication Notes 1 2 3 4 Cut 2 in diameter hole in center of raised portion of cover plate P N 5122281 Cut 7 16 in from end of coupling P N 5141773 Weld four tube sections onto raised side of cover plate centered on four bolt holes as shown Place shim s and 7 8 in section of coupling in hub of either air compressor or air compressor drive Install cover plate using two bolts to secure it to air compressor or drive Ensure that coupling contacts cover plate 0122 00 2 TM 9 2320 302 34 ILLUSTRATED LIST OF MANUFACTURED ITEMS CONTINUED 0122 00 FABRICATED TOOLS CONTINUED 5 Tack weld coupling to cover plate Remove cover plate from air compressor or drive and finish welding coupling to cover plate Ensure that inside diameter of coupling is free of excess weld 6 Weld two pieces of bar stock to opposite side of cover plate as shown 3 Item 3 a Materials Rod 1 2 x 20 x 13 UNC P N 1 213X20INLGSTL prc ll eco IN EON imma
31. 1 from steering gear 2 and drain power steering fluid into container 2 Disconnect and tag two hoses 3 from tee 4 and elbow 5 0088 00 1 TM 9 2320 302 34 STEERING GEAR REPLACEMENT CONTINUED 0088 00 REMOVAL CONTINUED NOTE Note orientation of hose fittings prior to removal aid in installation 3 Remove tee 4 and elbow 5 from steering gear 2 4 Remove screw 6 and lock washer 7 Discard lock washer 5 While an assistant supports steering gear 2 remove two screws 8 nuts 9 four washers 10 and steering gear P T A NSA 2 SSSA 2 342 798 INSTALLATION 1 Install elbow 5 and tee 6 and orient as noted in removal 2 With assistance position steering gear 2 and install two screws 8 four washers 10 and two nuts 9 Tighten nuts to 34 47 lb ft 47 63 Nm 3 Install new lock washer 7 and screw 6 4 Connect two hoses 3 to tee 4 and elbow 5 5 Connect lower end of universal steering shaft TM 9 2320 302 20 6 Install drag link TM 9 2320 302 20 7 Install drain plug 1 in steering gear 2 8 Fill power steering reservoir TM 9 2320 302 20 9 Check system for operation and leaks END OF WORK PACKAGE 0088 00 2 TM 9 2320 302 34 STEERING GEAR REPAIR 0089 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Tools and Special Tools Continued Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Wrenc
32. 11 13 and 9 Tighten all bolts to 7 10 Ib ft 10 13 Nm 0071 00 48 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Assembly Continued w I 342 1177 0071 00 49 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY n WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel NOTE Ensure all transmission components are cleaned and well lubricated before reassembling transmission assembly Before beginning assembly attach bracket J41445 and holding fixture 735926 to main transmission housing Use a suitable hoist to mount fixture and housing on a repair stand e Ensure main housing is horizontal when installing C3 C4 clutch Module Installation of C3 C4 Clutch Assembly 1 Install C3 C4 clutch assembly 51 through input end of main housing 23 aligning bolt holes in clutch assembly with holes in main housing Install two bolts 50 180 degrees from each other to hold clutch in place Rotate transmission housing on stand and install remaining 12 bolts 50 Tighten bolts to 38 45 Ib ft 51 61 Nm 342 11
33. 11 around panel 8 On engine side of hood 12 use router bit on grinder or drill to grind away shallow recess Grind recess to one quarter depth of laminate 13 and 1 2 in 13 mm outward from all sides 14 of panel 8 area Grind 1 2 in 13 mm inward from all sides 14 on engine side of patch 10 Slightly taper outside edge of ground area around panel and inside edge of ground area on patch Using 110 220 grit sandpaper scuff area at least 1 in 25 mm out from sides 15 of panel 8 area Scuff at least 1 in 25 mm in from sides 16 of patch 10 Scuff thoroughly to give surface to which patch can stick Completely sand off any undercoating sprayed on these areas Bevel edges of outer sides of both panel 8 and patch 10 to about 45 degrees Using 220 or higher grit sandpaper gently feather back outer painted surfaces about 1 2 in 13 mm beyond edges of repair areas of panel 8 and patch 10 Blow dust away with compressed air and wipe area with clean cloth 0106 00 4 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED 342 587 1 If patch 10 is close enough to edge use clamps to temporarily secure patch during repair If patch is too far from edge to use clamps use bond strips 17 1 Cut scrap SMC into strips 17 Make enough strips to hold patch 10 in place about one every 6 in 15 cm If surface of patch is contoured or curved use many small strips Large
34. 110 SAN f 10 ES A DEEN ZZS 12 gt lt A Er o p 13 8 9 342 1116 7 5 INSTALLATION V WARNING Front axle weighs 1060 lb 481 kg Support front axle with a suitable floor jack during installation to pre vent possible injury to personnel NOTE Procedure is same for both sides except where noted 1 With axle 7 installed and secured on suitable floor jack position axle under vehicle 2 Coat bottom of shim 13 with sealing compound and install shim on axle 7 with wide end of shim toward rear of vehi cle Install pin 14 in spacer 12 Coat top of spacer 12 with sealing compound and install spacer on top of shim 13 Install axle 7 Coat bottom and U bolt saddles of two axle stops 11 with sealing compound Coat threads of U bolts 10 with anti seize compound 3 Install two axle stops 11 four U bolts 10 eight washers 9 and eight nuts 8 on axle 7 Tighten nuts to 380 460 Ib ft 515 624 Nm 8 Remove floor jack from under vehicle 9 Install tie rod 6 and two castellated nuts 5 Tighten nuts to 165 180 Ib ft 224 244 Nm Own Bw 10 Install two new cotter pins 4 through castellated nuts 5 11 On left side install drag link 3 and castellated nut 2 Tighten nut to 165 180 Ib ft 224 244 Nm 12 Install new cotter pin 1 through castellated nut 2 0072 00 3 TM 9 2320 302 34 FRONT AXLE ASSEMBLY REPLACEMENT CONTINUED 0072 00 INSTALLATION CON
35. 23 2 Remove C3 C4 clutch assembly 51 by sliding it out of input end of housing Inspect and measure C5 clutch plate splines inside main housing for wear Maximum wear allowed is 0 045 in 1 15 mm 342 1155 0071 00 9 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL Torque Converter Module Disassembly Ow OANA PWN PE NOTE Prior to disassembling torque converter note balance marks or mark a line across converter cover to pump assembly with a scribe These marks will ensure correct assembly of torque converter and reduce balance problems Place converter assembly 1 on a flat work surface with pump drive tangs downward Remove 36 nuts 2 from outer diameter of cover assembly 3 Remove 36 T headed bolts 4 from outer diameter of pump assembly 5 Carefully without prying remove cover assembly 3 from pump assembly 5 Remove and discard o ring 6 from between converter assembly halves Remove turbine assembly 7 from cover assembly 3 Remove stator assembly 8 from pump assembly 5 Remove thrust bearing race 9 from pump assembly 5 Remove thrust bearing assembly 10 from turbine assembly 7 Remove bearing assembly 11 race 12 and selective shim 13 from pump assembly 5 Remove retaining ring 14 and star plate 15 from stator assembly 8 342 1156 0071 00 10 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE O
36. 24 342 941 Pull harness 110 out from under cab 111 Install ground wire 108 washer 107 new lock washer 106 and screw 105 in dual voltage control 109 Install five wires 104 three washers 103 nuts 102 on dual voltage control 109 Install two new tiedown straps 101 Connect plug 99 to voltage regulator 100 Install wire 97 new lock washer 96 and nut 95 on sending unit 98 111 103 104 N 342 940 0010 00 23 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 25 26 2 28 29 NOTE Steps 25 through 29 can be performed through center floor panel of cab Unplug and connect fuel return hose 93 to hose 94 Connect connector 91 to engine brake harness 92 Install clamp 90 with washer 89 and new lock nut 88 Install clamp 87 with washer 86 screw 85 washer 84 and new lock nut 83 Install clamp 82 with washer 81 and new lock nut 80 on rear of engine 342 939 0010 00 24 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 30 Install crossmember 75 washer 79 screw 78 washer 77 and nut 76 78 79 342 938 31 Install washer 74 screw 73 washer 72 and nut 71 in left end of crossmember 75 73 74 71 72 342 937 0010 00 25 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED NOTE
37. 3 Position seal inserter base 7 on rear of crankshaft 5 4 Install two guide studs 8 in two flywheel bolt holes 180 degrees apart 5 Hand tighten two guide studs 8 until seal inserter base 7 is tight against rear of crankshaft 5 6 Install oil seal 6 onto crankshaft 5 as far as it will go by hand Ws Install seal inserter spacer 9 on center screw 10 8 Position seal inserter collar 11 on oil seal 6 9 Place seal inserter housing 12 over center screw 10 and two guide studs 8 Position seal inserter housing against seal inserter collar 11 and crankshaft rear oil seal 6 10 Install thrust bearing 13 on center screw 10 with lettered side against seal inserter housing 12 11 Install nut 14 on center screw 10 Tighten nut until crankshaft rear oil seal 6 is firmly seated 342 669 12 Remove nut 14 thrust bearing 13 seal inserter housing 12 seal inserter collar 11 spacer 9 guide studs 8 and seal inserter base 7 from crankshaft 5 13 Install flex plate WP0025 00 14 Install power WPOOTO 00 END OF WORK PACKAGE 0023 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0023 00 4 TM 9 2320 302 34 FLYWHEEL HOUSING REPLACEMENT 0024 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Compound gasket forming Item 12 WP 0125 00 Tools and Special Tools References Tool kit
38. 32 from vehicle 32 0113 00 6 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 INSTALLATION 1 With assistance lift HVAC unit 32 into vehicle 2 Secure HVAC unit 32 with six screws 31 Tighten screws to 48 lb ft 65 Nm 3 Connect air line 29 to air cylinder 30 by pushing air line into fitting as far as it will go then gently pulling back air line to lock it in place 4 Pull rubber boot through firewall from engine side 5 On engine side of fire wall apply gasket forming compound to fresh air duct assembly 28 and secure with six screws 27 342 570 6 Slide drain tubes 22 through openings in cab floor 23 22 342 568 0113 00 7 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 INSTALLATION CONTINUED 7 Connect drain tubes 22 and secure with two hose clamps 21 8 Install heater core hoses 20 and tighten two hose clamps 19 342 567 9 Apply sealant 24 around drain tubes 22 on cab floor 23 22 342 568 WARNING Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 10 Remove caps from refrigerant lines 26 and expansion valve 25 0113 00 8 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 INSTALLATION CONTIN
39. 342 1197 0080 00 2 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 7 Rotate differential carrier 1 to horizontal position with pinion cover 4 at top 8 Remove five cap screws 5 washers 6 and pinion cover 4 342 1229 9 Loosen nut 7 on drive pinion 3 10 Using pinion holding bar loosen lock nut 8 on yoke 9 11 Remove seven cap screws 10 washers 11 and filter shield 12 342 1230 0080 00 3 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 12 Rotate differential carrier 1 until yoke 9 faces up and install suitable lifting device through yoke 9 NOTE There are two notches on side of pinion differential case When one is aligned with helical driven gear pin ion differential case can be removed 13 Rotate input shaft 13 until one notch on pinion differential case 14 is aligned over helical driven gear 15 14 Lift input shaft 13 from differential carrier 1 15 Remove shims 16 Measure and record thickness of shim pack 342 1231 16 Remove four socket head screws 17 cover 18 seal 19 and shift shaft 20 Discard seal 17 Remove adjusting screw 21 and jamnut 22 from differential carrier 1 18 Remove spring 23 from differential carrier 1 19 Remove side gear 24 with bearing cone 25 clutch 26 and fork 27 fro
40. 342 919 0034 00 5 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE CONTINUED 0034 00 INSTALLATION CONTINUED 4 Ensure that dimple 11 on rear face of thrust plate 6 is positioned at 12 o clock If necessary tap camshaft drive gear hub toward engine with fiber or plastic mallet until rear face of thrust plate is 1 4 in 6 35 mm from face of cylinder head 12 Ensure that thrust plate is not tilted in bore 1 4 in 6 35 mm 342 920 5 Install camshaft and bearings WP 0026 00 6 Install bull idler gear WP 0037 00 END OF WORK PACKAGE 0034 00 6 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT 0035 00 THIS WORK PACKAGE COVERS Removal Cleaning and Inspection Installation INITIAL SETUP Maintenance Level Personnel Required General Support Two Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Clamp material lift Item 20 WP 0126 00 Engine installed on repair stand Dispenser sealant Item 30 WP 0126 00 Camshaft and bearings removed WP 0026 00 Plate indexing Item 83 WP 0126 00 TRS d TM 9 2320 iming reference sensor remove Wrench torque 15 75 Ib ft Item 138 WP 0126 00 30200 Materials Parts Synchronous reference sensor SRS removed TM 9 Ring seal P N 8929740 2320 302 20 Washer e a assem Bull idler gear removed WP 0037 00 Washer P N 5180370 Compound gasket forming Item 12 WP 0125 00 Adjustable idler gear
41. 4 align thrust washer tangs with slots in planetary and retain them with petrolatum Slide pinion gear and bear ing assemblies into side of P1 planetary carrier between thrust washers Repeat procedure for remaining five pinion gears Install six spindles 7 so that lower step is positioned for proper installation of indexing ring 6 Install indexing ring 6 and retaining ring 5 to secure pinion gears in place Measure pinion end play Pinion end play must not exceed 0 037 in 0 94 mm Check all six pinion gears Install P2 planetary ring gear 2 over P1 planetary carrier assembly 4 Install internal retaining ring 1 into P2 planetary ring gear 2 connecting P1 planetary carrier assembly 4 and P2 planetary ring gear CAUTION Ensure thrust bearing is assembled with locating lip on either inner or outer thrust bearing race not prevent ing race from contacting thrust surface of mating part Failure to follow this caution leads to thrust bearing failure and incorrect shim selection to maintain proper part clearance Install thrust bearing 12 on P1 planetary carrier 4 342 1173 0071 00 34 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED P2 Planetary Module Disassembly 1 Remove retaining ring 1 and P3 planetary ring gear 2 from planetary module 3 Remove and inspect thrust bearing 4 Check P2 planetary carrier assembly 5 for pinion end play Pinion e
42. 48 342 992 Install seal ring 20 between raised lands on unloader piston 19 Install unloader spring 21 on opposite end of unloader piston 19 Support cylinder head 13 on bench deck side down and install long end of unloader piston 19 assembly in unloader bore Repeat steps 45 through 47 for second unloader piston 0084 00 15 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED NOTE Ensure old gasket material is removed from mating surfaces of unloader cover plate and cylinder head 49 Position new gasket 18 on cylinder head 13 and align bolt holes in gasket with bolt holes in cylinder head CAUTION Ensure seal rings are not cut when pressing unloader pistons in bores to prevent damage to equipment DO NOT allow old gasket material to drop in bores to prevent damage to equipment 50 Position unloader cover plate 17 on top of exposed unloader pistons 19 Press unloader cover plate carefully to press unloader pistons in bores 51 Hold down unloader cover plate 17 and install four new lock washers 16 and bolts 15 Tighten bolts to 175 225 1b in 20 25 Nm NOTE If beaded cylinder head gasket is used install gasket with bead side toward cylinder head Unbeaded cylinder head gasket can be installed with either side up e Ensure old gasket material is removed from mating surfaces of cylinder head and air compressor body 52 Position new cylin
43. 7 just inboard of accessory drive gear teeth NOTE As accessory drive gear is rotated dial indicator needle may register to left and right of zero Total amount of dial indicator needle movement gives total indicated runout TIR 16 Zero dial indicator 18 Rotate accessory drive gear 7 two full rotation Allowable TIR is 0 0015 in 0 04 mm 342 1113 END OF WORK PACKAGE 0039 00 11 TM 9 2320 302 34 This Page Intentionally Left Blank 0039 00 12 TM 9 2320 302 34 CYLINDER BLOCK PRESSURE TESTING 0040 00 THIS WORK PACKAGE COVERS Testing INITIAL SETUP Maintenance Level Materials Parts General Support Plug pipe P N 8923916 Detergent Item 19 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Adapter cylinder Item 1 WP 0126 00 All components removed from cylinder block except Tester cylinder Item 123 WP 0126 00 necessary cup plugs pipe plugs and cylinder liners used for pressure testing WP 0036 00 Tester cylinder Item 124 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Screw P N 8929129 TESTING 1 If present remove six weep hole plugs 1 342 903 0040 00 1 TM 9 2320 302 34 CYLINDER BLOCK PRESSURE TESTING CONTINUED 0040 00 TESTING CONTINUED NOTE Ensure all hose connectors and elbows are removed from block and holes are properly plugged
44. 7 on axle housing 8 with eight washers 6 screws 5 washers 4 and new lock nuts 3 Tighten lock nuts to 135 145 Ib ft 183 197 Nm 10 Connect two air lines 1 to brake chamber 2 11 Repeat steps 9 and 10 for opposite side of axle housing 8 342 1127 12 Install rear shock absorbers 13 Install rear brakeshoes 14 Install drivelines 15 Fill axle with oil 16 Install rear ABS sensors 17 If new rear axle was installed align tandem axles END OF WORK PACKAGE 0078 00 4 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT 0079 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Jack hydraulic Item 73 WP 0126 00 Equipment Condition Air system drained TM 9 2320 302 10 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 SL M Materials Parts Drivelines disconnected TM 9 2320 302 20 Compound sealing Item 14 WP 0125 00 Axle oil filter removed TM 9 2320 302 20 Rags wiping Item 31 WP 0125 00 Axle oil drained TM 9 2320 302 20 N WARNING e Use extreme caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warn
45. 8 from fan spindle Discard roller bearing inner race 342 807 0051 00 2 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 DISASSEMBLY CONTINUED 6 Remove and discard oil seal 9 7 Remove ball bearing retaining snap ring 10 342 808 NOTE Ball bearing assembly must be replaced whenever fan spindle is removed from spindle housing 8 Support spindle housing 5 as shown 9 Using bearing inserter and remover tool 11 remove and discard ball bearing assembly 12 342 809 0051 00 3 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 DISASSEMBLY CONTINUED 10 Remove roller bearing retaining snap ring 13 342 810 11 Support spindle housing 5 and remove roller bearing 14 12 Remove grease fitting 15 and lube pressure relief fitting 16 342 811 INSPECTION 1 Inspect parts for rust corrosion nicks burrs cracks and deterioration 2 Inspect spindle and housing machined surfaces for pits gouges and scratches 3 Inspect for stripped or damaged threads 0051 00 4 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 ASSEMBLY NOTE Ensure roller bearing inner race part number is facing up against installing tool 1 Install new roller bearing inner race 8 on fan spindle 1 2 Support fan spindle 1 on press bed Using installing tool 17 press roller bearing inner race 8 against shoulder of fan spindle 342
46. Assembly INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Nut tenz P N 2364 3 Tools and Special Tools Nut lock P N 26175 3 Tool kit general mechanic s Item 132 WP 0126 00 Nut tenz P N 2771 5 Caps vise jaw Item 17 WP 0126 00 Seal P N 57611 Dial indicator set Item 29 WP 0126 00 Seal P N 79403 Multimeter digital Item 78 WP 0126 00 Seal P N 79404 Soldering gun Item 118 WP 0126 00 Seal P N 79405 Test stand automotive generator and starter Item 122 2 Washer lock P N 2434 8 WP 0126 00 Vise machinist s Item 136 WP 0126 00 CUR abrasive Citem AAWE OLAS UOJ Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Compound sealing Item 14 WP 0125 00 Solder Item 33 WP 0125 00 Materials Parts Bearing P N A0790 79406 Equipment Condition Gasket P N 73814 Alternator removed 9 2320 302 20 0052 00 1 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 DISASSEMBLY 1 Remove fan 1 woodruff key 2 and spacer 3 2 Remove two nuts 4 lock washers 5 guard washers 6 cover 7 gasket 8 and two jumpers 9 Discard gasket and lock washers 3 Remove two brushes 10 4 Remove four screws 11 brush holder 12 and seal 13 Discard seal 5 Remove two nuts 14 lock washers 15 nuts 16 lock washers 17 and two terminal studs 18 Discard lock wash ers 4 5 2 342 523 6 Remove three lock nuts 19 and screws 20 Disc
47. BRAKE SYSTEM 1 The dual air brake system consists of two independent air brake systems that use a single set of brake controls Each sys tem has its own reservoirs plumbing and brake chambers The primary system operates the service brakes on the rear axle and the secondary system operates the service brakes on the front axle On tractor trailer configurations service brake signals from both systems are sent to the trailer 2 Loss of air pressure in the primary system causes the rear service brakes to become inoperative Front brakes will con tinue to be operated by secondary system air pressure In addition trailer brakes will be operated by the secondary sys tem Loss of secondary system air pressure causes the front axle brakes to become inoperative Rear service brakes and trailer brakes will be operated by the primary system 0003 00 5 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 BRAKE SYSTEM CONTINUED 3 The warning light and buzzer inside the cab are activated if air pressure drops below 64 psi 441 kPa in either brake system If this happens check air pressure gages to determine which system has low air pressure Although vehicle speed can be reduced using the foot brake control pedal either the front or rear service brakes will not operate resulting in a longer stopping distance Bring vehicle to a safe stop and have the air system repaired before continuing 4 If the primary brake system becomes inoperat
48. Clean out crankshaft oil passages with bore brush 2 Clean crankshaft bearings and main bearing caps with detergent and dry with compressed air 342 1077 0033 00 5 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSPECTION eno cR GD CAUTION Vibration damper must be replaced at normal engine overhaul or if crankshaft breakage is experienced Fail ure to do so could result in premature crankshaft failure NOTE e Crankshaft failures are rare When crankshaft cracks or breaks completely thoroughly inspect for con tributory factors Unless abnormal conditions are discovered and corrected crankshaft failure will be repeated Ensure all main bearing saddles and thrust bearing counterbores in cylinder block are clean e Each upper main bearing shell is grooved with oil hole Register oil hole in each upper main bearing shell with oil hole in each main bearing saddle of cylinder block e Install main bearings in sets only Do not mix old and new main bearing shells on same journal If old bearings are installed they must be installed in same journal they were removed from Inspect crankshaft timing gear keyway for evidence of cracks or wear Replace crankshaft if damage is evident Inspect crankshaft for evidence of overheating Replace crankshaft if damage is evident Check crankshaft journal surfaces for score marks or imperfections If excessively scored replace crankshaft Check crankshaft thrust surfac
49. Install axle stop 7 in position noted during removal Install two U bolts 6 four washers 5 and nuts 4 Tighten nuts to 380 460 Ib ft 515 624 Nm 9 If removed install stop cushion 8 in axle stop 7 TM 9 2320 302 20 0099 00 4 TM 9 2320 302 34 FRONT SPRING REPLACEMENT CONTINUED 0099 00 INSTALLATION CONTINUED 10 Install front shock absorber TM 9 2320 302 20 11 Install front wheel TM 9 2320 302 10 END OF WORK PACKAGE 0099 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0099 00 6 TM 9 2320 302 34 FRONT SPRING HANGERS REPLACEMENT 0100 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Front spring removed 0099 00 Tools and Special Tools Steering gear removed left side only WP 0088 00 Tool kit general mechanic s Item 132 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 REMOVAL NOTE e Vehicle may utilize huckbolts instead of screws and nuts Replace all loose or damaged huckbolts with grade 8 screws and lock nuts e Perform steps 1 through 3 on left front side of vehicle 1 Remove two lock nuts 1 washers 2 screws 3 and threaded block 4 Discard lock nuts LEFT FRONT RIGHT FRONT 342 967 0100 00 1 TM 9 2320 302 34 FRONT SPRING HANGERS REPLACEMENT CONTINUED 0100 00 REMOVAL CONTINUED 2 Remove lock nut 5 washer 6 and screw 7 Discard loc
50. Install two bolts 16 into flexplate adapter 17 Use two bars at an angle to prevent turbine shaft rotation Measure from top of end play gage tool J38548 to face of turbine shaft and record it as dimension B Subtract dimension B from dimension A to determine dimension C Note dimension A is height of tool J38548 3 937 inch 100 00 mm 0071 00 55 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Torque Converter Module and Selective Shim Measurement Continued 5 Use dimension C and Table 1 Torque Converter Selective Shims located at the end of this work package to determine proper selective shim part number Remove torque converter end play tool J37548 Install selective shim 20 with step side down toward turbine shaft Install converter center bolt 19 with converter tightening tool J38564 and retaining ring 13 NOTE Turbine and turbine shaft may rotate while attempting to tighten retaining bolt Prevent turbine shaft from turning in same manner as in step number 3 Tighten converter center bolt 19 to 74 88 lb ft 100 120 Nm Remove retaining ring 13 and tool 738564 replace with converter plug 14 o ring 15 and retaining ring 13 Install torque converter shipping bracket Tighten shipping bracket mounting bolts to 38 45 Ib ft 51 61 Nm CUPPED END DOWN 18 a A E J38564 VIEW C 3
51. Item 19 WP 0125 00 Dial indicator set Item 29 WP 0126 00 eui 23 WP 0125 00 lubricating Item 25 WPOIZSO0 Materials Parts Equipment Condition Key woodruff P N 8929810 Camshaft and bearings removed WP 0026 00 Ring seal P N 23524912 Bull idler gear removed WP 0037 00 REMOVAL 1 Tap rear face of camshaft gear assembly 1 with fiber or plastic mallet until camshaft gear assembly is free of gear housing 2 342 912 0034 00 1 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE CONTINUED 0034 00 REMOVAL CONTINUED 2 Remove camshaft drive gear assembly 3 from gear housing 2 3 Remove and discard camshaft thrust plate seal ring 4 4 Remove and discard racetrack shaped seal 5 342 913 DISASSEMBLY 1 Support camshaft drive gear assembly 3 with camshaft thrust plate 6 facing down 2 Press hub 7 out of camshaft drive gear 3 Separate hub 7 from camshaft thrust plate 6 4 Remove and discard woodruff key 8 0034 00 2 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE CONTINUED 0034 00 CLEANING AND INSPECTION 77 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 1 Clean parts with detergent and water solution and dry with compressed air 2 Inspect seal ring sealing
52. Minimum thickness allowed is 0 311 in 7 90 mm Check flatness of backplate Maximum allowable distortion is 0 006 in 0 15 mm 342 1168 5 Remove C2 clutch pack containing seven friction plates 8 and seven steel reaction plates 9 Perform the following measurements a Friction plate thickness minimum thickness allowed is 0 115 in 2 92 mm b Friction plate oil groove depth minimum depth allowed is 0 008 in 0 20 mm c Friction plate cone maximum cone allowed is 0 010 in 0 25 mm 0071 00 22 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Disassembly Continued d Reaction plate thickness minimum thickness allowed is 0 095 in 2 41 mm e Reaction plate cone maximum cone allowed is 0 010 in 0 25 mm 6 Remove C2 10 and C1 11 drive hubs with two thrust bearings 12 Measure drive hub splines Maximum allowable spline wear is 0 015 in 0 38 mm 7 Remove retaining ring 13 two backplates 14 seven friction plates 15 and six steel reaction plates 16 Per form the following measurements Friction plate thickness minimum thickness allowed is 0 115 in 2 92 mm Friction plate oil groove depth minimum depth allowed is 0 008 in 0 20 mm Friction plate cone maximum cone allowed is 0 010 in 0 25 mm Reaction plate thickness minimum thickness allowed is 0 095 in 2 41 mm Reaction plate cone maximum cone allowed is 0 010 i
53. NOTE Ensure piston ring gaps are staggered 23 Coat inside of piston ring compressor 32 with clean engine lubricating oil 24 Install tapered end of piston ring compressor 32 over end of connecting rod 12 and down on piston Slide piston ring compressor down until it contacts bottom of pan 342 1065 25 Position crankshaft connecting rod journal of cylinder being serviced at bottom dead center 0041 00 17 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED 26 Install upper connecting rod bearing shell 6 in connecting rod 12 Index tang on bearing shell with notch in connect ing rod bearing saddle 342 1066 NOTE Perform next step only if not performing plastigauge check 27 Lubricate upper connecting rod bearing shell 6 and crankshaft connecting rod journal with clean engine lubricating oil 28 Install two connecting rod guides 7 on two connecting rod bolts 8 29 Lift connecting rod assembly 9 and piston ring compressor 32 out of pan 342 1067 0041 00 18 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED CAUTION Number stamped on connecting rod indicates cylinder it should be installed in Number must be on oil cooler side of cylinder block when installing connecting rod to prevent damage to equipment NOTE Do not allow piston to slide out of bottom of piston ring compress
54. REAR REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT 0081 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Axle shafts removed TM 9 2320 302 20 Tools and Special Tools driveline disconnected TM 9 2320 302 Tool kit general mechanic s Item 132 WP 0126 00 Jack hydraulic Item 73 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Personnel Required Two Axle oil drained TM 9 2320 302 20 Materials Parts Compound sealing Item 14 WP 0125 00 Rags wiping Item 31 WP 0125 00 VA WARNING e Use extreme caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel e Spilled gear oil is very slippery Wipe up any spilled oil immediately Failure to do so could result in serious injury to personnel REMOVAL NOTE If axle assembly has been removed from vehicle perform steps 1 through 3 only 0081 00 1 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT CONTINUED 0081 00 REMOVAL CONTINUED WA WARNING Rear rear differential carrier weighs 860 Ib 390 kg Support with suitable floor jack prior to removal to pre vent injury to personnel 1 Remove 12 scre
55. Remove 43 bolts 31 securing control module 32 to main housing 23 4 Loosen control module 32 from main housing 23 by installing jacking screws into control module bolt holes that bot tom out against main housing 5 Remove control module 32 and gasket 33 from main housing 23 Discard gasket RIT FS 7 S P AN 125 eS f 7 2 4 re LU Eo sg FO daft Sak E 31 0071 00 6 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Rear Cover Module 1 Remove 19 bolts 34 securing rear cover module 35 to main housing 23 2 Remove rear cover module 35 and gasket 36 from main housing 23 Discard gasket 34 342 1149 Removal of Main Shaft Module Remove main shaft module assembly 37 with thrust bearing 38 and selective shim 39 from main housing 23 Tag thrust bearing and shim to aid in assembly and identification ite EA PETS FATTE 7 2 it pe res AIN T A 23 te RAR AL 2 fi MEET E d Seu Motte Mes P NES YE Uu PM 5 ate LEES E Dag wu e d 342 1150 0071 00 7 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of P2 Planetary Module C5 Clutch Pack and P1 Planetary Module 1 2 3 Lift P2 planetary module 40 from main hous
56. Remove three screws 11 and washers 12 from vent window 13 B 11 12 342 595 5 Remove 10 in 25 4 cm of window channel 14 from door 2 to allow removal of vent window 13 6 Remove window channel 15 from vent window 13 7 Remove vent window 13 from door 2 0108 00 2 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED di i8 342 596 8 Remove four nuts 16 washers 17 bracket 18 four cap screws 19 and washers 20 0108 00 3 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED 9 Remove screw 21 and window crank 22 10 Remove eight screws 23 from inside door panel 24 fi EJ 24 342 598 11 Remove three cap screws 25 and check arm bracket 26 from door hinge 27 342 599 0108 00 4 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED 12 Remove top two cap screws 28 from door latch assembly 29 342 600 13 Remove sill 30 as follows CAUTION Do not attempt to completely separate sill from door after completion of step b To do so could damage inte rior door components a Grip sill door handle 31 lean sill 30 away from door 2 and pull sill upward until entire lower edge of sill unseats from inside door panel 24 b Lean sill 30 away from door 2 and push door lock button 32 free 3 1 342 601 24 0108 00 5
57. Seal racetrack P N 23522975 Engine retarders removed WP 0022 00 Seal stat o P N 23521111 2 Rocker arm assemblies removed WP 0027 00 WA hi N WARNING Camshaft weighs 53 lb 24 kg Attach suitable lifting device prior to removal or installation to prevent pos sible injury to personnel 0026 00 1 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL 1 Remove three bolts 1 and rear camshaft cover 2 2 Attach dial indicator 3 and place pointer in contact with side of camshaft lobe 4 3 Grasp camshaft 5 between camshaft caps and move camshaft as far forward as possible Hold in that position and set dial indicator for zero 4 Move camshaft 5 to rear as far as possible Read and record total amount of end play Allowable camshaft end play is 0 003 0 015 in 0 076 0 381 mm 342 689 5 If end play is beyond maximum limit remove and repair or replace camshaft drive gear assembly WP 0034 00 CAUTION Use ONLY following method to hold camshaft drive gear stationary while loosening camshaft drive gear bolt 0026 00 2 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED NOTE After inserting shoe of retaining plate through access hole of camshaft drive gear it may be necessary to bar engine over slightly to align bolt holes in retaining plate with bolt holes in drive gear access cover If neces sary bar engine using acce
58. TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 INSTALLATION CAUTION Application of gasket forming compound to gear housing to cylinder block mating surfaces at top of cylin der block is critical to prevent damage to equipment 1 Apply 1 16 in bead of gasket forming compound to cylinder block 7 Smooth bead around block to gear housing oil passage carefully to avoid contamination or plugging of oil hole 2 Install new seal ring 8 in counterbore on top front face of cylinder block 7 342 924 CAUTION Bull idler gear hub recess must be clean and free of foreign material before installing gear case indexing plate to prevent damage to equipment 3 Install gear case indexing plate 9 on bull idler gear hub recess 10 in cylinder block 7 W WRAL 342 925 0035 00 4 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 V7 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel INSTALLATION CONTINUED 4 Using suitable lifting device and 1 2 in nylon rope through camshaft thrust plate opening support gear housing assem bly 5 Position bull idler gear hub opening in gea
59. The form should be submitted to the address specified in DA Pam 738 750 OZONE DEPLETING SUBSTANCES ODS Listing to be provided by requiring activity DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 6 PREPARATION FOR STORAGE OR SHIPMENT For preparation for storage or shipment procedures refer to TM 740 90 1 and MIL V 62038D WARRANTY INFORMATION The vehicle is warranted by Freightliner Corporation in accordance with TB 9 2320 302 15 Warranty starts on the date found in block 23 DA Form 2408 9 in the logbook Report all defects in material or workmanship to your supervisor who will take appropriate action 0001 00 1 TM 9 2320 302 34 GENERAL INFORMATION CONTINUED 0001 00 NOMENCLATURE CROSS REFERENCE LIST COMMON NAME OFFICIAL NOMENCLATURE Cold Start System cens eve HERES ORE P PRAISE Pale e UON Ether Quick start System Engine Coolant dreceres it EUER UU be ERR de mo e iac ea edendo Antifreeze Ethylene Glycol Mixture Gladband REDDERE eI RE EI EC DUAE ER Quick Disconnect Coupling Jake Blake o posersspeier exer uc eser rob toerer obe Bee ober unde reta He RO REI dep pes Engine Brake Komfort Lot WR ed Oe Seed Aine Seat Belt Adjustment TURLracg c tS AS SS I EE Rear Suspension System LIST OF ABBREVIATIONS NOTE Refer to MIL STD 12D for standard abbreviations ABBREVIATION DEFINITION sont On Oil E SU
60. This dimension is A 23 Remove bolt from tool J38548 Install tool into torque converter and position converter on work surface so converter is supported by tool 24 Using a depth micrometer measure from top of torque converter drive tang surface to thrust surface of turbine hub This dimension is B 25 Subtract dimension from dimension A to get dimension 26 Dimension should be 0 0060 0 0139 in 0 153 0 353 mm If dimension is not correct a shim is required If the dimension is correct proceed to step 29 27 Ifa shimis required select appropriate shim from list below DRIVE TANG SHIM LOCATION DRIVE TANG THRUST SURFACE SURFACE SURFACE OF TURBINE SURFACE HUB c _ wi TURBINE 342 1158 DIMENSION C USE P N SHIM THICKNESS 0 0140 0 0229 inch 0 356 0 581 mm 29503879 0 009 0 011 inch 0 23 0 27 mm 0 0230 0 0319 inch 0 585 0 810 mm 29503880 0 018 0 020 inch 0 46 0 50 mm 0 0320 0 0394 inch 0 813 1 000 mm 29503881 0 027 0 029 inch 0 69 0 73 mm 28 Disassemble torque converter and install selected shim Repeat step 22 through 27 to confirm dimension 29 Install remaining 32 nuts 2 and tighten to 22 26 lb ft 30 35 Nm 0071 00 14 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Torque Converter Housing Module Disassembly 1 2 3 4 5 o Remove ten bolts 1
61. This provides the other information you need to identify the item 5 Column 5 Unit of Measure U M This column shows the physical measurement or count of an item such as gal lon dozen gross etc Table 1 Expendable and Durable Items List 3 4 NATIONAL DESCRIPTION CAGEC STOCK NUMBER AND PART NUMBER ADHESIVE General Purpose Type II 18876 9995460 8040 00 664 4318 Pint Can 8040 01 250 3969 ADHESIVE Loctite 05972 242 8040 01 129 7171 ADHESIVE Loctite 05972 620 8040 00 142 9823 ADHESIVE Silicone Rubber 81349 MIL A 46106 8040 00 728 3088 ADHESIVE Silicone Rubber White 78500 1199 T 3842 ANTIFREEZE Permanent Ethylene Glycol Inhibited 81349 MIL A 46153 6850 00 181 7929 1 Gallon Bottle 6850 00 181 7933 5 Gallon Can 5340 00 450 5718 CAP SET Protective Dust and Moisture Seal 19207 10935405 0125 00 1 TM 9 2320 302 34 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0125 00 Table 1 Expendable and Durable Items List Continued 1 3 ITEM NUMBER NATIONAL STOCK NUMBER 5350 00 584 5654 8030 00 597 5367 8030 00 062 6950 8030 00 111 2762 8030 00 111 2763 8030 01 392 3276 8030 01 222 6400 8030 01 429 8188 8030 00 081 2286 8030 00 081 2327 7930 00 282 9699 4 DESCRIPTION CAGEC AND PART NUMBER CAULK Strip 64678 48 00118 001 CLOTH Abrasive Emery Fine 80204 ANSI B74 18 50 Sheet Package COMPOUND Antiseize High
62. VOU P VI Vx V S 4 on forward rear and rear rear axles ABS Anti lock Brake System TYPE LL 4 channel TOC AON cbe uUo INA S eldest mu e LL cate VE front axle and rear rear axle Wheels SV PEDE Hu TM TIE MM MEM 22 5 825 Number of Studs Stud 1 10 1 125 ANE AUR Ca a aC OD RU TATUS tubeless radial on highway ee Ma e OF antes tabe en lowes Fees Malate NO d SER 11R22 5 PI Rating oreet eg ERI ee D UNE ane wer NS cou eem 14PR Load Rage ter hee eo audes mese Sage ts H 0002 00 7 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Tires Continued Inflation Pressure Maximum Load BON be scare NC EE 105 psi 724 kPa ie tte ai eis ta ete EAS alec o Aetas ela aaa te 100 psi 690 kPa Spares eee Em 105 psi 724 kPa Steering Manufacturer 2 sts Wah ea hace eS crete en ee ee eae TRW Steering G ar Type sc ics secs teach eee gel eb Pee SS See ae ban ee ee Be eet single gear ACTUATION t Wee Ed Ga ee eee ee a hydraulic power booster Power Steering Pump 0 2 ee eee een ene eee Eaton B165R Turning Diameters o s eR eer Lee ne vA es ee ee ee d 53 ft 9 in 16 4 m Steering Column and Wheel VI EEUU DENM RE S NU E uH e S emt tilt telescoping Tilt Range nube ente REpRMRDHPRRRRRYE TR M E
63. WP 0126 00 Water level sensor removed TM 9 2320 302 20 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Exhaust manifold removed WP 0015 00 Materials Parts Air intake manifold removed WP 0014 00 Gasket P N 23506120 Air compressor cooling lines disconnected TM 9 Compound international no 2 Item 13 WP 0125 00 2320 302 20 Tags marker Item 35 WP 0125 00 Camshaft and bearings removed WP 0026 00 Personnel Required Fuel injectors removed WP 0046 00 Two Injector wiring harness removed WP 0069 00 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0018 00 1 0018 00 3 K A fmm d N o Q p Y jj WO 342 652 0018 00 2 TM 9 2320 302 34 Disconnect two fuel lines 1 and 2 from cylinder head 3 CYLINDER HEAD REPLACEMENT CONTINUED REMOVAL Mnt Disconnect air compressor hose 9 and clamp 10 from cylinder head 3 Remove two bolts 6 and washers 7 and set wiring harness 8 aside Remove bolt 4 and set bracket 5 aside 2 4 10 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 R
64. Wiring Harness Replacement Taillight Wiring Harness Replacement 0067 00 1 Air Conditioner Binary Switch Wiring Harness Replacement Engine Injector and ECM Wiring Harnesses Replacement Transmission Replacement 0070 00 1 Transmission Overhaul 0 000 0071 00 1 Front Axle Assembly 0072 00 1 Front Axle Caster Adjustment 0073 00 1 Tie Rod Maintenance 0 cette a 0074 00 1 Front Cross Tube Arm Replacement 0075 00 1 Front Steering Arm 1 0076 00 1 Front Steering Knuckle Replacement 0077 00 1 Rear Axle 0078 00 1 Forward rear Axle Differential Carrier Replacement 0079 00 1 Forward rear Axle Differential Carrier Repair 0080 00 1 Rear rear Axle Differential Carrier Replacement 0081 00 1 Rear rear Axle Differential Carrier Repair 0082 00 1 Foot Brake Valve 0083 00 1 Air Compressor 0084 00 1 Brake Drum
65. and bearing cage assembly 19 342 1205 0082 00 6 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED DISASSEMBLY CONTINUED NOTE e If shims are in good condition keep shims together to use for assembly e If shims are damaged measure and record thickness of shim pack before discarding shims 21 Remove shim pack 22 from differential carrier 1 342 1206 22 Press drive pinion 3 through bearing cage 23 23 Remove and discard oil seal 24 24 Remove outer bearing cone 25 from bearing cage 23 25 Remove spacer s 26 from drive pinion shaft 3 26 23 342 1207 0082 00 7 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED 26 Remove inner bearing cone 27 from drive pinion shaft 3 342 1208 27 Remove two bearing cups 28 and 29 from bearing cage 23 28 23 342 1209 28 342 1210 0082 00 8 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY 1 Install bearing cups 28 and 29 in bearing cage 23 28 342 1211 29 NOTE Apply light coat of lubricating oil to all bearing cups and cones prior to installation 2 Install inner bearing cone 27 on drive pinion shaft 3 until bearing cone is flat against drive pinion shaft gear head 3 27 342 1212 0082 00 9 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARR
66. eh este ber i dose ts pue Cana Zh hase E ah ut Dod ne Beak tS Meter EE E sade UE SEG Ue ERAS sio GRAB GALS Bae hes DOE RS ABN ES Millimeter MES Se ecm Seer sine oh uer Rede tell eines RII ER CREE RI Movement Tracking System NI etse x ee PD e pO o een Re mime MIN EA Tae moe SEE Newton Meter PM SA ptt sane Seg PUER CO Be bu CERE CRINE Preventive Maintenance Checks and Services PSL view aise bude geile as glo Pounds per Square Inch s lds Atego nS ERN ERREUR Wee eb idee Revolutions per Minute 0001 00 2 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES 1 Characteristics a The M915A3 Tractor Truck is used to transport M871 M872 and M1062 semitrailers on line haul missions It has a Gross Vehicle Weight Rating GVWR of 52 000 Ib 23 608 kg and is equipped with a two way oscillat ing sliding fifth wheel compatible with a two inch kingpin Maximum towed load on kingpin is 30 000 1b 13 620 kg Capabilities and Features While operating on Class I roads the fully loaded M915A3 can maintain a speed of 65 mph 105 kph on level roads and 29 mph 47 kph while ascending a 3 percent grade It has a minimum turning diameter curb to curb of 53 ft 9 in 16 4 m Average cruising ranges at Gross Combination Weight Rating GCWR
67. general mechanic s Item 132 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Dispenser sealant Item 30 WP 0126 00 Equipment Condition Guide stud set Item 43 Engine installed on stand Lifting bracket flywheel Item 77 WP 0126 00 Rear engine mounts removed WP 0012 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Starter removed Personnel Required Oil pan removed WP 0028 00 Two Flex plate removed WP 0025 00 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0024 00 1 TM 9 2320 302 34 FLYWHEEL HOUSING REPLACEMENT CONTINUED 0024 00 REMOVAL 1 Remove four bolts 1 and washers 2 from flywheel housing 3 2 Install two guide studs 4 3 Remove eight bolts 5 and washers 6 from flywheel housing 3 CAUTION Use soft mallet to tap flywheel housing loose from cylinder block Failure to use soft mallet could result in damage to equipment 4 Remove flywheel housing 3 342 684 5 Remove and discard crankshaft rear oil sea WP 0023 00 6 Remove two guide studs 4 from cylinder block 7 0024 00 2 TM 9 2320 302 34 FLYWHEEL HOUSING REPLACEMENT CONTINUED 0024 00 INSTALLATION 1 T
68. into outer circle of holes in oil seal remover 1 until bolts contact flywheel housing 2 4 Working clockwise turn each bolt 4 one full turn until crankshaft rear oil seal is removed Discard seal 342 666 0023 00 1 TM 9 2320 302 34 CRANKSHAFT REAR OIL SEAL REPLACEMENT CONTINUED 0023 00 INSPECTION NOTE Minor wear line on crankshaft surface should be evident where contact was made with oil seal This is nor mal 1 Inspect oil seal contact surface of crankshaft 5 2 Inspect exposed area of crankshaft 5 for dirt burrs or rough surfaces 3 If necessary clean smooth crankshaft surface with abrasive cloth 4 Check runout of oil seal bore Check bore with dial indicator mounted on end of crankshaft 5 This check must be made with flywheel housing cover in place on engine and oil seal removed Maximum runout of oil seal bore in fly wheel housing is 0 013 in 0 330 mm 342 667 INSTALLATION 1 Coat outside diameter of new oil seal 6 with light film of clean engine lubricating oil 2 Coat outside of crankshaft 5 with light film of clean engine lubricating oil 342 668 0023 00 2 TM 9 2320 302 34 CRANKSHAFT REAR OIL SEAL REPLACEMENT CONTINUED 0023 00 INSTALLATION CONTINUED CAUTION Ensure flywheel housing seal bore rear of crankshaft and both sides of oil seal installer base and spacer are clean smooth and free of any foreign material Failure to do so may cause damage to equipment
69. nel CAUTION Ensure oil is removed from bolt holes to prevent engine block from cracking when tightening bolts 1 Cover bolt holes with rags to minimize oil spray 0022 00 8 TM 9 2320 302 34 0022 00 ENGINE RETARDER MAINTENANCE CONTINUED INSTALLATION CONTINUED Attach tubing to compressed air gun nozzle and clear oil out of bolt holes 2 NOTE Position word OUT stamped on each spacer bar toward mid engine facing outside of engine Position two spacer bars 7 on exhaust manifold side of cylinder head 8 Align bolt holes in spacer bars with engine 3 retarder 6 bolt holes in cylinder head CAUTION Ensure engine retarder housings do not interfere with wiring harnesses Failure to do so could result in dam age to equipment 4 Install three engine retarder 6 housings over rocker shafts 5 Apply international compound 2 to threads and undersides of head of nine bolts 4 CAUTION Ensure wires are away from moving parts to prevent possible movement and contact with valve springs 0022 00 9 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 INSTALLATION CONTINUED NOTE Before tightening bolts move engine retarder housing from side to side and locate as far toward camshaft side of the engine as possible 6 Install nine bolts 4 and washers 5 in engine retarders 6 Tighten bolts to 40 lb ft 54 Nm 7 Repeat tightening of nine bolts 4
70. place rocker arm shaft 7 and three 7 rocker arm assembly sets 6 in position on cam caps 24 t if Y 24 PUE NM 342 704 Install six saddle spacers 2 on six retaining bolts 1 8 9 Install six retaining bolts 1 through rocker arm shaft 7 and cam cap saddles 10 Install two saddle spacers 4 and nuts 3 on rocker arm shaft studs 23 342 716 0027 00 9 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSTALLATION CONTINUED 11 Tighten six retaining bolts and two nuts to 75 86 lb ft 102 117 Nm in sequence shown c DS 342 717 3 1 24 7 5 6 8 TIGHTENING SEQUENCE ADJUSTMENT CAUTION Never set valves and injector of same cylinder at same time Doing this will result in engine damage NOTE When setting valve lash clearance or injector height always set them using valve overlap method 1 Adjust valves and set fuel injector heights as follows a Insert a 3 in drive breaker bar 25 or ratchet into square hole in center of crankshaft pulley 26 0027 00 10 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 ADJUSTMENT CONTINUED b Bar engine in direction of rotation and observe intake and exhaust valve rollers at any cylinder that is close to TDC top dead center Choose a cylinder that has exhaust valves almost completely closed Just as exhaust valves are closing intake valves will start to open This is
71. special P N 18 23530 00 Tools and Special Tools Detergent Item 19 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Gloves Item 411 WP 0126 00 Personnel Required Wrench set socket attachment torx Item 142 Tun 0126 00 ve Equipment Condition Materials P aiota kana Windshield wiper and wiper arms removed TM 9 Mount resilient locking strip P N 18 23531 00 2320 302 20 REMOVAL NOTE Steps 1 through 3 are the same for each windshield glass 1 If windshield glass 1 is cracked due to any cause other than being hit by a flying object mark seal 2 at location of crack 2 Using windshield pick remove and discard lockstrip 3 3 342 610 0109 00 1 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 REMOVAL CONTINUED WARNING Wear protective gloves when handling glass Failure to do so could result in injury to personnel CAUTION When handling windshield glass be careful not to nick or splinter edges of glass Chipped edges could cause cracking later NOTE If removing windshield glass only perform step 3 If removing seal or windshield glass and seal perform steps 3 through 11 3 Apply pressure to edge of windshield glass 1 from inside cab 4 Using windshield pick lift windshield glass out of seal 2 and remove 4 Remove seal 2 from mounting flange of cab 4 342 611 1 5 Remove torx screws 5 two bracket
72. taller deka dbase wae ae 0085 00 0085 00 1 Ducts Replacement Air 0111 00 0111 00 1 E ECM Wiring Harness Replacement 0069 00 0069 00 1 Electrical System Theory of Operation 0003 00 0003 00 3 Index 3 TM 9 2320 302 34 INDEX Continued Subject E Continued Engine Injector Wiring Harness Replacement Mount Adapter and Support Replacement Front Mounts Replacement Rear Power Wiring Harness Replacement Retarder Maintenance Troubleshooting serrr eee eee eee Wiring Harness Equipment Characteristics Capabilities and Features eR ESL Me ne a ua Evaporator Coil Replacement Air Conditioner Exhaust Manifold Replacement Exhaust System Theory of Operation Expansion Valve Replacement Air Conditioner Fan Clutch Repair 1 4lzz eee eee ee ee reis Cycling Switch Replacement Air Conditioner Drive Support Replacement Fifth Wheel Replacement
73. to 80 Ib ft 108 Nm 8 Position three wiring harness connectors 2 under three solenoid terminal screws 1 Tighten screws to 12 17 Ib in 1 4 1 9 Nm 342 657 ADJUSTMENT CAUTION Failure to use slave piston adjustment procedure will cause poor engine brake performance and or serious engine damage It is necessary to rotate engine to put exhaust valves in closed position for each cylinder being adjusted Make sure proper engine valve lash has been obtained to prevent damage to equipment 1 Loosen lock nut 22 and back out adjusting screw 23 in slave piston bridge 31 until end of adjusting screw is flush with bottom surface of slave piston bridge 31 2 Place 0 023 in 0 584 mm thickness gage between solid side of slave piston bridge 31 and exhaust rocker arm adjust ing screw 36 3 Loosen lock nut 38 and turn adjusting screw 37 clockwise until light drag is felt on thickness gage 4 Hold adjusting screw 37 in position and remove thickness gage 5 Tighten lock nut 38 to 26 Ib ft 35 Nm 6 Using 0 023 in 0 584 mm thickness gage check clearance between adjusting screw 23 and rocker arm adjusting screw 39 7 Turn adjusting screw 23 clockwise until light drag is felt on thickness gage 0022 00 10 ENGINE RETARDER MAINTENANCE CONTINUED TM 9 2320 302 34 0022 00 ADJUSTMENT CONTINUED 8 9 10 11 Hold adjusting screw 23 in position and remove thickness gage Tighten lock nut 22 to 26 lb ft
74. ture and must be replaced WP 0118 00 2 Cooling System a Although they are not physically connected there is a close tie between vehicle s air conditioner and cooling sys tem Poor air conditioner cooling can be the result of a problem in the cooling system b Ifthe cooling system does not work correctly the heat of the engine will rise to abnormal levels The added heat will transfer to the air conditioner other underhood parts and may make its way into the cab The added heat makes it necessary for the air conditioner to work harder and at the same time it reduces the air conditioner s abil ity to cool down the air in the cab Also if the water regulating valve isn t closing all the way heat will enter the cab giving the impression that the air conditioning system is not working c Referto TM 9 2320 302 20 to troubleshoot engine cooling system 3 Expansion Valve a Problems that start in the expansion valve show up as follows when stuck closed the evaporator coil and the expansion valve will be at outside temperature when stuck open both the coil and the valve will be extremely cold with frost or ice buildup b Because the expansion valve channels are very small blockages in the system tend to be found here the valve is very sensitive to contamination Usually the contaminant is water less than a drop of water is all it takes to make the valve inoperative When water reaches the valve the extreme cold that results f
75. 00 INSTALLATION CONTINUED 7 Connect ring terminal 6 6 pin female connector 9 four 3 pin female connectors 11 two 1 pin male connectors 12 two 1 pin female connectors 13 2 pin male connector 16 12 pin light switch connector 22 and 32 pin con nector 23 342 556 0057 00 11 TM 9 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED INSTALLATION CONTINUED pin female connectors 13 three 2 pin pin male connectors 24 three 4 pin female connec Connect five 6 pin female connectors 9 3 pin sealed connector 10 three 1 male connectors 16 three 2 pin female connectors 17 four 4 tors 25 and 2 pin sealed connector 26 8 N 0057 00 12 TM 9 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED INSTALLATION CONTINUED Connect two ring terminals 6 2 pin male connector 16 three 4 pin male connectors 24 and three 6 pin male con nectors 27 9 23 342 558 0057 00 13 0057 00 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 10 Secure main cab wiring harness 28 INSTALLATION CONTINUED S AZAA j FORLERN E J APEN A TANNI P WORN Lag paw 28 9 2320 302 20 0057 00 14 Connect battery cables END OF WORK PACKAGE 11 TM 9 2320 302 34 SWITCH PANEL WIRING HARNESS REPLACEMENT 0058 00 THIS WORK PACKAGE COVERS
76. 00 Refrigerant recovered WP 0112 00 3 Fx E WARNING y e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 0114 00 1 TM 9 2320 302 34 AIR CONDITIONER EXPANSION VALVE REPLACEMENT CONTINUED 0114 00 REMOVAL NOTE Tag all lines and wires prior to removal to aid in installation 1 Remove nine screws 1 and cover 2 342 574 2 Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 2 Remove insulation tape and strip caulk around expansion valve 3 CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid NOTE DO NOT disconnect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second w
77. 00 0103 00 1 V rod Replacement lt e 0103 00 0103 00 1 Switch Panel Wiring Harness Replacement 0058 00 0058 00 1 Symptom Index Troubleshooting 0005 00 0005 00 1 T Taillight Wiring Harness Replacement 0067 00 0067 00 1 Theory of Operation Air Conditioning System 0003 00 0003 00 9 Ai SyStelm wah ee nata RE S hia WEEDS Bees x Rs 0003 00 0003 00 5 5 zoning dep Rr XR eX Rap Kal agate 0003 00 0003 00 5 Collision Warning System 0003 00 0003 00 10 Index 8 TM 9 2320 302 34 INDEX Continued Subject T Continued Theory of Operation Continued Cooling System cece Drive Train 52 So oer eed me rese iov A ea 34S Electrical System ener mene de Re t Ha P ee Re Pu xe Exhaust System xd UNE Eae E eset FUG SyStem v s s ota SEA aiu me Pauca sen eap Ls EE Rear Suspension System Steering System Traction Control System Tie Rod Maintenance ee eee Top Plate RO pall nadie ned Sig Edu ee Replacement _ eed a baa be RP ey ee XD eee ead Torque Limits Ee dhe hw
78. 00 1 TM 9 2320 302 34 INDEX Continued Subject Work Package Page F Continued Front Continued Spring Replacement 0099 00 0099 00 1 Steering Arm Replacement 0076 00 0076 00 1 Steering Knuckle Replacement 0077 00 0077 00 1 Fuel Injector Replacement 0 0 00 4 eee 0046 00 0046 00 1 Injector Solenoid Replacement 0047 00 0047 00 1 Fuel System Theory of Operation 0003 00 0003 00 1 G Garrett Turbocharger Wastegate Actuator Maintenance 0045 00 0045 00 1 Gear Steeririg i ed ees citer xta Beebo x ERO Be 0089 00 0089 00 1 Replacement Steering 0088 00 0088 00 1 Gear Case Cover Replacement 0019 00 0019 00 1 Gear Housing Assembly Replacement 0035 00 0035 00 1 Gear Replacement 0037 00 0037 00 1 H Head Oylinder Repa apre e c bberePcssb6ebpenrieiesrwpeisedetuuibsgiedefexie 0032 00 0032 00 1 Replacement sw dete E Wu x ee AY vus 0018 00 0018 00 1 Hood SMG Repail iedereiabiederukfateebeieszumbebpirbeneibded jefiuhes 0106 00 0106 00 1 Hose Replacement Air Conditioner 01
79. 0016 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Compound gasket forming Item 12 WP 0125 00 Detergent Item 19 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Dispenser sealant Item 30 WP 0126 00 Air cleaner pre cleaner and duct assembly removed TM 9 2320 302 20 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Thermostat to radiator coolant tube removed TM 9 Materials Parts 2320 302 20 Gasket P N 23522260 Radiator support rod removed TM 9 2320 302 20 REMOVAL 1 Loosen hose clamp 1 and disconnect crankcase breather tube 2 from rocker arm cover neck 3 342 642 0016 00 1 TM 9 2320 302 34 ROCKER ARM COVER REPLACEMENT CONTINUED 0016 00 REMOVAL CONTINUED 2 Remove ten bolt assemblies 4 securing rocker arm cover 5 to cylinder head 6 CAUTION Handle rocker arm cover carefully dropping or bumping may cause damage 3 Remove rocker arm cover 5 from cylinder head 6 342 643 4 Free gasket saddle corners 7 and saddle arch areas 8 Lift rocker arm cover gasket 9 straight out of rocker arm cover groove to prevent tearing or stretching gasket If damaged or stretched discard gasket 342 644 5 Invert rocker arm cover 5 on bench Press and slide straight end of breather element retaining clip 10 until clip
80. 0028 00 5 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 INSTALLATION CONTINUED CAUTION Handle oil pan with care Dropping or bumping could cause damage 4 Position oil pan 2 on cylinder block 3 and install ten bolt assemblies 1 hand tight 342 743 5 Tighten ten bolt assemblies 1 to 18 22 lb ft 25 30 Nm in sequence shown 342 748 TIGHTENING SEQUENCE 0028 00 6 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 INSTALLATION CONTINUED 6 Install oil pan drain plug 14 and tighten to 33 41 Ib ft 45 56 Nm 7 Replace engine oil 9 2320 302 20 and check for leaks END OF WORK PACKAGE 0028 00 7 TM 9 2320 302 34 This Page Intentionally Left Blank 0028 00 8 TM 9 2320 302 34 OIL PUMP MAINTENANCE 0029 00 THIS WORK PACKAGE COVERS Removal Disassembly Inspection Assembly Installation INITIAL SETUP Maintenance Level Materials Parts General Support Gasket P N 23505992 Tools and Special Tools Nut lock P N 11502812 Tool kit general mechanic s Item 132 WP 0126 00 Ring seal P N 23505891 Caps vise jaw Item 17 WP 0126 00 Ring seal P N 23505892 Dial indicator set Item 29 WP 0126 00 Lubriplate Item 23 WP 0125 00 Press arbor Item 90 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Puller kit universal Item 97 WP 0126 00 References Vise machinist s Item 136 WP 0126 00 TM 9 237 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Equi
81. 0126 00 Engine mounted on stand REMOVAL 1 Insert 3 4 in extension 1 4 6 in long into square opening in center of crankshaft pulley 2 Hold extension with hinged handle bar 3 342 677 0025 00 1 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 0025 00 REMOVAL CONTINUED 2 3 4 5 Hold crankshaft against rotation and loosen 12 bolts 4 Remove two bolts 5 at 3 and 9 o clock positions and install two guide studs 6 Remove remaining ten bolts 5 Remove and discard scuff plate 7 342 678 342 679 0025 00 2 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 0025 00 DISASSEMBLY 1 Remove 12 bolts 4 securing flex plate 9 four disks 10 and disk assembly 11 to coupling 12 342 680 2 Separate disk assembly 11 from four disks 10 CLEANING AND INSPECTION WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel Use detergent and water to clean all parts Dry with compressed air Ensure all surfaces of coupling disk assembly disks and flex plate are clean and free from any foreign material Inspect parts for rust cracks or damage Replace damaged parts Box vg Inspect all parts for wear Replace worn parts 0025 00 3 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 002
82. 1 The Collision Warning System CWS consists of an antenna assembly central processing unit driver display unit side sensor side sensor display and wiring harness 2 The CWS is a forward and side looking radar system that transmits and receives signals reflected off of objects to the front and side of the tractor 3 The forward looking antenna assembly determines distance azimuth and approximate speed of vehicle forward of the tractor 4 The side sensor detects vehicles or objects from two to ten feet moving or stationary alongside the tractor SIDE SENSOR DISPLAY ice CENTRAL slept AONE PROCESSING UNIT ANTENNA ASSEMBLY WIRING HARNESS 242 011 0003 00 10 TM 9 2320 302 34 CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT TROUBLESHOOTING TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 TROUBLESHOOTING INTRODUCTION 0004 00 INTRODUCTION This work package contains introductory information on troubleshooting testing and repair of the M915A3 Tractor Truck Make sure the problems are real Be sure the electrical power is on when needed Refer to the preliminary troubleshoot ing procedures before you start troubleshooting and during troubleshooting when referenced PRELIMINARY TROUBLESHOOTING PROCEDURES NOTE Fluid leaks are classified as either Class I Class II or Class Class I Seepage of fluid as indicated by wetness or discoloration not great enough to form drops
83. 1000 1230 Ib ft 1356 1668 Nm 342 1204 29 Install ring gear 2 on ring gear subassembly 10 30 Install 12 bolts 15 washers 14 and nuts 13 Tighten nuts to 190 225 Ib ft 258 305 Nm 13 14 15 342 1203 0082 00 16 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 31 Install two bearing cones 12 342 1280 MES WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound contacts skin or clothing wash immediately with soap and water CAUTION Ensure all old adhesive has been removed from differential carrier and bearing caps to prevent damage to equipment 32 Set two bearing caps 4 and 5 on differential carrier 1 and apply continuous bead of adhesive around entire smooth ground surfaces on both sides Do not apply adhesive to threaded areas 33 Remove two bearing caps 4 and 5 342 1219 0082 00 17 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 34 35 36 37 38 39 Install two bearing cups 11 Using suitable lifting device install ring gear subassembly 10 in differential carrier 1 342 1201 Install two bearing caps 4 and 5 four cap screws 7 and washers 8
84. 14 Remove gear lash pedestal from camshaft drive gear 10 342 1098 15 Install washer 15 and bolt 14 Tighten bolt to 75 86 Ib ft 102 117 Nm 16 Install rocker arm assemblies WP 0027 00 END OF WORK PACKAGE 0038 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0038 00 6 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR 0039 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts General Support Bearing ball P N BBA194940 Tools and Special Equipment Bearing needle P N JH 2216 Tool kit general mechanic s Item 132 WP 0126 00 Nut lock P N 11509584 Checker gear lash Item 18 WP 0126 00 Pliers retaining ring Item 88 WP 0126 00 Seal P N V484156VG Pliers retaining ring Item 89 WP 0126 00 Lubriplate Item 23 WP 0125 00 Press arbor Item 90 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Service kit accessory drive Item 111 WP 0126 00 Vise machinist s Item 136 WP 0126 00 Equipment Condition Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Accessory drive removed WP 0021 00 DISASSEMBLY 1 Install accessory drive assembly 1 and three fixture screws 2 on service kit holding fixture 3 342 1099 0039 00 1 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 DISASSEMBLY CONTINUED 2 Place service kit holding fixture 3 in vise and remove accessory drive pulley lock nut 4 Discard
85. 16 0033 00 10 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED 3 Install remaining upper main bearing shells 16 in main bearing saddles of cylinder block 15 with tangs on upper main bearing shells in notches at parting line of main bearing saddles 17 342 1084 hi WARNING Crankshaft weighs 408 Ib 185 23 kg Use suitable lifting device to lift and support crankshaft Failure to do so could result in serious injury to personnel CAUTION Ensure thrust washers are not dislodged when positioning crankshaft Failure to do so could result in damage to equipment 0033 00 11 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED NOTE Ensure all crankshaft main bearing journals are clean Keyway on crankshaft goes to front of engine block 4 Coat main bearing journals and upper main bearing shells with clean engine lubricating oil Using nylon rope and suit able lifting device position crankshaft 14 in cylinder block 15 on upper main bearing shells 5 Remove nylon rope 342 1085 NOTE Ensure saddles of main bearing caps are clean e Install main bearings in sets only Do not mix old and new bearings on same journal If old bearings are installed they must be installed on same journal they were removed from 6 Install lower main bearing shells 13 in main bearing caps 12 with tang on bearing shells in notch at bearin
86. 2 0085 00 MAXIMUM INSIDE DIAMETER IN MM 15 12 384 00 16 62 422 15 TM 9 2320 302 34 POWER STEERING PUMP REPLACEMENT 0086 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Oil lubricating Item 25 WP 0125 00 Tool and Special Tools References Tool kit general mechanic s Item 132 WP 0126 00 TM 9 2320 302 10 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Equipment Condition Materials Parts Power steering reservoir drained TM 9 2320 302 20 Seal o ring P N 8929318 Washer lock P N 000127 008203 6 REMOVAL 1 Remove hose clamp 1 hose 2 and adapter 3 from power steering pump 4 2 Remove power steering line 5 and elbow 6 from power steering pump 4 3 Remove six screws 7 and lock washers 8 securing power steering pump 4 to gear case cover 9 Discard lock washers 4 Pull power steering pump 4 o ring seal 10 and gear coupling 11 from gear case cover 9 Discard o ring seal 342 1188 0086 00 1 TM 9 2320 302 34 POWER STEERING PUMP REPLACEMENT CONTINUED 0086 00 INSTALLATION NOTE Apply a light coating of lubricating oil to seal prior to installation Install gear coupling 11 and new o ring seal 10 on power steering pump 4 2 Position power steering pump 4 on gear case cover 9 and secure with six screws 7 and new lock washers 8 Tighten screws to 17 25 lb ft 23 34
87. 20 16 Remove any paint or corrosion from input shaft 2 17 Remove four torx head screws 21 valve housing 20 input shaft 2 and rack piston 22 as an assembly Remove and discard two packings 23 and 24 342 847 0089 00 5 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED CAUTION Position rack piston so that return cap faces up during removal Failure to do so could result in loss of one or more balls of 32 ball set If any balls are lost or damaged balls must be replaced as a set 18 Using torx socket remove two screws 25 return cap 26 and seal 27 from rack piston 22 Discard screws and seal 342 848 19 Remove two guide halves 28 and 32 balls 29 by rotating input shaft 2 Discard guide halves 20 Remove rack piston 22 from valve housing 20 and input shaft 2 342 849 0089 00 6 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED 21 Remove and discard seal ring 30 and packing 31 from rack piston 22 22 30 31 342 850 22 Place valve housing 20 in vise 23 Unstake valve housing 20 from adjuster lock nut 32 Unstake adjuster lock nut from adjuster 33 342 851 0089 00 7 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED NOTE Tag thrust bearings and washers prior to disassembly to aid in assembly 24 Using spanner wrenches 34 and 35 rem
88. 20 until it contacts cylinder liner puller thrust bearing 21 19 342 1049 18 Continue tightening until cylinder liner 3 is free in cylinder block bore 19 Remove cylinder liner 3 and cylinder liner puller 18 from block 20 Remove cylinder liner 3 from cylinder liner puller 18 21 Remove and discard two seal rings 22 and crevice seal 23 from cylinder liner 3 3452 1050 22 Repeat procedures in step 16 through 21 for each cylinder liner 3 being serviced 0041 00 6 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSPECTION 1 Examine piston skirt and dome for score marks cracks damaged ring groove lands or indications of overheating 5 Replace any piston if any of these conditions are present Using piston top ring groove gage 24 check tapered fire top compression ring groove 25 in piston dome If shoul der A or B of gage contacts piston dome discard dome Insert center tang of piston top ring groove gage 24 into fire compression ring groove 25 Hold gage at 90 degree angle to fire compression ring groove 25 with center tang of gage in ring groove as far as it will go to prevent false readings There should be no contact of piston by shoulders of gage If gage makes contact at point A or B fire compres sion ring groove is worn beyond usable limits and piston dome must be discarded Check fire compression ring groove 25 clearance at four locations at
89. 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED REMOVAL CONTINUED 0057 00 3 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057 00 REMOVAL CONTINUED 7 Disconnect ring terminal 6 6 pin female connector 9 four 3 pin female connectors 11 two 1 pin male connectors 12 two 1 pin female connectors 13 2 pin male connector 16 12 pin light switch connector 22 and 32 pin con nector 23 342 556 0057 00 4 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057 00 REMOVAL CONTINUED 8 Disconnect five 6 pin female connectors 9 3 pin sealed connector 10 three 1 pin female connectors 13 three 2 pin male connectors 16 three 2 pin female connectors 17 four 4 pin male connectors 24 three 4 pin female connec tors 25 and 2 pin sealed connector 26 17 342 557 0057 00 5 TM 9 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED REMOVAL CONTINUED Disconnect two ring terminals 6 2 pin male connector 16 three 4 pin male connectors 24 and three 6 pin male connectors 27 9 23 342 558 0057 00 6 TM 9 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED REMOVAL CONTINUED 10 Remove main cab wiring harness 28 342 559 INSTALLATION NOTE Wiring harness and leads are secured in place by clips tiedown straps cushion clamps and
90. 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED Clean inside and outside of new cylinder liner 3 and cylinder block bore Install new crevice seal 23 and two new seal rings 22 on cylinder liner 3 1 2 3 Coat two seal rings 22 and crevice seal 23 with a thin film of lubricating oil 4 Coat cylinder block liner bore with lubricating oil where seal rings 22 and crevice seal 23 seat 5 Install cylinder liner 3 in cylinder block bore by hand until lower seal meets upper crevice seal bore 342 1059 NOTE When correctly positioned side of cylinder liner installer stamped COOLER is on oil cooler side of cylinder block and cylinder liner installer holding bolts will align with cylinder head bolt holes 6 Center and install cylinder liner press 28 over cylinder liner 3 and tighten three bolts 29 7 Turn center bolt 30 of cylinder liner press 28 until cylinder liner 3 bottoms in counterbore Apply a tightening torque of 44 lb ft 60 Nm to center bolt 8 Using dial indicator measure cylinder liner 3 protrusion in three equal positions Measure distance from top of cylin der liner flange to tip of cylinder block 31 Allowable cylinder liner protrusion is 0 000 0 003 in 0 000 0 076 mm with no more than 0 002 in 0 05 mm variation between any two adjacent cylinders 0 000 0 003 in 0 000 0 076 mm F b 342 1060 0041 00 12 TM
91. 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P SC 4910 95 A31 SC 4910 95 A02 SC 4910 95 A31 SC 4910 95 A31 M 9 2320 302 24P T T T T SC 4910 95 A31 M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P TOOL IDENTIFICATION LIST CONTINUED TM 9 2320 302 34 Table 1 Tool Identification List Continued 2 ITEM NAME Compressor Spring C2 use with J37030 3 Compressor Spring C5 use with J37030 3 Crowfoot Attachment Set Socket Wrench Dial Indicator Set Dispenser Sealant Drill Electric Portable 3 8 in size Drill Set Twist Driver Bushing Gage Depth Micrometer 0 6 in Range Gage Oil Level Gage Profile Gage Profile Gage Profile Gage Profile Gloves Chemical and Oil Protective rubber Gloves Welders leather Goggles Industrial Guide Stud Set Guides Connecting Rod Handle Drive Handle Installer Holding Bar Pinion Inserter Bearing Inserter Gear Inserter Seal 3 NATIONAL STOCK NUMBER 5120 01 429 1110 5210 00 794 9178 5120 00 061 1283 5130 00 935 7354 5133 00 293 0983 5120 01 353 2521 5210 00 619 4045 5220 01 388 1460 8415 00 641 4601 8415 00 268 7859 4240 00 816 3819 5120 01 322 3505 5120 00 677 2259 5120 00 977 5578 5120 01 166 0573 5120 01 354 2943 5120 01 322 1132 5120 01 322 1129 0126 00 3 4 PART NUMBER CAGEC
92. 3 Install four pole pieces 68 and eight screws 67 CAUTION Insulator must be installed between field coil and field ring Failure to do so will cause a short damaging starter motor 4 Install insulator 65 and stud terminal 63 through field coil 64 and field ring 13 5 Install bushing 66 new packing 62 insulator 61 washer 60 and nut 59 on stud terminal 63 0054 00 6 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 ASSEMBLY CONTINUED 6 Install new packing 58 bushing 57 and new seal 56 in shift housing 39 39 58 342 549 7 Install shift housing 39 on field ring 13 with five new lock washers 55 and screws 54 8 Install two cams 53 shift lever 52 insulator 51 drive assembly 50 washer 49 and armature 48 9 Install new packing 47 shaft 46 washer 45 and screw 44 in shift housing 39 0054 00 7 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 ASSEMBLY CONTINUED 10 11 12 13 14 15 16 17 18 19 20 21 If removed install six new plugs 43 new felt wick 42 new plug 41 and new bushing 40 in nose housing 36 NOTE Install nose housing as noted in disassembly sequence Install washer 38 packing 37 nose housing 36 and six screws 35 on shift housing 39 35 342 547 If removed install new bushing 34 in commutator housing 10 Install felt wick 33 pipe plug 32 and new
93. 31 23 Do not tighten bolts Position cutout portion of stop block beneath injector tube 64 342 1028 0032 00 19 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED CAUTION Be careful not to drop reconditioning set seat reamer into pilot or allow seat reamer to strike injector tube Sharp cutting edges may gouge injector tube causing chatter marks in seat 24 Install injector tube reconditioning set seat reamer pilot 66 in injector tube bore until it contacts cylinder head 2 CAUTION When using seat reamer use only light pressure Heavier pressure will result in chatter marks in seat 25 Apply a few drops of cutting oil on edges of injector tube reconditioning set seat reamer 70 and place gently in pilot 66 26 Using speed handle with 12 point 23 mm socket turn injector tube reconditioning set seat reamer 70 in clockwise direction Use light pressure until reamer bottoms against injector tube reconditioning set stop block 69 7 x WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 27 Remove reamer and pilot Using compressed air clean out injector tube 342 1029 28 Inspect tube seating surface for irregularities or chatter marks 71 in seating surface If irregularities or chatter
94. 34 CYLINDER BLOCK ASSEMBLY REPAIR 0036 00 THIS WORK PACKAGE COVERS Disassembly Cleaning and Inspection Assembly INITIAL SETUP Maintenance Level Personnel Required General Support Two Tools and Special Tools References Tool kit general mechanic s Item 132 WP 0126 00 TM 9 237 Bolts eye Item 9 WP 0126 00 Bolts eye Item 10 WP 0126 00 WP 0040 00 Caliper micrometer inside Item 14 WP 0126 00 Handle installer Item 46 WP 0126 00 Electronic control module removed TM 9 2320 302 Inserter set dowel Item 55 WP 0126 00 20 lug Item 72 WP 0126 00 ee pine diem Cleo 0U Engine injector wiring harness removed WP 0069 00 Puller kit universal Item 97 WP 0126 00 j d TM 9 2320 302 2 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Fuel filter adapters removed TM 9 2320 302 20 Equipment Condition Wrench torque 100 600 Ib ft Item 140 Oil pressure and oil temperature sending units WPOD26 00 removed TM 9 2320 302 20 Wrench set socket 3 4 in drive Item 141 Oil cooler core and oil filter adapter removed TM 9 WP 0126 00 2320 302 20 Materials Parts Oil dipstick and tube removed TM 9 2320 302 20 Plug cup P N 5139988 2 Oil fill tube removed TM 9 2320 302 20 Plug cup P N 5139991 5 Adhesive loctite Item 3 WP 0125 00 Compound corrosion preventive Item 11 Cylinder head removed WP 0018 00 Pistons and cylinder assemblies removed WP 0041 WP 0125 00 ee Compoun
95. 35 Nm TO 38 ull E a 23 e Eel 22 GA 39 342 665 Adjust the remaining engine retarders using steps through 9 Install rocker arm cover WP 0016 00 END OF WORK PACKAGE 0022 00 11 TM 9 2320 302 34 This Page Intentionally Left Blank 0022 00 12 TM 9 2320 302 34 CRANKSHAFT REAR OIL SEAL REPLACEMENT 0023 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Seal P N 23519651 Tools and Special Tools Cloth abrasive Item 9 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Oil lubricating Item 251 WP 0125 00 Dial indicator set Item 29 WP 0126 00 Equipment Condition Inserter seal Item 50 WP 0126 00 Power pack removed WP 0010 00 Remover seal Item 101 WP 0126 00 Flex plate removed WP 0025 00 REMOVAL NOTE If oil seal remover screws strip out of oil seal sealing casing remove screws and bolts Rotate oil seal remover half the distance between existing screw holes in seal casing and repeat steps to remove seal 1 Position oil seal remover 1 over rear of crankshaft against flywheel housing 2 NOTE Oil seal remover screws must be evenly snug against oil seal remover but not overtightened and stripped in oil sealing casing 2 Install six oil seal remover screws 3 through inner circle of holes in oil seal remover 1 and into oil seal casing 3 Thread three bolts 4
96. 5 Remove bracket 11 342 194 INSTALLATION 1 Install bracket 11 2 Install bracket 10 with eight washers 9 screws 8 and new lock nuts 7 3 Install two resilient mounts 6 washers 5 and screws 4 4 Lower cab assembly 3 and maintain just enough support to keep slack out of chain 5 Install two washers 2 and new lock nuts 1 6 Install front cab mount WP 0097 00 342 193 END OF WORK PACKAGE 0098 00 2 TM 9 2320 302 34 FRONT SPRING REPLACEMENT 0099 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Front wheel removed TM 9 2320 302 10 Jack hydraulic Item 73 WP 0126 00 Front shock absorber removed TM 3 2320 302 20 Trestle hoist portable 2 Item 135 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Wrench torque 100 600 Ib ft Item 140 WA 0126 00 Wrench set socket 3 4 in drive Item 141 WA 0126 00 V WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0099 00 1 TM 9 2320 302 34 FRON
97. 50 Ib in 5 1 5 6 Nm to turn 180 degrees from center in both directions 53 Back off adjusting screw 11 turn and note torque required to turn input shaft 2 180 degrees from center in both directions 54 Tighten adjusting screw 11 so that torque required to turn input shaft 2 180 degrees from center in both directions increases 6 8 Ib in 0 68 0 90 Nm from reading noted in step 53 55 Hold adjusting screw 11 firmly against steering gear assembly 1 and tighten nut 7 to 40 45 Ib ft 54 61 Nm 56 Check torque reading on input shaft 2 If reading exceeds 40 Ib in 4 5 Nm repeat steps 51 through 56 342 876 57 Install steering geaf WP 0088 00 END OF WORK PACKAGE 0089 00 22 TM 9 2320 302 34 STEERING COLUMN REPLACEMENT 0090 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Compound sealing Item 17 WP 0125 00 Tools and Special Tools Detergent Item 19 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Primer adhesive Item 30 WP 0125 00 Wrench torque 0 300 16 Item 137 WP 0126 00 References Wrench torque 15 75 Ib ft Item 138 WP 0126 00 TM 9 2320 302 10 Materials Parts Equipment Condition Bolt P N 14 09683 000 Steering wheel removed TM 9 2320 302 20 Nut P N 115307A Steering column covers removed TM 9 2320 302 20 0090 00 1 TM 9 2320 302 34 STEERING COLUMN REPLACEMENT CONTINUED
98. 812 3 Install inner roller bearing snap ring 6 in groove of fan spindle 1 Ensure snap ring is fully seated in groove dx Qe 6 342 813 0051 00 5 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 ASSEMBLY CONTINUED 4 Pack new roller bearing 14 with grease 5 Support spindle housing 5 on press bed and install roller bearing 14 in spindle housing Using stepped side of bearing inserter and remover tool 11 press roller bearing against shoulder of spindle housing 342 814 6 Install roller bearing retaining snap ring 13 in groove of spindle housing 5 342 810 7 Using smooth side of bearing inserter and remover 11 press new oil seal 9 in spindle housing 5 against roller bear ing retaining snap ring 13 8 Lubricate lip of new oil seal 9 with clean engine lubricating oil 0051 00 6 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 ASSEMBLY CONTINUED 342 815 9 Pack new ball bearing assembly 12 with grease 10 Turn spindle housing 5 over on press bed and install ball bearing assembly 12 in spindle housing NOTE Ensure ball bearing outer race part number is facing up against installing tool 11 Using wide end of installing tool 18 press on ball bearing assembly 12 outer race Press ball bearing assembly firmly against shoulder in spindle housing 5 342 816 0051 00 7 TM 9 2320 302 34 SPINDLE AND HOUSING R
99. 9 Check crankshaft for cracks which start at oil hole 21 and follow journal surface at angle of 45 degrees to axis Replace any crankshaft with such cracks Determine presence of cracks not visible to eye by magnetic particle fluores cent magnetic particle or fluorescent penetrant method 10 Replace crankshaft if circumferential fillet cracks 22 at connecting rod or fillet cracks or 45 degree cracks 45 degrees to axis of crankshaft at main bearing journal are evident 22 342 1080 11 Inspect all parts for wear or damage NOTE Ensure all main bearing saddles and thrust bearing counterbores in cylinder block are clean e Each upper main bearing shell is grooved with oil hole Register oil hole in each upper main bearing shell with oil hole in each main bearing saddle of cylinder block e Install main bearings in sets Do not mix old and new main bearing shells on same journal If old bearings are installed they must be installed in same journal they were removed from 12 Invert engine block Install seven upper main bearing shells 16 in cylinder block journals 23 13 Wipe oil from bearing shells and crankshaft journals to be checked WARNING Crankshaft weighs 408 Ib 185 23 kg Use suitable lifting device to lift and support crankshaft Failure to do so could result in serious injury to personnel 14 Using nylon rope and suitable lifting device position crankshaft 14 in cylinder block 15
100. 90 degree intervals Measure ring land parallel to and at 90 degrees to wrist pin 25 A 342 1051 Using piston second ring groove gage 26 check second middle compression ring groove in same way If shoulder A or B of gage contacts piston dome discard dome 342 1052 0041 00 7 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSPECTION CONTINUED 6 Hold new oil control ring 16 in oil control ring groove so that oil control ring face is flush with edge of piston dome Do not push ring to bottom of oil control ring groove Insert feeler gage 27 between top of oil control ring and ring land of oil control ring groove in piston dome If clearance is greater than 0 004 in 0 11 mm discard dome 342 1053 CAUTION In order to prevent possible damage to equipment DO NOT use crocus cloth to polish or refinish piston pin Piston pins cannot be polished or refinished 7 If piston pin 11 shows signs of fretting overheating or is worn to diameter of 1 77 in 44 96 mm replace piston pin 11 1 77 in 44 96 mm y 342 1054 N 8 Replace connecting rod 12 if subjected to any of the following a Visual damage bent b Previous bearing or related failure c Connecting rod bluing at top or bottom end d Fretting at split line between connecting rod and connecting rod cap e Excessive pound in of rod bolt heads nuts and of piston pin bolt and spacer f Unusual cy
101. A31 SC 4910 95 A31 SC 4910 95 A31 GSA Catalog TM 9 2320 302 34 This Page Intentionally Left Blank 0126 00 8 TM 9 2320 302 34 INDEX Subject Work Package Page Numerics Turbocharger Wastegate Actuator Maintenance 0044 00 0044 00 1 A Accessory Drive ate he xeu essere EX EE 0039 00 0039 00 1 Replacement oiu iR peo Waa ER RA Ee Mane andes 0021 00 0021 00 1 Adjustable Idler Gear Replacement 0038 00 0038 00 1 Air Compressor Repair oresiadaohiqqoache beeieckerszUberbebpesrsstedbva 0084 00 0084 00 1 Ducts Replacement nan a n nh 0111 00 0111 00 1 Intake Manifold Replacement 0014 00 0014 00 1 Air Conditioner Binary Switch Wiring Harness Replacement 0068 00 0068 00 1 Compressor Replacement 0117 00 0117 00 1 Compressor Service 0116 00 0116 00 1 Condenser Replacement 0119 00 0119 00 1 Evaporator Coil 0115 00 0115 00 1 Expansion Valve Replacement 0114 00 0114 00 1 Fan Cycling Switch Replacement 0120 00 0120 00 1 Hose Replacement srao ewe Re Rena Maite Route s 0121 00 0121 00 1 Receiver drier Replaceme
102. ADHESIVES AND SEALING COMPOUNDS Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in a well ventilated area If adhesive or sealing compound contacts skin or clothing wash immediately with soap and water WARNING 2 AIR LINES AND FITTINGS e DO NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air system pressure is relieved Failure to follow this warning could result in serious injury to personnel Ensure that all air lines and fittings are clear of debris and excess pipe sealing compound does not enter air lines or fittings Failure to follow this warning could result in injury to personnel and damage to equipment e Always wear eye protection when disconnecting air lines Residual air will be expelled Failure to fol low this warning may result in serious eye injury e WARNING D ZA BATTERIES HE e To avoid eye injury eye protection is required when working around batteries DO NOT smoke use open flame make sparks or create other ignition sources around batteries If a battery is giving off gases it can explode and cause injury to personnel Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating injury to personnel and damage to equipment e Sulfu
103. BETWEEN DRIVEN GEAR OD AND DRIVEN GEAR PUMP HOUSING cp 0 30 mm 0 012 in Inspect and measure bushing 6 inside inner gear of gear set 5 The maximum ID of bushing is 2 635 in 66 93 mm If bushing is damaged or out of tolerance remove Remove 14 bolts 7 securing wear plate 8 to front support 2 Remove wear plate Inspect roller bearing 9 If damaged remove using drift and hammer Inspect and measure front support sleeve 10 Minimum OD diameter of front support sleeve is 4 717 in 119 81 mm If sleeve is damaged or out of tolerance remove Inspect front support dowel pins 11 and 12 If damaged remove 0071 00 19 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Front Support and Charging Oil Pump Module Disassembly Continued 14 15 16 Inspect ground sleeve 13 If damaged or worn press from front support 2 Using tool J41462 compress spring 14 until load is removed from dowel pin 15 Remove dowel pin and carefully release load on spring by rotating handle on tool in counterclockwise direction When spring has reached its free length remove tool Remove spring and ball 16 from front support 2 Check spring tension in accordance with Table 3 Wear Limits and Spring Data located at the end of this work package Inspect ball seat area of front support 2 for damage If damage is found replace front support 342 1160 Front Support and Cha
104. Class I Leakage of fluid great enough to form drops but not enough to cause drops to drip from the item being checked or observed Class II Leakage of fluid great enough to form drops that fall from the item being checked or observed Before starting any specific troubleshooting procedures perform the following a Visually check for ruptured oil hoses or tubes and for Class or Class III leaks b Check for mechanical jamming or binding caused by rocks or other foreign matter c Check fluid levels in subject area and service as required TM 9 2320 302 10 or Unit PMCS 0004 00 1 TM 9 2320 302 34 This Page Intentionally Left Blank 0004 00 2 TM 9 2320 302 34 TROUBLESHOOTING SYMPTOM INDEX 0005 00 Malfunction Symptom Page Number ENGINE EngimeFaisto C Oe oen nee nat ee dre ok Sale ek 0006 00 1 2 Engine Cranks But Does Not Start ene n tenet b ene ee eee 0006 00 1 3 Engine Runs Erratically SEPAN E RSS 4 High Oil Consumption ss seee terie deite eoe ani m e e hme TRANSMISSION Refer td WP 0007 00 STEERING Abnormal N is cem SUP RH E E RUE SE RR dE d dee e Reed du e UE Dee 0008 00 1 2 INO RECOVELY erori ey dea ee Red eed ar oed oru ahs boa Feat ae UR eth aa doo 0008 00 1 3 External Oil Leaks from Steering 0008 00 2 4 Overste r or Darn
105. DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 45 Install two bearing cups 51 46 Using suitable lifting device install ring gear subassembly 50 in differential carrier 1 342 1201 47 Install two bearing caps 44 and 45 four cap screws 47 and washers 49 48 Install two adjusting rings 48 in differential carrier 1 49 Tighten four cap screws 47 to 345 430 Ib ft 470 585 Nm 50 Install dial indicator on flange of differential carrier 1 with plunger against back surface of ring gear 2 0080 00 23 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED CAUTION Pry bars must not touch bearing cones to prevent damage to bearing cones 51 Loosen adjusting ring 48 on gear side of ring gear 2 until small amount of end play shows on dial indicator when ring gear is moved left and right with two pry bars between two adjusting rings and ends of ring gear subassembly 50 52 Tighten adjusting ring 48 loosened in step 51 until no end play shows on dial indicator 342 1222 53 Tighten two adjusting rings 48 one notch from zero end play measured in step 52 Bearing preload is now set 342 1221 0080 00 24 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 54 95 56 57 58 Adjust dial indicator to zero Rotate ring gear 2 while reading
106. Direct Support Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Wiring harness and leads are secured in place by cushion clamps and screw terminals Only remove hardware securing harness or lead to be removed Tag wiring harness and leads prior to removal to aid in installation Disconnect and remove engine power wiring harness using illustration as a guide Gl ts TABLE QTY 1 Fuse Holder Plug 2 2 1 pin Connector 1 3 6 pin Connector 1 4 Terminal 4 5 Screw 1 6 Washer 1 7 Nut 1 8 Clamp 1 9 Crown Nut 2 342 560 0055 00 1 TM 9 2320 302 34 ENGINE POWER WIRING HARNESS REPLACEMENT CONTINUED 0055 00 INSTALLATION NOTE Wiring harness and leads are secured in place by cushion clamps and screw terminals Ensure harness is secure and all hardware is tight 1 Install connect and secure engine power wiring harness using illustration as a guide TABLE QTY Fuse Holder Plug 1 pin Connector 6 pin Connector Terminal Screw Washer Nut Clamp Crown Nut NOR hee LP 342 560 2 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0055 00 2 TM 9 2320 302 34 ENGINE WIRING HARNESS REPLACEMENT 0056 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Straps tied
107. If repairing crack 1 use 1 8 in diameter bit to drill hole 2 completely through uncracked laminate Drill hole 1 8 in 3 mm from each end of crack to prevent crack from lengthening WARNING Wear goggles and air purifying respirator when cutting grinding or sanding during fiberglass repairs Ground dust and particles could cause temporary or permanent damage to eyes and if inhaled could cause respiratory irritation e On engine side of hood 3 use router bit on grinder or drill to grind away shallow recess Grind recess to one quarter depth of laminate 4 and 1 2 in 13 mm outward from all sides of damage Taper outside edge of ground area 5 If repairing crack 1 grind outward to drilled hole 2 at end of crack but not beyond f Use 100 220 grit sandpaper to scuff area at least 1 in 25 mm away from fracture on all sides 6 Scuff thoroughly to give surface to which patch can stick 7 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel g Blow dust away with compressed air and wipe area with clean cloth h If necessary align panel sections on both sides of crack 1 using weights or clamps to establish original panel profile i Using razor knife cut section of woven fiberglass cloth 7 to overlay crack 1 about 3 4 in 19 m
108. Install drive pinion 3 in gear 15 Ensure splines on drive pinion engage splines in gear CAUTION To prevent damage to cup cone and drive pinion do not apply pressure after inner bearing cone touches inner bearing cup Using press press drive pinion 3 into gear 15 until inner bearing cone 60 touches inner bearing cup 62 we 1 2 3 59 m Turn differential carrier 1 over and install supports so that differential carrier is level on press CAUTION To prevent damage to spacer do not apply pressure after gear touches spacer in front of inner bearing on drive pinion Using press and sleeve that fits inside pinion bore of differential carrier 1 press gear 15 on drive pinion 3 until gear touches spacer 59 Cut two pieces of lead or solder approximately 9 16 in long 5 8 in wide and thicker than spacer removed in disassem bly step 45 Install two lead pieces opposite each other on top of gear 15 0080 00 18 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED ASSEMBLY CONTINUED A WOOD BLOCK 1 59 DEVE PINION MUST TOUCH On Ty lt SUPPORT iN m 8 SUPPORT 342 1258 WOOD BLOCK 25 Install outer bearing cone 57 on top of lead pieces 26 Using press apply two tons of pressure to outer bearing cone 57 27 Release pressure and remove wood block CAUTION To pr
109. Left Blank 0044 00 6 TM 9 2320 302 34 GARRETT TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE 0045 00 THIS WORK PACKAGE COVERS Removal Installation Adjustment INITIAL SETUP Maintenance Level Materials Parts Direct Support Clip retaining P N 400702 25 Tools and Special Tools Compound antiseize Item 10 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 NOTE Turbocharger wastegate actuators are NOT interchangeable REMOVAL 1 Remove hose clip 1 and hose 2 from wastegate 3 2 Remove bolt 4 hose clamp 5 and hose 2 342 2020 0045 00 1 TM 9 2320 302 34 GARRETT TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0045 00 REMOVAL CONTINUED 3 Remove hose clip 6 and hose 2 from elbow 7 4 Remove elbow 7 CAUTION Never remove actuator rod end from stud on turbocharger lever without applying light pressure to wastegate inlet port Failure to follow this caution could result in damage to wastegate diaphragm 5 Remove retaining clip 8 securing actuator rod 9 to stud 10 on turbocharger lever 11 Discard retaining clip 6 Remove three bolts 12 and wastegate 3 from turbocharger 13 12 13 10 0045 00 2 TM 9 2320 302 34 GARRETT TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0045 00 INSTALLATION 1 Coat three bolts 12 with high temperature a
110. NOTE e Manufacturer s ID number must be at lower center corner of windshield glass when installed e If installing windshield glass only perform steps 1 through 7 If installing seal or windshield glass and seal perform steps 8 through 23 e Steps 1 through 7 are the same for each windshield glass 1 Lubricate window channel of seal 2 with soap and water solution 2 Slide windshield glass 1 into window channel of seal 2 as far as it will go without forcing 3 Stretch seal 2 around outside of windshield glass 1 and install windshield glass in window channel of seal 4 Using windshield pick alternate between top and bottom of mounting flanges of cab 4 to work seal 2 over mounting flange 5 With assistant pushing lightly on outside of windshield glass 1 finish working seal 2 over mounting flange of cab 4 6 Finish sealing windshield glass 1 and seal 2 by gently pushing all the way around outside edge 342 617 0109 00 5 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION CONTINUED 7 Install new lockstrip 3 342 610 3 8 Install each windshield glass 1 in center strip of seal 2 until windshield glass bottoms out in channel of seal 9 Install outside edge of seal 2 on outside edge of each windshield glass 1 until windshield glass bottoms out in chan nel of seal 10 Install remainder of seal 2 on each windshield glass 1 until windshield gla
111. Nm 3 Install elbow 6 and power steering line 5 4 Install adapter 3 hose 2 and hose clamp 1 342 1188 5 Fill power steering reservoir TM 9 2320 302 20 6 Start vehicle TM 9 2320 302 10 and check system for leaks END OF WORK PACKAGE 0086 00 2 TM 9 2320 302 34 POWER STEERING PUMP REPAIR 0087 00 THIS WORK PACKAGE COVERS Disassembly Inspection Assembly INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Rotary pump parts kit P N ERS 28310 ary pump p Tools and Special Tools Oil lubricating Item 25 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Rel eferences Pliers retaining ring Item 87 WP 0126 00 TM 9 2320 302 20 Materials Parts Gasket set P N 20510093 25Z Equipment Condition O ring P N 3 908N552 90 Power steering pump removed WP 0086 00 DISASSEMBLY NOTE Note position of elbow and tube prior to disassembly to aid in assembly 1 Loosen jam nut 1 and remove elbow 2 and packing 3 from rear cover 4 Discard packing 2 Remove two bolts 5 washers 6 tube 7 and gasket 8 from pump body 9 Discard gasket 342 799 0087 00 1 TM 9 2320 302 34 POWER STEERING PUMP REPAIR CONTINUED 0087 00 DISASSEMBLY CONTINUED 3 Remove screw 10 and two washers 11 and 12 from shaft 13 4 Remove gear 14 from shaft 13 5 Remove woodruff key 15 from shaft 13 342 799 NOTE Note position of flange prior to disass
112. P N 2 015C944 70 Equipment Condition Adhesive loctite Item 2 WP 0125 00 Refrigerant recovered WP 0112 00 gt Fx y e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death REMOVAL NOTE Tag all lines and wires prior to removal to aid in installation 0115 00 1 TM 9 2320 302 34 AIR CONDITIONER EVAPORATOR COIL REPLACEMENT CONTINUED 0115 00 REMOVAL CONTINUED 1 Remove nine screws 1 and cover 2 342 574 gt WARNING Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 2 Remove insulation tape and strip caulk around expansion valve 3 3 Remove four screws 4 and cover 5 CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air i
113. PTO cover 2 and gasket 3 Discard gasket Remove 11 bolts 4 securing bearing retainer assembly 5 and PTO gear 6 assembly to converter housing 7 Remove seal rings 8 and 9 from bearing retainer 5 Discard seal rings Remove bearing retainer oil seal 10 using tool J24171 A Discard oil seal Inspect bushing 11 for damage or wear Maximum allowable bushing ID is 3 511 in 89 19 mm Remove if damaged Or worn Remove oil pump drive hub 12 from PTO gear 6 Inspect oil pump drive hub 12 for excessive wear on drive tangs Maximum allowable tang wear is 0 012 in 0 31 mm Remove seal ring 13 from PTO gear 6 Inspect PTO gear bearings 14 and 15 If damaged remove and discard 342 1159 0071 00 15 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Torque Converter Housing Module Assembly 1 10 11 12 13 If PTO gear bearings 14 and 15 were discarded install new bearings using tool 737041 CAUTION Oil pump drive hub can be incorrectly installed backwards Position oil pump drive hub tangs toward oil pump Install oil pump drive hub 12 into PTO gear 6 aligned with hub tangs toward oil pump NOTE Butt joint seal rings require special handling during assembly Seal rings contain materials that absorb mois ture from atmosphere causing them to expand Check seal ring end clearance before installation to ensure seal ring ha
114. Parts Nut lock P N 23 09247 210 16 Tags marker Item 35 WP 0125 00 V WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0078 00 1 TM 9 2320 302 34 REAR AXLE REPLACEMENT CONTINUED 0078 00 REMOVAL eo en NOTE Tag air lines to aid in installation Disconnect two air lines 1 from brake chamber 2 NOTE Note position of spider assembly prior to removal to aid in installation Remove eight lock nuts 3 washers 4 screws 5 washers 6 and spider assembly 7 from axle housing 8 Discard lock nuts Repeat steps 1 and 2 for opposite side of axle housing 8 342 1127 V WARNING Axle housing is heavy and can injure personnel if dropped Support axle housing during removal to prevent injury to personnel Using suitable hydraulic jack support axle housing 8 Remove two nuts 9 and screws 10 to disconnect two v rods 11 from top of axle housing 8 NOTE Note position of axle clamps on axle for installation Remove four nuts 12 washers 13 and two u bolts 14 from axle clamp 15 Remove top half of axle clamp 15 from axle housing 8 Position bottom half of axle clamp 15 downw
115. Perform steps 8 through 66 to determine contact pattern 72 If contact pattern is too far toward heel of gear teeth repeat step 62 to decrease backlash to move pattern toward toe of gear teeth 73 If contact pattern is too far toward toe of gear teeth repeat step 61 to increase backlash to move pattern toward heel of gear teeth 342 1254 74 Install pin 46 in bearing caps 44 and 45 so that pin is between lugs of adjusting ring 48 0080 00 27 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED CAUTION To prevent damage to oil pump ensure drive flats in bore of oil pump are aligned with input shaft 75 Install oil pump 33 and bearing cup 43 on input shaft 13 342 1264 76 Install bearing cone 42 on input shaft 13 342 1265 0080 00 28 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 77 Install bearing cage 41 on input shaft 13 342 1266 78 Install six cap screws 39 and washers 40 in oil pump 33 Tighten cap screws to 21 26 lb ft 28 35 Nm 40 342 1267 0080 00 29 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED ASSEMBLY CONTINUED 79 Install relief valve 38 spring 37 washer 36 and plug 35 342 1268 80 Install two new packings 34 342 1267 0080 00 30 0080 00 TM 9 2320 30
116. REMOVAL CONTINUED CAUTION Do not mix engine retarders Tag each engine retarder to aid in installation 3 Remove six bolts 4 washers 5 three engine retarders 6 and two spacer bars 7 from cylinder head 8 Gro r7 arp ii T gt t R k G GVA MEN UA Wo Gay A WATT S DISASSEMBLY NOTE Procedure is the same for all three engine retarder housings 1 Place engine retarder 6 housing on bench CAUTION Do not disassemble or tamper with solenoid valve Engine damage could result 2 Remove solenoid valve 3 with 12 point socket 0022 00 2 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 DISASSEMBLY CONTINUED 3 Remove and discard three seal rings 9 10 and 11 If seal ring 11 stays in bottom of engine retarder 6 housing remove with wire WARNING Parts are under spring tension Release tension slowly to prevent personal injury Press down on washer 12 and remove retaining ring 13 Discard retaining ring Remove washer 12 and spring 14 Using a magnet remove accumulator piston 15 from engine retarder 6 housing aT 10 a Le EN 342 659 NOTE To remove control valve from right side of engine retarder housing perform steps 7 through 9 Repeat steps to remove control valve from left side of retarder housing 0022 00 3 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022
117. Replace receiver dridr 0118 00 9 Service air conditioner compressof WP 0116 00 10 Charge air conditioning systen WP 0112 00 WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 11 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0121 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0121 00 4 TM 9 2320 302 34 ILLUSTRATED LIST OF MANUFACTURED ITEMS 0122 00 INTRODUCTION 1 This work package includes complete instructions for making items authorized to be manufactured at Direct Support Maintenance It also includes instructions for fabricating select tools 2 Part Number Index Table 1 in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to Table 2 which covers fabrication criteria 3 All bulk materials needed for manufacture of an item are listed by part number or specification number Table 1 Part Number Index PART NUMBER NAME TABLE NUMBER 48 02454 106X27 TAPE URETH FOAM 5516170 HOSE 77620 7 5 HOSE MANUFACTURED ITEMS Table 2 Manufactured Items FABRICATED TOOLS 1 Item 1 a Materials 1 Capscrew Hex 1 2 x 2 1 2 x 13 UNC P N 23 9440 300 2 Sleeve P N 166JX Ri T E 342 889
118. Steps 32 through 34 can be performed through center floor panel of cab 32 Install two clamps 70 with washer 69 and new lock nut 68 33 Install bracket 67 washer 66 and new lock nut 65 on crossmember 34 Install clamp 64 on bracket 67 with washer 63 and new lock nut 62 KG en EU Op 342 936 35 Position harness 58 and install two clamps 61 washers 60 and screws 59 36 Remove screw 57 Position harness 58 and install screw 57 57 58 342 935 37 Remove nut 53 Install solenoid 56 wire 55 washer 54 and nut 53 0010 00 26 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 56 342 934 38 Install two wires 51 new lock washers 50 and screws 49 on temperature sending unit 52 39 Install wire 47 new lock washer 46 and nut 45 on temperature sending unit 48 342 933 0010 00 27 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 40 Install exhaust pipe 44 with new seal clamp 43 and clamp 42 44 342 932 CAUTION Ensure arrow on wrench flat of atomizer is facing to front of engine Failure to do so will cause ether start to malfunction 41 Install atomizer 40 and tube 39 42 Connect two tubes 37 and hose 36 to air compressor 38 Install new tiedown strap 41 342 931 0010 00 28 TM 9 2320 302 34
119. Temperature 73165 51008 25 Pound Can COMPOUND Corrosion Preventive 81349 MIL C 16173 1 Quart Can COMPOUND Gasket Forming Silicone 05972 77MA 8 Ounce Tube 05972 77C 13 Ounce Cartridge COMPOUND International No 2 72582 5198563 COMPOUND Sealing 81349 MIL S 46163 50 CC Bottle Box of 10 Bottles 10 CC Each Bottle COMPOUND Sealing Dissimilar Metal Protection 71961 6099 1 Gallon Can COMPOUND Sealing Loctite 05972 635 COMPOUND Sealing 05972 680 COMPOUND Sealing Pipe 05972 079 21 50 CC Bottle Box of 10 Bottles 10 CC Each Bottle DETERGENT General Purpose Liquid 83421 7930 00 282 9699 1 Gallon Can 0125 00 2 TM 9 2320 302 34 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0125 00 Table 1 Expendable and Durable Items List Continued 1 3 ITEM NUMBER NATIONAL 5210 00 640 6177 5210 00 640 6178 5210 00 640 6176 9150 00 119 9291 9150 00 269 8255 9150 01 197 7693 9150 01 197 7688 9150 01 197 7690 9150 01 197 7692 9150 01 197 7691 7050 00 961 7663 9150 00 825 9161 9150 00 189 6727 9150 00 186 6668 9150 00 191 2772 9150 01 048 4591 9150 01 035 5395 9150 01 035 5396 STOCK NUMBER 4 DESCRIPTION CAGEC AND PART NUMBER GAGE Bearing Clearance Box of 12 0 001 0 003 Inch Clearance Range Green Color 77220 PG 1 0 002 0 006 Inch Clearance Range Red Color 77220 PLASTIGAGEPR1 0 004 0 009 Inch Clearance Rang
120. When bends must be made use softer 6061 T4 aluminum alloy and increase material thickness by at least 50 percent As a rule of thumb 6061 T4 should be bent with minimum bend radius of one to two times material thickness whereas 6061 T4 requires at least three times material thickness radius for bends In all cases bends should be closely inspected for cracks Suitable method for avoiding bending cracks is to obtain angles that are extruded from 6061 T6 alloy or use preformed angles for repairs 2 Foam Adhesive Tape Where it is necessary to remove parts note that foam adhesive tape is used in joints Use care in parts removal to avoid unnecessary distortion Parts should be separated by peeling them apart using knife or chisel to start peeling action Before parts are assembled remove any remaining foam adhesive tape from joints so parts will fit together with good even contact 0105 00 9 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 ALUMINUM REPAIR CONTINUED 3 Rivet Patterns a Rivet patterns are denoted by rivet spacing and rivet edge distance Rivet edge distance is distance from center of rivet to nearest edge of sheet Rivet spacing is defined from center of rivet to center of adjacent rivet b Required rivet spacing is determined by strength needed in joint General feel for strength required can be obtained by inspecting rivet patterns in surrounding areas Body repairs made using single rows of rivets should be per
121. a second wrench 0119 00 1 TM 9 2320 302 34 AIR CONDITIONER CONDENSER REPLACEMENT CONTINUED 0119 00 REMOVAL CONTINUED 1 Tag and disconnect refrigerant lines 1 from condenser 2 Install plugs in refrigerant and condenser lines Remove and discard preformed packings 2 Remove fasteners attaching condenser 2 to radiator 342 578 INSTALLATION 1 Position condenser 2 on radiator and install fasteners 2 Remove plugs from refrigerant lines 1 and line ports on new condenser 2 3 Install new preformed packings and apply refrigerant oil to preformed packings 4 Apply loctite to male fitting threads and connect but do not tighten refrigerant lines 1 to condenser 2 NOTE DO NOT connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 5 Tighten connections in accordance with WP 0123 00 NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 6 Replace receiver dri r WP 0118 00 7 Service air conditioner compressor WP 0116 00 8 Charge air conditioning system WP 0112 00 0119 00 2 TM 9 2320 302 34 AIR CONDITIONER CONDENSER REPLACEMENT CONTINUED 0119 00 INSTALLATION CONTINUED WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or ex
122. all parts for damage INSTALLATION 1 Secure center section of exhaust manifold 4 in vise NOTE If turbocharger mounting studs were removed perform steps 2 and 3 2 Using one nut as jam nut install two nuts on four turbocharger mounting studs 8 3 Thread turbocharger mounting studs 8 into exhaust manifold 4 until unthreaded portion of stud bottoms against mounting flange Tighten studs to 18 24 Ib ft 25 32 Nm Remove two nuts from each stud 4 Install exhaust manifold end sections 7 on center section of exhaust manifold 4 Position and seat end sections by tapping with fiber or plastic mallet 5 Install six guide studs in upper bolt hole locations 6 Install three new gaskets 6 and exhaust manifold 4 on guide studs 342 640 0015 00 2 TM 9 2320 302 34 EXHAUST MANIFOLD REPLACEMENT CONTINUED 0015 00 INSTALLATION CONTINUED 7 Install six bolts 1 and spacers 3 in lower bolt holes and tighten hand tight 8 Remove six guide studs and replace with remaining six bolts 1 and spacers 3 Tighten hand tight 9 Tighten all bolts 1 to 43 54 lb ft 58 73 Nm in sequence shown 5 2 3 342 641 TIGHTENING SEQUENCE 10 Install turbocharget WP 0042 00 11 Install breather tubd WP0017 00 12 Runengine TM 9 2320 302 10 and check for leaks END OF WORK PACKAGE 0015 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0015 00 4 TM 9 2320 302 34 ROCKER ARM COVER REPLACEMENT
123. and General Support TM 9 2320 302 34 28 May 2001 Maintenance Manual for M915A3 Tractor Truck ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA n RM 2028 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V1 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part I freverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is ODISC4 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE title Direct Support and General Support TM 9 2320 302 34 28 May 2001 Maintenance Manual for M915A3 Tractor Truck ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA n RM 2028 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V1 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part I freverse for Repair Parts and BLANK FORMS S
124. and close vent valve Adjust dial indicator 18 to contact actuator rod 5 end and adjust to a zero reading Open air supply at shutoff valve 20 and slowly adjust regulator valve 19 to 34 psi 234 kPa Switch pressure on and off with vent valve 22 to ensure dial indicator travel from 0 00 in to 0 070 in 1 79 mm and that pressure reading is consistent Actuator adjustment should be set for an indication of 0 070 0 075 in 1 79 1 91 mm actuator rod travel at 34 psi 234 kPa pressure setting NOTE If travel is within limits relieve and disconnect air pressure to wastegate actuator If travel is not within lim its proceed to next step to adjust actuator rod travel Loosen jamnut 17 on actuator rod 5 Remove retaining ring 4 securing actuator rod 5 to wastegate lever 7 0044 00 4 TM 9 2320 302 34 3K TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0044 00 ADJUSTMENT CONTINUED 12 13 14 15 Remove actuator rod 5 from wastegate lever 7 Turn rod 1 2 turn 180 degrees 0 020 in 0 5 mm clockwise to increase or counterclockwise to decrease setting Repeat steps 7 and 8 to check if adjustment of travel rod is within limits Install retaining ring 4 on wastegate lever 7 and tighten jamnut 17 on actuator rod 5 Disconnect regulated air supply from actuator 3 Connect hose 2 to wastegate 3 END OF WORK PACKAGE 0044 00 5 TM 9 2320 302 34 This Page Intentionally
125. and is parallel to crankshaft surface Install woodruff key 9 in keyway Tap key with plastic mallet or brass hammer to seat it Index keyway of timing wheel 8 with woodruff key 9 in crankshaft 14 Slide timing wheel onto crankshaft with word out on timing wheel 8 facing you Slide timing wheel on as far as it will go by hand Coat bore of crankshaft timing gear 4 with a film of lubriplate Index keyway of crankshaft timing gear 4 with wood druff key 9 Tap crankshaft timing gear with plastic hammer or fiber mallet to ensure woodruff key is started in key way Install three crankshaft gear inserter remover legs 3 in threaded holes in crankshaft timing gear 4 Tighten three inserter remover legs Install crankshaft gear inserter remover pressure plate 6 on three inserter remover legs 3 Seat inserter remover pres sure plate against inserter remover leg flanges Install three crankshaft gear inserter remover retaining nuts 7 on inserter remover legs 3 Thread retaining nuts past first set of inserter remover leg threads Slide retaining nuts past unthreaded portion of shafts and engage second set of threads Tighten retaining nuts 0033 00 15 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED 23 Install hydraulic ram and pump 5 on crankshaft gear inserter remover base post 2 threaded rod as shown Install inserter remover stop nut 26 on end of inserter
126. bearing cap bolt 10 to 347 391 Ib ft 471 530 Nm Turn crankshaft 14 1 8 turn to ensure crankshaft is not binding within journals 342 1086 0033 00 13 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED NOTE Crankshaft end play is controlled by thrust washers located at no 6 upper main bearing saddle of engine Oversize thrust washers are available to correct for excessive end play 13 Install dial indicator on cylinder block 15 as shown NOTE End play should be 0 004 0 017 0 101 0 419 mm Insufficient end play can be result of misaligned no 6 main bearing jammed upper thrust washer or burr or dirt on inner face of one or more thrust washers 14 Using small pry bar less than 12 in long move crankshaft 14 toward dial indicator to check crankshaft end play Keep constant pressure on pry bar and zero pointer on dial indicator 15 Remove and insert pry bar on other side of main bearing cap Force crankshaft in opposite direction and note amount of end play on dial indicator 342 1087 16 Using two crankshaft gear inserter remover bolts 1 install crankshaft gear inserter remover base post 2 on front end of crankshaft 14 Tighten bolts to 140 150 Ib ft 190 203 Nm 342 1088 0033 00 14 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED 17 18 19 20 21 22 NOTE Ensure woodruff key is fully seated
127. block tool J33884 25 is used to help make these checks 0071 00 40 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Disassembly Continued 342 1177 0071 00 41 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Disassembly Continued w I 342 1177 0071 00 42 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Disassembly Continued 11 12 13 14 15 16 17 18 19 Solenoid retention pins 19 must be removed from bottom of solenoid body Note grooved end of pin for positive retention Remove face seal 20 two solenoids 21 and one solenoid 22 by removing retention pins 19 Remove three smaller o rings 23 and three larger o rings 24 Remove three solenoid regulator valves 25 and three springs 26 Check resistance of each solenoid Resistance must be 2 5 ohms Remove valve retention pin 27 stop 28 valve 29 and spring 30 from rotating clutch solenoid body 12 NOTE Stationary clutch solenoid body disassembly procedures are steps 15 through 20 Remove two seals 31 from stationary clutch solenoid body 14 NOTE Solenoid retention pin 32 must be removed from bottom of solenoid body Note grooved end of pin for positive retention
128. cables disconnected TM 9 2320 302 20 REMOVAL NOTE e number and location of tiedown straps to aid in installation Tag wiring harness and leads prior to removal to aid installation 1 Remove tiedown straps securing front ABS wiring harness Discard tiedown straps 2 Disconnect front ABS wiring harness connections using illustration as a guide TO REAR BULKHEAD HARNESS CONNECTOR TO BULKHEAD CONNECTOR TO R F SENSOR SENSOR 342 513 TO L F VALVE 0063 00 1 TM 9 2320 302 34 FRONT ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT CONTINUED 0063 00 INSTALLATION 1 Connect front ABS wiring harness connections using illustration as a guide 2 Install same number of new tiedown straps as were removed to secure front ABS wiring harness BULKHEAD CONNECTOR R F SENSOR TO REAR HARNESS L F n ud 942 514 SENSOR 3 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0063 00 2 TM 9 2320 302 34 REAR ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT 0064 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE Note number and location of tiedown straps to aid
129. camshaft bearing shells 24 and camshaft bearing caps 23 0026 00 8 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED 342 696 CLEANING 1 Clean all removed parts and components in detergent and water 2 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 2 Use compressed air to clean all oil passages INSPECTION 1 Inspect camshaft lobes and journals for scoring pitting or flat spots If camshaft is scored inspect camshaft follower rollers 0026 00 9 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSPECTION CONTINUED 2 If there is doubt of camshaft acceptability determine extent of camshaft lobe wear as follows a Using set of 0 0015 0 010 in 0 038 0 254 mm thickness gages 17 and piece of square hard material 18 mea sure flats on injector rise side 19 of camshaft lobes 4 D ER 9 v 7 19 7 2 y EM o A y AS 18 FEED REAR VIEW 4 342 693 b flats measure less than 0 0003 in 0 076 mm in depth but there are no other camshaft defects camshaft is satis factory NOTE If one camshaft bearing needs replacement replace all camshaft bearing shells c Inspect
130. camshaft bearings for signs of excessive wear scoring or pitting d Determine camshaft bearing clearance NOTE Ensure locating tangs are correctly positioned 1 With lower camshaft bearing shells 29 installed in cylinder head install camshaft 5 on seven lower camshaft bearing shells 2 Install seven upper camshaft bearing shells 24 in seven camshaft bearing caps 23 3 Wipe any oil from camshaft bearing shells and camshaft journals 4 Place a piece of plastiguage 30 full width of each upper camshaft bearing shell 24 about in 6 7 mm off center 5 Install camshaft bearing caps 23 and camshaft bearing shells 24 on correct camshaft journals and install seven camshaft cap bolts 20 Tighten bolts to 75 86 Ib ft 102 117 Nm 6 Install two rocker shaft studs 21 in camshaft bearing caps 23 no 1 and no 7 Tighten studs to 75 86 1b ft 102 117 Nm 7 Install two rocker shafts 31 on seven camshaft bearing caps 23 8 Install eight rocker shaft saddle washers 32 six bolts 33 and two nuts 34 Tighten bolts and nuts to 75 86 lb ft 102 117 Nm 0026 00 10 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSPECTION CONTINUED 9 Remove two rocker shaft nuts 34 six bolts 33 eight saddle washers 32 and two rocker shafts 31 10 Remove two rocker shaft studs 21 11 Remove seven outboard camshaft cap bolts 20 seven camshaft caps 23 and se
131. compartment 13 and secure with two screws 11 342 565 24 Position cover 8 on dash 9 and secure with seven screws 7 M 342 564 0113 00 10 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 INSTALLATION CONTINUED 25 Position cover 6 on dash 9 and secure with two screws 5 26 Position cover 4 on dash 9 and secure with three screws 3 27 Position cover 2 on dash 9 and secure with nine screws 1 342 563 END OF WORK PACKAGE 0113 00 11 TM 9 2320 302 34 This Page Intentionally Left Blank 0113 00 12 TM 9 2320 302 34 AIR CONDITIONER EXPANSION VALVE REPLACEMENT 0114 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Cap set Item 7 WP 0125 00 Tools and Special Tools Caulk strip Item 8 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Oil refrigerant Item 27 Crowfoot attachment set Item 28 WP 0126 00 Rags wiping Item 31 WP 0125 00 Gloves rubber Item 40 WP 0126 00 ping Goggles Item 42 WP 0126 00 Tags marker Item 35 WP 0125 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Tape insulation Item 36 WP 0125 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 References Materials Parts TM 92320 30220 Packing preformed P N 2 011C944 70 Packing preformed P N 2 015C944 70 Equipment Condition Adhesive loctite Item 2 WP 0125
132. converter holding bars and bolts 16 Attach a suitable lifting sling to flexplate adapter 17 by positioning adapter connections equal distances apart from each other Using a suitable hoist remove torque converter 18 from torque converter housing 21 Place torque converter on a work bench supported by two wooden blocks 15 VIEW C 342 1146 0071 00 4 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Torque Converter Housing Module 1 Remove seven bolts 22 from inside of torque converter housing 21 that secure converter housing to main housing 23 Remove remaining 18 bolts from outside of housing 2 Attach suitable lifting sling and hoist to torque converter housing 21 3 Remove torque converter housing 21 and gasket 24 from main housing 23 Discard gasket 342 1147 0071 00 5 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Control Valve Module NOTE Control module and filters may contain residual transmission fluid 1 Remove retaining nut 25 and lock washer 26 securing feed through harness 27 to mounting bracket 28 Do not discard lock washer unless damaged 2 Remove retaining nut 29 and lock washer 30 securing feed through harness 27 to main housing 23 Do not dis card lock washer unless damaged N Y i Wy An SS dw P j 342 1166 3
133. damaged area 9 insert piece of material 10 into removed area and reinforce this with doubler 11 This is repair by insertion This method of repair is typically stronger and stiffer than an added patch NUNT OP 7 O SSK SS 342 585 END OF WORK PACKAGE 0105 00 13 TM 9 2320 302 34 This Page Intentionally Left Blank 0105 00 14 TM 9 2320 302 34 HOOD SMC REPAIR 0106 00 THIS WORK PACKAGE COVERS Inspection Repair INITIAL SETUP Maintenance Level Materials Parts Direct Support Glass reinforced plastic Tool kit body and fender repair Item 39 WP Tools and Special Tools 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Drill electric portable Item 31 WP 0126 00 Drill set twist Item 32 WP 0126 00 INSPECTION 1 The SMC sheet molded compound hood consists of several parts including fenders hood and inner reinforcements which are bonded together with a structural adhesive and rivets If the hood is damaged determine which parts are affected 2 Damage at any joint between two parts in not repairable For example if fender and reinforcements bonded inside the fender are damaged replace the entire hood assembly 3 If a joint between two parts has separated and there is no damage at the joint the parts can be rebonded Or if a part is damaged and adjoining parts are not the damaged part can be separated from the hood and new or used parts ca
134. disen gages from rocker arm cover Lift clip upward to disengage curved end 6 Remove breather mesh element 11 from rocker arm cover 5 0016 00 2 TM 9 2320 302 34 ROCKER ARM COVER REPLACEMENT CONTINUED 0016 00 REMOVAL CONTINUED 342 645 CLEANING 2 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 1 Clean rocker arm cover gasket and ten bolt assemblies with detergent and water Dry with compressed air 2 Clean all old gasket forming compound from rocker arm cover grooves Clean all dirt and foreign matter from rocker arm cover 3 Remove old gasket forming compound from corners of cylinder head located at front and rear cam cap area 4 Clean mesh breather element with detergent and water solution and dry with compressed air INSPECTION 1 Inspect rocker arm cover gasket for cuts nicks and breaks If found discard gasket 25 Inspect all components for wear or damage INSTALLATION 1 Press mesh breather element 11 into breather pocket 2 Insert curved end of breather element retaining clip 10 into one breather pocket hole Press and slide straight end of clip into opposite breather pocket hole 0016 00 3 TM 9 2320 302 34 ROCKER ARM COVER REPLACEMENT CONTINUED 0016 00 INSTALLATION CONTINUED NOTE To ease ga
135. e e me C4 Retainer 29507882 No Code 2 367 12 527 11 2 16408 0 093 0 497 0 44 Pen 3689 C4 Retainer 29515628 No Code 4 2 36 12 62 11 1 10 40 15403 oe ee ee ee x Retarder 6880775 Yellow 1 93 16 61 53 8 35 30 81 4 ours _ eme ee em Retarder 29510495 Silver 1 L4 s 1 3 08 18 0 Control 0 055 0 594 1 212 0 71 2 Retarder 29512792 Lt Green 7 5 1 40 15 09 33 69 18 0 40 oma UU mn em axo e _ Retarder 29510494 Orange 7 1 60 15 50 27 8 18 0 ndividual springs For complete spring assembly v c0 0c c 6 INL 79 00 1 00 Table 3 Wear Limits and Spring Data Continued APPROX LENGTH UNDERLOAD UNDER LOAD SPRING FREE PART COLOR NO OF WIRE DIA OD LENGTH MM SPRING NUMBER CODE COILS MM IN MM IN MM IN IN uy Retarder 23049391 No Code 17 0 61 7 80 29 2 18 2 ff em C5 Return 29503036 No Code 12 2 10 17 00 57 3 37 6 3086 Solenoid 29502195 No Code 4 0 67 11 05 6 5 3 45 3 meme 7 eee eu ow ow o Accumulator 29507455 Silver 1 28 11 68 43 6 20 0 S S UT eoo exo em o e Overdrive 23049332 Orange 0 76 LAS 26 6 12 5 12 0 e e e Lem Solenoid 29502195 No Code 0 767 11 105 5 5 3 ds Dee d me es em on Lockup 23049326 Yellow 1 37 14 1 42 1 17 0 Lube 23049327 1 22 11 1 46 3 3 5 47
136. ete Nero ee RS Traction Control System Theory of Operation Transmission OVEN AUD reruns pto rotto o ax AERE ax diae tes Replacement xke ec RR e pa RE REED Troubleshooting oie REDE UE YR eM ES Troubleshooting Engines redo ug erect ER dor eda S Ceo bs Introd ction sm reden Rr ec aem i eio Rea ep Steering System Symptom Index icr erecib ibr ede eke Obagad desee Transmission 4e ve ea hed tke Troubleshooting and Testing Air Conditioning System Tube Replacement Breather Turbocharger Wastegate Actuator Maintenance Garrett Wastegate Actuator Maintenance aC m Replacement a sce e ee b e ieu EUN OPEM PI Turn Signal Thru deck Wiring Harness Replacement Turn Signal Marker Light Wiring Harness Replacement Valves Oil Pressure Relief and Regulator Replacement Vibration Damper Replacement Index 9 Work Package 0003 00 0003 00 0003 00 0003 00 0003 00 0003 00 0003 00 0003 00 0074 00 0094 00 0093 00 0123 00 0003 00 0071 00 0070 00 0007 00 0006 00 0004 00 0008 00 0005 00 0007 00 0009 00 0017 00 0044 00 0045 00 0043 00 0042 00 0060 00 0059 00 0030 00 0020 0
137. fins is blocked air is not able to absorb enough heat to turn the hot refrigerant gas into a liquid High head pres sures will result In these cases carefully clean off the outer surfaces of the condenser with compressed air or a soap and water solution be careful not to bend the fins b High head pressures will also occur if the condenser s tubing is abnormally bent blocking the flow of refrigerant Frost will appear at the point where the flow is restricted c Less common internal blockages bits of foreign material or metallic grit buildup will stop the flow of refrigerant d quick test to check that poor system performance is caused by the condenser is to direct a spray of water onto the condenser while the system is running If the air conditioner cools better because of the assist provided by the water it is a sign that the condenser is not working e When troubleshooting a suspected condenser problem remember that the problem may be caused by the radiator transferring high levels of heat to the condenser Refer to TM 9 2320 302 20 to troubleshoot the engine cooling system 7 Thermostatic Switch a IMPORTANT Before troubleshooting the thermostatic switch check for a full charge of refrigerant in the system The compressor will not operate or will cycle too often if there is not enough refrigerant in the system Quick or delayed cycling of the compressor may be caused by a thermostatic switch that is working but is
138. formed using rivet spacing not greater than 1 1 2 in 4 cm and not less than 5 8 in 16 mm Use in rivet spacing as general practice for repairs Rivet spacing used in original construction may be greater due to additional strength obtained by using foam adhesive tape Do not use rivet edge distances less than 3 8 in 5 mm c High strength joints or large area patches may require use of double or multiple rows of rivets to obtain sufficient strength D DIAMETER OF RIVET 21 1 PREFERABLY ABOUT Ad UL 3X THICKNESS OF esq THICKER SHEET TRIPLE OR MULTIPLE ROW RIVETING PATTERN CAUTION Be careful not to distort original holes to prevent damage to equipment d Care must be taken to ensure rivet hole patterns are transferred accurately in the case where part with no holes is mated to one which already has rivet holes Hole patterns may be transferred using one of the following 1 Lay new part in place and use holes in mating part as drill template New part must be underneath mating part 2 Use removed part as drill template by clamping old and new parts together Parts must nest flat and rivet flange must be undistorted 0105 00 10 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 ALUMINUM REPAIR CONTINUED 4 Joint Design a Loads are applied through joint to fasteners holding joint together These loads are applied to fasteners in form of shear loads or tension loads If load is perpendicular to axis of fas
139. gear a Position dial indicator to read between scribed lines 7 on gear lash checker 8 b Gear lash should be 0 001 0 010 in 0 025 0 254 mm 342 676 6 Install alternator belt 9 2320 302 20 END OF WORK PACKAGE 0021 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0021 00 4 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE 0022 00 THIS WORK PACKAGE COVERS Removal Disassembly Cleaning and Inspection Assembly Installation Adjustment INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Ring seal P N 001083 Tools and Special Tools Ring seal P N 20229 Tool kit general mechanic s Item 132 WP 0126 00 Compound international no 2 Item 13 WP 0125 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Rags wiping Item 31 WP 0125 00 Wrench torque 50 250 lb ft Item 139 WP 0126 00 Tags marker Item 35 WP 0125 00 Materials Parts Wipes lint free Item 40 WP 0125 00 Ring retaining P N 012991 2 Equipment Condition Ring seal P N 001082 Rocker arm cover removed WP 0016 00 REMOVAL 1 Loosen screw 1 on three solenoid terminals and remove three wiring harness connectors 2 from three solenoid valves 3 2 Remove three bolts 4 and washers 5 from three engine retarders 6 342 657 0022 00 1 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00
140. harness protector 4 on engine injector wiring harness 12 and secure to cylinder head 6 with two screws 3 Tighten screws to 84 132 Ib in 10 15 Nm NOTE Ensure wires are against cylinder head rail away from possible contact with exhaust valve spring Insert guide clip 11 into oil drain hole at rear of cylinder head 6 to retain injector wires in corner away from exhaust valve springs 342 1186 11 Connect two engine injector wiring harness connectors 1 to top and bottom outboard connections on ECM 2 Ensure locking tangs on connectors are engaged Secure engine injector wiring harness 12 to engine with new tiedown straps as required Install rocker arm covet WP 0016 00 Connect battery cables TM 9 2320 302 20 0069 00 3 TM 9 2320 302 34 ENGINE INJECTOR AND ECM WIRING HARNESSES REPLACEMENT CONTINUED 0069 00 ECM WIRING HARNESS REMOVAL NOTE e Wiring harness and leads are secured in place by cushion clamps screws and tiedown straps e Only remove hardware securing harness or lead to be removed e all wires prior to removal to aid in installation 1 Remove screws 13 and clamps 14 as necessary to release ECM wiring harness 15 from engine 2 Use illustration and table as a guide to disconnect and remove ECM wiring harness 15 EN esf S t Je V A wes 7 7 M 18 15 1 ee 342 1187 Connector Number Qty 16 30 pin Plug 1 17 3 pin Connector 2 18 2 pin Connector 5
141. in the list and is referenced in the initial setup of maintenance tasks to identify the item e g Tool kit general mechanic s Item 132 WP0126 00 2 Column 2 Item Name This column lists the item by noun nomenclature and other descriptive features e g Tester Cylinder 3 Column 3 National Stock Number This is the National Stock Number NSN assigned to the item Use it to requi sition the item 4 Column 4 Part Number CAGEC Indicates the primary number used by the manufacturer individual company firm corporation or Government activity which controls the design and characteristics of the item by means of its engi neering drawings specifications standards and inspection requirements to identify an item or range of items The man ufacturer s Commercial and Government Entity Code CAGEC is also included in parentheses 5 Column 5 Unit of Measure U M This column shows the physical measurement or count of an item such as gal lon dozen gross etc 0126 00 1 TM 9 2320 302 34 TOOL IDENTIFICATION LIST CONTINUED 0126 00 Table 1 Tool Identification List 2 3 4 5 NATIONAL STOCK NUMBER PART NUMBER ITEM NAME CAGEC REFERENCE M 9 2320 302 24P 9 2320 302 24P 9 2320 302 24P 4910 01 319 6971 3950 01 319 6973 5120 00 215 8200 Adapter Cylinder J38768 A 33287 J35635 33287 11663358 2 19207 Adapter Motor Hoist E Adapter Torque Wrench
142. indicator reading must not exceed 0 013 in 0 33 mm for bore or face Adjust dial indicator 8 to read zero Rotate crankshaft one full revolution taking readings at 90 degree intervals B and D four readings each for bore bolting and face If runout exceeds maximum limits remove flywheel housing 3 and check for dirt or foreign material between flywheel housing and cylinder block or oil pan mating surface Clean mating surfaces install flywheel housing 3 and perform steps 9 through 13 to recheck runout 342 687 If readings are not within specification replace flywheel housing 3 Repeat step 9 through 13 to check flywheel concentricity and bolting flange face runout for new flywheel housing Install oil WP 0028 00 Install starter Install rear engine mount WP0012 00 END OF WORK PACKAGE 0024 00 4 TM 9 2320 302 34 FLEX PLATE MAINTENANCE 0025 00 THIS WORK PACKAGE COVERS Removal Disassembly Cleaning and Inspection Assembly Installation INITIAL SETUP Maintenance Level Materials Parts Plate scuff P N 5100532 Compound international no 2 Item 13 WP 0125 00 Tool ial Tool Detergent Item 19 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Direct Support Personnel Required Pin shoulder headless Item 82 WP 0126 00 Two Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Equipment Condition Wrench torque 50 250 Ib ft Item 139 WP
143. lines TM 9 2320 302 20 24 Install air intake manifold WP 0014 00 25 Install exhaust manifold WP 0015 00 26 Install water level sensor 27 Install thermostat and thermostat housing cover 28 Install alternator 29 Install air conditioner compressor WP 0117 00 END OF WORK PACKAGE 0018 00 8 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Dispenser sealant 30 WP 0126 00 Guide stud set Item 43 WP 0126 00 Trestles Item 135 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Materials Parts Ring seal P N 5141452 Compound gasket forming Item 12 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Straps tiedown Item 34 WP 0125 00 0019 00 References Equipment Condition Alternator removed Water pump removed Air compressor removed TM 9 2320 302 20 Front engine mount adapter removed Fan drive support removed WP 0013 00 Accessory drive removed WP 0021 00 Oil pan removed Power steering pump removed WP 0086 00 4 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting devi
144. lock bar 21 new spring 20 and new roll pin 19 Install new washer 18 on primary lock handle 16 Install primary lock handle 16 in top plate 17 Install new cam plate 14 on primary lock handle 16 NOTE Install washers with rounded sides facing away from cam plate Install new washer 15 new roller 13 new washer 12 new screw 11 and new lock nut 10 in top plate 17 Install new washer 9 new roller 8 new washer 7 and new screw 6 in cam plate 14 Install new lock adjust tag 5 new rubber washer 4 new washer 3 and new nut 2 on shaft 23 WARNING Locks must be closed while adjusting to ensure contact is made with locks yoke and top plate Failure to do so will result in loss of trailer and possible injury to personnel Tighten nut 2 until plug fits snugly but can just be rotated by hand Open two locks 1 and remove kingpin lock tester plug Install top platd WP 0093 00 Lubricate fifth wheel Adjust fifth wheel TM 9 2320 302 20 END OF WORK PACKAGE 0094 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0094 00 6 TM 9 2320 302 34 RAMP REPLACEMENT 0095 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Nut lock P N MS51922 33 6 Tools and Special Tools Nut lock P N MS51922 49 6 Tool kit general mechanic s Item 132 WP 0126 00 P 5 WARNING Use extreme cautio
145. marks are present remove and replace injector tube 0032 00 20 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 342 1030 29 Remove two cylinder head bolts and injector tube reconditioning set stop block from cylinder head 2 30 Insert injector tube reconditioning set tip refinisher 72 into injector tube 64 342 1031 0032 00 21 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED NOTE e Cylinder head repair conditions may warrant cylinder head pressure testing before complete head assembly Testing should be performed before intake and exhaust valve components are installed Ensure all cup plugs pipe plugs and injector tubes are installed before pressure testing cylinder head Refer to inspection steps 2 through 10 for testing 31 Using 12 point 23 mm socket and speed handle turn injector tube reconditioning set tip refinisher to remove excess stock so that lower end of injector tube 64 is from flush to 0 008 in 0 20 mm 73 below fire deck surface of cylinder head Remove chips from injector tube N 78 64 32 Position cylinder head 2 fire deck side down 342 1032 33 Insert chamfered end of new valve guide 14 into cylinder head 2 with seal groove up 34 Insert driver 74 into valve guide installer 75 Install assembly over valve guide 14 Drive valve guide into cylinder head 2 with air chisel 23 until drive
146. missing gear teeth Clean and inspect engine for signs of external oil leaks Inspect rear of engine for signs of leaking oil Inspect front of engine for signs of leaking oil Inspect turbocharger for signs of leaking oil Inspect oil pan for signs of leaking oil 0006 00 1 If engine cannot be rotated internal damage is indicated Remove engine WP 0010 00 Remove gear case cover and confirm timing mark alignment WP 0019 00 Replace damaged gear train components WP 0035 00 Remove gear case cover and confirm timing mark alignment WP 0019 00 Replace damaged gear train components WP 0035 00 If no oil leaks are identified internal damage is indicated Remove engine WP 0010 00 If oil leaks are found inspect and replace crankshaft rear oil seal WP 0023 00 If oil leaks are found inspect and replace crankshaft front oil seal WP 0031 00 If oil leaks are found replace or repair turbocharger WP 0042 00 WP 0043 00 If oil leaks are found replace oil pan gasket WP 0028 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0006 00 2 TM 9 2320 302 34 TRANSMISSION TROUBLESHOOTING 0007 00 NOTE Refer to TM 9 2320 302 20 for transmission troubleshooting 0007 00 1 TM 9 2320 302 34 This Page Intentionally Left Blank 0007 00 2 TM 9 2320 302 34 STEERING SYSTEM TROUBLESHOOTING 0008 00 Table 1 Steering System Troublesh
147. necessary to remove tie rod end e Left tie rod end has left hand threads and right tie rod end has right hand threads 3 Remove tie rod end 7 from tie rod 3 4 If damaged remove lubrication fitting 8 ASSEMBLY NOTE Procedure is same for both tie rod ends 1 If removed install new lubrication fitting 8 NOTE Left tie rod end has left hand threads and right tie rod end has right hand threads 2 Install tie rod end 7 on tie rod 3 the same number of turns noted during disassembly 3 Install dust cover 6 4 Install capscrew 5 and lock nut 4 0074 00 2 TM 9 2320 302 34 TIE ROD MAINTENANCE CONTINUED 0074 00 INSTALLATION 1 Install each end of tie rod 3 with castellated nut 2 and new cotter pin 1 Tighten castellated nuts to 165 180 lb ft 224 244 Nm 342 1115 2 Check front axle toe in alignment 9 2320 302 20 END OF WORK PACKAGE 0074 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0074 00 4 TM 9 2320 302 34 FRONT CROSS TUBE ARM REPLACEMENT 0075 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Pin cotter P N MS24665 357 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Tie rod removed WP 0074 00 Multiplier torque wrench Item 79 WP 0126 00 Wrench torque 100 600 Ib ft Item 140 Wrench set socket 3 4 in drive Item 141 WA NOT
148. no 7 Tighten bolts and studs to 75 86 lb ft 102 117 Nm Use rocker stud socket to tighten studs 342 699 0026 00 13 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSPECTION CONTINUED NOTE If camshaft runout exceeds 0 002 in 0 050 mm replace camshaft j Using dial indicator 3 check runout of camshaft 5 at bearing journal no 4 k Remove two camshaft bearing caps 23 no 1 and no 7 from cylinder head 26 M WARNING Camshaft weighs 53 Ib 24 kg Attach suitable lifting device prior to removal to prevent possible injury to personnel 0026 00 14 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED INSPECTION CONTINUED 1 Remove camshaft 5 0026 00 15 342 699 0026 00 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION NOTE If new bearings are installed replace upper and lower bearing shells as sets Observe position of oil holes and locating tangs 1 Install seven lower bearing shells 29 in cylinder head 26 Lubricate lower camshaft bearings shells with clean engine lubricating oil 2 Install two upper camshaft bearing shells 24 in camshaft bearing caps 23 no 1 and no 7 Lubricate upper camshaft bearing shells with clean engine lubricating oil NOTE If new camshaft is installed steam clean camshaft to remove rust preventive and dry with compressed air Ensure dimple in thrust p
149. of travel 342 1041 0041 00 1 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 REMOVAL CONTINUED 3 With ridge reamer remove carbon ridge 2 at top of cylinder liner 3 above upper travel limit of top piston ring 342 1042 NOTE Ensure connecting rods and caps are stamped with correct location number If not stamped stamp correct location 1 through 6 on tang side cooler side of rod cap and rod 4 Remove two connecting rod nuts 4 connecting rod cap 5 and lower connecting rod bearing shell 6 342 1043 0041 00 2 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 REMOVAL CONTINUED CAUTION When removing piston from engine use care and avoid damaging piston cooling nozzle installed in base of cylinder bore 5 Install two connecting rod guides 7 on two connecting rod bolts 8 to protect crankshaft journal Push connecting rod and piston assembly 9 through top of cylinder block 342 1044 NOTE Connecting rod caps are numbered according to cylinder position with matching numbers stamped on tang side of connecting rod Always assemble rods and caps in original positions as marked 6 Assemble connecting rod and piston assembly 9 connecting rod cap 5 and lower connecting rod bearing shell 6 7 Install two connecting rod cap nuts 4 hand tight 342 1046 0041 00 3 TM 9 2320 302 34 PISTON AND CY
150. of two axle clamps 3 Remove rear suspension center bearing WP 0101 00 With rear of vehicle still raised remove wheels TM 9 2320 302 10 Using a suitable lifting device remove rear spring assembly 4 from vehicle FY rm 342 972 0102 00 1 TM 9 2320 302 34 REAR SPRING ASSEMBLY REPLACEMENT CONTINUED 0102 00 INSTALLATION 1 Using a suitable lifting device position rear spring assembly 4 to vehicle 2 Install rear suspension center bearing WP 0101 00 3 Install top pad 2 to each of two axle clamps 3 with four screws 1 Tighten screws to 37 Ib ft 50 Nm 2 l 1 4 N 342 972 4 Install wheels TM 9 2320 302 10 5 Tighten wheel lug nuts TM 9 2320 302 20 END OF WORK PACKAGE 0102 00 2 TM 9 2320 302 34 REAR SUSPENSION CONTROL ROD AND V ROD REPLACEMENT 0103 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Tools and Special Tools Continued Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Direct Support Wrench torque 100 600 Ib ft Item 140 WA Tools and Special Tools 0126 00 UT Tool kit general mechanic s Item 132 WP 0126 00 om Socket 3 4 indeve tem 141 Jack hydraulic Item 73 WP 0126 00 Personnel Required Trestle hoist portable 2 Item 135 WP 0126 00 Two REMOVAL NOTE e Toremove control rods perform steps 1 and 2 e Toremove V rods perform steps 1 and 3 l Using floor jack lift rear of vehi
151. oil drain line 8 and gasket 9 Discard gasket 5 Remove four nuts 10 and washers 11 securing turbocharger 3 to exhaust manifold 12 V7 WARNING Turbocharger weighs 50 Ib 23 kg Use two persons or suitable lifting device during removal to prevent per sonal injury or damage to equipment 6 Remove turbocharger 3 and gasket 13 from mounting studs 14 Discard gasket 0042 00 2 TM 9 2320 302 34 TURBOCHARGER REPLACEMENT 0042 00 REMOVAL CONTINUED 7 Tape all openings of turbocharger 3 14 342 629 INSPECTION 1 Inspect turbocharger mounting studs on exhaust manifold for damage or looseness Tighten stud s if loose 2 Remove and replace damaged stud as follows a Remove threaded turbocharger stud by unscrewing using two nuts one as a jamnut b Thread new stud into exhaust manifold until unthreaded portion of stud is bottomed against mounting flange Tighten stud s to 18 24 Ib ft 24 33 Nm 3 Inspect mounting flange of exhaust manifold to ensure all gasket material is removed INSTALLATION 1 Remove tape from all openings of turbocharger 3 2 Position new gasket 13 on mounting studs 14 WA n WARNING Turbocharger weighs 50 Ib 23 kg Use two persons or suitable lifting device during installation to prevent personal injury or damage to turbocharger NOTE Ensure turbocharger mounting flange is free of all gasket material 3 Place turbocharger 3 on mounting st
152. packing 31 in commutator housing 10 If removed install new bushing 30 in commutator housing 10 Install washer 29 insulation washer 28 and new packing 27 on ground stud 26 Install ground stud 26 in commutator housing 10 Install new packing 25 insulator 24 four washers 23 and nut 22 on ground stud 26 Install ground jumper 21 four insulation washers 20 and brush holders 19 in commutator housing 10 Install four insulation bushings 18 eight insulation washers 17 four washers 16 new lock washers 15 and screws 14 Install insulation washer 11 washer 12 and commutator housing 10 in field ring 13 Apply silicone adhesive to threads of four screws 8 and install four new lock washers 9 and screws 8 0054 00 8 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 ASSEMBLY CONTINUED 342 546 22 Pull two springs 6 upward and install brush 7 lock plate 4 and two screws 5 23 Repeat step 22 for remaining brushes 7 342 545 0054 00 9 TM 9 2320 302 34 STARTER REPAIR CONTINUED ASSEMBLY CONTINUED 24 Install brush opening band 3 with two screws 2 and nuts 1 342 544 25 Install starter solenoid 0053 00 END OF WORK PACKAGE 0054 00 10 0054 00 TM 9 2320 302 34 ENGINE POWER WIRING HARNESS REPLACEMENT 0055 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts
153. piston 22 WARNING Guide halves must be held in place during installation of balls Failure to do so will result in balls being trapped outside closed ball track causing steering lockup and possible injury to personnel Failure to install all 32 balls in guide halves will also result in steering lockup and possible injury to personnel NOTE e Rotate input shaft slightly if necessary to ensure guide halves are properly seated e If guide halves are unseated during or after ball loading remove all balls and input shaft from rack pis ton and repeat steps 21 and 22 e Ensure all 32 balls are installed 24 Install 32 balls 29 in slot in guide halves 28 20 342 849 25 Applya light coat of grease to new seal 27 and install in return cap 26 26 Using torx socket install return cap 26 and two new screws 25 in rack piston 22 Tighten screws alternately to 168 264 b in 19 30 Nm WARNING Do not allow valve housing to move more than 2 72 in 69 1mm away from rack piston If this occurs balls will be out of place resulting in possible loss of steering and injury to personnel CAUTION During step 27 do not allow poppet 54 to touch valve housing 20 To do so will result in incorrectly pre set poppet 27 Rotate input shaft 2 into and out of rack piston 22 several times while checking for smooth movement 28 If input shaft 2 does not move smoothly remove balls 29 and rack piston 22 and
154. plug 1 are clean Install preformed packing over threads of oil fill plug being careful not to twist preformed packing 6 Install oil fill plug 1 and tighten snugly NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 7 Replace receiver dri r WP 0118 00 8 Charge air conditioning system WP 0112 00 WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 9 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0116 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0116 00 4 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR REPLACEMENT 0117 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Cap set Item 7 WP 0125 00 Tools and Special Tools Oil refrigerant Item 27 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Rags wiping Item 31 WP 0125 00 Gloves rubber Item 40 WP 0126 00 Tags marker Item 35 WP 0125 00 Goggles Item 42 WP 0126 00 References Materials Part Ha C TM 9 2320 302 20 Nut lock 6 Packing preformed P N 2 013C557 70 2 Equipment Condition Washer lock P N AN935 616 6 Alternator belt removed TM 9 2320 302 20 Adhesive loctite It
155. prior to installation Failure to do so may cause shim slippage resulting in equipment damage and or injury to personnel NOTE Install shims with tapered end toward front of vehicle 6 Install new shim s 6 to obtain 43 5 to 6 5 degrees of caster angle 342 1117 Ensure dowel protrudes through shim s enough to hold spacer place If dowel does not protrude into spacer replace dowel 7 Install spacer 7 8 Lower spring 4 onto axle 5 9 Coat threads of two U bolts 3 with antiseize compound 10 Install four washers 2 and nuts 1 on two U bolts 3 Tighten nuts to 380 460 Ib ft 515 624 Nm END OF WORK PACKAGE 0073 00 2 TM 9 2320 302 34 TIE ROD MAINTENANCE 0074 00 THIS WORK PACKAGE COVERS Removal Disassembly Assembly Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Pin cotter P N MS24665 357 2 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 References Wrench torque 50 250 Ib ft Item 139 WP 0126 00 9 2320 302 20 REMOVAL Remove cotter pin 1 and castellated nut 2 at each end of tie rod 3 Remove tie rod Discard cotter pins 342 1115 0074 00 1 TM 9 2320 302 34 TIE ROD MAINTENANCE CONTINUED 0074 00 DISASSEMBLY NOTE Procedure is same for both tie rod ends 1 Remove lock nut 4 and capscrew 5 2 Remove dust cover 6 4 BM 6 7 5 8 342 1118 Note number of turns
156. removed TM 9 2320 302 20 Vise machinist s Item 136 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 REMOVAL 1 Remove nut 1 lock washer 2 and wire 3 from starter solenoid 4 Discard lock washer 2 Remove nut 5 from starter solenoid 4 342 536 3 Hold nut 6 on starter motor 7 and remove nut 8 and jumper 9 from stud 10 4 Remove two screws 11 5 Pull starter solenoid 4 away from housing 12 and rotate so that mounting bracket 13 faces away from starter motor 7 0053 00 1 TM 9 2320 302 34 STARTER SOLENOID REPLACEMENT CONTINUED 0053 00 REMOVAL CONTINUED 6 Remove spool 14 from shift fork 15 NOTE It may be necessary to use a soft jawed vise to hold solenoid plunger for removal of spool 7 Remove spool 14 and boot 16 from solenoid plunger 17 INSTALLATION 1 Install boot 16 and spool 14 on solenoid plunger 17 Rotate starter solenoid 4 so that mounting bracket 13 faces away from starter motor 7 Install spool 14 in shift fork 15 2 3 4 Rotate starter solenoid 4 to mounting position and press flush with housing 12 5 Apply silicone adhesive to threads and install two screws 11 6 Install jumper 9 on stud 10 7 Apply silicone adhesive to last in 6 4 mm of threads on stud 10 Hold nut 6 and install nut 8 Tighten nut to 21 29 lb ft 28 39 Nm 8 Install nut 5 on starter solenoid 4 Tighten nut to 18 22 Ib
157. retaining clips 36 2 Ensure top plate mating surface is clean and dry 0094 00 3 TM 9 2320 302 34 TOP PLATE REPAIR CONTINUED ASSEMBLY CONTINUED 3 Install two lube plates 35 to top plate 17 with 18 washers 34 and new lock nuts 33 4 Tighten lock nuts 33 to 156 Ib in 18 Nm 35 m 17 bao 34 33 5 If removed install two new grease fittings 32 6 Coat pin holes of two locks 1 with antiseize compound and install two locks with larger opening facing toward top of top plate 17 7 Install two new pins 31 and new pins 30 8 Install new lock guard 29 spring 28 new pin 27 and two new cotter pins 26 Install kingpin lock tester plug between two locks 1 and close locks 4 3 5 y und 94 ES 11 6 a 25 a 12 Y 7 MM dE gt N 29 0094 00 4 TM 9 2320 302 34 TOP PLATE REPAIR CONTINUED 0094 00 ASSEMBLY CONTINUED 10 11 12 13 14 15 16 17 18 19 20 21 22 e Tips of yoke must be flush 1 32 in with ends of two locks If yoke falls short grind outside edges of yoke tips evenly until yoke fits exactly If yoke extends beyond two locks build up outside edges of yoke tops using low hydrogen E70XX welding rod After welding grind beads smooth and even until yoke fits exactly Ensure threaded hole is up when installing shaft Install new spring 24 and new shaft 23 on yoke 25 Install handle 22 new
158. same time Repeat for other cord 342 616 18 Finish seating windshield glass 1 and seal 2 by gently pushing all the way around outside edge 342 617 0109 00 8 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION CONTINUED 19 Install windshield support 15 with four washers 14 and screws 13 342 614 13 14 20 Install cover 12 with two washers 11 and torx screws 10 21 Install defroster vent 9 with torx screw 8 0109 00 9 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION CONTINUED 22 Install cover 7 two brackets 6 and four torx screws 5 6 23 Install new lockstrip 3 342 610 24 Install windshield wiper and wiper arms TM 9 2320 302 20 END OF WORK PACKAGE 0109 00 10 TM 9 2320 302 34 REAR WINDOW REPLACEMENT 0110 00 THIS WORK PACKAGE COVERS Removal Cleaning and Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Compound sealing Item 14 WP 0125 00 Direct Support Detergent Item 19 WP 0125 00 Tools and Special Tools Personnel Required Gloves Item 411 WP 0126 00 Two REMOVAL WARNING Wear protective gloves when handling glass Failure to do so could result in injury to personnel NOTE If removing rear window glass only perform steps 1 through 3 If removing rear window glass and seal per form steps through 5 1 If rear window glass 1 is
159. screw terminals Ensure wiring harness is secure and all hardware is tight 0057 00 7 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057 00 INSTALLATION CONTINUED 1 Connect relay and fuse panel 1 2 Connect 42 pin connector 2 34 pin connector 3 32 pin connector 4 6 pin sealed connector 5 and four ring ter minals 6 BW S Ne 342 553 0057 00 8 TM 9 2320 302 34 0057 00 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED INSTALLATION CONTINUED 3 Connect three ring terminals 6 12 pin connector 7 female terminal blade 8 6 pin female connector 9 3 pin sealed connector 10 two 3 pin female connectors 11 1 pin male connector 12 and six 1 pin female connectors 13 11 0057 00 9 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057 00 INSTALLATION CONTINUED 4 5 Install 9 pin engine diagnostic connector 21 and 6 pin diagnostic connector 20 and secure with eight screws 19 Connect 2 pin male connector 18 Connect three ring terminals 6 6 pin female connector 9 two 3 pin female connectors 11 1 pin male connector 12 1 pin female connector 13 12 pin diagnostic connector 14 3 pin male connector 15 two 2 pin male connec tors 16 and 2 pin female connectors 17 342 555 0057 00 10 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057
160. sequence n Bar engine over in direction of normal rotation until next cylinder in adjustment sequence is in its valve overlap period o Repeat valve adjustment and fuel injector height adjustment procedures until all valves and injectors have been adjusted 2 Install engine retardet WP 0022 00 END OF WORK PACKAGE 0027 00 14 TM 9 2320 302 34 OIL PAN MAINTENANCE 0028 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Repair Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Gasket P N 8929102 O ring P N 2 223V747 75 Tools and Special Tools Compound gasket forming Item 121 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Compound sealing pipe Item 18 WP 0125 00 Dispenser sealant Item 30 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Personnel Required Two Equipment Condition Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Engine oil drained TM 9 2320 302 20 REMOVAL 1 Remove ten bolt assemblies 1 securing oil pan 2 to cylinder block 3 342 743 0028 00 1 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 REMOVAL CONTINUED CAUTION Handle oil pan with care Dropping or bumping could cause damage 2 Remove oil pan 2 carefully to avoid damage to oil pump pickup tube 4 and screen assembly 5 3 342 745 0028 00 2 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 CLEANING
161. surface of gear housing assembly thrust plate and head for cleanliness burrs or damage 3 Inspect woodruff key slot in hub and drive gear for evidence of cracks or wear Replace camshaft drive gear assembly if key slot is damaged 4 Inspect camshaft drive gear teeth for scoring pitting or excessive wear If scoring pitting or excessive wear is evident discard gear 5 Inspect camshaft drive gear hub 7 for scoring pitting or galling If excessive discard hub Measure diameter A Min imum dimension should be 2 283 in 58 0 mm Measure thrust plate contact area B Minimum dimension should be 0 254 in 6 45 mm If any dimensions are below minimum discard hub i 342 915 6 Inspect camshaft thrust plate 6 for scoring pitting or galling If scoring pitting or galling is evident discard thrust plate Measure thrust plate contact area C Minimum dimension should be 0 437 in 11 1 mm If measurement is below minimum discard thrust plate 342 916 0034 00 3 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE CONTINUED 0034 00 ASSEMBLY NOTE Minimum force of 4500 Ib 20 kN must be obtained when pressing gear on hub When pressing only apply force to inner hub of gear Lubricate contact surfaces of drive gear hub 7 and camshaft thrust plate 6 with clean engine lubricating oil Install drive gear hub 7 on camshaft thrust plate 6 Install new woodruff key 8 in keyway of drive gear hub 7 Apply a
162. those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System TAMMS as contained in the Maintenance Man agement Update REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRS If your truck needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance Put it on an SF Form 368 Product Quality Deficiency Report Mail it to us at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA LC CIP WT Rock Island Illinois 61299 7630 We will send you a reply CORROSION PREVENTION AND CONTROL CPC 1 Corrosion Prevention and Control CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items 2 While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem 3 If a corrosion problem is identified it can be reported using SF Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem
163. through 6 Replace ring gear and drive pinion as matched set Gear set match number is on head of drive pinion and front face or outer diameter of ring gear e Pinion cone variation number is used to adjust depth of pinion in differential carrier Pinion cone varia tion number is on end of gear head of drive pinion or outer diameter of ring gear Record new pinion cone variation number Record old pinion cone variation number If old pinion cone variation number is subtract number from shim pack thickness in disassembly step 48 If old pinion cone variation number is add number to shim pack thickness in disassembly step 48 If new pinion cone variation number is add number to shim pack thickness determined in step 3 or 4 If new pinion cone variation number is subtract number from shim pack thickness determined in step 3 or 4 NOTE Coat all bearing cones and bearing cups with axle oil prior to installation Using press install inner bearing cone 60 on drive pinion 3 until bottom of inner bearing cone touches bottom of drive pinion 342 1253 0080 00 15 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 8 Install differential carrier 1 on press with legs of differential carrier toward top of press NOTE If installing new ring gear and drive pinion use shim pack thickness determined in step 5 or 6 If installing same ring gear and drive pinion u
164. tightly attached to housing no movement is allowed Install new seal rings 13 and 14 on piston 12 Install piston with seal rings into C3 clutch housing 15 Install C3 clutch housing assembly 15 on top of assembled C4 clutch housing assembly 26 Ensure index notches on clutch housings are aligned Install spring retainer 11 on piston 12 and in C3 clutch housing 15 If removed install new return spring assemblies 10 and attach them securely to piston return plate 9 Install piston return plate 9 with return spring assemblies 10 into C3 clutch housing 15 Install P1 ring gear 6 Install C3 clutch pack starting with a friction plate 7 alternately install five friction plates and four steel reaction plates 8 NOTE Perform step number 14 only if C3 backplate was disassembled If clutch housing was not disassembled proceed to step number 15 Install four thrust plates 4 using 12 rivets 5 into C3 backplate 3 Use tool J39534 to cold form rivets Insert rivet from front so that preformed head is below active surface of thrust plate Use cold forming tool to upset rivet at rear of backplate to complete riveted joint A correctly formed rivet upset will be 0 157 in 4 00 mm in diameter and no more than 0 039 in 1 00 mm above surface of backplate Thrust plate must be tightly attached to backplate no movement is allowed Install C3 backplate assembly 3 aligning notches on C3 and C4 housings Insta
165. to bushing in side cover 9 and new seal 13 Install seal on installation end of bearing inserter with spring side toward shoulder of tool gt 38 Install seal 13 in side cover 9 13 a 342 870 0089 00 18 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 39 Apply a light coat of lubricating oil to bearing surface of sector shaft 3 Install sector shaft in side cover 9 by thread ing adjusting screw 11 counterclockwise until solid then backing off 1 2 turn so that side cover rotates freely 40 Install vent plug 14 and nut 7 hand tight 342 871 WARNING Rack piston and sector shaft must be meshed correctly Failure to do so will severely limit gear travel in one direction resulting in possible injury to personnel 4 Rotate input shaft 2 so that valley between second and third tooth of rack piston 22 is even with and centered in opening of housing 4 342 872 0089 00 19 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 42 Replace masking tape on sector shaft 3 with one layer of new masking tape 43 Install new gasket 10 sector shaft 3 and side cover 9 as an assembly in housing 4 Center tooth of sector shaft 3 must be in valley between second and third tooth of rack piston 22 44 Apply a light coat of lubricating oil to six screws 8 Install screws in housing 4 and tig
166. turn other fitting with a second wrench 14 Apply loctite to threads of compressor 4 fittings and install two hoses 3 15 Connect compressor clutch electrical lead 1 to engine harness 2 NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 16 Replace receiver drief WP 0118 00 17 Install and adjust alternator belt 18 Charge air conditioning systen WP 0112 00 0117 00 3 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR REPLACEMENT CONTINUED 0117 00 INSTALLATION CONTINUED WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 19 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0117 00 4 TM 9 2320 302 34 AIR CONDITIONER RECEIVER DRIER REPLACEMENT 0118 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Oil refrigerant Item 27 WP 0125 00 Tools and Special Tools Rags wiping Item WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Gloves rubber Item 40 WP 0126 00 Tags marker Item 35 WP 0125 00 Goggles Item 42 WP 0126 00 Equipment Condition Binary switch removed TM 9 2320 302 20 Packing preformed P N J200AR11 2 Adhesive loctite Ite
167. with a full tank of fuel will vary based on conditions e g varying loads prolonged idle and climatic conditions Cruising range is optimally 400 miles 640 km The M915A3 is equipped with an instrument panel mounted speedometer and tachometer which register truck ground speed and engine speed The M915A3 has the following capabilities and features 1 air activated front and rear non asbestos cam brakes with a four channel anti lock brake system ABS to provide significantly improved handling and braking during emergency stops 2 operation in temperatures from 25 F 32 C to 125 F 452 C and to 40 F 40 C with arctic kit installed 3 start and climb capability of a 20 percent grade at GCWR in both forward and reverse directions 4 fording capability up to 20 in 51 cm deep for 5 minutes without damage or requiring maintenance before operations can continue 5 two passenger aluminum corrosion proof cab with a 90 degree tilt forward hood for service accessibility 6 six cylinder 12 7 liter 430 horsepower in line turbocharged diesel engine built by Detroit Diesel 7 Allison HD 4560P six speed automatic transmission 8 Collision Warning System CWS that warns the driver of potentially dangerous driving situations by acti vating visual and audible alerts For operation in arctic conditions the M915A3 can be equipped with an arctic heater mounted under the cab above the battery box This provides heat for
168. 0 Page 0003 00 3 0003 00 1 0003 00 3 0003 00 2 0003 00 1 0003 00 8 0003 00 7 0003 00 7 0074 00 1 0094 00 1 0093 00 1 0123 00 1 0003 00 7 0071 00 1 0070 00 1 0007 00 1 0006 00 1 0004 00 1 0008 00 1 0005 00 1 0007 00 1 0009 00 1 0017 00 1 0044 00 1 0045 00 1 0043 00 1 0042 00 1 0060 00 1 0059 00 1 0030 00 1 0020 00 1 TM 9 2320 302 34 INDEX Continued Subject Work Package Page W Warranty Information lssseeee RI RII A et 0001 00 0001 00 1 Wastegate Actuator Maintenance SK T rbocharger eder a ERE XEM REG DARE P ek ee dr 0044 00 0044 00 1 Garrett Turbocharger eee 0045 00 0045 00 1 Water Pump Ropars Sci wae nek qx Deu dae 0049 00 0049 00 1 Wheel Replacement Fifth 0091 00 0091 00 1 Window Replacement Rear 0110 00 0110 00 1 Windshield Replacement 0109 00 0109 00 1 Wiring Harness Replacement Air Conditioner Binary Switch 0068 00 0068 00 1 Anti lock Brake System ABS 0065 00 0065 00 1 Anti lock Brake System ABS Front 0063 00 0063 00 1 Anti lock Brake System ABS Rear 0064 00 0064 00 1 jute ora Sh ee aa een Ra pales tee
169. 0 REMOVAL CONTINUED 342 1135 24 25 8 Remove six nuts 26 washers 27 screws 28 washers 29 and rear engine mount 5 from frame rail 25 9 Repeat steps 5 through 8 for right side INSTALLATION V WARNING Engine weighs 2850 16 1294 kg Use hoist with lifting capacity of 5000 Ib 2270 kg to lift and support engine Failure to do so could result in injury to personnel On right side install rear engine mount 5 six washers 29 screws 28 washers 27 and nuts 26 on frame rail 25 On right side install two isolators 23 and washers 22 in rear engine mount 5 On right side install rear engine leg 20 two screws 19 washers 18 and screws 17 in flywheel housing 21 Repeat steps 1 through 3 for left side Remove jack stands from cab mounts 24 On left side install two washers 4 screws 3 washers 2 and nuts 1 hand tight in rear engine mount 5 On right side install washer 15 bracket 11 two screws 14 washers 13 and nuts 12 on rear engine mount 5 Lower engine 16 onto engine mounts and tighten four nuts 1 and 12 on left and right sides 00 4 6 deo qoo rn On right side install clamp 10 washer 9 screw 8 clamp 7 and new lock nut 6 on bracket 11 END OF WORK PACKAGE 0012 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0012 00 4 TM 9 2320 302 34 FAN DRIVE SUPPORT REPLACEMENT 0013 00 THIS WORK PACKAGE COVER
170. 0 REMOVAL CONTINUED WARNING Do not slide gear case cover off guide studs Failure to observe this warning may result in injury to person nel or damage to equipment 10 Move gear case cover 4 away from gear housing 5 and position lifting sling through camshaft gear cover opening on gear case cover V WARNING Gear case cover weighs 89 Ib 40 kg Attach suitable lifting device prior to removal to prevent possible injury to personnel 11 Secure lifting sling to suitable lifting device Remove gear case cover 4 from two guide studs 14 12 Remove and discard seal ring 20 between bull idler gear hub recess 21 and gear case cover 4 13 Remove two guide studs 14 342 980 14 Remove all old gasket material from mating surfaces of gear case cover 4 and gear housing 5 15 Remove front oil seal 22 from gear case cover 4 Discard seal 0019 00 3 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED 0019 00 INSTALLATION 1 Position lifting sling through camshaft drive gear cover opening of gear case cover 4 and secure to suitable lift device NOTE Gasket forming compound cures in presence of air Keep time to minimum between gear case cover installa tion and tightening gear case cover mounting bolts 2 Apply continuous thin bead of gasket forming compound to mating surfaces of gear housing 5 3 Install two guide studs 14 in bolt holes on opposite side of gear housing 5
171. 0 The Army Maintenance Management System TAMMS for instructions on the use of main tenance forms Equipment Inspection and Maintenance 8555 DA Form 2404 Equipment Log Assembly Records t DA Form 2408 Maintenance Request e e em eee DA Form 2407 Preventive Maintenance Schedule and Record 1 0 ununun nuenaren renner rererere DD Form 314 Processing and Deprocessing Record for Shipment Storage and Issue of Vehicles and Spare Engines DD Form 1397 Product Quality Deficiency Reports cscs ene enna SF Form 368 Recommended Changes to Equipment Technical Publications DA Form 2028 2 Recommended Changes to Publications and Blank 0 ee eee DA Form 2028 Report of Discrepancy ROD 1 0 e e rh SF Form 364 FIELD MANUALS Metal Body Repair and Related I e FM 43 2 Operation and Maintenance of Ordnance Material in Extreme Cold Weather to 65 FM 9 207 TECHNICAL BULLETINS AND SUPPLY BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materiels Handling Equipment 0 rnrn rrenen arrra cece teen hn TB 43 0209 Corrosion Preven
172. 0 600 lb ft Item 140 WP 0126 00 0081 00 DISASSEMBLY V M WARNING Rear rear axle differential carrier weighs 860 Ibs 390 kg Attach suitable floor jack prior to disassembly to prevent possible injury to personnel 0082 00 1 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED 1 Install differential carrier 1 on repair stand 342 1196 2 Turn differential carrier 1 so ring gear 2 is up NOTE If reinstalling same ring gear and drive pinion perform steps 3 through 5 to measure backlash 3 Move ring gear 2 so ring gear teeth fully engage with drive pinion 3 4 Install dial indicator on flange of differential carrier 1 so that tip of indicator is against drive side of tooth ring gear 2 Adjust dial indicator to zero 5 Rotate ring gear 2 in both directions and record reading 6 Repeat step 5 two more times in different locations 342 1197 0082 00 2 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED 7 Matchmark position of two bearing caps 4 5 on differential carrier 1 342 1198 8 342 1199 0082 00 3 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED CAUTION To prevent damage to adjusting rings do not hit adjusting rings with hammer or use hammer and drift pin to loosen rings 9 Re
173. 00 DISASSEMBLY CONTINUED Press down washer 16 and remove retaining ring 17 Discard retaining ring 8 Remove washer 16 spring 18 spring 19 and collar 20 9 Remove control valve 21 from engine retarder 6 housing 10 Loosen lock nut 22 and remove adjusting screw 23 from engine retarder 6 housing 11 Turn engine retarder 6 housing over 12 Remove screw 24 washer 25 and flat spring 26 from engine retarder 6 housing 13 Remove master piston 27 from engine retarder 6 housing 342 661 14 Remove screw 28 washer 29 torsion spring 30 slave piston bridge 31 and slave piston 32 15 Loosen lock nut 22 and remove adjusting screw 23 from piston bridge 31 0022 00 4 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 DISASSEMBLY CONTINUED 342 662 CLEANING AND INSPECTION CAUTION Do not use rags that may leave lint and residue which can plug oil passageways 1 Using clean lint free wipes clean engine retarder housing bores Dip control valves and pistons in clean engine lubricat ing oil 2 Verify ball 33 moves freely by pushing wire through hole 34 in base of control valve 21 Light pressure on wire should move ball Ball should return when pressure is released 342 663 0022 00 5 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 CLEANING AND INSPECTION CONTINUED 3 Ensure plunger 35 prot
174. 00 895 N 1234 250 339 660 895 1342 0123 00 2 TM 9 2320 302 34 Table 2 Refrigerant Line Torque Specifications OUTSIDE DIAMETER OF TORQUE FOR STEEL TORQUE FOR ALUMINUM OR METAL TUBE IN TUBES LB FT NM COPPER TUBES 3 4 30 35 41 47 15 20 20 27 30 35 41 47 21 27 28 37 30 35 41 47 28 33 38 45 When tightening fittings always use torque reading for softer metal when unlike metals are used 0123 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0123 00 4 TM 9 2320 302 34 CHAPTER 4 SUPPORTING INFORMATION TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 REFERENCES 0124 00 SCOPE This work package lists all forms field manuals technical bulletins technical manuals and other publications refer enced in this manual and which apply to Direct Support and General Support Maintenance of the M915A3 Line Haul Tractor Truck PUBLICATIONS INDEXES The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this technical manual Consolidated Index of Army Publications and Blank Forms 0 0 00 eee ee cee eee DA Pam 25 30 Functional User s Manual for the Army Maintenance Management DA Pam 738 750 U S Army Equipment Index of Modification Work Orders 00000 cece eens DA Pam 750 10 FORMS Refer to DA Pam 738 75
175. 00 1 Index 6 TM 9 2320 302 34 INDEX Continued Subject Work Package Page P Continued Power Steering Pump RODA tc eae hots erie ints antes etary Ga ea ita ocd bea Se ee 0087 00 0087 00 1 Replacement GARE Ra ane BU a Rep E EE ETE 0086 00 0086 00 1 Preparation for Storage or Shipment 0001 00 0001 00 1 Pressure Testing Cylinder Block 0040 00 0040 00 1 Pump Repair Water raren iaaa tiean n 0049 00 0049 00 1 Pump Oil Maintenance 0029 00 0029 00 1 R Radiator Flepalt cemere de ake al eR Rae we E uk de ee ee 0048 00 0048 00 1 Ramp Replacement nh 0095 00 0095 00 1 Rear Anti lock Brake System ABS Wiring Harness Replacement 0064 00 0064 00 1 Axle Replacement 0 000 cece nh 0078 00 0078 00 1 Cab Mounts Replacement 0098 00 0098 00 1 Engine Mounts Replacement 0012 00 0012 00 1 Oil Seal Replacement Crankshaft 0023 00 0023 00 1 Spring Assembly Replacement 0102 00 0102 00 1 Suspension Center Bearing Replacement 0101 00 0101 00 1 Suspension Control Rod and V rod Replacement 0103 00 0103 00 1 Suspension System Theory of
176. 00 4 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 INSTALLATION CONTINUED 3 4 5 Install air compressor fitting 26 in cylinder head 3 Remove tags and install two elbows 24 and 25 in cylinder head 3 Install lifter 17 between fuel injectors no 3 and no 4 a Install bolt 18 using bolt hole for center cam cap bolt b Install two bolts 19 using two tapped holes for engine retarder assembly VA WARNING Cylinder head weighs 421 lb 191 kg Use suitable lifting device to lift and support cylinder head Failure to do so could result in injury to personnel Attach suitable lifting device to lifter eye 20 and position cylinder head 3 over engine block 27 Seat cylinder head 3 on diamond dowel 28 and round dowel 29 until full contact is made with cylinder head gasket 21 Remove lifting device from lifter eye 20 NOTE If cylinder head is other than one removed or if resurfaced cylinder head is being installed three nuts retain ing adjustable idler gear must be loosened before installing and tightening camshaft drive gear retaining bolt Notify General Support Maintenance to perform adjustment Remove lifter 17 0018 00 5 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 INSTALLATION CONTINUED 10 Lubricate threads of 38 cylinder head bolts 15 and bolt head contact areas with a small amount of international com pound no 2 11 In
177. 00 Ib ft Item 140 Equipment Condition Wrench set socket 3 4 in drive Item 141 WA Taillight brackets removed TM 9 2320 302 20 0126 00 Pintle hook removed TM 9 2320 302 20 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel NOTE This task covers replacement of the REAR crossmember and is typical of procedures used to replace other crossmembers of the vehicle 0096 00 1 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT CONTINUED 0096 00 REMOVAL 1 Remove four lock nuts 1 and clamps 2 and set wiring harness 3 aside Discard lock nuts NOTE Vehicle may utilize huckbolts instead of screws and lock nuts Replace all loose or damaged huckbolts with grade 8 screws and lock nuts 2 Remove eight lock nuts 4 four washers 5 towing bracket 6 four screws 7 four washers 8 and reinforcement assembly 9 Discard lock nuts 3 Remove five lock nuts 10 washers 11 screws 12 washers 13 two spacers 14 and left side gusset 15 Discard lock nuts 4 Repeat step 3 for right side gusset 16 B Ks WARNING Plate weighs 96 Ib 44 kg Use hoist with lifting capacity of 200 Ib 91 kg to remove plate F
178. 0027 00 12 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 ADJUSTMENT CONTINUED NOTE Ensure injector timing height gage is seated on machined surface with tip in pilot hole Foreign material in pilot hole or on machined surface may prevent accurate setting of injector height Adjust height of fuel injector 29 for cylinder indicated on valve overlap adjustment sequence Table 1 Position small end of injector timing height gage 30 in hole in fuel injector body 31 with flag 32 of gage toward fuel injector plunger 33 as shown 33 31 29 WW O 0 te K 0 cc 342 721 0027 00 13 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 ADJUSTMENT CONTINUED j Loosen jamnut 11 and turn adjusting screw 12 until flag 32 of injector timing height gage 30 just clears top of fuel injector plunger 33 An accurate feel will be developed Adjust all injectors to the same feel k Tighten jamnut 11 to 30 35 lb ft 41 47 Nm Check adjustment with injector timing height gage 30 and if nec essary readjust l Remove injector timing height gage 30 11 12 A 33 vA LA s 8 2 a y Le L J i A y di we 1085 e pem 24 C 32 Ss 7 CN j SZ PNEU NSSSSSS TIT x 342 722 m Refer to adjusting sequence Table 1 and proceed to next cylinder in adjustment
179. 010 00 5 0010 00 342 934 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED NOTE Steps 17 through 19 can be performed through center floor panel of cab 17 Remove lock nut 62 washer 63 and clamp 64 Discard lock nut 18 Remove lock nut 65 washer 66 and bracket 67 Discard lock nut 19 Remove lock nut 68 washer 69 and two clamps 70 Discard lock nut Si KC m NT Op 342 936 20 Remove nut 71 washer 72 screw 73 and washer 74 from left side of crossmember 75 73 74 71 72 A Y 44 EA LI 2 S j ee M 342 937 21 Remove nut 76 washer 77 screw 78 and washer 79 Remove crossmember 75 0010 00 6 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 78 79 342 938 Steps 22 through 26 can be performed through center floor panel of cab 22 Remove lock nut 80 washer 81 and clamp 82 Discard lock nut 23 Remove lock nut 83 washer 84 screw 85 washer 86 and clamp 87 Discard lock nut 24 Remove lock nut 88 washer 89 and clamp 90 from rear of engine block 26 Discard lock nut 25 Disconnect connector 91 from engine brake harness 92 26 Disconnect fuel return hose 93 from hose 94 Plug fuel return hose and set aside 82 gt 0010 00 7 TM 9 2320 302 34 POWE
180. 1 11 Pound Spool STRAP Tiedown Electrical Components Box of 100 96906 MS3367 1 0 6 Inch Length 1 75 Inch Maximum Bundle Black 96906 MS3367 2 1 13 35 Inch Length 4 Inch Maximum Bundle Brown 96906 MS3367 4 0 4 Inch Length Black TAG Marker 64067 9905 00 537 8954 Bundle of 50 0125 00 4 TM 9 2320 302 34 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0125 00 Table 1 Expendable and Durable Items List Continued 1 3 4 ITEM NATIONAL DESCRIPTION CAGEC NUMBER STOCK NUMBER AND PART NUMBER TAPE Insulation Thermal 2 Inches Wide 73030 HS7495 618 5640 00 580 6276 30 Foot Length TAPE Pressure sensitive Adhesive Masking 1 5 Inches Wide 58536 A A 883 75 10 00 266 6709 60 Yard Roll TETRAFLUOROETHANE Technical Refrigerant R 134A Type 4V886 R134A 6830 01 439 0614 43 Pound Cylinder 5180 00 754 0643 TOOL KIT Body and Fender Repair 50980 SC5180 90 N34 8305 01 301 1031 WIPES Lint free 28480 92193W WIRE 14 Gage 0125 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0125 00 6 TM 9 2320 302 34 TOOL IDENTIFICATION LIST 0126 00 SCOPE This work package lists all common tools and supplements and special tools fixtures needed to maintain the M915A3 Tractor Truck at Direct Support and General Support Maintenance EXPLANATION OF COLUMNS IN THE TOOL IDENTIFICATION LIST 1 Column 1 Item Number This number is assigned to the entry
181. 1 TM 9 2320 302 34 RADIATOR REPAIR CONTINUED 0048 00 DISASSEMBLY CONTINUED 1 Remove two lock nuts 1 expansion tank 2 and radiator 3 from radiator top channel 4 Discard lock nuts NOTE Position radiator front face down on workbench with right hand outlet tank over edge It may be necessary to place radiator on blocks to gain access to end tank hardware 2 Remove lock nuts 1 bolting bars 5 and 6 and screws 7 and 8 securing right hand outlet tank 9 and header gasket 10 to top and bottom channel 4 and 11 Discard lock nuts 3 Remove right hand outlet tank 9 and header gasket 10 Discard gasket 4 Remove lock nuts 1 bolting bars 5 and 6 and screws 7 and 8 securing left hand inlet tank 12 and header gasket 10 to top and bottom channel 4 and 11 Discard lock nuts 5 Remove left hand inlet tank 12 and header gasket 10 Discard gasket 6 Remove drain plug 13 from inlet tank 12 1 342 802 0048 00 2 TM 9 2320 302 34 RADIATOR REPAIR CONTINUED 0048 00 DISASSEMBLY CONTINUED WARNING Radiator core vanes are sharp and can easily cut Gloves should be worn when handling bare radiator cores to prevent injury to personnel CAUTION Use care when handling or storing radiator cores as core vanes are thin and easily bent If many vanes are bent air flow through radiator core will not be sufficient for cooling Equipment damage will result 3
182. 11 WARNING CARBON MONOXIDE EXHAUST GASES CAN KILL e Carbon monoxide is a colorless odorless deadly poison which when breathed deprives the body of oxygen and causes suffocation Exposure to air containing carbon monoxide produces symptoms of headache dizziness loss of muscular control apparent drowsiness and coma Permanent brain damage or death can result from severe exposure e Carbon monoxide occurs in exhaust fumes of internal combustion engines Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation The following precau tions must be observed to ensure safety of personnel when engine of truck is operated l DO NOT operate truck engine in enclosed areas 2 DO NOT idle truck engine without adequate ventilation 3 DO NOT drive truck with inspection plates or cover plates removed 4 BE ALERT for exhaust poisoning symptoms They are e Headache e Dizziness e Sleepiness e Loss of muscular control 5 If you see another person with exhaust poisoning symptoms Remove person from area e Expose to fresh air e Keep person warm e not permit physical exercise e Administer cardiopulmonary resuscitation CPR if necessary e Notify a medic 6 BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from car bon monoxide poisoning The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation TM 9 2320 302 34
183. 11 00 1 342 883 TM 9 2320 302 34 AIR DUCTS REPLACEMENT CONTINUED 0111 00 REMOVAL CONTINUED Remove two self tapping screws 3 and separate flex tubing 4 from duct 5 Remove two screws 6 duct outlet 7 and duct 5 Remove two self tapping screws 8 duct 9 and flex tubing 4 Remove five clips 10 and separate flex tubing 4 from duct 9 Remove hose clamp 11 flex tubing 12 and duct outlet 13 Remove two self tapping screws 14 and separate flex tubing 12 from duct outlet 13 Remove self tapping screw 15 speed nut 16 and outlet duct 17 from duct 18 PF oO ono Remove self tapping screw 19 washer 20 spring nut 21 and duct 18 e Remove screw 22 vent 23 and gasket 24 Remove three self tapping screws 25 and face duct 26 342 883 0111 00 2 TM 9 2320 302 34 AIR DUCTS REPLACEMENT CONTINUED 0111 00 INSTALLATION Install face duct 26 and secure with three self tapping screws 25 Install gasket 24 vent 23 and secure with screw 22 Install duct 18 and secure with spring nut 21 washer 20 and self tapping screw 19 Secure outlet duct 17 to duct 18 with speed nut 16 and self tapping screw 15 1 2 3 4 5 Connect flex tubing 12 to duct outlet 13 and secure with two self tapping screws 14 6 Connect flex tubing 12 to face duct 26 and secure with hose clamp 11 7 Connect flex tubing 4 to duct 9 a
184. 120 00 1 Air Conditioner Hose 0121 00 1 Illustrated List of Manufactured 0122 00 1 WP 0123 00 Torque 0123 00 1 SUPPORTING INFORMATION Referentes NETT T ETE T T T TU TT 0124 00 1 Expendable and Durable Items 4 0125 00 1 Tool Identification Lis e 0126 00 1 TM 9 2320 302 34 HOW TO USE THIS MANUAL This manual is designed to help you maintain the M915A3 Tractor Truck FEATURES OF THIS MANUAL A Table of Contents is provided at the beginning of this manual WARNINGs CAUTIONS NOTEs subject headings and other important information are highlighted in BOLD print as a visual aid WARNING A WARNING indicates a hazard which results in death or serious injury CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE A NOTE is a statement containing information that will make the procedures easier to perform Statements and words of particular importance are printed in CAPITAL LETTERS to create empha sis Instructions are located with illustrations that show the specific task on which the mechanic is work ing Dashed leader lines used in illustrations indicate that called out items are not visible i e they are loca
185. 19 Connector 1 ECM WIRING HARNESS INSTALLATION 1 Install and connect ECM wiring harness using illustration and table as a guide 2 Secure ECM wiring harness 15 to engine with clamps 14 and screws 13 0069 00 4 TM 9 2320 302 34 ENGINE INJECTOR AND ECM WIRING HARNESSES REPLACEMENT CONTINUED 0069 00 ECM WIRING HARNESS INSTALLATION CONTINUED 3 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0069 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0069 00 6 TM 9 2320 302 34 TRANSMISSION REPLACEMENT 0070 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Air system drained 9 2320 302 10 i Tools and Special Tools Spare tire removed TM 9 2320 302 10 Tool kit general mechanic s Item 132 WP 0126 00 Transmission fluid drained TM 9 2320 302 20 Barring tool engine Item 8 WP 0126 00 Driveline removed TM 9 2320 302 20 Lift transmission Item 75 WP 0126 00 o ms cooler lines disconnected TM 9 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Transmission electrical harness s disconnected Materials Parts 9 2320 302 20 Washer lock P N MS35333 43 12 Transmission tunnel access cover removed TM 9 2320 302 20 Personnel Required Transmission oil fill tube removed TM 9 2320 302 Two 20 va WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce
186. 1in 11 709 mm to surface C Split line B should measure 1 726 in 43 84 mm to surface C NOTE Bushings must be installed flush to specified depth below finished surface of pump body 6 Press bushings 24 in pump body bushing bores 33 not more than 0 031 in 0 78 mm below finished surface of oil pump body 20 0029 00 7 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY CONTINUED 7 Place oil pump cover 19 pump body side down on press support Apply thin film of lubriplate to bushing bores 25 8 Position bushings 24 loosely over bushing bores 25 24 342 733 9 Rotate bushings 24 so split lines A are aligned in pump cover bushing bores 25 as shown NOTE Bushings must be installed to specified depths below finished surface of oil pump cover 10 Press bushings 24 in pump cover bushing bores 25 0 011 0 031 in 0 28 0 78 mm below finished surface of oil pump cover 19 342 734 NOTE Pump body and pump cover bushings are finished to size after installation in their respective bores Use sin gle point tooling to avoid smearing oil retention surfaces 0029 00 8 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY CONTINUED 11 Bore out inside diameter of bushings 24 in oil pump body 20 and oil pump cover 19 to 0 879 0 880 in 22 33 22 35 mm 342 735 12 If removed install tubular shaped dowel 27 in bore of pump body 20 mou
187. 2 C 93 C Leave cylinder head in water for 20 minutes Watch for bubbles indicating crack or leak If cracked replace cylinder head 11 Using heavy straightedge 41 and thickness gage 42 check for warped cylinder head fire deck 20 0032 00 10 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 CLEANING AND INSPECTION CONTINUED 342 1015 12 Check cylinder head fire deck 20 for longitudinal warpage in 5 places 1 through 5 and transverse warpage at 12 places A through L Fire deck must be flat within 0 011 in 0 279 mm front to rear and 0 003 in 0 076 mm side to side If not resurface fire deck ark 342 1016 0032 00 11 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 CLEANING AND INSPECTION CONTINUED CAUTION Maximum amount of resurfacing is 0 030 in 0 762 mm Limit resurfacing to 0 030 in 0 762 mm If exceeded replace cylinder head to prevent damage to equipment 13 Record amount of stock removed from cylinder head by stamping amount removed on pad 43 on front of cylinder head Measure from top rail 44 to fire deck surface 45 Resurface finish must be 90 U in AA 2 3 UM AA T 6 4901 6 3019 in 164 85 165 15 mm 44 342 1017 45 NOTE It may be necessary to restore injector tube counterbore when cylinder head is resurfaced 14 Ensure countersink injector tube bores 46 land width is 0 040 0 080 in 1 0 2 0 mm 47 x 45 degrees 48
188. 2 2358 4910 01 157 3571 4910 01 160 3618 Tester Impeller J35687 33287 TFTLN 1000 74410 J 26487 B 33287 Tester Kingpin Lock Tester Power Steering Tester grams Spring Resiliency Tool Torque Converter Bolt Tool Base Spring Compressor C1 C2 and C5 Tool Kit Electrical Connector Repair Tool Kit Automotive General Mechanic s Tool Set Spanner Nut Torque Tray Set Valve Body Parts Trestle Hoist Portable 7 ton capacity Vise Machinist s Wrench Torque 3 8 in drive 0 300 Ib in capacity Wrench Torque 3 8 in drive 15 75 Ib ft capacity Wrench capacity Torque 50 250 lb ft Wrench Torque 3 4 in drive 100 600 lb ft capacity Wrench Set Socket 3 4 in drive Wrench Set Socket Attachment screwdriver torx 1 4 and 3 8 in drive 6635 00 182 7534 5180 00 876 9336 5180 00 177 7033 3950 00 25 1 8013 5120 00 293 1439 5120 00 776 1841 5120 01 355 1734 5120 01 042 0982 5120 01 113 9564 5120 00 204 1999 5120 01 178 6342 0126 00 7 1 20 08292 J38564 33287 J37030 3 33287 7550526 19204 SC5180 90 N26 50980 J37035 33287 J33163 33287 306 79805 504M2 79416 2163993 10001 QC2FR75 55719 VB 2503MFR 27464 7379 45225 FEDSTD353 06542 J 29843 33287 SC 4910 95 A31 TM 9 2320 302 24P TM 9 2320 302 24P SC 4910 95 A31 SC 5180 95 N26 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95
189. 2 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 81 Install thrust washer 32 in pilot bore on gear 31 82 Install gear 31 on input shaft 13 342 1238 83 Install pinion differential case 14 with screw heads facing gear 31 and snap ring 30 on input shaft 13 342 1269 0080 00 31 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 84 85 86 87 88 89 90 91 Install yoke 9 an 0 5 in 12 7 mm assembly spacer 70 and lock nut 8 Hand tighten lock nut 70 AXA pore 0 comm 342 1270 Install bearing cone 25 on side gear 24 342 1271 Rotate differential carrier 1 so that ring gear 2 is toward floor Install bearing cup 28 in differential carrier 1 Install fork 27 clutch 26 and side gear 24 in differential carrier 1 Install spring 23 in differential carrier 1 Install jamnut 22 and adjusting screw 21 in differential carrier 1 Install shift shaft 20 new seal 19 cover 18 and four socket head screws 17 Tighten screws to 49 76 Ib in 5 5 8 5 Nm 0080 00 32 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 342 1232 92 NOTCHES ON CASE MUST BE ALIGNED OVER HELICAL DRIVE GEAR 342 1272 0080 00 33 TM 9 2320 302 34 FORWARD REAR AXLE D
190. 2 34 Table 1 Steering System Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 2 No Recovery Continued f With engine idling close If pressure is less than 900 psi load valve and read pressure 62 07 bars repair or replace gage Pressure must be 900 power steering pump to 1000 psi 62 07 to 68 97 WP 0087 00 oi WP 0086 00 bars 3 Check for sufficient pump flow as follows a Perform steps a through e of step 2 WARNING Maximum flow rate is 7 gpm 26 5 liters min Flow rate in excess of 7 gpm 26 5 liters min will damage steering gear and could cause loss of steering and injury to personnel b With engine idling read Repair or replace power steering flow meter Rate of flow pump WP 0087 00 or must be 7 gpm 26 5 liters WP 0086 00 min c With engine idling close Repair or replace power steering load valve until pressure pump WP 0087 00 or gage indicates pump relief WP 0086 00 and pump relief pressure drops to 0 Immediately open load valve Flow rate must return to 7 gpm 26 5 liters min d Run engine at 2100 rpm and Repair or replace power steering fully close load valve until pump WP 0087 00 or pressure gage indicates WP 0086 00 pump relief and flow rate drops to 0 Immediately open load valve Flow rate must return to 7 gpm 26 5 liters min Check for defective teflon seals Repair or replace steering gear in steering contro
191. 20 01 322 1133 J33190 33287 TM 9 2320 302 24P Replacing Tool Engine 5120 01 322 2955 J34983 33287 TM 9 2320 302 24P Riveter Blind Hand 3 32 in 1 8 in 5120 00 017 2849 250K 10054 SC 4910 95 A74 5 32 in and 3 16 in diameters Scale 4910 00 707 9178 J544 01 33287 Service Kit Accessory Drive 5120 01 322 3499 J36024 33287 Service Kit Water Pump 5120 01 322 6115 J35988 C 33287 Shield Turbo Protect 4910 01 127 7959 J26554 A 33287 Slider Spring Compression 4910 01 165 6015 TFTLN 2500 74410 Sling Beam Type 3940 01 353 8561 J 39520 33287 GSA Catalog Socket Socket Wrench 5120 01 322 1123 J36003 A 33287 Socket Socket Wrench 19 mm deep 5120 01 348 9154 SM19 55719 G5A Catalog well 12 pt Soldering Gun 3439 00 542 0396 8200G3 97049 SC 4910 95 A31 Spanner Attachment 5120 01 353 8490 J 37464 33287 Spreader Sling 3940 01 354 9446 38841 45225 Test Block Pressure Switch J33884 33287 Test Stand Automotive Generator 4910 00 767 0218 MILT4544 81349 SC 4910 95 A02 and Starter Tester Cylinder 4910 01 320 4638 J29006 5 33287 TM 9 2320 302 24P Tester Cylinder 4910 01 319 6990 J36223 D 33287 TM 9 2320 302 24P 0126 00 6 TM 9 2320 302 34 TOOL IDENTIFICATION LIST CONTINUED 0126 00 Table 1 Tool Identification List Continued 2 3 4 5 NATIONAL STOCK NUMBER PART NUMBER ITEM NAME CAGEC REFERENCE TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P 5120 01 32
192. 21 from piston Discard packings 7 If damaged remove and discard studs 22 from housing 13 342 839 ASSEMBLY 1 If removed install new studs 22 in housing 13 2 Install two new packings 19 and 20 and spring carrier 21 to piston 18 3 Install piston assembly 18 and retaining ring 17 4 Install new spring 16 end cap 15 new seal 14 and housing 13 on shaft assembly 12 5 Compress housing 13 and shaft assembly 12 using two clamps and install new lining 11 three retaining plates 10 six new lock washers 9 and new screws 8 in shaft assembly 6 Remove two clamps from opposite sides of clutch assembly 7 ds Install new dust seal 6 new packing 5 new seal 4 cylinder 3 new tab washer 2 and new nut 1 on clutch assembly 7 8 Install fan clutch TM 9 2320 302 20 END OF WORK PACKAGE 0050 00 2 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR THIS WORK PACKAGE COVERS Disassembly Inspection Assembly INITIAL SETUP 0051 00 Materials Parts Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Caps vise jaw Item 17LWP 0126 00 Inserter and remover Item 53 WP 0126 00 Pliers retaining ring Item 88 WP 0126 00 Pliers retaining ring Item 89 WP 0126 00 Press arbor Item 90 WP 0126 00 Puller kit mechanical Item 95 WP 0126 00 Vise machinist s Item 136 WP 0126 00 Wre
193. 21 00 0121 00 1 Housing Assembly Replacement Gear 0035 00 0035 00 1 Housing Replacement Flywheel 0024 00 0024 00 1 HVAC Unit Replacement errereen eee 0113 00 0113 00 1 l Idler Gear Replacement Adjustable 0038 00 0038 00 1 Illustrated List of Manufactured lt 0122 00 0122 00 1 Injector Replacement 0046 00 0046 00 1 L List Abbreviations 3 ed etu gated guna p parete BAER rae S 0001 00 0001 00 2 Nomenclature Cross reference 0001 00 0001 00 2 Index 5 TM 9 2320 302 34 INDEX Continued Subject Work Package Page L Continued Location and Description of Major Components 0002 00 0002 00 2 M Main Cab Wiring Harness Replacement 0057 00 0057 00 1 Maintenance Forms Records and Reports 0001 00 0001 00 1 Major Components Location and Description 0002 00 0002 00 2 Manifold Replacement en ee ee Speen eee ee 0014 00 0014 00 1 ExHallSt 5 edu ene epatis ies Da be te eb dece 0015 00 0015 00 1 Manufactured Items Illustrated List 0122 00 0122 00 1 Mounts Replacement Front
194. 27 0096 00 4 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT CONTINUED 0096 00 INSTALLATION CONTINUED 27 26 7 V e e 8 E 22280425 WA TI WARNING Plate weighs 96 Ib 44 kg Use hoist with lifting capacity of 200 lb 91 kg to install plate Failure to do so could result in injury to personnel Attach hoist and install plate 21 with 12 washers 20 screws 19 washers 18 and new lock nuts 17 Install right side gusset 16 two spacers 14 five washers 13 screws 12 washers 11 and new lock nuts 10 Repeat step 5 for left side gusset 15 RB Install reinforcement assembly 9 four washers 8 screws 7 towing bracket 6 four washers 5 and eight new lock nuts 4 10 11 1213 12 13 10 26 0096 00 5 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT CONTINUED INSTALLATION CONTINUED 8 9 10 11 12 13 14 Move wiring harness 3 into position and install four clamps 2 and new lock nuts 1 NOTE Perform steps 9 through 12 for this and other crossmembers Tighten 1 2 13 grade 8 lock nuts to 68 Ib ft 92 Nm Tighten 5 8 11 grade 8 lock nuts to 136 Ib ft 184 Nm Tighten 3 4 10 grade 8 lock nuts to 241 Ib ft 327 Nm Tighten 1 8 grade 8 lock nuts to 582 lb ft 789 Nm Install pintle hook TM 9 2320 302 20 Install taillight brackets END OF WORK PACKAGE 0096 00 6 342 959 0096 00 TM 9 2320 302 34
195. 3 5 Cover spined end of sector shaft 3 with masking tape 6 342 841 6 Remove nut 7 six screws 8 side cover 9 sector shaft 3 and gasket 10 from housing 4 Discard gasket 0089 00 2 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED 342 842 7 Remove sector shaft 3 from side cover 9 by turning adjusting screw 11 clockwise 342 843 0089 00 3 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED NOTE Remove adjusting screw to install temporary screw to pry against during bearing removal 8 Install 1 2 20 UNF 2 X 3 in screw in adjusting screw hole 12 in side cover 9 CAUTION Use care when removing seal to prevent damage to side cover bushing 9 Remove and discard seal 13 from side cover 9 10 Remove temporary screw and replace with adjusting screw 11 11 Remove vent plug 14 from side cover 9 342 844 NOTE If adjusting screw or retainer are damaged perform steps 12 and 13 12 Place sector shaft 3 in soft jawed vise 13 Unstake remove and discard retainer 15 and adjusting screw 11 342 845 0089 00 4 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED 14 Remove two plugs 16 packings 17 and grease fitting 18 from housing 4 Discard packings and grease fitting 342 846 15 Remove and discard seal 19 from valve housing
196. 3 Nm Install new gasket 17 and camshaft gear cover 16 on gear case cover 4 Install five bolts 15 to secure camshaft gear cover 16 Tighten bolts to 22 28 lb ft 30 38 Nm 342 981 Install power steering pump WP 0086 00 Install oil pai WP 0028 00 Install accessory driv WP 0021 00 Install fan drive 0013 00 0019 00 6 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED INSTALLATION CONTINUED 21 22 23 24 Install front engine mount adapter WP 0011 00 Install air compressor TM 9 2320 302 20 Install water pump Install alternator END OF WORK PACKAGE 0019 00 7 0019 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0019 00 8 TM 9 2320 302 34 VIBRATION DAMPER REPLACEMENT 0020 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Fan belts removed TM 9 2320 302 20 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 REMOVAL CAUTION To prevent damage to pulley and vibration damper support pulley and damper during removal 1 Remove six crankshaft pulley attaching bolts 1 and washers 2 from crankshaft pulley 3 342 670 0020 00 1 TM 9 2320 302 34 VIBRATION DAMPER REPLACEMENT CONTINUED 0020 00 REMOVAL CONTINUED CAUTION Do not pry on pulley or damper
197. 30 Nm Rotate input shaft 13 in each direction to ensure bearings are installed correctly 104 Remove lock nut 8 0 5 in 12 7 mm assembly spacer 70 and yoke 9 105 Install new oil seal 29 yoke 9 and lock nut 8 Using pinion holding bar tighten lock nut to 450 600 Ib ft 610 815 Nm 106 Rotate input shaft 13 and push yoke 9 toward differential carrier 1 to ensure input shaft is at bottom of travel 029 342 1276 107 Install dial indicator with point on end of input shaft 13 Zero dial indicator 108 Using pry bar pry up on flange of yoke 9 and read dial indicator Acceptable reading is 0 002 0 008 in 0 05 0 2mm 0080 00 36 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 109 If input bearing end play is not within specification add or remove shim s from shim pack 16 Repeat steps 98 through 103 342 1277 110 Install pinion cover 4 five washers 6 and cap screws 5 Tighten cap screws to 45 55 lb ft 60 75 Nm 342 1276 0080 00 37 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 111 Install cover 69 four washers 68 four cap screws 67 washer 66 plug 65 and screen plug assembly 64 65 66 64 342 1278 112 Install forward rear axle differential carrier WP 0079 00 END OF WORK PACKAGE 0080 00 38 TM 9 2320 302 34
198. 302 34 EXHAUST MANIFOLD REPLACEMENT 0015 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 References Guide stud set Item 43 WP 0126 00 Vise mechanist s Item 136 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Equipment Condition Materials Parts Turbocharger removed WP 0042 00 Gasket P N 23511666 3 Breather tube removed WP 0017 00 Y amp WARNING Exhaust manifold weighs 60 Ib 27 kg Use assistance and extreme caution during replacement to prevent possible injury to personnel REMOVAL 1 Remove six upper bolts 1 heat shield 2 and six spacers 3 from exhaust manifold 4 2 Install six guide studs in place of removed bolts 342 640 0015 00 1 TM 9 2320 302 34 EXHAUST MANIFOLD REPLACEMENT CONTINUED 0015 00 REMOVAL CONTINUED 3 Remove remaining six bolts 1 spacers 3 and exhaust manifold 4 assembly from cylinder head 5 4 Remove and discard three gaskets 6 5 Secure center section of exhaust manifold 4 in vise Using brass drift remove each end section 7 of exhaust mani fold 6 If damaged remove and discard four turbocharger mounting studs 8 INSPECTION 1 Inspect exhaust manifold for cracks particularly in mounting bolt boss areas If cracked discard exhaust manifold 2 Inspect
199. 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED 17 Position fire top and middle compression ring gaps 180 degrees from each other and 90 degrees from oil control ring and oil expander ring gaps OIL CONTROL RING GAP FIRE COMPRESSION RING GAP TOP MIDDLE COMPRESSION RINGGAP 4 OIL EXPANDER RING GAP 342 1063 18 Apply a light coat of clean engine lubricating oil to connecting rod 12 pin bushing piston pin bushing ends and piston pin 11 Place piston skirt 13 over piston dome 14 and align piston pin bores in dome and skirt 19 Install connecting rod 12 inside dome 14 and slide piston pin 11 through piston skirt 13 bore and crown Using retaining ring pliers secure piston pin in piston with two retaining rings 10 20 Place piston assembly 9 dome down in clean pan Coat piston assembly liberally with clean engine lubricating oil 10 342 1045 0041 00 16 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED 21 Perform procedures in step 11 through 20 for remaining connecting rod and piston assemblies 22 Remove two connecting rod cap nuts and connecting rod cap temporarily installed during Removal step 7 CAUTION Nicks or burrs on no tapered inside diameter end of piston ring compressor may result in damage to piston rings Inspect piston ring compressor for nicks or burrs
200. 4 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Wiring harness and leads are secured in place by clips tiedown straps cushion clamps and screw termi nals Only remove hardware securing harness to be removed Tag wiring harness and leads prior to removal to aid in installation 1 Disconnect relay and fuse panel 1 2 Disconnect 42 pin connector 2 34 pin connector 3 32 pin connector 4 6 pin sealed connector 5 and four ring terminals 6 342 553 0057 00 1 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT CONTINUED 0057 00 REMOVAL CONTINUED 3 Disconnect three ring terminals 6 12 pin connector 7 female terminal blade 8 6 pin female connector 9 3 pin sealed connector 10 two 3 pin female connectors 11 1 pin male connector 12 and six 1 pin female connectors 13 4 Disconnect three ring terminals 6 6 pin female connector 9 two 3 pin female connectors 11 1 pin male connector 12 1 pin female connector 13 12 pin diagnostic connector 14 3 pin male connector 15 two 2 pin male connec tors 16 and 2 pin female connectors 17 5 Disconnect 2 pin male connector 18 6 Remove eight screws 19 and remove 6 pin diagnostic connector 20 and 9 pin engine diagnostic connector 21 0057 00 2 TM 9
201. 42 1146 0071 00 56 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Control Valve Module 1 Position transmission in a vertical position torque converter up 2 Install two guide pins in two main housing bolt holes Install new control module gasket 33 over guide pins 3 Lubricate wiring harness feed through hole with petrolatum 4 With assistance guide control module 32 onto main housing 23 and pass feed through harness 27 through feed through hole in the main housing 5 Align control module 32 bolt holes with guide pins Ensure feed through harness standoff is aligned with hole in main housing 23 6 Lower control module 32 over guide pins until it seats against main housing 23 and feed through harness standoff seats against tapered hole in main housing 7 Remove guide pins and install 43 bolts 31 Evenly tighten bolts to 38 45 lb ft 51 61 Nm 8 Install retaining nut 25 and lock washer 26 to secure feed through harness 27 to mounting bracket 28 9 Install retaining nut 29 and lock washer 30 to secure feed through harness 27 to transmission housing 23 FIT ome Cup STR ERN KAX 2 CUR Mir 2 AN we USES dtr 532 Na ees PRE Milks S5 do EM k oh n 27 a 29 30 342 1166 342 1148 0071 00 57 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Filte
202. 49 2 Nut lock P N MS51922 57 2 Personnel Required Three Equipment Condition Cab doors removed WP 0107 00 Muffler and exhaust stack removed TM 9 2320 302 20 Exterior grabhandles removed Fender extensions removed Hood latches removed TM 9 2320 302 20 Utility lights removed Clearance lights removed Windshield wiper linkage removed TM 9 2320 302 20 Voltage regulator removed TM 9 2320 302 20 Dual voltage alternator control DUVAC removed TM 9 2320 302 20 Starter regulator removed Foot brake valve removed Rear window removed CWP 0110 00 Windshield removed WP 0109 00 Radio mounting bracket removed TM 9 2320 302 20 0104 00 1 0104 00 Equipment Condition Continued Transmission shift control removed TM 9 2320 302 20 Floor mats removed Arctic heater removed Cab air ducts removed Head liners removed Beacon warning light bracket removed TM 9 2320 302 20 Sunvisors removed TM 9 2320 302 20 Air horn and valve removed Interior grabhandle removed Cab liners removed TM 9 2320 302 20 Electronic throttle removed Steering column support bracket removed TM 9 2320 302 20 Brake pedal removed TM 9 2320 302 20 Cab overhead wiring harness removed TM 9 2320 302 20 Chassis wiring harness removed TM 9 2320 302 20 Air tubes removed TM 9 2320 302 20 Anti lock brake system ABS electronic control unit removed TM 9 2320 302 20 Anti lock brake system ABS fuse and
203. 5 lock washers 26 and bracket 13 from compressor 4 Discard lock washers 13 Remove screw 27 and washer 28 from bracket 22 14 Remove two screws 29 washers 30 and bracket 22 from engine 18 INSTALLATION 1 Install bracket 22 to engine 18 with two washers 30 and screws 29 2 Install washer 28 and screw 27 to bracket 22 3 Install bracket 13 to compressor 4 with four new lock washers 26 and screws 25 4 Install bracket 21 to compressor 4 with four new lock washers 24 and screws 23 5 Position compressor 4 to engine 18 6 Install bracket 22 to bracket 21 with two screws 20 washers 19 and new lock nuts 6 Do not fully tighten lock nuts 7 Install adjustment rod 14 to engine 18 with screws 17 washer 16 and new lock nut 15 8 Install two jamnuts 7 and link end 12 to adjustment rod 14 9 Install link end 12 to bracket 13 with screw 10 washer 11 and new lock nut 9 Do not fully tighten lock nut 10 Position compressor drive belt 8 over compressor 4 pulley 11 Adjust two jamnuts 7 to tighten compressor belt 8 and tighten jamnuts against link end 12 12 Tighten two lock nuts 6 and lock nut 9 13 Remove protective plugs from hoses 3 and compressor fittings install two new preformed packings 5 and lubricate with refrigerant oil NOTE DO NOT connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and
204. 5 from engine block 26 Set cable harness 27 aside 7 Remove nut 28 washer 29 and wire 30 from fuel pressure sending unit 31 8 Disconnect electronic control module harness connectors 32 and 33 from connectors located at rear of ECM 34 Cut tiedown straps as required to free harness 35 from engine Discard tiedown straps 0010 00 2 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 342 930 9 Disconnect hose 36 and two tubes 37 from air compressor 38 10 Remove tube 39 atomizer 40 and tiedown strap 41 Set tube 39 and two tubes 37 aside Discard tiedown strap 342 931 0010 00 3 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 11 Remove clamp 42 seal clamp 43 and exhaust pipe 44 Discard seal clamp 342 932 12 Remove nut 45 lock washer 46 and wire 47 from temperature sending unit 48 Discard lock washer 13 Remove two screws 49 lock washers 50 and wires 51 from temperature sending unit 52 Discard lock washers 342 933 0010 00 4 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED REMOVAL CONTINUED 14 Remove nut 53 washer 54 wire 55 and solenoid 56 Reinstall nut 15 Remove screw 57 and set harness 58 aside Reinstall screw 57 16 Remove two screws 59 washers 60 and clamps 61 Set harness 58 aside 57 58 342 935 0
205. 5 to screw with lock nut 24 7 Install primary piston retainer 20 to upper body 18 8 Install preformed packing 19 to lower body 7 and install lower body to upper body 18 with four lock washers 17 and screws 16 0083 00 6 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 ASSEMBLY CONTINUED 342 196 0083 00 7 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 ASSEMBLY CONTINUED 9 10 11 12 13 Install two preformed packings 14 and 15 to retainer 11 and install seat 13 spring 12 retainer and washer 10 to valve 8 with retaining ring 9 Install valve 8 assembly to lower body 7 Install cover 4 to lower body 7 with four lock washers 6 and screws 5 Install diaphragm 3 to cover 4 with washer 2 and screw 1 Install foot brake valve 342 195 END OF WORK PACKAGE 0083 00 8 TM 9 2320 302 34 AIR COMPRESSOR REPAIR 0084 00 THIS WORK PACKAGE COVERS Disassembly Inspection Assembly INITIAL SETUP Maintenance Level Materials Parts Direct Support Crankshaft bearing kit P N 107969 Tools and Special Tools Cylinder head maintenance kit 107516 Tool kit general mechanic s Item 132 WP 0126 00 Plate cover WP 0122 00 Caps vise jaw Item 17 WP 0126 00 Piston and rod kit P N 108842 Piston ring kit P N 107639 Inserter and remover Item 51 WP 0126 00 Unloader kit P N 107515 Pliers retaining ring Item
206. 5 00 ASSEMBLY 1 Place coupling 12 recessed side down on bench 2 Install disk assembly 11 on coupling 12 with reinforcement side down 3 Install four disks 10 on top of disk assembly 11 342 681 4 Install flex plate 9 on top of four disks 10 5 Align bolt holes and install 12 bolts 4 hand tight 11 342 680 0025 00 4 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 0025 00 INSTALLATION NOTE Ensure mating surfaces of crankshaft butt and flex plate assembly are clean and dry 1 Install flex plate assembly 8 on two guides studs 6 and slide forward against crankshaft butt 342 679 2 Install new scuff plate 7 on two guide studs 6 and slide forward against flex plate assembly 8 NOTE Do not apply international compound no 2 on underside of bolt heads 3 Apply international compound no 2 on threads of 10 bolts 5 4 Install ten bolts 5 through scuff plate 7 and flex plate assembly 8 Tighten bolts to 50 Ib ft 68 Nm 5 Remove two guide studs 6 and install remaining two bolts 5 Tighten bolts to 50 Ib ft 68 Nm 342 678 0025 00 5 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 0025 00 INSTALLATION CONTINUED 6 Insert 3 4 in extension 1 4 6 in long into square opening in center of crankshaft pulley 2 and hold extension with hinged handle bar 3 342 677 7 Hold crankshaft against rotation and tighten 12 inner bolts in crissc
207. 52 and door latch assembly 53 53 50 51 52 50 51 52 342 600 0108 00 8 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED 25 Disconnect door latch retainer 54 and remove door latch rod 46 from door latch assembly 53 342 607 26 Remove two window channels 14 and 15 1 5 342 608 0108 00 9 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY 1 Install two window channels 14 and 15 1 5 342 608 2 Install door latch rod 46 on door latch assembly 53 and connect door latch retainer 54 342 607 0108 00 10 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 3 Install door latch assembly 53 four cap screws 52 washers 51 and nuts 50 53 50 51 52 50 51 52 342 600 Lubricate all rotating points of exterior handle assembly 47 with grease Install exterior handle assembly 47 and fastening clip 49 in door 2 Install stud 48 in exterior handle assembly 47 Install door latch rod 46 in exterior handle assembly 47 and connect door latch retainer 45 Install door lock rod 44 in exterior handle assembly 47 and connect door lock retainer 43 oF ND FF Install release handle rod 34 in exterior handle assembly 47 and connect release handle retainer 42 49 342 606 0108 00 11 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY
208. 55 Installation of Rotating Clutch Module and Front Support and Charging Pump Module 1 Install an M16 eye bolt into turbine shaft 48 Using a suitable hoist install rotating clutch module 49 into main hous ing 23 Remove eye bolt Lower front support and charging pump module 47 over top of turbine shaft 48 Align bolt holes in front support and charging pump module 47 with threaded holes in main housing 23 Install seven bolts 46 and seven bolts 45 in front support and charging pump module 47 Tighten bolts to 38 45 Ib ft 51 61 Nm 0071 00 50 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED 342 1154 342 1153 Installation of P1 P2 Planetary Modules Install P1 planetary module 44 consisting of P1 carrier and P2 ring gear Mesh P1 pinion gears with P1 ring gear inside C3 C4 clutch assembly Install P2 planetary module 40 consisting of P2 carrier and P3 ring gear Mesh P2 pinion gears with P2 ring gear during installation Installation of C5 Clutch Pack 1 Install C5 clutch pack 41 in main housing 23 Clutch pack consists of nine steel reaction plates 43 and eight friction plates 42 stacked alternately starting with a steel reaction plate Stack all plates so that plate cone faces same direction Steel plates mesh with main housing 23 and reaction plates mesh with P3 ring gear 342 1151 342 1152 0071 00 51 TM 9 2320 302 34 T
209. 6 0026 00 6 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED 16 Remove pilot puller screw 16 Camshaft gear pilot 13 will remain in place holding camshaft drive gear 9 in contact with adjustable idler gear 342 692 7 WARNING Camshaft weighs 53 Ib 24 kg Attach suitable lifting device prior to removal to prevent possible injury to personnel 0026 00 7 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED CAUTION Due to size and bulk of camshaft care must be taken and two persons used to lift camshaft Use non metallic sling positioned inboard of camshaft bearing no 1 and no 7 to prevent damage to equipment 17 Using slings slide camshaft 5 toward rear to disengage dowel 27 from camshaft drive gear hub 28 Remove cam shaft NE One Pict yaw R M P 2 V AN NE N S Voy DS PN nd NS ONE a 07 D ce or V UA YS Ver AV qb 16 MGC Val 342 695 CAUTION Upper and lower bearing shells are in sets and cannot be interchanged If either upper or lower bearing is replaced upper and lower bearing shells must also be replaced to prevent damage to equipment 18 Remove seven lower camshaft bearing shells 29 Keep lower bearing shells with their corresponding upper
210. 7 3 Install four new screws 3 through load plate 4 follower retainer 5 solenoid 6 and spacer 8 4 Thread four screws 3 into body and tighten all screws until heads contact follower retainer 5 and load plate 4 5 Tighten screws 3 to 19 Ib in 2 Nm following sequence shown 6 Connect fuel injector harness wiring terminals 2 and tighten two screws 1 0047 00 2 TM 9 2320 302 34 FUEL INJECTOR SOLENOID REPLACEMENT 0047 00 INSTALLATION CONTINUED 342 626 7 Install rocker arm cover 0016 00 END OF WORK PACKAGE 0047 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0047 00 4 TM 9 2320 302 34 RADIATOR REPAIR 0048 00 THIS WORK PACKAGE COVERS Disassembly Repair Assembly INITIAL SETUP Maintenance Level Materials Parts Direct Support Gasket P N 05 12295 000 2 Tools and Special Tools Nut self locking P N 32WLF3816 36 Tool kit general mechanic s Item 132 WP 0126 00 Grease GAA Item 22 WP 0125 00 Gloves Item 41 WP 0126 00 References Wrench torque 0 300 Ib in Item 137 WP 0126 00 TM 750 254 Equipment Condition Radiator removed from vehicle TM 9 2320 302 20 DISASSEMBLY NOTE Additional items are mounted or attached to radiator when installed in vehicle These items use radiator hardware for installation During disassembly note the location orientation size and quantity of screws nuts and bolting bars as an aid in assembly 0048 00
211. 7 END OF WORK PACKAGE 0097 00 7 TM 9 2320 302 34 This Page Intentionally Left Blank 0097 00 8 TM 9 2320 302 34 REAR CAB MOUNTS REPLACEMENT 0098 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s Item 132 WP 0126 00 Two Sling beam type Item 115 WP 0126 00 Equipment Condition Materials Parts Front cab mounts removed WP 0097 00 Nut lock P N MS51922 17 8 Nut lock P N MS51922 49 2 V WARNING e Use extreme caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel e Cab assembly weighs 1100 Ib 499 kg Use hoist with lifting capacity of 1400 Ib 636 kg to support cab assembly Failure to do so could result in injury to personnel and or damage to equipment REMOVAL 1 Remove two lock nuts 1 and washers 2 Discard lock nuts 2 Lift cab assembly 3 approximately 5 in 13 cm 3 Remove two screws 4 washers 5 and resilient mounts 6 342 193 0098 00 1 TM 9 2320 302 34 REAR CAB MOUNTS REPLACEMENT CONTINUED 0098 00 REMOVAL CONTINUED 4 Remove eight lock nuts 7 screws 8 washers 9 and bracket 10 Discard lock nuts
212. 8 Apply continuous thin bead of gasket forming compound to rear face of cylinder block 7 where it contacts flywheel housing 3 Install two guide studs 4 on cylinder block 7 Position flywheel housing 3 carefully on guide studs 4 working it forward until flywheel housing contacts cylinder block 7 Install eight washers 6 and bolts 5 and two washers 2 and bolts 1 hand tight Remove guide studs 4 and install two remaining washers 2 and bolts 1 hand tight Tighten 12 bolts 1 and 5 to 118 148 lb ft 160 201 Nm in sequence shown 342 686 TIGHTENING SEQUENCE Install crankshaft rear oil seal WP0023 00 Install flex plate WP 0025 00 0024 00 3 TM 9 2320 302 34 FLYWHEEL HOUSING REPLACEMENT CONTINUED 0024 00 INSTALLATION CONTINUED 10 11 12 13 14 15 16 17 18 19 CAUTION To prevent damage to equipment ensure contact between flywheel housing and end of bolt does not occur Assemble dial indicator 8 to flex plate 9 NOTE Ensure dial indicator is positioned straight and square with flywheel housing bell face or inside bore of bell and has adequate travel in each direction Check flywheel housing concentricity and bolting flange face runout Ensure engine is in vertical position with flywheel housing 3 end up Ensure end play is on one direction only Tap end of crankshaft with soft hammer to position it toward one end of block NOTE Maximum total
213. 89 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Press arbor Item 90 WP 0126 00 Tags marker Item 35 WP 0125 00 Vise machinist s Item 136 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Equipment Condition Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Air compressor removed TM 9 2320 302 20 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Governor removed TM 9 2320 302 20 DISASSEMBLY 1 If installed remove two gaskets 1 and 2 Discard gaskets 342 986 0084 00 1 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEMBLY CONTINUED 2 Engage teeth 3 of cover plate 4 with air compressor drive 5 Align spacer legs of cover plate with mounting bolt holes in flange face of air compressor 6 Install two bolts 7 nuts 8 and cover plate on flange face of air compressor om 23 lt 1 NN d y 342 987 8 3 Secure air compressor 6 in soft jawed vise and remove drive hub retaining bolt 9 4 Remove two nuts 8 bolts 7 and cover plate 4 342 988 5 Remove drive hub 10 and drive gear 5 from crankshaft 6 Remove four bolts 11 from drive hub 10 and drive gear 5 T Remove air compressor 6 from vise NOTE It may be necessary to tap cylinder head with fiber or plastic mallet to break cylinder head gasket seal 0084 00 2 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEM
214. 9 2320 302 24P 9 2320 302 24P SC 4910 95 A31 TOOL IDENTIFICATION LIST CONTINUED TM 9 2320 302 34 Table 1 Tool Identification List Continued 2 ITEM NAME Lathe Brakedrum Lift Transmission and Differential Lifter Rocker Arm Lifting Bracket Flywheel Multimeter Digital Multiplier Torque Wrench Pan Drain 4 gallon capacity Pilot Cam Gear Pin Shoulder Headless Plate Indexing Plate Retaining Pliers Piston Ring Pliers Retaining Ring Pliers Retaining Ring external 0 038 1 000 in diameter Pliers Retaining Ring internal 0 120 in diameter 3 15 6 5 in ring diameter Pliers Retaining Ring internal 1 75 to 2 in ring size Press Arbor hand operated Press Cylinder Liner Protector Crankshaft Protector Piston Puller Mechanical Puller Kit Mechanical gear and bearing Puller Kit Universal Puller Kit Universal Pump Hydraulic Ram 3 NATIONAL STOCK NUMBER 49 10 01 028 9848 49 10 00 585 3622 5120 01 322 6116 5120 01 116 6049 6625 01 265 6000 5120 00 169 2986 49 10 00 387 9592 5120 01 322 3508 5315 01 333 2771 3460 01 319 5533 3040 01 319 0848 5120 01 142 2459 5120 01 322 6888 5120 00 288 9717 5120 00 293 0186 5120 00 293 0045 3444 00 449 7295 3449 01 319 5599 2815 01 321 9248 5120 01 048 2156 5120 01 322 1128 5180 00 423 1596 5180 01 048 2153 5180 00 313 9496 4320 01 320 4618 0126 00 5 4 PART NUMBER CAGEC 4100 4T928
215. 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED 9 Perform procedures in step 1 through 8 for remaining cylinder liners 3 being installed 10 Perform cylinder block pressure testing WP 0040 00 NOTE e Fire top compression ring has plasma dull finish face Top of fire compression ring is identified by vendor s mark dimple or color dot located 30 degrees from ring gap e Middle compression ring has chrome shiny face Top of middle compression ring is identified by dim ple or color dot located 30 degrees from ring gap Inner ring edge has groove e Oil control ring has chrome flashed face and can be installed with either side up 11 Insert three piston rings 15 and 16 inside cylinder liner one at a time using piston dome 14 inserted upside down into liner to push ring down Insert piston dome into liner to same depth as ring being positioned This will ensure rings are parallel with top of liner and positioned in liner within normal areas of ring travel 342 1061 0041 00 13 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED NOTE e Increase insufficient compression ring gap by filing or stoning ends of piston ring File or stone both ends of piston ring with cutting action from outer surface to inner surface to prevent chipping or peeling of plasma or chrome plate e Piston ring ends must remain s
216. AE e tnb scene E dee feos Anti lock Brake System n Centigrade or Celsius S E RN AERE e Ee eit Cubic Inch Displacement CDD scoop aie Ren SSIs era tele MeN ne A as UE Sa HL cete SUE ale LASCIA RU e ARE IS ts en ae Centimeter COWS hee CHR EO ELK eei Qu WP We PC E ee qe OO OD ete a Collision Warning System sais RE eR IER ep CRASS RID REV emp IDA Ga OU OPERI e E Electronic Control Unit Ah bab be bd RN OU EAM d a E Fahrenheit GOWR eR E EE ESSO ES FT eh Set ce ESSO ende Mews Ed glans Gross Combination Weight Rating GVWR ot Sek e SER ee Gross Vehicle Weight Rating ke scope dac E doe DON REC p Po RARI ER Kilogram dee nites Deb dcs ped derit Kilometer SU RD CERE SEU YT RI DERE SOUPE SOT EEN IE e REPARARE INED EO E ER case ae Oct Kilopascal Eph ise Ero a ped wr ee por eol a deep Mable nap pega er EA UE EUM de RUE Kilometers per Hour Kilowatt Vg sapere ba sah Panter Pan dis ye bed Eee Path pe daha AE E Eni Ta dee ole tee abe ate Se Meenas ae Liter DD siete ts ete eR a ERE RC E RNC ERR QR whee ses Pound CDU OG ERES Pound Foot Dp Ia et Liters per Hour TD Peters
217. BLY CONTINUED 10 Turn adjusting wheel 22 until extension tool 21 contacts water pump shaft 5 for support 342 826 11 Apply a thin film of corrosion preventive compound to inside diameter of new water seal 14 where contact will be made with water pump shaft 5 342 830 0049 00 7 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED 12 Apply a thin film of gasket forming compound to water seal bore 23 in water pump housing 4 CAUTION To prevent damage to equipment ensure water pump shaft is supported by holding fixture extension 13 Position new water seal 14 over square end of water pump shaft 5 with closed end of water seal down 14 Using water seal installer 24 press water seal 14 in water pump seal bore 23 until water seal installer bottoms against water pump seal bore 342 831 0049 00 8 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED D D WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION e Use care when applying sealing compound Too much can cause damage to sealing surface Wait four 4 hours after applying sealing compound to allow for drying Water pu
218. BLY CONTINUED 8 Remove six bolts 12 cylinder head 13 and cylinder head gasket 14 Discard gasket WARNING Unloader cover plate is under spring tension Use care when removing bolts securing unloader cover plate to prevent injury to personnel 9 Place cylinder head 13 on bench deck side down and remove four bolts 15 and lock washers 16 Discard lock washers 10 Remove unloader cover plate 17 and gasket 18 Discard gasket 11 Remove unloader piston 19 seal ring 20 and unloader spring 21 from each bore 0084 00 3 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEMBLY CONTINUED 12 Place cylinder head 13 on bench deck side up and insert inserter and remover tool 22 in inlet valve stop 23 Remove inlet valve stop 13 Remove inlet valve spring 24 inlet valve 25 inlet valve seat 26 and copper gasket 27 from bore Discard gasket 14 Repeat step 12 and 13 for second valve stop 23 23 342 991 15 Remove two discharge valve seats 28 16 Remove two discharge valves 29 and springs 30 from bores of cylinder head 13 342 992 17 Remove six bolts 31 crankcase cover 32 and gasket 33 Discard gasket 18 Rotate crankshaft 34 until connecting rod and piston assembly 35 is at bottom of travel 0084 00 4 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEMBLY CONTINUED CAUTION Connecting rod c
219. Blank 0106 00 8 TM 9 2320 302 34 CAB DOOR REPLACEMENT 0107 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Rear view mirror removed TM 9 2320 302 20 Materials Parts Tape foam 48 02454 106x27 WP 0122 00 NOTE Procedure is the same for both doors REMOVAL 1 Remove capnut 1 and socket head screw 2 WARNING Due to size of door and angle for removal use minimum of two personnel to remove door Failure to do so could result in injury to personnel 2 Remove eight capscrews 3 and door 4 342 590 0107 00 1 TM 9 2320 302 34 CAB DOOR REPLACEMENT CONTINUED 0107 00 REMOVAL CONTINUED Remove and discard foam tape 5 o 342 591 CLEANING 1 Use general cleaning methods to clean all parts 2 Ensure that all traces of old foam tape have been removed INSPECTION 1 Inspect door seals and window channels for damage 2 Inspect door locks regulators and release handles for proper operation If damaged refer to door repair WP 0108 00 INSTALLATION CAUTION Make sure all old foam tape has been removed Failure to do so could cause water leakage and damage 1 Install new foam tape 5 and using a sharp tool cut holes for installation of capscrews 3 WARNING Due to size of door and
220. CAUTION To prevent damage to crankshaft use care to guide connecting rod on crankshaft journal when pushing pis ton assembly in cylinder bore Pistons must be installed in same location Failure to do so could result in pre mature air compressor failure 26 With ring compressor 55 square against top of air compressor 6 body push connecting rod and piston assembly 35 into cylinder bore 342 1001 CAUTION Tangs on one end of connecting rod lower bearing insert must be installed in corresponding notches on side of connecting rod bearing saddle to prevent damage to equipment 27 Install new connecting rod lower bearing insert 38 in connecting rod cap 37 28 Apply a film of clean engine lubricating oil to connecting rod lower bearing insert 38 0084 00 12 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 29 30 31 32 CAUTION Connecting rod bearing insert tangs should be on same side of connecting rod and connecting rod cap to pre vent damage to equipment Ensure connecting rod is fully seated on crankshaft journal to prevent damage to equipment Position connecting rod cap 37 on connecting rod so that wide ear on connecting rod cap matches corresponding ear on connecting rod Install two connecting rod bolts 36 and tighten to 80 100 Ib in 9 11 Nm Position new gasket 33 and crankcase cover 32 on bottom of air compressor 6 body Install six bolts 31 a
221. CONTINUED 10 Install cover plate 41 and four screws 40 on inside door panel 24 WARNING Wear protective gloves with handling glass Failure to do so could result in injury to personnel 11 Tilt window guide 39 toward hinge side of door 2 and with window glass 3 tilted toward inside door panel 24 carefully install window glass 342 604 0108 00 12 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 12 Lubricate teeth on window regulator 36 with grease 342 609 13 Install window regulator 36 in inside door panel 24 14 Insert window regulator roller 37 in one end of window lift channel 38 15 Install four screws 35 in window regulator 36 342 603 0108 00 13 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 16 Insert sill 30 as follows a Install sill 30 just enough to allow installation of release handle rod 34 and connect release handle rod retainer 33 342 602 b Lean sill 30 away from door 2 and insert door lock button 32 c Grip sill door handle 31 lean sill 30 away from door 2 and push sill downward until lower edge of sill is seated on inside door panel 24 3 1 342 601 24 0108 00 14 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 17 Install top two cap screws 28 in door latch assembly 29 342 600 18 Install check arm br
222. D 12 Inspect backs of bearing shells for bright spots If such spots are present replace bearing shells Inspect connecting rod bearing bores for burrs or foreign particles NOTE Install new upper and lower connecting rod bearing shells if new crankshaft is used 13 Using micrometer and ball attachment measure thickness of connecting rod bearing shell 6 Minimum thickness of worn standard connecting rod bearing shell should not be less than 0 1215 in 3 086 mm If either upper or lower con necting rod bearing shell of connecting rod set is less than minimum thickness replace both bearing shells 342 1056 14 Examine cylinder liner for cracks scoring glazing ring ridge formation and cavitation erosion If any of these condi tions are present liner must be discarded 15 Examine outside diameter of liner for fretting at flange and cylinder block bore area If light fretting is present surface can be restored with abrasive cloth or flat stone 16 Measure cylinder as follows 0 984 in 25 mm 6 30 in 160 mm 0 394 in 10 mm 9 25 in 235 mm 342 1057 342 1058 0041 00 10 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSPECTION CONTINUED Table 1 Cylinder Liner Dimensions MINIMUM MAXIMUM LIMITS CYLINDER LINER IN MM IN MM IN MM Outside diameter below flange A 5 864 5 866 148 95 149 00 Flange thickness B 0 3527 0 3543 8 960 9 000 Inside diamete
223. D WARNING Do not place finger in hole of engine flywheel housing while engine is being barred over Failure to follow this warning could result in injury 8 Remove access plug 1 and drain plug 2 from engine flywheel housing 3 342 947 9 Rotate torque converter to align holes in flex plate with holes in torque converter CAUTION e Step 10 must be followed in barring engine over Any other method may damage engine e f bolts are dropped in engine flywheel housing retrieve immediately Failure to do so could result in damage to equipment 10 Have an assistant bar engine 4 over using accessory drive 5 until placement for bolt 6 has been located through access hole Install bolt through access hole Repeat until 12 bolts have been installed 342 1141 0070 00 5 TM 9 2320 302 34 TRANSMISSION REPLACEMENT CONTINUED 0070 00 INSTALLATION CONTINUED 11 Install access plug 1 and drain plug 2 in engine flywheel housing 3 gue 342 947 12 Install transmission oil fill tube 13 Connect transmission oil cooler lines TM 9 2320 302 20 14 Connect transmission electrical harness s TM 9 2320 302 20 15 Install driveline TM 9 2320 302 20 16 Install transmission access tunnel cover TM 9 2320 302 20 17 Refill transmission fluid TM 9 2320 302 20 18 Install spare tire END OF WORK PACKAGE 0070 00 6 TM 9 2320 302 34 TRANSMISSION OVERHAUL 0071 00 THIS
224. D 0071 00 MODULE OVERHAUL CONTINUED Front Support and Charging Oil Pump Module Disassembly 1 Remove three seal rings 1 from hub of front support assembly 2 2 Remove eight bolts 3 securing pump housing assembly 4 to front support assembly 2 3 Remove pump housing assembly 4 and gear set 5 from front support 2 PUMP HOUSING GEAR CAVITY 19 04 mm 0 75 in 342 1161 0071 00 17 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Front Support and Charging Oil Pump Module Disassembly Continued 5 Measure gear cavity diameter of pump housing 4 Maximum depth allowed is 5 915 in 150 25 mm MAX ID OF GEAR CAVITY 150 25 mm 5 915 in 342 1162 6 Install gear set 5 into pump housing 4 Measure pump gear side clearance of both gears Maximum allowable clear ance is 0 004 in 0 10 mm po DRIVE MAX SIDE GEAR CLEARANCE DRIVEN GEAR 0 10 mm 0 004 in 342 1163 0071 00 18 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Front Support and Charging Oil Pump Module Disassembly Continued 7 10 11 12 13 Measure gear tooth tip clearance Maximum allowable clearance is 0 006 in 0 15 mm MAX GEAR TOOTH TIP CLEARANCE 0 15 mm 0 006 in 342 1164 Measure driven gear to pump housing clearance Maximum allowable clearance is 0 012 in 0 30 mm PUMP HOUSING CLEARANCE
225. E Procedure is same for both cross tube arms REMOVAL Remove cotter pin 1 castellated nut 2 cross tube arm 3 and woodruff key 4 Discard cotter pin 342 1119 0075 00 1 TM 9 2320 302 34 FRONT CROSS TUBE ARM REPLACEMENT CONTINUED 0075 00 INSTALLATION 1 Install woodruff key 4 cross tube arm 3 and castellated nut 2 Tighten nut to 550 740 lb ft 746 1003 Nm CAUTION Castellated nut may be tightened to 1025 lb ft 1390 Nm for purpose of installing cotter pin Overtightening may damage steering arm 2 Install new cotter pin 1 342 1119 3 Install tie WP 0074 00 END OF WORK PACKAGE 0075 00 2 TM 9 2320 302 34 FRONT STEERING ARM REPLACEMENT 0076 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Pin cotter P N MS24665 357 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Drag link removed TM 9 2320 302 20 Multiplier torque wrench Item 79 WP 0126 00 Front brake spider and brake chamber bracket Wrench torque 100 600 Ib ft Item 140 WA removed TM 9 2320 302 20 0126 00 Wrench set socket 3 4 in drive Item 141 WA 0126 00 REMOVAL Remove cotter pin 1 castellated nut 2 steering arm 3 and woodruff key 4 Discard cotter pin INSTALLATION 1 Install woodruff key 4 steering arm 3 and castellated nut 2 Tighten nut to 775 1050 Ib ft 1051 1424
226. E OVERHAUL CONTINUED Control Valve Module Assembly 22 lt O NAM 10 11 12 13 14 15 16 17 18 NOTE Channel plate assembly procedures are steps 1 through 4 Install eight pressure tap plugs 86 and new o rings 87 Tighten plugs to 7 10 1b ft 10 13 Nm Install drain plug 84 and new o ring 85 Tighten drain plug to 18 24 lb ft 25 32 Nm If removed install two pins 83 in channel plate assembly 82 Install new gaskets 79 and 80 with separator plate 81 on channel plate assembly 82 NOTE Main valve body assembly procedures are steps 5 through 18 Install converter regulator valve 78 spring 77 and stop 76 Install valve retention pin 75 by pushing against stop 76 to compress spring 77 Install C1 latching valve 74 spring 73 and stop 72 Install retention pin 71 Install exhaust back pressure valve 70 spring 69 and stop 68 Install retention pin 67 Install C2 latch valve 66 spring 65 and stop 64 Install retention pin 63 WARNING Spring 55 is highly compressed Be extremely careful during assembly Personal injury can occur if spring force is not controlled Install main control valve 62 spring 60 and stop 59 Install retention pin 61 Install main regulator valve 58 spring 55 and stop 57 Using spring compressor tool J35924 compress spring 55 and install valve retention pin 56 Carefully remove compressor tool I
227. EMENT CONTINUED 0101 00 INSTALLATION 1 Install center bearing 6 to vehicle with two screws 5 Tighten screws to 68 lb ft 92 Nm 2 Using floor jack raise rear axle until bottom of center bearing 6 contacts spring assembly 8 3 Apply adhesive to threads of two new screws 7 Install center bearing 6 to top of spring assembly 8 with screws Tighten screws to 155 lb ft 210 Nm 4 Remove trestles and floor jack 5 Install rebound stop 3 to mounting bracket 4 with screw 2 and nut 1 Tighten nut to 68 Ib ft 92 Nm e 6 7 342 973 END OF WORK PACKAGE 0101 00 2 TM 9 2320 302 34 REAR SPRING ASSEMBLY REPLACEMENT 0102 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools References Tool kit general mechanic s Item 132 WP 0126 00 Jack hydraulic Item 73 WP 0126 00 1 9 25320 302 1 Wrench torque 15 75 lb ft Item 138 WP 0126 00 TM 9 2320 302 20 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVAL 1 Remove four screws 1 and top pad 2 from each
228. EMOVAL CONTINUED 5 Remove two bolts 11 nut 12 bolt 13 and bracket 14 6 Remove 38 cylinder head bolts 15 and washers 16 342 653 Ts Install lifter 17 between fuel injector holes no 3 and no 4 a Install bolt 18 using bolt hole for center cam cap bolt b Install two bolts 19 using two tapped holes for engine retarder assembly 0018 00 3 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 REMOVAL CONTINUED V WARNING Cylinder head weighs 421 Ib 191 kg Use suitable lifting device to lift and support cylinder head Failure to do so could result in injury to personnel 8 Attach suitable lifting device to lifter eye 20 and remove cylinder head 3 9 Remove and discard cylinder head gasket 21 10 Remove bolt 22 and left rear lifting bracket 23 11 Tag and remove elbows 24 and 25 from cylinder head 3 12 Remove air compressor fitting 26 from cylinder head 3 342 655 INSPECTION 1 Ensure piston domes cylinder head cylinder block deck surfaces and injector tubes are clean and free of foreign mat ter 2 Inspect cylinder block bolt holes and block to head gasket mating surfaces for oil water dirt or old gasket material INSTALLATION 1 Install left rear lifting bracket 23 and secure to cylinder head 3 with bolt 22 Tighten bolt to 75 93 lb ft 102 126 Nm 2 Install new cylinder head gasket 21 on cylinder block 27 0018
229. EMOVAL NOTE e Wiring harness and leads are secured by clips tiedown straps cushion clamps and screw terminals Only remove hardware securing harness or lead to be removed Tags wiring harness and leads prior to removal to aid in installation Disconnect and remove overhead cab wiring harness using illustration as a guide Discard tiedown straps INSTALLATION NOTE Wiring harness and leads are secured by clips new tiedown straps cushion clamps and screw terminals Ensure harness is secure and all hardware is tight 1 Install connect and secure overhead cab wiring harness using illustration as a guide 2 Install head liners TM 9 2320 302 20 3 Connect battery cables TM 9 2320 302 20 0061 00 1 TM 9 2320 302 34 OVERHEAD CAB WIRING HARNESS REPLACEMENT CONTINUED 0061 00 INSTALLATION CONTINUED 342 551 6 pin Connector 1 3 pin Connector 2 2 pin Connector 5 1 pin Connector 2 Cable Connector 2 Ring Terminal 4 END OF WORK PACKAGE 0061 00 2 TM 9 2320 302 34 CHASSIS WIRING HARNESS REPLACEMENT 0062 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Straps tiedown Item 34 WP 0125 00 Tags marker 35 WP 0125 00 Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 Direct Support Tools and Special Tools REMOVAL NOTE e Wiring harness and leads are s
230. EPAIR CONTINUED 0051 00 ASSEMBLY CONTINUED NOTE Ensure snap ring is fully seated in groove of spindle housing 12 Install ball bearing retaining snap ring 10 in spindle housing 5 342 817 Do not pack spindle housing more than 2 3 full 13 Pack spindle housing 5 with grease 14 Support fan spindle 1 on press bed and carefully install spindle housing 5 on fan spindle 15 Using narrow end of installing tool 18 press ball bearing assembly 12 inner race on fan spindle 1 until ball bearing assembly inner race is firmly seated against shoulder of fan spindle 342 818 0051 00 8 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 ASSEMBLY CONTINUED 16 Secure fan spindle 1 in vise Install spacer 4 and spacer retaining bolt 3 in spindle housing 5 Tighten bolt to 43 54 lb ft 58 73 Nm 11 342 819 17 Coat edge of new cup plug 2 with adhesive Using flat side of bearing inserter and remover tool 11 press new cup plug in spindle housing 5 until raised center of cup plug is flush with edge of spindle housing 18 Install lube pressure relief fitting 16 and grease fittings 15 Tighten to 72 Ib in 8 Nm minimum 19 Install spindle and housing TM 9 2320 302 20 END OF WORK PACKAGE 0051 00 9 TM 9 2320 302 34 This Page Intentionally Left Blank 0051 00 10 TM 9 2320 302 34 ALTERNATOR REPAIR 0052 00 THIS WORK PACKAGE COVERS Disassembly Testing
231. ETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 NOTE Procedure is same for left and right side harnesses REMOVAL NOTE Wiring harness and leads are secured by clips tiedown straps cushion clamps and screw terminals Only remove hardware securing harness or lead to be removed Disconnect and remove turn signal marker light wiring harness using illustration as a guide Discard tiedown straps INSTALLATION NOTE Wiring harness and leads are secured by clips new tiedown straps cushion clamps and screw terminals Ensure harness is secure and all hardware is tight l Install connect and secure turn signal marker light wiring harness using illustration as a guide 2 Connect battery cables TM 9 2320 302 20 0059 00 1 TM 9 2320 302 34 0059 00 TURN SIGNAL MARKER LIGHT WIRING HARNESS REPLACEMENT CONTINUED INSTALLATION CONTINUED 9 9 TABLE 2 2 3 pin Female Sealed Connector 4 pin Female Connector 1 2 END OF WORK PACKAGE 0059 00 2 TM 9 2320 302 34 TURN SIGNAL THRU DECK WIRING HARNESS REPLACEMENT 0060 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tools and Special Tools Equipment Co
232. FRONT CAB MOUNTS REPLACEMENT 0097 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Tools and Special Tools Materials Parts Continued Tool kit general mechanic s Item 132 WP 0126 00 Nut lock P N MS51922 17 4 Nut lock P N MS51922 57 Sling beam type Item 115 WP 0126 00 Personnel Required Materials Parts Two Clamp seal P N 04 19249 000 Equipment Condition Nut lock P N MS51922 1 4 Fender extension removed TM 9 2320 302 20 VA WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVAL NOTE Procedure is the same for both sides except as noted e Perform step 1 on right side 1 Remove seal clamp 1 v clamp 2 and outlet pipe 3 Discard seal clamp 342 187 0097 00 1 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 REMOVAL CONTINUED 2 Remove nut 4 washer 5 bolt 6 and washer 7 4 5 6 7 342 188 NOTE Perform step 3 on left side 3 Remove two lock nuts 9 washers 10 screws 11 and four clamps 12 Discard lock nuts 12 9 10 11 342 189 0097 00 2 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 REMOVAL
233. FUEL INJECTOR REPLACEMENT CONTINUED 0046 00 INSTALLATION NOTE Perform steps 1 through 10 for each injector being installed 1 Lubricate three new o ring seals 12 and 13 lightly with clean ethylene glycol 2 Install larger o ring seal 12 in upper groove 3 Install two lower o ring seals 13 in two lower grooves CAUTION Ensure injector port is free of dirt or other foreign matter which may cause damage to engine 4 Insert injector 11 into cylinder head 3 and visually align injector for equal clearance between valve springs 5 Press down on top of injector body until injector 11 is fully seated 6 Install holddown clamp 10 on injector 11 342 630 7 Install and hand tighten washer 9 and holddown bolt 8 with beveled side facing engine 0046 00 5 TM 9 2320 302 34 FUEL INJECTOR REPLACEMENT CONTINUED 0046 00 INSTALLATION CONTINUED CAUTION Check position of injector and holddown clamp to ensure clearance between intake valve spring and injector follower Failure to do so will result in equipment damage 8 Tighten holddown bolt 8 to 43 49 Ib ft 58 66 Nm 9 Connect injector wiring harness terminals 7 and tighten two screws 6 to 12 17 Ib in 1 36 1 92 Nm 342 626 10 Connect fuel supply hose 1 to elbow fitting 2 and fuel return line 4 to elbow fitting 5 at rear of cylinder head 3 342 633 11 Install rocker arm assemblies WP 0027 00 12 Install rocker arm co
234. Follow tightening sequence and tighten screws to 120 16 1 1360 Ncm Repeat sequence and tighten to 180 Ib in 20 Nm 8 Install two new lock nuts 1 expansion tank 2 and radiator cap 3 CAUTION DO NOT apply excessive air pressure when testing radiator Too much pressure will damage radiator core Air pressure should not exceed 20 psi 138 kPa 9 Pressure test radiator 0048 00 4 TM 9 2320 302 34 0048 00 RADIATOR REPAIR CONTINUED ASSEMBLY CONTINUED END OF WORK PACKAGE 0048 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0048 00 6 TM 9 2320 302 34 WATER PUMP REPAIR 0049 00 THIS WORK PACKAGE COVERS Disassembly Assembly Test and Inspection INITIAL SETUP Maintenance Level Tools and Special Tools Continued Direct Support Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Materials Parts Kit water pump O H P N 23509105 Compound corrosion preventive Item 11 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Caps vise jaw Item 17 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Dispenser sealant Item 30 WP 0126 00 WP 0125 00 Pliers retaining ring Item 88 WP 0126 00 Compound gasket forming Item 121 WP 0125 00 Compound sealing Item 14 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Rags wiping Item 31 WP 0125 00 E
235. G R 134A REFRIGERANT e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death e DO NOT work in an area where refrigerant may contact an open flame or burning material such as a cigarette When refrigerant contacts extreme heat refrigerant breaks down into poisonous phosgene gas which if breathed causes severe respiratory irritation DO NOT breathe fumes from an open flame leak detector Kz S EN 9 2320 302 34 WARNING WORK SAFETY Hydraulic jack is intended only for lifting truck not for supporting vehicle to perform maintenance DO NOT get under truck after it is raised unless it is properly supported with blocks or jackstands Failure to observe this warning may result in death or injury to personnel Use extreme caution when handling heavy parts Provide adequate support and use assistance dur ing procedure Ensure that any lifting device used is in good condition and of suitable load capac ity Keep clear of heavy parts supported only by lifting device Failure to fol
236. HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED NOTE Eccentric grinding method is recommended for fine accurate finish Grinding wheel contacts valve seat at only one point at any time and micrometer feed permits controlled fine adjustment 44 Grind valve seats to 31 degree angle using valve seat grinder 80 342 1037 45 Clean valve seat thoroughly Check seat to valve face contact by applying light coat of Prussian blue paste to valve seat land Insert valve in guide and bounce head on seat insert without rotating valve Full 360 degree contact line should appear centered on valve face NOTE If firedeck has been resurfaced valves will have to be seated deeper to restore valve head recess depth to specification limits 46 Valve head recess depth from cylinder head fire deck is increased by grinding valve seat Check with sled gage 81 Replace valve seat if not between 0 055 0 067 in 1 4 1 6 mm c Cz iem DES S o C EGS oN 342 1019 0032 00 25 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 47 Position cylinder head step NOTE Intake valves have larger faces and are installed in guides on cam side of cylinder head Smaller exhaust valves are installed in guides on thermostat side of cylinder head 48 Lubricate valve stem 10 with clean engine lubricating oil and insert valve into valve guide 14 from fire deck side of cylinder head CAUTION If other than st
237. IBLE CAUSE REMEDY There is an internal restriction in Replace condenser WP 0119 00 condenser Ice buildup on the condenser or a cool spot on the line from the condenser to the receiver drier Air is present in system Repair any leaks evacuate system WP 0112 00 replace receiver drier WP 0118 00 and add a full charge of refrigerant WP 0112 00 Restriction in compressor discharge line Repair or replace line WP 0121 00 Table 4 Problem Evaporator Outlet Air Temperature Increases as Compressor Discharge Pressure Drops POSSIBLE CAUSE REMEDY The expansion valve setting is toolow Replace expansion valve WP 0114 00 Add a full charge of refrigerant WP 0112 00 0009 00 7 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 AIR CONDITIONING SYSTEM TROUBLESHOOTING CONTINUED Table 5 Problem Compressor Operates Too Often or Continuously POSSIBLE CAUSE REMEDY There is too little refrigerant in system Repair any leaksl WP 0121 00 and add a full charge of refrigerant WP 0112 00 There is arestriction in refrigerant system Remove restriction from line Table 6 Problem Quick or Delayed Cycling of Compressor POSSIBLE CAUSE REMEDY Loss of refrigerant is causing a delayed Add a full charge of refrigerant WP 0112 00 cycling of the compressor 0009 00 8 TM 9 2320 302 34 CHAPTER 3 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTR
238. IER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 3 Install spigot bearing 31 and retaining ring 30 4 Install drive pinion shaft 3 in bearing cage 23 31 342 1210 342 1207 5 Install spacer s 26 on drive pinion shaft 3 6 Install outer bearing cone 25 on drive pinion shaft 3 against spacers 26 7 Apply 25 tons 22 7 Mt of pressure to two bearing cones 24 and 27 and as pressure is applied rotate bearing cage 23 several times so that two bearing cones make normal contact 342 1207 0082 00 10 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED NOTE To perform steps 10 and 11 a 20 in 50 8 cm piece of 14 gage wire must be used 8 Maintain pressure and wrap 14 gage wire around bearing cage 23 several times NOTE For accuracy reading must be taken while bearing cage is rotating 9 Attach spring scale to end of wire and pull As bearing cage 23 rotates read and record value on scale 342 1213 10 Measure diameter of bearing cage 23 where wire was wrapped and divide measurement in half to determine radius 342 1214 MEASURE DIAMETER OF CAGE 0082 00 11 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 11 Multiply reading from step 9 by radius from step 10 to determine preload New pinion drive gear preload must be 5 45 Ib in 0 56 5 08 Nm Used pi
239. IFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 93 Install wood block between ring gear 2 and differential carrier 1 to prevent ring gear from rotating KI 342 1273 NOTE Rotate input shaft in both directions to ensure bearings are correctly installed 94 Install seven cap screws 10 and hand tighten 95 Measure gap between bearing cage 41 and differential carrier 1 at four equally spaced places on bearing cage Note measurements 96 Add four measurements obtained in step 95 and divide by four to get average Add 0 005 in 0 13 mm to determine thickness of shim pack to be installed 342 1274 0080 00 34 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 97 Using at least three shims with thickest in middle assemble new shim pack 16 98 Remove seven cap screws 10 99 Using suitable lifting device lift input shaft 13 1 4 1 2 in 6 12 mm 100 Install shim pack 16 under bearing cage 41 Ensure shim pack installation pattern matches bearing cage installation pattern 342 1275 101 Install filter shield 12 seven washers 11 and cap screws 10 342 1230 0080 00 35 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 102 Lower input shaft 13 and remove lifting device 103 Tighten seven cap screws 10 to 75 95 lb ft 100 1
240. If force is needed use rubber mallet or soft faced hammer to prevent dam age to pulley and damper 2 Remove crankshaft pulley 3 3 Remove vibration damper 4 342 671 INSPECTION NOTE Vibration damper is replaced during major engine overhaul crankshaft replacement or when conditions identified below are found 1 Inspect vibration damper for dents gouges fluid leaks or bulges Replace vibration damper if any of these conditions are found 2 Inspect crankshaft pulley for cracked broken or bent flanges Replace crankshaft pulley if any of these conditions are found 3 Inspect crankshaft pulley and vibration damper mating surfaces for dirt and other foreign matter prior to installation INSTALLATION 1 Install vibration damper 4 against crankshaft 5 with stamped part number facing away from engine and seat firmly 342 672 0020 00 2 TM 9 2320 302 34 VIBRATION DAMPER REPLACEMENT CONTINUED 0020 00 INSTALLATION CONTINUED 2 Install crankshaft pulley 3 and seat firmly against vibration damper 4 3 Install six washers 2 and bolts 1 hand tight 4 Tighten six bolts 1 to 134 155 Ib ft 182 210 Nm 342 670 5 Install fan belts TM 9 2320 302 20 END OF WORK PACKAGE 0020 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0020 00 4 TM 9 2320 302 34 ACCESSORY DRIVE REPLACEMENT 0021 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenan
241. Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Oil lubricating Item 25 WP 0125 00 Tools and Special Tools Tape masking Item 37 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Personnel Required Adapter torque wrench Item 3 WP 0126 00 du Shield turbo protect Item 113 WP 0126 00 Wrench torque 15 75 lb ft Item 139 WP 0126 00 Equipment Condition Exhaust pipes removed from turbocharger TM 9 Materials Parts 2320 302 20 Gasket drain tube P N 8929285 Air intake tubes and hoses removed from turbocharger Gasket exhaust inlet P N 8929529 TM 9 2320 302 20 REMOVAL 204 WARNING Hot turbocharger and exhaust pipe can cause serious burns Do not work on exhaust system until it is cool To do so could result in serious injury to personnel NOTE If removal of wastegate actuator is required refer t WP 0044 00 for turbochargers Refer tq WP 0045 00 for Garrett turbochargers Wastegate removal is not required to remove turbocharger 0042 00 1 TM 9 2320 302 34 TURBOCHARGER REPLACEMENT 0042 00 REMOVAL CONTINUED 1 Disconnect oil supply line 1 from oil inlet port fitting 2 on top of turbocharger 3 2 Remove top mounting bolt 4 and washer 5 from oil supply line clip 6 on oil filter adapter upper mounting leg and move away from turbocharger 3 3 Remove two bolts 7 securing oil drain line 8 to bottom of turbocharger 3 4 Remove
242. Installation of Torque Converter Housing Module 1 2 Position transmission with input end up Install a new converter housing gasket 24 on main housing 23 Lower torque converter housing 21 onto main housing 23 while rotating PTO drive gear to align gear teeth with charging pump Install seven bolts 22 into inside of torque converter housing 21 Use of mechanical fingers or similar tool may be required to insert and start bolts Install remaining 18 bolts 22 Tighten all bolts to 55 65 Ib ft 74 88 Nm 342 1147 Installation of Torque Converter Module and Selective Shim Measurement NOTE e Torque converter is installed over turbine shaft which rotates inside stator shaft or ground sleeve Splines on ground sleeve engage converter stator Splines on turbine shaft engage converter turbine End of turbine shaft is threaded and machined to accept converter retaining bolt and lockup seal ring e Splines of ground sleeve and turbine shaft must engage with their respective splines in torque converter module Tangs on converter pump hub must engage charging pump s drive gear or PTO oil pump drive gear hub Using a suitable hoist and sling install torque converter module 18 into torque converter housing 21 Ensure that torque converter module 18 is properly seated Rotate PTO gear to engage pump hub with charging pump Install converter end play gage tool 738548 and tighten attaching bolts to 20 25 Ib ft 27 34 Nm
243. Intentionally Left Blank 0067 00 2 TM 9 2320 302 34 AIR CONDITIONER BINARY SWITCH WIRING HARNESS REPLACEMENT 0068 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level References Direct Support TM 9 2320 302 20 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 Battery cables disconnected TM 9 2320 302 20 Materials Parts Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 REMOVAL NOTE Tag wiring harness and leads prior to removal to aid in installation 1 Unlock three fasteners 1 by turning counterclockwise and remove access panel 2 2 Remove fuse relay and circuit breaker holder TM 9 2320 302 20 3 Locate circuit 98A on circuit breaker panel 3 and disconnect wiring harness connector from panel 0068 00 1 TM 9 2320 302 34 AIR CONDITIONER BINARY SWITCH WIRING HARNESS REPLACEMENT CONTINUED 0068 00 REMOVAL CONTINUED NOTE Note number and location of tiedown straps to aid in installation Trace wiring harness 4 from circuit breaker panel to firewall removing and discarding tiedown straps Remove grommet from firewall and feed wiring harness 4 into engine compartment Trace wiring harness 4 to receiver drier 5 removing and discarding tiedown straps BR Disconnect wiring harness connector 6 from binary switch 7 on receiver drier 5 342 542 8 Trace wiring harness 4 to compressor 8 rem
244. J37030 1 33287 J37030 2 33287 214FC 55719 J5959 01 33287 45RCT 88736 6635 55111 800434 19203 PT 4365 1 33287 52 225 015 1E258 99 431 OW4A6 135884 33287 138548 33287 J38689 A 33287 J42749 33287 ZZ G 381 81348 A A 50022 58536 WA60 5H0746 0315 74936 J36107 33287 J43661 33287 J8092 33287 J7079 2 33287 J 3453 1 33287 J 37071 A 33287 J35949 33287 J35686 B 33287 0126 00 5 REFERENCE TM 9 2320 302 24P TM 9 2320 302 24P GSA Catalog SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A31 TM 9 2320 302 24P GSA Catalog GSA Catalog TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P SC 4910 95 A74 SC 4910 95 A31 SC 4910 95 A31 TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P TM 9 2320 302 24P TOOL IDENTIFICATION LIST CONTINUED TM 9 2320 302 34 Table 1 Tool Identification List Continued 2 ITEM NAME Inserter and Remover Inserter and Remover Inserter and Remover Inserter and Remover Spring Inserter Set Dowel Installation Tool Seal Installer Charging Pump Bushing Installer Cup Plug Installer Front Support Sleeve and PTO Bearing Installer Output Bearing Installer Output Bearing Cup use with J37034 Installer Output Shaft Installer P1 Carrier Bushing and Ground Sleeve Bearing Pump Body Bushi
245. L 1 Remove two lock nuts 1 washers 2 screws 3 washers 4 isolators 5 and sleeves 6 from front engine mount adapter 7 Discard lock nuts 342 1139 0011 00 1 TM 9 2320 302 34 FRONT ENGINE MOUNT ADAPTER AND SUPPORT REPLACEMENT CONTINUED 0011 00 REMOVAL CONTINUED M WARNING Engine weighs 2850 Ib 1294 kg Support engine from lower block pan rail Failure to do so could result in injury to personnel and damage to equipment 2 Support engine 8 and remove spacer 9 and two isolators 10 3 Remove four bolts 11 and front engine mount adapter 7 342 1139 4 Remove four nuts 12 washers 13 three capscrews 14 washers 15 and screw 16 14 6 na 2 342 1136 5 On left side remove two nuts 17 washers 18 capscrews 19 and washers 20 from frame 21 0011 00 2 TM 9 2320 302 34 FRONT ENGINE MOUNT ADAPTER AND SUPPORT REPLACEMENT CONTINUED 0011 00 REMOVAL CONTINUED 6 Repeat step 5 for right side 7 Remove front engine mount support 22 8 Remove four spacers 23 21 17 18 19 20 342 1137 INSTALLATION 1 Install front engine mount support 22 2 Install four spacers 23 3 On left side install two washers 20 capscrews 19 washers 18 and nuts 17 on frame 21 17 18 19 20 342 1138 0011 00 3 TM 9 2320 302 34 FRONT ENGINE MOUNT ADAPTER AND SUPPORT REPLACEMENT CONTINUED 0011 00 INSTALLATION
246. LEANING 1 Soak rocker arm shaft 7 in solution of detergent and water Run wire brush through center oil passage 17 oth e WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 2 Clean out center oil passage 17 and oil holes 18 with compressed air Wipe exterior with clean lint free wipes 18 17 7 342 708 INSPECTION 1 Measure rocker arm shaft 7 where contact is made with rocker arm bushings 19 If rocker arm shaft diameter is less than 1 415 in 35 943 mm minimum replace shaft 342 709 1 415 in 35 943 mm 0027 00 4 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSPECTION CONTINUED NOTE Rocker arm bushing inside diameter is the same for each rocker arm exhaust intake and injector Exhaust arm only is shown 2 Inspect rocker arm bushings 19 for excessive wear or scoring Measure rocker arm bushing inside diameter If diame ter is more than 1 4191 in 36 050 mm replace rocker arm assembly 1 4191 in 36 050 mm 342 710 NOTE Rocker arms are not matched sets and each rocker arm may be replaced The checks in step 3 through 5 apply to each rocker arm 3 Check each cam follower roller 20 for scoring pitting or flat spots If any of these conditions are evident rep
247. LINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 REMOVAL CONTINUED 8 10 11 12 13 Repeat procedures in step 2 through 7 for each piston and cylinder being serviced NOTE Piston assembly components should be segregated by cylinder and matchmarked during disassembly to ensure installation in same position Place connecting rod and piston assembly 9 dome side down on workbench Remove two piston retaining rings 10 and piston pin 11 Remove connecting rod 12 Remove piston skirt 13 from dome 14 10 342 1045 Using piston ring pliers remove and discard fire top and middle compression rings 15 lower oil control ring 16 and oil control ring expander 17 from piston dome 14 0041 00 4 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 REMOVAL CONTINUED 342 1047 14 Repeat procedures in step 9 through 13 for each piston assembly being serviced 15 Rotate engine stand so that engine is horizontal and cylinder liners 3 are up 16 Center cylinder liner puller 18 over cylinder liner 3 Position cylinder liner puller shoe 19 at bottom of cylinder liner with lip on each side engaging bottom edge of liner 342 1048 0041 00 5 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 REMOVAL CONTINUED 17 Keep cylinder liner puller shoe 19 in position on cylinder liner bottom and turn cylinder liner puller nut
248. Lights Bee Sha hel a ee IURE RE Eu e E SQ ge 2 fixed top rear of cab PUPAL ORM er ec ia aee tre dd eL bte a tegi Econ oM E RE e 1 under cab Military Load Classification Vehicle w o Trailer ee eee eee es 8 Vehicle w Trailer OER Reh let OR RS 14 35 unloaded loaded METZ x id eee ei We neta ge Se Ga he eee ae meu 14 46 unloaded loaded 2 tee ean CE 11 34 unloaded loaded 0002 00 9 TM 9 2320 302 34 This Page Intentionally Left Blank 0002 00 10 TM 9 2320 302 34 THEORY OF OPERATION 0003 00 INTRODUCTION 1 The M915A3 Tractor Truck consists of the following functional systems drive train fuel system exhaust system cool ing system electrical system air system brake system steering system traction control system suspension system air conditioning system and collision warning system 2 This work package explains how the components and systems of the M915A3 work together functional description is provided for each major component and system DRIVE TRAIN The drive train of the M915A3 consists of a Detroit Diesel DDEC IV engine and an Allison 6 speed automatic transmission connected to RT 40 145P rear tandem axles REAR REAR AXLE FORWARD REAR AXLE TRANSMISSION ENGINE FUEL SYSTEM 1 Fuel to power the engine is pumped out of the fuel tank by an engine mounted fuel pump The engine fuel system con sists of one electronic uni
249. M 9 2320 302 34 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A3 NSN 2320 01 432 4847 Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY May 2001 TM 9 2320 302 34 LIST OF EFFECTIVE PAGES WORK PACKAGES NOTE A vertical line in the outer margins of the page indicates the portion of text affected by the change Changes to illustrations are indicated by miniature pointing hands Change to wiring diagrams is indicated by shaded areas Dates of issue for original and change pages work packages are Original 28 May 01 Change Not Applicable TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 40 AND TOTAL NUMBER OF WORK PACK AGES IS 126 CONSISTING OF THE FOLLOWING Page WP No Cover Back Blank A B Blank a to g h Blank i to v vi Blank WP 0001 00 to 0126 00 Index 1 to Index 10 Authentication Page Back Blank Sample DA Form 2028 2 Blank DA Form 2028 2 Metric Conversion Chart Back Cover Change No Zero in this column indicates an original page or work package A TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during maintenance of this equipment Failure to observe these precautions could
250. Maintenance n nananana nnana enere 0028 00 1 Oil Pump Maintenance n on 0 0 cece eee 0029 00 1 Oil Pressure Relief and Regulator Valves Replacement Crankshaft Front Oil Seal 0031 00 1 Cylinder Head paces esa UIT ce eda bap PR RR PERS 0032 00 1 Crankshaft Replacement nieri eens 0033 00 1 Camshaft Drive Gear Maintenance 0034 00 1 Gear Housing Assembly 0035 00 1 Cylinder Block Assembly 0036 00 1 Bull Idler Gear Replacement 0037 00 1 WP 0038 00 Adjustable Idler Gear 0038 00 Accessory Drive Fa Uh eed a eee 0039 00 1 Cylinder Block Pressure Testing lise 0040 00 1 Piston and Cylinder Assembly 0041 00 1 Turbocharger Replacement 0042 00 1 Turbocharger Repair 0043 00 1 Turbocharger Wastegate Actuator Maintenance Garrett Turbocharger Wastegate Actuator Fuel Injector Replacement n nannan nnana eee eee 0046 00 1 Fuel Injector Solenoid Replacement
251. NTINUED 0039 00 ASSEMBLY CONTINUED NOTE Support opposite end of accessory drive shaft on press bed when pressing gear on shaft 9 Place accessory drive gear 7 on accessory drive shaft 9 with chamfered end of bore toward accessory drive shaft Using press install accessory drive gear until accessory drive gear is flush with end of accessory drive shaft Obtain minimum press load of 4000 Ib 17 8 kN 342 1112 10 Install service kit holding fixture 3 and three fixture screws 2 on accessory drive gear 7 11 Install service kit holding fixture 3 in vise 342 1099 0039 00 9 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 ASSEMBLY CONTINUED NOTE If necessary use narrow opening end of service kit bearing installer to seat accessory drive pulley If press ing is necessary support opposite gear end of accessory drive shaft 12 Install accessory drive pulley 5 on accessory drive shaft 9 13 Install new accessory drive pulley lock nut 4 and tighten to 162 184 Ib ft 220 250 Nm 342 1100 14 Remove service kit holding fixture 3 from vise and remove three fixture screws 2 from accessory drive gear 7 342 1099 0039 00 10 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 ASSEMBLY CONTINUED 15 Support accessory drive assembly 1 as shown Position dial indicator 18 so indicator stem 19 rests on face of acces sory drive gear
252. Nm CAUTION Castellated nut may be tightened to 1450 lb ft 1966 Nm for purpose of installing cotter pin Overtightening may damage steering arm 2 Install new cotter pin 1 3 Install drag link TM 9 2320 302 20 0076 00 1 TM 9 2320 302 34 FRONT STEERING ARM REPLACEMENT CONTINUED 0076 00 INSTALLATION CONTINUED 4 Install front brake spider and brake chamber bracket TM 9 2320 302 20 END OF WORK PACKAGE 0076 00 2 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT 0077 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Seal assembly P N A 1205 X 1428 2 Tools and Special Tools Shim P N 2203 K 3001 Tool kit general mechanic s Item 132 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Driver bushing Item 33 WP 0126 00 Shim P N 2203 L 3002 Tags marker Item 35 WP 0125 00 Jack hydraulic Item 73 WP 0126 00 References Press arbor Item 90 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Equipment Condition Materials Parts Bushing P N 1225 W 985 2 Tie rod removed WP 0074 00 Gasket P N 3208 M 1027 2 Front cross tube arm removed WP 0075 00 Seal assembly P N A 1205 B 1432 2 Front steering arm removed WP 0076 00 NOTE Procedure is same for both steering knuckles REMOVAL 1 If damaged remove two lubrication fittings 1 2 Remove six cap screws 2 flat washers 3 two caps 4 g
253. O nn A UU N _ e gt e N KF Adapter Kit Mechanical Adjuster Lash Cam I Adjusting Tool Worm Alignment Stud Set Barring Tool Engine Bolt Eye Bolt Eye Cylinder Block Lift Tool Bracket Engine Mounting Bracket Transmission Holding Bracket Transmission Holding Caliper Micrometer Inside 2 12 in range Caliper Micrometer Outside 0 1 in Range Caliper Vernier English and metric measurements 0 6 in and 1 150 mm Caps Vise Jaw 4 in Checker Gear Lash Clamp C Clamp Material Lift Main Pressure Relief Compressor Spring Compressor Piston Ring Compressor Spring Compressor Spring Compressor Spring 4940 01 353 7038 5120 01 322 8885 5120 01 371 7369 5120 01 322 3498 5306 01 294 3028 5306 01 319 1987 2510 01 320 8905 5210 00 221 1921 5210 00 540 2973 5210 01 113 1548 5120 00 221 1506 5120 01 353 2520 5120 00 203 6431 3940 01 324 4713 5120 01 353 8567 5120 01 353 2522 0126 00 2 J 28593 33287 135596 33287 J 37070 33287 143431 33287 J36237 33287 993 042 75377 J35595 33287 135636 33287 J35926 33287 J41445 33287 124BZ 57163 T230RL 57163 GGG C 111 81348 A A 2938 58536 J 38662 33287 A A 431 58536 135641 33287 141462 33287 J 35598 A 33287 J24203 3 33287 J8062 1 33287 J8062 3 33287 M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302 24P M 9 2320 302
254. OTE DO NOT disconnect or connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 0120 00 1 TM 9 2320 302 34 AIR CONDITIONER FAN CYCLING SWITCH REPLACEMENT CONTINUED 0120 00 REMOVAL CONTINUED 1 Disconnect harness connector 1 from fan cycling switch 2 2 Unscrew fan cycling switch 2 from coupling 3 on receiver drier 4 Remove and discard preformed packing an 342 579 INSTALLATION 1 Lubricate new preformed packing with refrigerant oil and install over male threads of coupling 3 on receiver drier 4 2 Screw fan cycling switch 2 into coupling 3 Tighten switch to 20 25 lb ft 27 34 Nm 3 Connect harness connector 1 to fan cycling switch 2 NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 4 Replace receiver dridr WP 0118 00 5 Service air conditioner compressof WP 0116 00 6 Charge air conditioning systen WP 0112 00 WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 7 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0120 00 2 TM 9 2320 302 34 AIR CONDITIONER HOSE REPLACEMENT 0121 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETU
255. OTE If system is contaminated with moisture compressor oil must be replaced with clean oil If system is heavily contaminated with desiccant or grit replace compressor and expansion valve 5 Service air conditioner compressoF WP 0117 00 EVACUATING RECYCLING NOTE System must have been recovered and compressor filled with correct amount of refrigerant oil Replace receiver drier if system is opened l Wearing protective goggles and non leather gloves attach recovery recycling station s hoses to valves NOTE Push down firmly on hose connectors until a clicking sound is heard This will ensure coupler is locked a Ensure recovery recycling station s valves are closed b Connect red high side hose to discharge service valve c Connect blue low side hose to suction service valve d Turn knob clockwise on each coupler to open shrader valves 0112 00 2 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE CONTINUED 0112 00 EVACUATING RECYCLING CONTINUED gt To Vacuum Pump Manifold Suction Hand Valve Open Low Side Gage High Side Gage Manifold Discharge Hand Valve Open Suction Service Valve Discharge Service Valve a 342 561 AUN nn 2 Follow recovery recycling manufacturer s instructions and evacuate recycle refrigerant system 0112 00 3 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE CONTINUED 0112 00 PURGING NOTE Dry nitr
256. P Maintenance Level Materials Parts Continued Direct Support Cap set Item 7 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Goggles Item 42 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Caulk strip Item 8 WP 0125 00 Crowfoot attachment set Item 28 WP 0126 00 Oil refrigerant Item 271 WP 0125 00 Gloves rubber Item 40 WP 0126 00 Rags wiping Item 31 WP 0125 00 Tape insulation Item 36 WP 0125 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 References Materials Parts TM 9 2320 302 20 Gasket P N 22 46774 000 Preformed packing as required Adhesive loctite Item 2 WP 0125 00 Refrigerant recovered WP 0112 00 Equipment Condition gt Use care to prevent refrigerant from touching your skin eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death REMOVAL 1 The following air conditioning system hoses can be replaced a Compressor to tube assembly on firewall b Compressor to condenser c Receiver drier to tube assembly on firewall d Receiv
257. P 0125 00 Multiplier torque wrench Item 79 WP 0126 00 Rags wiping Item 31 WP 0125 00 Press arbor Item 90 WP 0126 00 Solder Item 33 WP 0125 00 Puller mechanical Item 95 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Personnel Required Two Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Wrench torque 100 600 Ib ft Item 140 References 0126 00 TM 9 214 Materials Parts Equipment Condition Nut lock P N 40X 1026 Forward rear axle differential carrier removed Nut lock P N 40 1 145 0079 00 bl WARNING Forward rear axle differential carrier weighs 1160 Ib 526 kg Attach suitable lifting device when lifting assembly to prevent possible injury to personnel 0080 00 1 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 1 Install differential carrier 1 on repair stand 342 1228 2 Turn differential carrier 1 so that ring gear 2 is up NOTE If reinstalling same ring gear and drive pinion perform steps 3 through 6 to measure backlash 3 Move ring gear 2 so that ring gear teeth fully engage with drive pinion 3 teeth 4 Install dial indicator on flange of differential carrier 1 so that tip of indicator is against drive side of tooth on ring gear 2 Adjust dial indicator to zero 5 Rotate ring gear 2 in both directions and record reading 6 Repeat step 5 twice more in different locations
258. PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 48 Left side only remove two nuts 170 washers 171 screws 172 and washers 173 from left engine mount 174 172 Ie E 342 951 VA WARNING Power pack weighs 3750 Ib 1702 kg Use hoist with lifting capacity of 5000 Ib 2270 kg to lift and support power pack Failure to do so could result in injury to personnel CAUTION Ensure all harnesses tubes and hoses are clear of power pack prior to removal Failure to do so could result in damage to equipment e Keep power pack clear of frame Failure to do so could result in damage to equipment 49 Using suitable hoist and sling spreader lift power pack slightly 50 Adjust load so that front of engine is raised as high as possible to clear frame crossmember Remove power pack from vehicle POWER PACK SEPARATION WARNING Do not place finger in hole of engine flywheel housing while engine is being barred over To do could result in serious injury to personnel 0010 00 14 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 POWER PACK SEPARATION CONTINUED CAUTION e Step 1 must be followed for barring engine over Any other method could cause damage to equipment e If bolts are dropped in engine flywheel housing retrieve immediately Failure to do so could result in damage to equipment 1 Have assistant bar engine 156 over using accessory drive 175 Locate and remov
259. R PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 27 28 29 30 Remove nut 95 lock washer 96 and wire 97 from sending unit 98 Discard lock washer Disconnect plug 99 from voltage regulator 100 Remove two tiedown straps 101 three nuts 102 washers 103 and five wires 104 Discard tiedown straps Remove screw 105 lock washer 106 washer 107 and ground wire 108 from dual voltage control 109 Feed harness 110 under cab 111 and out of the way Discard lock washer 108 342 940 0010 00 8 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 31 Disconnect fuel hose 112 from primary fuel filter 113 Plug fuel hose and set aside 342 941 32 Remove screw 114 and clamp 115 from gear case 116 33 Remove six screws 117 lock washers 118 drive coupler 119 and power steering pump 120 Set power steering pump aside Discard lock washers 117 118 342 942 0010 00 9 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 34 Disconnect and plug oil pressure hose 121 and set aside 342 943 35 Remove two bolts 122 washers 123 and tiedown strap 124 Discard tiedown strap 36 Remove lock nut 125 washer 126 clamp 127 screw 128 washer 129 and clamp 130 Discard lock nut 37 Remove four clamps 131 and disconnect three hoses 132 133 and 134 38 Remove f
260. RANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Main Shaft Module and Selective Shim Measurement 1 Install main shaft module assembly 37 in main housing 23 without selective shim 39 and thrust bearing 38 ARTEI Li sige Up 2 7 Ies Uf a 23 Han i iy LESE ri RANGES Qo La ara Di X Uu FA SALA A f 37 a SES BAS d 38 MN 39 y Sm 7 342 1150 2 Place a straightedge across rear cover mounting surface 3 Measure dimension A from top of straightedge to selective shim thrust surface on main shaft bearing spacer 4 Measure dimension B thickness of straightedge Subtract B from A remainder is dimension 0071 00 52 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Main Shaft Module and Selective Shim Measurement Continued 5 Place rear cover output end down facing work bench Install an uncompressed gasket on rear cover mounting surface and place a straightedge across P3 planetary carrier Measure dimension D from top of straightedge to rear cover mounting gasket Measure dimension E thickness of straightedge Subtract dimension E from dimension D remainder is dimen sion F Dimension is remainder of minus F and determines thickness of selective shim 39 CAUTION Ensure thrust be
261. RANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Assembly Continued 17 18 19 20 21 22 23 24 Install C1 clutch pack first install one backplate 14 then alternately install friction 15 and steel reaction plates 16 starting with a friction plate and ending with a backplate Secure clutch pack in place with retaining ring 13 Install C1 drive hub 11 over clutch pack while aligning external splines Install thrust bearing 12 on each side of C2 drive hub 10 then position this group over C1 drive hub 11 Install C2 clutch plates alternating between friction plates 8 and steel reaction plates 9 starting with steel reaction plates Install C2 backplate 7 and retaining ring 6 Install thrust bearing 5 on sun gear 4 Install 1 sun gear assembly 4 and retaining ring 2 Install thrust bearing 1 on rotating clutch module 3 342 1168 0071 00 27 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED C3 C4 Clutch Assembly and Main Housing Module Disassembly 1 2 3 10 11 12 13 14 Remove 14 bolts 1 securing C3 C4 clutch assembly 2 Remove C3 backplate assembly 3 from clutch assembly 2 Inspect and measure four thrust plates 4 backplate 3 and check 12 rivets 5 on clutch backplate Perform the fol lowing measurements a Thrust plate thickness at contact surfac
262. REMOVAL 1 Loosen clamp and remove trailer brake control valve 1 2 Loosen clamp screw and remove turn signal switch 2 3 Disconnect connector from turn signal switch 2 4 Disconnect horn wire from steering column 3 2 2 0090 00 2 342 1114 0090 00 TM 9 2320 302 34 STEERING COLUMN REPLACEMENT CONTINUED 0090 00 REMOVAL CONTINUED NOTE Heat base of yoke if necessary for ease in removal Remove nut 4 and bolt 5 from steering column yoke 6 and separate yoke from steering column 3 Discard nut and bolt 6 Remove two screws 7 and spacer block 8 from steering column 3 and steering column bracket 9 7 Loosen two screws 10 and remove steering column 3 from vehicle INSTALLATION 1 Position steering column 3 on steering column bracket 9 and install two screws 7 Tighten screws to 180 Ib in 20 Nm 2 Tighten two screws 10 to 180 Ib in 20 Nm 3 Using wire brush and liquid detergent clean serrations of steering column yoke 6 and steering column shaft 11 4 Apply adhesive primer to steering column shaft 11 Let dry for five minutes 5 Apply sealing compound to inside of steering column yoke 6 and install yoke to steering column shaft 11 6 Install new bolt 5 and nut 4 Tighten nut to 37 Ib ft 50 Nm 7 Apply sealing compound to exposed threads of screw 8 Connect horn wire to steering column 3 9 Connect connector to turn signal switch 2 10 I
263. Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Wiring harness and leads are secured in place by clips tiedown straps cushion clamps and screw termi nals Only remove hardware securing harness or lead to be removed Tag wiring harness and leads prior to removal to aid in installation Disconnect and remove switch panel wiring harness using illustration as a guide Discard tiedown straps INSTALLATION NOTE Wiring harness and leads are secured in place by clips new tiedown straps cushion clamps and screw ter minals Ensure harness is secure and all hardware is tight 1 Install connect and secure switch panel wiring harness using illustration as a guide 2 Connect battery cables TM 9 2320 302 20 0058 00 1 TM 9 2320 302 34 SWITCH PANEL WIRING HARNESS REPLACEMENT CONTINUED 0058 00 INSTALLATION CONTINUED _ N v 342 537 3 pin Female Connector 1 2 pin Female Connector 1 2 pin Male Connector 2 Ring Terminal 9 END OF WORK PACKAGE 0058 00 2 TM 9 2320 302 34 TURN SIGNAL MARKER LIGHT WIRING HARNESS REPLACEMENT 0059 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL S
264. Remove top and bottom channels 4 and 11 from radiator core 14 REPAIR NOTE No more than 12 tubes of radiator core can be blocked off If more than 12 are blocked core is not service able Replace with new core prior to assembly Refer to TM 750 254 for additional information on radiator repair ASSEMBLY 1 Position radiator core 14 front face down on workbench and apply a light coat of grease to surface of each new header gasket 10 2 Position two new header gaskets 10 on radiator core 14 3 Place top 4 and bottom 11 channels on radiator core 14 NOTE Ensure bolting bars screws and mounting hardware are installed as noted in disassembly 4 Install inlet tank 12 with bolting bars 5 and 6 screws 7 and 8 and new lock nuts 1 0048 00 3 TM 9 2320 302 34 RADIATOR REPAIR CONTINUED 0048 00 ASSEMBLY CONTINUED 5 Follow tightening sequence and tighten screws to 120 Ib in 1360 Ncm Repeat sequence and tighten to 180 Ib in 20 Nm 39 40 38 ALEAT 35 Cj 26 HORSE joi SHOE o 27 PLATE o o 22 23 18 oj 19 15 Ol 14 ep 7 ole Back 2 IO Front 1 0 oj 4 8 ols 9 of 12 16 1 17 Oi 20 24 21 HORSE m SHOE 0 28 loll PATE foll as 32 010 5031 7 gt 342 804 TIGHTENING SEQUENCE Install outlet tank 9 with bolting bars 5 and 6 screws 7 and 8 and new lock nuts 1 7
265. S Removal Installation INITIAL SETUP Maintenance Level Tools and Special Tools Continued Direct Support Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Materials Parts Compound gasket forming Item 121 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Dispenser sealant Item 30 WP 0126 00 Spindle and housing assembly removed TM 9 2320 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 302 20 Equipment Condition REMOVAL NOTE If repairing an oil leak do not remove lifter bracket 1 Remove two bolts 1 and front engine lifting bracket 2 from fan support bracket 3 342 974 0013 00 1 TM 9 2320 302 34 FAN DRIVE SUPPORT REPLACEMENT CONTINUED 0013 00 REMOVAL CONTINUED 2 Hold nut 4 and remove gear housing stabilizer bracket bolt 5 3 Remove nut 4 842 975 4 Remove two bolts 6 at top of fan support bracket 3 5 Remove short bolt 7 at bottom of fan support bracket 3 6 Remove long bolt 8 at right side of fan support bracket 3 342 976 7 Remove five adjustable idler gear cover bolts 9 8 Using plastic or fiber mallet tap fan support bracket 3 to break loose from gear case cover 10 0013 00 2 TM 9 2320 302 34 FAN DRIVE SUPPORT REPLACEMENT CONTINUED 0013 00 REMOVAL CONTINUED 342 91 INSTALLATION 1 Apply thin bead of gasket forming compound to machined surface 11 of adjustable idler acce
266. T SPRING REPLACEMENT CONTINUED 0099 00 REMOVAL 1 Using floor jack and two trestles lift and support frame 1 and front axle 2 to relieve weight from spring 3 NOTE Axle stop is offset to one side to align with frame Note position of axle stop prior to removal to aid in instal lation 2 Remove four nuts 4 washers 5 two U bolts 6 and axle stop 7 from front axle 2 and spring 3 342 968 3 Remove stop cushion 8 from axle stop 7 if excessively worn or damaged TM 9 2320 302 20 4 Remove grease fitting 9 two nuts 10 washers 11 screws 12 washers 13 wear plates 14 four shims 15 and pin 16 from rear end of spring 3 5 Remove grease fitting 17 two nuts 18 washers 19 screws 20 washers 21 shackles 22 wear plates 23 four shims 24 and pin 25 from rear spring hanger 26 0099 00 2 TM 9 2320 302 34 FRONT SPRING REPLACEMENT CONTINUED 0099 00 REMOVAL CONTINUED 6 Remove grease fitting 27 four screws 28 washers 29 and two saddle caps 30 JT Lower front axle 2 to allow spring 3 to clear front spring hanger 31 Remove two washers 32 and pin 33 from front of spring 3 NOTE Note position and number of shim s prior to removal to aid in installation 8 With assistance remove spring 3 spacer 34 shock absorber bracket 35 shim s 36 and pin 37 from front axle 2 INSTALLATION WARNING Shim s is used to ad
267. TINUED 13 Install front shock absorbers TM 9 2320 302 20 14 Install ABS sensors TM 9 2320 302 20 15 Install front brake spider and brake chamber bracket TM 9 2320 302 20 END OF WORK PACKAGE 0072 00 4 TM 9 2320 302 34 FRONT AXLE CASTER ADJUSTMENT 0073 00 THIS WORK PACKAGE COVERS Adjustment INITIAL SETUP Maintenance Level Materials Parts Direct Support Compound antiseize Item 10 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Wrench torque 100 600 Ib ft Item 140 WP 0126 00 Wrench set socket 3 4 in drive Item 141 WP 0126 00 ADJUSTMENT NOTE The following caster adjustment must be performed with the assistance of a local Freightliner dealer or a supporting Contractor Logistic Support CLS maintenance activity 1 Measure caster angle Angle must be 3 5 to 6 5 degrees NOTE Perform steps 2 through 9 if caster angle is incorrect 2 Remove four nuts 1 and washers 2 from two U bolts 3 342 1117 0073 00 1 TM 9 2320 302 34 FRONT AXLE CASTER ADJUSTMENT CONTINUED 0073 00 ADJUSTMENT CONTINUED WARNING Before removing shim s ensure vehicle is properly supported to prevent possible injury to personnel 3 Raise spring 4 high enough from axle 5 to allow removal of shim s 6 4 Remove spacer 7 shim s 6 and dowel 8 5t Install dowel 8 in axle 5 WARNING If more than one shim is to be added shims must be welded together
268. TIONER RECEIVER DRIER REPLACEMENT CONTINUED 0118 00 REMOVAL CONTINUED 1 Tag and disconnect refrigerant lines 1 from receiver drier 2 Install plugs in refrigerant lines Remove and discard preformed packings 2 Loosen hose clamp 3 attaching receiver drier 2 to mounting bracket and remove receiver drier 342 577 INSTALLATION 1 Position receiver drier 2 in mounting bracket Tighten hose clamp 3 2 Remove plugs from refrigerant lines 1 and line ports on new receiver drier 2 3 Install new preformed packings and apply refrigerant oil to preformed packings 4 Apply loctite to male fitting threads and connect refrigerant lines 1 to receiver drier 2 Apply proper torque in accor dance 0123 00 Service air conditioner compressok WP 0116 00 Install fan cycling switch WP 0120 00 Install binary switch TM 9 2320 302 20 Charge air conditioning systerh WP0112 00 tA WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 9 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0118 00 2 TM 9 2320 302 34 AIR CONDITIONER CONDENSER REPLACEMENT 0119 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Suppor
269. These steps are the same as for solid riveting operations refer to Rivet Hole Drilling on page 0105 00 e Proper drill sizes for standard and oversize blind rivets are given in Table 2 e Countersinking dimensions and minimum sheet gage for countersunk blind rivets are shown in Tables 3 and 4 e Grip lengths are determined as shown in Table 7 e Use rivet installation tool kit D 100 MIL I and puller head adapters if required for all blind rivets 0105 00 8 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 RIVET REPLACEMENT CONTINUED Table 7 Rivet Grip Length Determination MATERIAL THICKNESS RANGE IN MINIMUM MAXIMUM a Insert rivet stem into pulling head of rivet gun or adapter b Hold rivet gun in line with axis of rivet as accurately as possible c Apply steady firm pressure against rivet head d Squeeze handles of manual gun Rivet clamping action will pull sheets together seat rivet head and break stem flush with head of rivet ALUMINUM REPAIR CAUTION Repairs should not be made on body using welding or heat for forming Heat will weaken material and cause further problems 1 Material Aluminum material used for repair should be of the same alloy and temper as original if possible In general 6061 T6 should be used Material thickness must be the same or thicker This alloy will work well for flat repairs but is not well suited to bending because it is hard and cracks easily when bent sharply
270. UCTIONS TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 POWER PACK REPLACEMENT 0010 00 THIS WORK PACKAGE COVERS Removal Power Pack Separation Power Pack Assembly Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Engine oil drained TM 9 2320 302 10 Air system drained 9 2320 302 10 Tools and Special Tools NE Transmission tunnel access cover removed TM 9 Tool kit general mechanic s Item 132 WP 0126 00 2320 302 20 Barring tool engine Item 8 WP 0126 00 Hood removed TM 9 2320 302 20 Lift transmission Item 75 WP 0126 00 Fan impeller and shroud removed TM 9 2320 302 Spreader sling Item 120 WP 0126 00 20 Air intake tubes hoses and cl d TM 9 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 nie Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Air cleaner pre cleaner and duct assembly removed Materials Parts IM 2 2320 302 20 Alternator air conditioner belt removed TM 9 2320 Clamp seal P N KY X00 5833 302 20 Nut self locking P N MS51922 33 Alternator and alternator adjusting rod removed Nut self locking P N MS51922 49 26 9 2320 302 20 Nut self locking P N MS51922 57 2 Fender extensions removed TM 9 2320 302 20 Oil sampling valves removed 9 2320 302 20 Driveline disconnected 9 2320 302 20 Washer lock P N 20930 78423 2 Air conditioner compressor removed WP 0117 00 Washer lock P N 78328 2 ae T
271. UED 11 Install new preformed packings 33 and lubricate them with refrigerant oil 12 Apply loctite to male fitting threads 34 and connect two refrigerant lines 26 to expansion valve 25 Remove tags 13 Torque refrigerant line connection WP 0123 00 E d Ur YY x Mm u 33 A40 R72 14 Apply insulation tape to refrigerant lines 26 and expansion valve 25 15 Connect connectors for blower motor 16 resistor block 17 and thermostatic switch 18 342 566 16 Connect blue air line to air cylinder behind compartment 13 17 Connect two flex hoses to ducts behind compartment 13 NOTE Any time air conditioning system is evacuated replace receiver drier 18 Replace receiver driet WP 0118 00 0113 00 9 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 INSTALLATION CONTINUED 19 Charge system with refrigerant WP 0112 00 20 Add refrigerant oil to compressor to replace that which was lost during system discharge WP 0116 00 WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 2 Leak test air conditioner system TM 9 2320 302 20 22 Install compartment 13 into dash 9 and secure with three nuts 14 and spring washers 15 23 Install top panel 12 to
272. VAL CONTINUED 3 Install crankshaft protector 5 on end of crankshaft over engine barring tool 1 4 Remove two lower bolts 3 CAUTION Do not allow bull idler gear to come in contact with crankshaft oil seal contact surface Oil leaks may result if this surface is scratched NOTE Bull idler gear will rotate slightly as it is being removed 5 Grasp bull idler gear 6 and pull out of cylinder block recess 6 Remove two guide studs 4 1 CLEANING AND INSPECTION 1 Use general cleaning methods to clean all parts 2 Inspect bull idler gear recess 7 in cylinder block Ensure surfaces are clean and free of foreign material or damage and that two lubrication holes 8 are clear 0037 00 2 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT CONTINUED 0037 00 CLEANING AND INSPECTION CONTINUED 342 908 3 Inspect all parts for wear or damage INSTALLATION CAUTION Ensure all timing marks are aligned as shown Failure to do so will result in engine damage 1 Install two guide studs 4 in two upper bull idler gear bolt holes 342 909 0037 00 3 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT CONTINUED 0037 00 INSTALLATION CONTINUED 2 Bar engine over until crankshaft timing gear timing mark 9 is at 12 o clock position 3 Align timing mark 10 on camshaft drive gear with timing mark 11 on adjustable gear CAUTION Do not allow bull idler gear to come in contact with crankshaft oil
273. VERHAUL CONTINUED Torque Converter Module Disassembly Continued 12 13 14 15 16 17 18 19 20 Remove thrust plate 16 from stator assembly 8 Measure note and tag thrust plate Minimum thickness allowed is 0 372 in 9 45 mm Remove thrust washer 17 from stator assembly 8 Remove stator race 18 13 springs 19 and rollers 20 Inspect components for damage Remove 44 bolts 21 securing lockup clutch backup plate 22 to cover assembly 3 Remove backup plate from cover Measure thickness of backup plate wear surface Minimum thickness allowed is 0 464 in 11 79 mm Check for backup plate distortion Maximum distortion allowed is 0 006 in 0 15 mm Remove lockup clutch damper assembly 23 from cover assembly 3 Perform the following measurements a Lockup clutch thickness minimum thickness allowed is 0 335 in 8 51 mm b Lockup clutch distortion maximum allowable distortion is 0 020 in 0 51 mm c Spline wear check measure between turbine and lockup clutch damper Maximum allowable wear is 0 015 in 0 38 mm on either spline Remove lockup clutch piston 24 inner seal ring 25 and outer seal ring 26 from cover assembly 3 Measure thick ness of lockup clutch piston Minimum thickness allowed is 0 257 in 6 53 mm Inspect and measure inside diameter ID of converter cover bushing 27 Maximum allowed inside diameter of bush ing is 2 634 in 66 90 mm Remove bushing if repl
274. WORK PACKAGE COVERS Disassembly Module Overhaul Assembly Tabulated Data INITIAL SETUP Maintenance Level Tools and Special Tools Continued General Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Bracket transmission holding Item 12 WP 0126 00 Bracket transmission holding Item 13 WP 0126 00 Caliber micrometer Item 15 WP 0126 00 Compressor main pressure relief spring Item 21 WA Compressor spring C2 Item 26 WP 0126 00 Compressor spring C5 Item 27 WP 0126 00 Gage micrometer depth Item 34 WP 0126 00 Gage profile Item 37 WP 0126 00 Inserter and remover spring C1 Item 54 WA 0126 00 Installer charging pump bushing Item 57 0126 00 Installer front support sleeve Item 59 WP 0126 00 Installer output bearing Item 60 WP 0126 00 Installer output bearing cup Item 61 WP 0126 00 Installer bearing retainer bushing Item 63 0126 00 Installer rotating clutch bushing Item 64 WP 0126 00 Installer seal input Item 65 WP 0126 00 Installer seal output Item 66 WP 0126 00 Installer torque converter cover bushing Item 67 WA 0126 00 0071 00 1 Installer carrier bushing Item 68 WP 0126 00 Installer wear plate Item 71 WP 0126 00 Lifting bracket flywheel Item TI WP 0126 00 Press arbor Item 90 WP 0126 00 Puller kit universal Item 96 WP 0126 00 Remover wheel bearing cup Item 10 WP 0126 00 Remover installer m
275. Wiring Harness Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Torque wrench 0 300 Ib in Item 137 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 CAUTION Grasp connector and terminal body when removing or installing wiring harness connectors Do not pull on wires or harness to prevent damage to equipment ENGINE INJECTOR WIRING HARNESS REMOVAL NOTE Engine injector wiring harness connectors are top and bottom connectors at front of electronic control module Do not remove center outboard connector Ensure all wires are tagged before removal as an aid to installation 1 Remove rocker arm cov r WP 0016 00 0069 00 1 TM 9 2320 302 34 ENGINE INJECTOR AND ECM WIRING HARNESSES REPLACEMENT CONTINUED 0069 00 ENGINE INJECTOR WIRING HARNESS REMOVAL CONTINUED 2 Disconnect locking tangs on two engine injector wiring harness connectors 1 at front of Electronic Control Module ECM 2 and disconnect connectors from top and bottom outboard connectors of ECM Pa J p N 94 ML PE A we SALW Yr 7 I rT t 2 d 342 1185 3 Remove two screws 3 and harness protector 4 from harness plate 5 at rear of cylinder head 6 4 Disconnect harness leads 7 from three engine ret
276. YLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 342 1022 Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in a well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water NOTE e Coat inside sealing edges of cup plugs with adhesive e Coat pipe plugs with pipe sealing compound 0032 00 15 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 3 If removed use cup plug installer to install 11 cup plugs 55 on top front and rear sides of cylinder head Install cup plugs to 0 098 0 138 in 2 5 3 5 mm below machined surface 4 If removed install two cup plugs 56 on front and rear sides of cylinder head to 0 098 0 138 in 2 5 3 5 mm below machined surface 5 Install two square drive pipe plugs 57 on front side of cylinder head flush to below surface 6 Install connector 58 on left rear side of cylinder head 7 Install elbow 59 on left front side of cylinder head 8 Install two pipe plugs 60 on right side rear of cylinder head 9 Install pipe plug 61 on right side rear of cylinder head 10 Install fuse plug 62 on right side front of cylinder head 342 1023 NOTE Do not lubricate outside of injector tube or inside cylinder head injector tube bore 11 Lubricate new in
277. ace valve and spring ASSEMBLY NOTE Coat all interior components with a light coat of clean engine lubricating oil prior to assembly 1 Install new seal 37 with lip facing bushing until seal is seated against inside lip of pump body 9 Install new seal 38 with lip facing outward until seal is seated against seal 37 Install new drive pin 36 new carrier 35 and two snap rings 34 on shaft 13 Re e Install two new o rings 31 and two new seals 30 in end plate 33 0087 00 4 TM 9 2320 302 34 POWER STEERING PUMP REPAIR CONTINUED 0087 00 ASSEMBLY CONTINUED 5 Install end plate 33 on pump body 9 with two seals 30 facing up CAUTION Failure to install locating pin in correct position may cause pump to operate in reverse which could result in equip ment damage 6 Install new locating pin 32 in lower left hole of end plate 33 NOTE If seals can be seen port plate must be reversed 7 Install new port plate 29 and new cam 28 with arrow on cam pointing up toward locating pin 32 8 Install shaft 13 and ten new rollers 27 9 If removed install two new guide pins 26 in rear cover 4 10 Install valve 25 spring 24 new packing 23 and valve 22 11 Install new small packing 21 and new large packing 20 in pump body 9 12 Install cover 4 and secure to pump body 9 with five screws 19 13 Install new gasket 18 on pump body 9 14 Install fl
278. acement is necessary Remove thrust bearing 28 from converter cover 3 Torque Converter Module Assembly 1 2 Install stator race 18 into stator assembly 8 Install 13 springs 19 and rollers 20 into stator assembly 8 Use petrolatum to help hold springs and rollers in place ROLLER TO BE iNSTALLED IN SMALL END OF CAM POCKET SPRING STATOR CAM 342 1157 0071 00 11 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Torque Converter Module Assembly Continued 3 4 5 16 17 18 19 20 21 Install thrust washer 17 and thrust plate 16 on stator assembly 8 Install star plate 15 and retaining ring 14 Install bearing assembly 11 race 12 and selective shim 13 to pump assembly 5 CAUTION When installing thrust bearings ensure that locating lip on either inner or outer thrust bearing race is not pre venting race from contacting thrust surface of mating part Failure to follow this caution leads to premature thrust bearing failure and incorrect shim selection to maintain proper internal part clearance Install thrust bearing assembly 10 into turbine assembly 7 If removed install new bushing 27 into cover assembly 3 using installer tool 739949 Insert turbine assembly 7 into converter cover bushing 27 Check for free rotation Install thrust bearing 28 in cover assembly 3 Install lockup clutch piston inne
279. acity of 1400 Ib 636 kg to support cab assembly Failure to do so could result in injury to personnel and or damage to equipment NOTE e Procedure is the same for both sides except as noted e Perform step 1 on right side Install plate 39 three washers 38 screws 37 washers 36 and new lock nuts 35 NOTE Perform step 2 on left side Install plate 34 three washers 33 screws 32 two brackets 31 three washers 30 and new lock nuts 29 Install front cab mount 21 with four washers 28 screws 27 washers 26 and new lock nuts 25 Install bushing 23 washer 24 and screw 22 Install resilient mount 19 washer 18 and new lock nut 17 Lower cab assembly 20 and remove cab sling and hoist NOTE Perform steps 7 and 8 on left side Connect cable 16 and install screw 15 washer 14 and new lock nut 13 20 23 13 14 15 25 26 27 28 342 190 25 26 27 28 0097 00 5 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 INSTALLATION CONTINUED 8 Install four clamps 12 with two screws 11 washers 10 and new lock nuts 9 9 10 11 342 189 9 4 5 6 7 342 188 0097 00 6 TM 9 2320 302 34 FRONT CAB MOUNTS REPLACEMENT CONTINUED 0097 00 INSTALLATION CONTINUED NOTE Perform step 10 on right side 10 Install outlet pipe 3 v clamp 2 and new seal clamp 1 11 Install fender extension TM 9 2320 302 20 342 18
280. acket 26 and three cap screws 25 in door hinge 27 342 599 0108 00 15 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 19 Install eight screws 23 in inside door panel 24 20 Install window crank 22 and screw 21 23 S44 f gt 6 21 22 342 598 21 Install four washers 20 cap screws 19 bracket 18 four washers 17 and nuts 16 0108 00 16 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 22 Install vent window 13 in door 2 23 Install window channel 15 in vent window 13 24 Install remainder of window channel 14 in door 2 ic js 342 596 25 Install three washers 12 and screws 11 in vent window 13 11 12 342 595 0108 00 17 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 ASSEMBLY CONTINUED 26 Install four washers 10 three spacers 9 cap screw 8 three screws 7 bracket 6 four washers 5 and nuts 4 342 594 27 Raise window glass 3 28 removed install new seal 1 on door 2 and apply sealing compound to each end of seal joint 29 Install cab dooi_ WP 0107 00 END OF WORK PACKAGE 0108 00 18 TM 9 2320 302 34 WINDSHIELD REPLACEMENT 0109 00 THIS WORK PACKAGE COVERS Removal Cleaning and Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Seal nonmetallic
281. ackout conditions Trailer Gladhands Provide air supply for trailer brakes Pintle Hook Coupling device for trailers with lunettes Taillights Contain composite tail stop backup and turn signal lights 0002 00 5 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA Dimensions Eength 1 A LERRA a tee M a Sain Gos i ee ae aed 276 in 701 cm Height Overall sang tn eee ow RE aha kee S bw ee eek 118 in 300 cm Width Overall outer tesa blur sube Thee iur Sale sloth E UE 100 in 254 cm Wheelbase cscs o os ERE Se des Seed as 162 in 411 cm Ground Clearance deus Pla udin bip de n ER Ra 9 in 23 cm Angle of Approach EE MR NI RUP 27 Weights inei Sue ea eb ks GAG AGS eae Rk eS Rb eee ees 19 080 Ib 8662 kg GVWR cx xh tome e eI RT EO deve eee 52 000 1b 23 608 kg GCWR heec Hr dere ers 105 000 Ib 46 670 kg Front Axle Eoaded iile RR ERE ER e S ha See eee RSEN 12 000 Ib 5448 kg Rear Axle Loaded eu RR VR ERES eda DET VES 40 000 1b 18 160 kg Capacities Engine Oil Refill w Filters esee e 41 qt 38 81 1 Cooling System 25 o v bebe pe eee eae she Sra 65 qt 61 5 1 Fuel Tank otv ite eei UU eg edu dre P RR UNE 100 gal 378 5 1 Power Steering Reservoir llle eee een eee 2 qt 1 9 1 Transmission ime eux ea ea Ode Rs 51 qt 48 1 Rear Axl
282. ackward until marked gear teeth go past drive pinion shaft 3 six times Repeat if needed for clearer pattern 342 1224 0082 00 21 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED NOTE e Location of good hand rolled contact pattern for new gear set is toward toe of gear tooth and in center between top and bottom of tooth e Location of good hand rolled contact pattern of used gear set must match wear pattern in ring gear Con tact pattern will be smaller than wear pattern e During tooth contact pattern checks backlash can be adjusted within specification limits if needed to change pattern location 55 Compare contact pattern with examples shown SO TW S T ANN S SS Io SS 342 1225 GOOD HAND ROLLED PATTERN HIGH PATTERN LOW PATTERN 56 If contact pattern requires adjustment perform disassembly steps 16 through 21 57 Perform steps 23 through 28 and 53 through 55 a correct high contact pattern decrease thickness of shim pack 22 b correct low contact pattern increase thickness of shim pack 22 342 1206 0082 00 22 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 58 If contact pattern is too far toward heel of tooth repeat step 50 59 If contact pattern is too far toward toe of tooth repeat step 51 60 Install two pins 6 between lugs of two adjus
283. action When the inter axle differential lock is applied the drive shaft becomes a solid connection between the two rear axles 342 158 0003 00 7 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 REAR SUSPENSION SYSTEM The TufTrac rear suspension system consists of two parabolic taper leaf springs and two shock absorbers per side and an arrangement of torque rods The rear suspension system is designed to provide a high degree of ground clearance and articula tion while maintaining an equal load over each wheel Ride characteristics are similar whether loaded or unloaded 0003 00 8 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 AIR CONDITIONING SYSTEM 1 The air conditioning unit is part of the heater and is mounted under the glove compartment It is a single unit consisting of a heater core air conditioning evaporator coil blower motor control valves and air ducts The system is turned on by the mode control lever on the instrument panel in the cab The four speed blower switch con trols flow rate An even cab temperature is maintained by controlling the coolant flow through the heater core or refrigerant flow through the evaporator coil THERMOSTATIC HEATER SWITCH CONDENSER CORE EXPANSION VALVE EVAPORATOR COIL 342 010 RECEIVER DRIER 0003 00 9 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 COLLISION WARNING SYSTEM CWS
284. ailure to do so could result in injury to personnel 5 Attach hoist and remove 12 lock nuts 17 washers 18 screws 19 washers 20 and plate 21 Discard lock nuts 0096 00 2 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT CONTINUED 0096 00 REMOVAL CONTINUED 342 959 6 Remove four lock nuts 22 washers 23 screws 24 washers 25 and right side support 26 Discard lock nuts 7 Repeat step 6 for left side support 27 27 X 1s e 2 me 8 n amp amp OR 342 960 22 23 24 25 0096 00 3 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT CONTINUED 0096 00 REMOVAL CONTINUED V WARNING Rear crossmember weighs 460 Ib 209 kg Use hoist with lifting capacity of 600 Ib 272 kg to remove rear crossmember Failure to do so could result in injury to personnel 8 Attach hoist and remove four lock nuts 28 washers 29 screws 30 washers 31 and rear crossmember 32 Dis card lock nuts 28 29 30 31 342 961 30 31 INSTALLATION VA WARNING Rear crossmember weighs 460 Ib 209 kg Use hoist with lifting capacity of 600 Ib 272 kg to install rear crossmember Failure to do so could result in injury to personnel 1 Install rear crossmember 32 with four washers 31 screws 30 washers 29 and new lock nuts 28 2 Install right side support 26 with four washers 25 screws 24 washers 23 and new lock nuts 22 3 Repeat step 2 for left side support
285. ain bearing shells and thrust washers with respective main bearing caps and lower main bearing shells If reused install upper and lower main bearing shells and thrust bearing in original posi tions Main bearing caps are bored in position and stamped with position number Caps must be installed in their original positions with marked numbered side of each cap toward cooler right side of cylinder block e Slightest burr or particle of dirt between backs of no 6 main bearing thrust washers and saddle or cap may decrease clearance between washer and crankshaft beyond specified limits 13 Remove seven main bearing caps 12 and lower main bearing shells 13 342 1075 V WARNING Crankshaft weighs 408 1b 185 23 kg Use suitable lifting device to lift and support crankshaft Failure to do so could result in serious injury to personnel 14 Using nylon rope and suitable lifting device lift crankshaft 14 from cylinder block 15 15 Remove seven upper main bearing shells 16 16 Remove two thrust washers 17 from sides of main bearing saddle no 6 18 0033 00 4 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 REMOVAL CONTINUED 342 1076 CLEANING 2 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 1
286. ain pressure spring Item 106 Test block pressure switch Item 121 WP 0126 00 Tool torque converter bolt Item 129 WP 0126 00 Tool base spring compressor Item 130 WP 0126 00 Tool set spanner nut Item 133 WP 0126 00 Tray set valve body parts Item 134 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Materials Parts Converter housing kit P N 29524152 Filter kit P N 29526899 Seal and gasket kit P N 29518437 Seal and gasket kit P N 29518442 Shim kit torque converter P N 29503828 Oil lubricating Item 25 WP 0125 00 Petrolatum technical Item 29 WP 0125 00 Tags marker Item 35 WP 0125 00 Personnel Required Two Equipment Condition Transmission installed on maintenance stand Engine turbine and output speed sensors removed TM 9 2320 302 20 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 B z WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel DISASSEMBLY NOTE Confirm transmission has been drained prior to disassembly Removal of Filters and Breather 1 Remove 12 bolts 1 two filter covers 2 o rings 3
287. air conditioner belt 61 Install air cleaner pre cleaner and duct assembly 62 Install air intake tubes hoses and clamps 0010 00 30 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED INSTALLATION CONTINUED 63 64 65 66 Install fan impeller and shroud TM 9 2320 302 20 Install hood TM 9 2320 302 20 Install transmission tunnel access cover TM 9 2320 302 20 Fill engine with oil TM 9 2320 302 10 END OF WORK PACKAGE 0010 00 31 0010 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0010 00 32 TM 9 2320 302 34 FRONT ENGINE MOUNT ADAPTER AND SUPPORT REPLACEMENT 0011 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Jack hydraulic Item 73 WP 0126 00 Front ABS quick release valve removed TM 9 2320 Trestles Item 135 WP 0126 00 302 20 Materials Parts Front crossmember removed WP 0096 00 Nut lock P N MS51922 57 Vibration damper removed WP 0020 00 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVA
288. al P N 23505892 Tools and Special Tools Oil lubricating Item 25 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Oil pan removed WP 0028 00 Materials Parts Ring seal P N 23505891 OIL PRESSURE REGULATOR VALVE REPLACEMENT 1 Remove two bolts 1 from cylinder block 2 2 Remove oil pressure regulator valve 3 3 Position oil pressure regulator valve 3 on cylinder block 2 4 Install two bolts 1 and tighten to 22 28 Ib ft 30 38 Nm 5 Install oil pah WP 0028 00 342 742 0030 00 1 0030 00 TM 9 2320 302 34 OIL PRESSURE RELIEF AND REGULATOR VALVES REPLACEMENT CONTINUED 0030 00 OIL PRESSURE RELIEF VALVE REPLACEMENT 1 2 10 Remove two bolts 4 from cylinder block 2 Remove oil pressure relief valve outlet tube elbow assembly 5 from oil outlet tube 6 and remove oil outlet tube from oil pump assembly 7 Remove and discard two seal rings 8 and 9 342 723 Coat two new seal rings 8 and 9 with clean engine lubricating oil Install smaller seal ring 8 on oil pressure relief valve elbow assembly 5 end of oil outlet tube 6 Install larger seal ring 9 on oil pump end of oil outlet tube Install larger diameter end of oil outlet tube 6 in outlet neck of oil pump assembly 7 until oil outlet tube bottoms in bore Install oil pressure relief valve outlet tube elbow assembly 5 on smaller diamete
289. aling compound gets on skin or clothing wash immediately with soap and water 9 Coat threads of air temperature sensor 11 with pipe sealing compound and install in air intake manifold 4 10 Apply lubricating oil to new seal ring 13 and install in intake manifold 4 11 Install turbo boost sensor 10 on intake manifold 4 and secure in place with two retaining bolts 12 Tighten bolts to 21 26 Ib in 2 4 2 9 Nm 12 Connect engine wiring harness 9 to turbo boost sensor 10 and air temperature sensor 11 0014 00 4 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT CONTINUED 0014 00 INSTALLATION CONTINUED 1 3 342 636 5 9 13 Coat threads of nipple 8 and fitting 6 with pipe sealing compound and install nipple 8 check valve 7 and fitting 6 in intake manifold 4 14 Connect air line 5 to fitting 6 342 635 0014 00 5 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT CONTINUED 0014 00 INSTALLATION CONTINUED 15 Apply a light coat of pipe sealing compound to threads of air supply connector 3 install in air intake manifold 4 and attach air compressor inlet hose 2 to connector 16 Position hose clamp 1 and secure in place 342 634 17 Install air intake intercooler tubing TM 9 2320 302 20 18 Install ether atomizer and bushing TM 9 2320 302 20 19 Operate vehicle TM 9 2320 302 10 and check for leaks END OF WORK PACKAGE 0014 00 6 TM 9 2320
290. all spring 30 valve 29 and stop 28 in rotating clutch solenoid body 12 with retention pin 27 Install three springs 26 three solenoid regulator valves 25 new smaller o rings 23 and new larger o rings 24 Install face seal 20 two solenoids 21 and solenoid 22 Install solenoid retention pins 19 smooth end first from bottom of rotating clutch solenoid body 12 Install pressure switch assembly 18 and two bolts 17 Tighten bolts to 44 71 Ib in 5 8 Nm NOTE Control valve module assembly procedures are steps 28 through 37 Install main valve body assembly 16 and two bolts 15 see page 0072 00 45 for illustration Tighten bolts only fin ger tight Install control harness assembly 10 with three bolts 9 Tighten bolts to 18 26 Ib in 2 3 Nm Install new gasket 6 new face seal 5 and new filter 4 in suction filter housing 3 Install suction filter housing 3 with bolts 1 and two bolts 2 Tighten bolts only finger tight Install solenoid separator plate 41 Install stationary clutch solenoid body assembly 14 with eight bolts 13 Tighten bolts only finger tight Install rotating clutch solenoid body 12 with three bolts 11 Tighten bolts only finger tight Install wiring harness cover plate 8 with four bolts 7 Tighten bolts only finger tight Connect all electrical connectors Remove tags Evenly tighten cover plate bolts 7 suction filter bolts 1 and 2 valve body bolts
291. ance piston 24 Install spring assembly 25 Align mark on balance piston 24 with slot on piston 32 Position balance piston onto the C1 piston Install tool J35923 2 with bearing washer and handle Tighten tool compressing C1 balance piston 24 and Cl spring assembly 25 Install retaining ring 26 View A page 0072 00 24 Remove tools If turbine shaft bushing 21 was removed replace using tool J37036 Lubricate with transmission oil and install new o ring 23 on turbine shaft 20 NOTE Butt joint seal rings require special handling during assembly Seal rings contain materials that absorb mois ture from atmosphere causing them to expand Check seal ring end clearance before installation to ensure seal ring has not expanded Install each rotating seal ring 22 into ground sleeve bore and measure end gap Seal ring end gap must be 0 026 0 040 in 0 65 1 01 mm Install three rotating seal rings with correct end gap into rear of turbine shaft 20 Install turbine shaft 20 and retain with retaining ring 19 CAUTION Ensure thrust bearing is assembled with locating lip on either inner or outer thrust bearing race not prevent ing race from contacting thrust surface of mating part Failure to follow this caution leads to thrust bearing failure and incorrect shim selection to maintain proper part clearance Install thrust bearing 17 on rotating clutch hub 18 0071 00 26 TM 9 2320 302 34 T
292. and remove and discard needle bearing and oil seal 12 342 1104 8 Remove snap ring 13 from accessory drive shaft and bearing assembly 9 342 1105 9 Place two steel press plates 14 under ball bearing assembly 15 outer race Apply pressure to top of accessory drive shaft and bearing assembly 9 and remove and discard ball bearing assembly 0039 00 4 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 DISASSEMBLY CONTINUED ASSEMBLY 1 Place new ball bearing assembly 15 on accessory drive shaft 9 Place small opening of service kit bearing installer 16 over ball bearing assembly inner race Press until ball bearing assembly bottoms against shoulder of accessory drive shaft 342 1107 0039 00 5 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 ASSEMBLY CONTINUED NOTE Ensure tapered side of snap ring is installed away from bearing Ensure snap ring is fully seated in groove of accessory drive shaft 2 Install snap ring 13 in groove of accessory drive shaft 9 342 1105 Word INSTALL an arrow etched on needle bearing installer remover to aid installation Place needle bearing installation numbers up against needle bearing installer remover 3 Install new needle bearing 11 in accessory drive housing 1 Using long end of service kit needle bearing installer remover 10 press needle bearing into accessory drive housing flus
293. and remove drain tubes 22 23 342 568 WARNING Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 0113 00 4 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 REMOVAL CONTINUED CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid NOTE DO NOT disconnect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 13 Remove insulation tape from expansion valve 25 Disconnect two refrigerant lines 26 from expansion valve 14 Cap expansion valve 25 and refrigerant lines 26 342 569 26 15 Remove six screws 27 and fresh air duct assembly 28 on engine side of cab firewall 16 Remove gasket forming compound from duct and push rubber boot inside cab 342 570 0113 00 5 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 REMOVAL CONTINUED 17 Disconnect air line 29 from air cylinder 30 by pushing in on cover ring then pulling out on air line 342 571 18 Remove six screws 31 holding HVAC unit 32 in place 19 With assistance lift HVAC unit
294. andard valve seat has been installed use corresponding thicker valve spring seat Failure to do so could result in damage to equipment 49 Install valve spring seat 15 over valve guide 14 and against top of cylinder head 342 1006 50 Check length of plastic valve kit seal protector cap 82 relative to valve lock groove 83 on valve stem If seal protec tor cap extends more than 1 16 in 1 5 mm beyond groove trim off excess 82 342 1038 83 51 Hold valve face and install seal protector cap 82 on valve stem 10 0032 00 26 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED SS oss 82 ay A i wig 2 Zee 5 E 0 lA Rs MET 342 1039 NOTE Ensure all valve spring seats are in place before valve stem oil seals are installed Install valve stem oil seal dry 52 Wipe any oil from outside of valve guide 14 Install new valve stem oil seal 13 over seal protector cap 82 against valve guide Remove seal protector cap 82 53 Using valve stem seal installer push valve stem oil seal 13 down until seal lip is fully in groove on valve guide 14 When installer tool contacts head seal is correctly positioned S d 76 o 342 1040 0032 00 27 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED CAUTION Position valve spring and rotator so valve lock grooves on valve stem do not contact oil seal Failure to do so could r
295. andle 16 down Grasp valve seat collet handle 21 and rotate back and forth several times Hold valve seat remover body 19 flat on cylinder head fire deck 20 and pull valve seat remover handle 16 down until valve seat is removed Return valve seat remover handle 16 to vertical position and remove valve seat from valve seat collet Discard valve seat 342 1009 If valve guides 14 are worn or damaged install valve guide remover 22 in air chisel 23 and insert valve guide remover into bottom of valve guide 14 from fire deck side WARNING Valve guide is removed from cylinder head under force Position heavy block of wood at an angle beneath guide to deflect valve guide and prevent personal injury Hold valve guide remover 22 vertical to cylinder head fire deck and drive valve guide 14 down until free Discard valve guide 0032 00 6 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED 342 1010 0032 00 7 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED NOTE e Replace dowels and plugs only if necessary e Dowel removal procedure is the same for round diamond or hollow dowels e Cover exposed areas to guard against welding sparks 24 Fabricate piece of sheet brass 24 with hole large enough to fit over dowel being removed 25 Tack weld flat washer 25 to top of dowel as shown 26 Tack weld nut 26 to flat washer 25 Ensur
296. ange 17 as noted during disassembly and secure with three screws 16 16 342 800 0087 00 5 TM 9 2320 302 34 POWER STEERING PUMP REPAIR CONTINUED 0087 00 ASSEMBLY CONTINUED 15 Install woodruff key 15 in shaft 13 16 Install gear 14 on shaft 13 until gear bottoms out 17 Install two washers 11 and 12 and screw 10 on shaft 13 18 Install tube 7 with new gasket 8 and secure in place with two washers 6 and bolts 5 19 Install new packing 3 and elbow 2 with jam nut 1 on rear cover 4 342 799 20 Install power steering pump WP 0086 00 END OF WORK PACKAGE 0087 00 6 TM 9 2320 302 34 STEERING GEAR REPLACEMENT 0088 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tool Equipment Conditions Tool kit general mechanic s Item 132 WP 0126 00 Drag link removed 9 2320 302 20 Pan drain Item 80 WP 0126 00 Power steering reservoir drained TM 9 2320 302 20 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Lower end of universal steering shaft disconnected TM 9 2320 302 20 Materials Parts Washer lock MS35338 147 Rags wiping Item WP 0125 00 Tags marker Item 35 WP 0125 00 REMOVAL WARNING Spilled power steering fluid is very slippery Clean up any spilled fluid immediately Failure to do so could result in serious injury to personnel 1 Remove drain plug
297. angle for installation use minimum of two personnel to install door Failure to do so could result in injury to personnel 2 Position door 4 and install two capscrews 3 in locations indicated 0107 00 2 TM 9 2320 302 34 CAB DOOR REPLACEMENT CONTINUED INSTALLATION CONTINUED 342 592 3 Perform door adjustment 9 2320 302 20 4 Install remaining six capscrews 3 5 Install socket head screw 2 and capnut 1 342 590 6 Install rear view mirror 9 2320 302 20 END OF WORK PACKAGE 0107 00 3 0107 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0107 00 4 TM 9 2320 302 34 CAB DOOR REPAIR 0108 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts Direct Support Compound sealing Item 14 WP 0125 00 Grease GAA Item 22 WP 0125 00 Tools and Special Tools Tags marker Item 35 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Gloves Item 411 WP 0126 00 Cab door removed WP 0107 00 DISASSEMBLY 1 If damaged remove and discard seal 1 from door 2 2 Lower window glass 3 0108 00 1 TM 9 2320 302 34 CAB DOOR REPAIR CONTINUED 0108 00 DISASSEMBLY CONTINUED NOTE Tag screws spacers and washers during disassembly to aid in assembly 3 Remove four nuts 4 washers 5 bracket 6 three screws 7 cap screw 8 three spacers 9 and four washers 10 342 594 4
298. aps are not interchangeable and must be kept with connecting rods to prevent damage to equipment 19 Remove two connecting rod bolts 36 connecting rod cap 37 and lower bearing insert 38 Discard bearing insert 31 CAUTION Mark or tag pistons and note location in air compressor prior to removal to prevent premature air compressor failure 20 Remove connecting rod and piston assembly 35 from cylinder bore 21 Remove upper bearing insert 39 from connecting rod 40 Discard bearing insert 342 994 0084 00 5 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEMBLY CONTINUED 22 23 24 25 26 2 28 29 30 3 Push wrist pin 41 out of piston 42 and connecting rod 40 Pull plastic wrist pin button 43 from each end of wrist pin 41 Remove three piston rings 44 Remove four oil control rings 45 and two oil ring expanders 46 342 995 Remove four bolts 47 and rear cover 48 Remove seal ring 49 from groove in rear cover 48 Press crankshaft 34 out of ball bearing 50 to rear and remove Remove retaining ring 51 CAUTION Use care when removing crankshaft ball bearing to prevent damage to bearing bore Using brass drift and hammer remove ball bearing 50 by tapping around inside edge and driving ball bearing toward air compressor mounting flange 52 Using brass drift and hammer remove crankshaft rear sleeve bearing 53 b
299. ar as possible Read and record total amount of end play Allowable camshaft end play is 0 003 0 015 in 0 076 0 381 mm 342 689 21 If end play is beyond maximum limit remove and repair or replace camshaft drive gear assembly WP 0034 00 NOTE Ensure old gasket forming compound has been removed from rear camshaft cover and surfaces 0026 00 21 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 22 Apply thin bead of gasket forming compound to camshaft bearing cap 23 no 7 mating surface and install camshaft bearing cap no 7 on cylinder head 26 23 Install rear camshaft cover 2 and three bolts 1 Tighten bolts to 22 28 lb ft 30 38 Nm j 24 Install five camshaft bearing shells 24 in camshaft bearing caps 23 no 2 through no 6 25 Install five camshaft bearing caps 23 on correct saddles on cylinder head 26 and install two camshaft cap bolts 20 hand tight in camshaft bearing caps no 3 and no 5 26 Install rocker arm assemblies WP 0027 00 27 Tighten 12 camshaft and rocker arm bolts and nuts to 75 86 lb ft 102 117 Nm in sequence shown 0026 00 22 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 9 11 342 702 TIGHTENING SEQUENCE 28 Install engine retarderg WP 0022 00 END OF WORK PACKAGE 0026 00 23 TM 9 2320 302 34 This Page Intentionally Left Blank
300. ard away from axle housing 8 Repeat steps 6 through 8 for opposite side of axle housing 8 0078 00 2 TM 9 2320 302 34 REAR AXLE REPLACEMENT CONTINUED 0078 00 REMOVAL CONTINUED 10 Remove axle housing 8 from under vehicle 11 If new rear axle housing 8 will not be equipped with brake chambers 2 remove brake chambers TM 9 2320 302 20 INSTALLATION 1 If new rear axle housing 8 is not equipped with brake chambers install brake chambers TM 9 2320 302 20 V WARNING Axle housing is heavy and can injure personnel if dropped Support axle housing during installation to pre vent injury to personnel Using hydraulic jack position axle housing 8 under vehicle Position bottom half of axle clamp 15 upward against axle housing 8 Position top half of axle clamp 15 to top of axle housing 8 AF Install two u bolts 14 four washers 13 and nuts 12 to axle clamp 15 Tighten nuts initially in diagonal sequence to 60 lb ft 81 Nm Tighten nuts again in diagonal sequence to 130 lb ft 176 Nm Apply final torque of 200 lb ft 271 Nm 6 Repeat steps 3 through 5 for opposite side of axle housing 8 7 Connect two v rods 11 to top of axle housing 8 with two screws 10 and nuts 9 Tighten nuts to 427 lb ft 579 Nm 8 Remove hydraulic jack 0078 00 3 TM 9 2320 302 34 REAR AXLE REPLACEMENT CONTINUED 0078 00 INSTALLATION CONTINUED 9 Install spider assembly
301. ard lock nuts CAUTION If drive end housing binds tap gently on mounting ears Ensure drive end housing separates from stator and stator remains attached to slip ring end housing to avoid damage to stator leads T Remove rotor and drive end housing 21 from stator 22 and slip ring end housing 23 8 Remove and discard three tenz nuts 24 Disconnect three leads 25 and remove stator 22 0052 00 2 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 DISASSEMBLY CONTINUED 19 23 342 524 9 Remove two tenz nuts 26 insulator bushings 27 and terminal screws 28 Discard tenz nuts 342 525 0052 00 3 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 DISASSEMBLY CONTINUED 10 11 12 13 14 15 16 17 18 19 Remove two screws 29 and capacitor 30 Remove two screws 31 lock washers 32 washers 33 insulating washers 34 positive rectifier 35 and negative rectifier 36 Discard lock washers Remove two insulator bushings 37 from positive rectifier 35 and negative rectifier 36 NOTE Note position of insulator bushings in slip ring end housing prior to disassembly to aid in assembly Remove two insulator bushings 38 from slip ring end housing 23 Remove six nuts 39 three washers 40 insulator 41 three insulators 42 three terminal studs 43 and insulator 44 Remove tenz nut 45 and washer 46 from each of three terminal s
302. arder solenoid terminals 8 NOTE Do not remove terminal screws from injector Loosen terminal screws only enough to allow terminal to be disconnected 5 Loosen terminal screws 9 on each injector and remove terminals 10 6 Remove guide clip 11 in rear corner drain hole of cylinder head 6 NOTE Carefully feed wires and terminals through hole at rear of cylinder head 7 Remove engine injector wiring harness 12 ENGINE INJECTOR WIRING HARNESS INSTALLATION NOTE When installed correctly all connectors should reach terminals without strain or repositioning of injector wire IE Feed engine injector wiring harness 12 into cylinder head 6 through hole at rear of cylinder head 2 Position leads of engine injector wiring harness 12 in cylinder head 6 so that wires follow inside rail of cylinder head on oil cooler side of engine under engine retarder assembly 0069 00 2 TM 9 2320 302 34 ENGINE INJECTOR AND ECM WIRING HARNESSES REPLACEMENT CONTINUED 0069 00 ENGINE INJECTOR WIRING HARNESS INSTALLATION CONTINUED 3 n RB 10 11 12 Begin with two longest leads and install terminals 10 over terminal screws 9 on front injector Tighten screws to 12 17 Ib in 1 25 1 92 Nm Perform procedure in step 3 for remaining injector leads Install harness lead 7 on engine retarder solenoid terminal 8 Perform procedure in step 5 for remaining engine retarder solenoid terminals Install harness plate 5 and
303. are found replace wastegate actuator 6 Open vent valve 19 to relieve pressure and observe pressure gage 18 for zero indication Adjust regulator valve 16 to zero and close vent valve 7 Adjust dial indicator 15 to contact actuator rod 9 end and adjust to a zero reading 8 Open air supply shutoff valve 17 and slowly adjust regulator valve 16 to 31 psi 214 kPa Switch pressure on and off with vent valve 19 to ensure dial indicator travel from 0 00 in to 0 040 in 1 02 mm and that pressure reading is con sistent 9 Actuator adjustment should be set for an indication of 0 040 1 02 mm at 31 psi 214 kPa pressure setting 0045 00 4 TM 9 2320 302 34 GARRETT TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0045 00 ADJUSTMENT CONTINUED 10 11 12 13 14 15 If travel is within limits relieve and disconnect air pressure to wastegate actuator If travel is not within lim its proceed to next step to adjust actuator rod travel Loosen jamnut 14 on actuator rod 9 Remove retaining clip 8 securing actuator rod 9 to wastegate lever pin 11 Remove actuator rod 9 from wastegate lever pin 11 Turn rod 1 2 turn 180 degrees 0 020 in 0 5 mm clockwise to increase or counterclockwise to decrease setting Repeat steps 7 and 8 to check if adjustment of travel rod is within limits Install retaining clip 8 on wastegate lever pin 11 and tighten jamnut 14 while holding actua
304. aring is assembled with locating lip on either inner or outer thrust bearing race not prevent ing race from contacting thrust surface of mating part Failure to follow this caution leads to thrust bearing failure and incorrect shim selection to maintain proper part clearance Install proper thickness selective shim 39 and thrust bearing 38 UNCOMPRESSED STRAIGHTEDGE BEARING AND GASKET IN STRAIGHTEDGE SHIM REMOVED PLACE BITE 1 DIM F 342 1180 MAIN SHAFT MODULE REAR COVER MODULE PROCEDURE FORMULA 29503218 1 Notch 29503219 2 Notches 29503220 3 Notches 0071 00 53 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED Installation of Rear Cover Module 1 Install new rear cover gasket 36 on main housing 23 2 Place rear cover module 35 on main housing 23 using suitable hoist and sling as a lifting fixture 3 Install 19 bolts 34 Evenly tighten bolts to 66 81 Ib ft 90 110 Nm 4 Retighten retainer lock nut using tool J37035 1 to 55 65 lb ft 74 88 Nm NOTE Do not reuse lock nut retainer locking tang once it has been bent If all tangs have been used bent replace lock nut retainer 5 Locate one new locking tang on retainer and bend it up to hold retainer lock nut 34 342 1149 0071 00 54 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 ASSEMBLY CONTINUED
305. arness 2 CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid NOTE DO NOT disconnect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 2 Tag and disconnect two hoses 3 from top of compressor 4 3 Remove two preformed packings 5 and install protective plugs in hoses 3 and compressor fittings Discard pre formed packings 4 Loosen two lock nuts 6 and two jamnuts 7 1 5 eg e 16 342 520 5 Allow compressor 4 to tilt and remove compressor drive belt 8 from pulley of compressor 0117 00 2 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR REPLACEMENT CONTINUED 0117 00 REMOVAL CONTINUED 6 Remove lock nut 9 screw 10 washer 11 and link end 12 from bracket 13 Discard lock nut 7 Remove two jamnuts 7 and link end 12 from adjustment rod 14 8 Remove lock nut 15 washer 16 screw 17 and adjustment rod 14 from engine 18 Discard lock nut 9 Remove two lock nuts 6 washers 19 and screws 20 to separate bracket 21 from bracket 22 Discard lock nuts 10 Remove compressor 4 with brackets 13 and 21 from engine 18 11 Remove four screws 23 lock washers 24 and bracket 21 from compressor 4 Discard lock washers 12 Remove four screws 2
306. asher 36 spring 37 and relief valve 38 342 1241 31 Remove six cap screws 39 washers 40 and oil pump 33 from bearing cage 41 32 342 1243 0080 00 9 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 33 Rotate differential carrier 1 until ring gear 2 faces up 34 Matchmark position of two bearing caps 44 and 45 on differential carrier 1 35 Remove pin 46 from two bearing caps 44 and 45 36 Loosen four cap screws 47 CAUTION To prevent damage to adjusting rings do not hit adjusting rings with hammer or use hammer and drift pin to loosen rings 37 Loosen two adjusting rings 48 38 Remove four cap screws 47 washers 49 two bearing caps 44 and 45 and two adjusting rings 48 45 46 47 48 49 47 49 MATCHMARKS as y 342 1198 48 1 39 Using suitable lifting device remove ring gear subassembly 50 and two bearing cups 51 342 1201 0080 00 10 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 40 Using bearing puller remove two bearing cones 52 342 1244 41 Remove 12 nuts 53 washers 54 and bolts 55 from ring gear 2 53 54 55 342 1245 0080 00 11 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 42 Remove ring gear 2 from ring g
307. askets 5 and seal assemblies 6 Discard gaskets and seal assemblies 3 Remove two nuts 7 342 1121 0077 00 1 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT CONTINUED 0077 00 REMOVAL CONTINUED NOTE Tag draw keys prior to removal to aid in installation 4 Remove two draw keys 8 CAUTION Be careful when removing pin If pin is dropped damage may occur Remove pin 9 6 Remove steering knuckle 10 thrust bearing 11 shim s 12 and seal assembly 13 Discard seal assembly and shim s 342 1121 7 Remove two bushings 14 from steering knuckle 10 Discard bushings 14 10 342 1123 INSTALLATION 1 Using bushing driver install two new bushings 14 as follows a Press bushing 14 into steering knuckle 10 1 8 in 3 2 mm and relieve pressure b Press bushing 14 into steering knuckle 10 another 1 2 in 12 7 mm and relieve pressure 0077 00 2 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT CONTINUED 0077 00 INSTALLATION CONTINUED C Press bearing 14 into steering knuckle 10 another 5 16 in 7 9 mm below seal counterbore 342 1124 Install new seal assembly 13 on chamfered side of thrust bearing 11 Install steering knuckle 10 Install thrust bearing 11 and seal assembly 13 Using suitable jack raise steering knuckle 10 until seal assembly 13 is flush with bottom side of axle Oa Ro Dm Using thickness gage measur
308. assembly above center section of injector rocker assembly Lifter fingers fit between intake and injector rockers 3 Using rocker arm lifter 5 on rocker arm assembly sets 6 from cam roller side lift three rocker arm assembly sets and rocker arm shaft 7 from cylinder head 342 704 4 Slide exhaust 8 injector 9 and intake 10 rocker arms off rocker arm shaft 7 NOTE Note adjusting screw type and rocker arm combination as an aid in installation Adjusting screws with annu lar Allen wrench adjustment are used on intake short arm and injector rocker arms Hex head adjusting screws are used on exhaust long arm rocker arms 5 Remove jamnuts 11 and adjusting screws 12 from each rocker arm 342 705 0027 00 2 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 REMOVAL CONTINUED CAUTION Do not expand retaining clip more than 0 61 in 15 50 mm when removing intake valve button To do so could result in damage to equipment 6 Hold adjusting screw 12 and with retaining ring pliers 13 spread legs of retaining clip 14 and remove intake valve button 15 ds Remove retaining clip 14 from threaded end of adjusting screw 12 N 342 706 8 Punch hole in two cup plugs 16 at ends of rocker arm shaft 7 Pry cup plugs from shaft Discard cup plugs 16 ow 342 707 0027 00 3 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 C
309. ation connected to service and discharge port connections 1 Obtain enough refrigerant to fully charge system Set tank on a scale and weigh for correct amount of refrigerant to enter system This prevents overcharging which could cause damage to compressor 2 Charge refrigerant system NOTE If equipped with a recovery recycling and recharging system charge system on high side following manu facturer s instructions If charging from a bulk container perform following steps a tank bulk container upside down With engine off open high side hand valve DO NOT open low side hand valve b Allow refrigerant to enter system until correct charge by weight has entered Close high side hand valve c Start engine and run it at 1500 rpm Set cab air conditioner controls at maximum cooling and fan speed refrigerant compressor must engage 0112 00 5 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE CONTINUED 0112 00 CHARGING CONTINUED d If a charge did not enter system place tank bulk container in upright position then open LOW SIDE valve to draw vapor into system leave valve open until correct weight of refrigerant has entered system then close low side valve NOTE If refrigerant is slow to enter system because of low outside temperatures vaporization can be quickened by placing refrigerant tank in a tub of warm water no warmer than 125 F 52 3 Disconnect high side ho
310. backlash meets specification Record setting for use when adjusting pinion bearing pre load 342 1197 NOTE Always check tooth contact pattern on drive side of ring gear teeth Apply Prussian blue dye to approximately 12 teeth of ring gear 2 Rotate ring gear so marked gear teeth are next to drive pinion 3 To get contact pattern rotate ring gear 2 forward and backward until marked gear teeth go past drive pinion 3 six times Repeat if needed for clearer pattern 0080 00 26 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED NOTE e Location of good hand rolled contact pattern for new gear set is toward toe of gear tooth and in center between top and bottom of tooth e Location of good hand rolled contact pattern for used gear set must match wear pattern in ring gear Contact pattern will be smaller than wear pattern e During tooth contact pattern checks backlash can be adjusted within specification limits if needed to change pattern location 66 Compare contact pattern with examples shown 342 1263 GOOD HAND ROLLED HIGH PATTERN LOW PATTERN PATTERN 67 If contact pattern requires adjustment perform disassembly steps 38 39 and 43 through 45 68 Remove inner bearing cup 62 and shim pack 63 69 correct high contact pattern add shim s to shim pack 63 70 correct low contact pattern remove shim s from shim pack 63 71
311. caps in original positions Lubricate cap bolt threads and head contact surfaces with a small amount of international compound no 2 Install and tighten main cap bolts to 347 391 lb ft 470 530 Nm NOTE Replace engine block if not within specification 6 Measure each crankshaft main bearing bore 21 in vertical axis with inside micrometer Dimension should be 5 236 5 237 in 133 000 133 025 mm If dimension exceeds limits replace cylinder block 342 897 0036 00 5 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 CLEANING AND INSPECTION CONTINUED 7 Check cylinder block deck 22 for flatness with straightedge and thickness gage NOTE Because camshaft is mounted in cylinder head resurfacing of block and or head affects position of camshaft in relation to adjustable idler gear and gear train Limit resurfacing on cylinder block to maximum of 0 01 in 0 25 mm Limit resurfacing on block and head to combined total of 0 03 in 0 75 mm If limits are exceeded replace cylinder block 8 Check front to rear flatness next to cylinder liner flanges on both sides and side to side flatness between liner flanges as shown Deck must be flat within 0 005 in 0 127 mm front to rear and 0 003 in 0 076 mm side to side If not resurface cylinder block 342 899 9 Spray machined surfaces with engine lubricating oil if cylinder block is not to be used immediately Spray or dip cylin der block in corr
312. card lock nut 3 Remove 14 lock nuts 6 washers 7 screws 8 and washers 9 from fifth wheel 10 Discard lock nuts 4 Using suitable lifting device remove fifth wheel 10 from frame 11 3 4 5 nog SPP INSTALLATION 1 Using suitable lifting device align and install fifth wheel 10 on frame 11 2 Install 14 washers 9 screws 8 washers 7 and new lock nuts 6 3 Install clamp 5 screw 4 and new lock nut 3 4 Connect air hose 1 to cylinder 2 END OF WORK PACKAGE 0091 00 2 TM 9 2320 302 34 SLIDE BRACKET AND PLATE REPAIR 0092 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level References TM 9 2320 302 20 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Slider spring compression Item 114 WP 0126 00 Top plate removed WP 0093 00 DISASSEMBLY 1 Install spring compressor tool 1 342 955 0092 00 1 TM 9 2320 302 34 SLIDE BRACKET AND PLATE REPAIR CONTINUED 0092 00 DISASSEMBLY CONTINUED 2 Compress spring 2 Remove pin 3 and swing air cylinder 4 out of the way 3 Remove spring compressor tool 1 342 956 4 Remove spring retainer 5 spring 2 pin retainer 6 and plunger assembly 7 5 Repeat steps 1 through 4 for opposite side plunger assembly 6 Disconnect air hose 8 and remove air cylinder 4 342 957 ASSEMBLY 1 I
313. ce Failure to follow this warning may result in death or injury to personnel NOTE Procedure may be accomplished in vehicle or on engine stand REMOVAL CAUTION Use wood blocks on trestles to protect oil pan flange 1 Install trestles under each side of oil pan flange 0019 00 1 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED 0019 00 REMOVAL CONTINUED 2 3 Remove two nuts 1 and bolts 2 securing alternator mounting bracket 3 on gear case cover 4 and gear housing 5 Remove and discard tiedown straps 6 as required securing fan clutch solenoid air line 7 and move air line away from gear case cover 4 and gear housing 5 Remove bolt 8 from standoff bracket 9 and gear case cover 4 Move standoff bracket away from gear case cover Remove nut 10 bolt 11 and standoff bracket 12 from gear case cover 4 Move standoff bracket away from gear case cover Remove two bolts 13 from opposite sides of gear case cover 4 Replace two bolts 13 with guide studs 14 Remove five bolts 15 from camshaft gear cover 16 Remove camshaft gear cover 16 and gasket 17 from gear case cover 4 NOTE Different length bolts are used to secure gear case cover to gear housing Note location of long and short bolts as an aid for use in installation Remove ten short bolts 18 and four long bolts 19 342 979 0019 00 2 TM 9 2320 302 34 GEAR CASE COVER REPLACEMENT CONTINUED 0019 0
314. ce Level Materials Parts Direct Support Ring seal P N 8929253 Tools and Special Tools Oil lubricating Item 25 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Checker gear lash Item 18 WP 0126 00 Alternator belt removed TM 9 2320 302 20 Dial indicator set Item 29 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 REMOVAL NOTE If necessary tap accessory drive with a soft faced mallet to aid in removal 1 Remove five bolts 1 and accessory drive 2 from gear case cover 3 2 Remove and discard seal ring 4 from accessory drive 2 342 674 0021 00 1 TM 9 2320 302 34 ACCESSORY DRIVE REPLACEMENT CONTINUED 0021 00 INSTALLATION 1 Lubricate new seal ring 4 with clean lubricating oil and install in groove on accessory drive 2 NOTE Install accessory drive with word UP cast into housing in 12 o clock position 2 Install accessory drive 2 on gear case cover 3 engaging accessory drive gear 5 with bull gear 6 3 Align bolt holes of accessory drive 2 and gear case cover 3 Press accessory drive 2 into place and install five bolts 1 342 674 4 342 675 TIGHTENING SEQUENCE 0021 00 2 TM 9 2320 302 34 ACCESSORY DRIVE REPLACEMENT CONTINUED 0021 00 INSTALLATION CONTINUED NOTE If gear lash specification is not met replace accessory drive 5 Use dial indicator with clamp base to measure gear lash between accessory drive gear and bull
315. center rod of inserter remover base post 2 4 Install crankshaft gear inserter remover pressure plate 6 on three inserter remover legs 3 5 Install three crankshaft gear inserter remover retaining nuts 7 on inserter remover legs 3 Tighten three retaining nuts against inserter remover pressure plate 6 to 43 54 Ib ft 58 73 Nm 342 1072 NOTE Due to manufacturer s tolerances as much as 9 tons of pressure may be required to remove crankshaft tim ing gear 6 Operate hydraulic ram and pump 5 to pull crankshaft timing gear 4 off crankshaft 0033 00 2 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 REMOVAL CONTINUED 7 When crankshaft timing gear 4 moves freely release hydraulic pressure and remove crankshaft gear inserter remover tool from crankshaft timing gear and crankshaft 342 1073 CAUTION Do not use sharp tools to pry on timing wheel or crankshaft timing gear Use care to prevent damaging crankshaft seal contact surface when removing crankshaft timing gear and timing wheel from crankshaft 8 Remove crankshaft timing gear 4 from crankshaft 9 Remove timing wheel 8 from crankshaft 10 Remove woodruff key 9 from crankshaft 0033 00 3 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 REMOVAL CONTINUED 11 Rotate engine on stand so crankshaft is in up position 12 Remove main bearing cap bolts 10 and washers 11 NOTE e Place upper m
316. cle and place a trestle under each frame rail Lower vehicle onto trestles 2 Remove four nuts 1 screws 2 and two control rods 3 from vehicle 342 970 0103 00 1 TM 9 2320 302 34 REAR SUSPENSION CONTROL ROD AND V ROD REPLACEMENT CONTINUED 0103 00 REMOVAL CONTINUED 3 Remove two nuts 4 six screws 5 spacers 6 and two V rods 7 from vehicle 342 971 INSTALLATION NOTE e To install V rods perform steps 1 through 3 and 5 e To install control rods performs steps 4 and 5 e When installing V rods ensure labels on rods are facing upward Forward V rods are marked FDA Rear V rods are marked RDA 1 Position two V rods 7 to vehicle and loosely install spacers 6 six screws 5 and two nuts 4 2 Tighten four screws 5 at frame bracket to 136 lb ft 184 Nm 3 Tighten nut 4 at each axle bracket to 427 Ib ft 579 Nm 4 Install two control rods 3 to vehicle with four screws 2 and nuts 1 Tighten nuts to 136 Ib ft 184 Nm EY 342 970 2 1 5 Remove trestles and floor jack END OF WORK PACKAGE 0103 00 2 TM 9 2320 302 34 CAB REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level General Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Sling beam type Item 115 WP 0126 00 Materials Parts Nut kep Nut lock P N MS51922
317. collar that is swaged over the serrations causing the fastener to be locked in place To facilitate repairs to the body it is acceptable to replace lock bolts and rivets with 1 4 in AN4 series bolts Do not replace lock bolts with rivets Standard threaded fasteners should not be used as these will quickly wear the aluminum structure Bolt lengths should be chosen so that the cylindrical portion of the bolt is bearing on all members being joined Bolts are designated as NA4 XX or ANAC XX where XX defines grip length Tighten all bolts to 70 75 Ib in 8 Nm All riveted joints have adhesive foam between both components riveted together The purpose of this tape is to ensure watertight joints and to ensure aluminum components will not wear prematurely Tape may be either in or 2 in wide depending on the joint Replace adhesive tape with the same size removed during disassembly The only time adhesive foam tape is to be replaced is if a riveted joint is completely taken apart 0105 00 1 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 INSPECTION 1 General The damaged area should be thoroughly cleaned and inspected to determine cause and extent of damage Body parts should be inspected for holes cracks dents distortion or breaks Fasteners should be inspected for breaks stretch ing looseness cocked heads or hole elongation Seams flanges and joints should be inspected for straightness or local deformation as an indication that fast
318. cord new pinion cone variation number Record old pinion cone variation number If old pinion cone variation number is subtract number from shim pack thickness in disassembly step 21 If old pinion cone variation number is add number to shim pack thickness in disassembly step 21 If new pinion cone variation number is add number to shim pack thickness determined in step 19 or 20 If new pinion cone variation number is subtract number form shim pack thickness determined in step 19 or 20 NOTE finstalling same ring gear and drive pinion use shim pack removed in disassembly step 21 e Tf installing new shim pack use at least three shims with thickest shim in middle of pack Aline oil slots on shim pack 22 with oil slots on differential carrier 1 and install shim pack 342 1218 0082 00 14 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 24 Install bearing cage assembly 19 in differential carrier 1 342 1206 25 Install eight washers 21 and cap screws 20 Tighten cap screws to 74 96 Ib ft 100 130 Nm 342 1205 0082 00 15 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 26 Install yoke 16 and new lock nut 18 27 Rotate differential carrier 1 so that yoke 16 is in horizontal position 28 Using yoke holder bar 17 to hold yoke 16 in place tighten lock nut 18 to
319. cracked due to any cause other than being hit by a flying object mark rubber extrusion 2 at location of crack 2 Using windshield pick release locking strip 3 from rubber extrusion 2 CAUTION When handling glass be careful not to nick or splinter edges Chipped edges could cause cracking later Apply pressure to one edge of rear window glass 1 from inside of cab 4 Using windshield pick lift and remove rear window glass out of rubber extrusion 2 4 Remove rubber extrusion 2 from cab 4 342 877 0110 00 1 TM 9 2320 302 34 REAR WINDOW REPLACEMENT CONTINUED 0110 00 REMOVAL CONTINUED 5 Remove sealing compound from between ends of rubber extrusion 2 342 878 CLEANING AND INSPECTION 1 Use general cleaning methods to clean all parts TM 9 2320 302 20 2 If rear window glass has been removed under criteria outlined in Removal step 1 inspect channel of rubber extrusion where marked for foreign objects Inspect mounting flange of cab for irregularities 3 Inspect all parts for wear or damage INSTALLATION WARNING Wear protective gloves when handling glass Failure to do so could result in injury to personnel CAUTION e When handling glass be careful not to nick or splinter edges Chipped edges could cause cracking later e Do not use sealant around rear window glass Sealing compounds are not needed and if applied unevenly can cause leaks resulting in water damage NOTE If ins
320. crews 14 lock washers 15 washers 16 eight insulation washers 17 and four insulation bushings 18 Discard lock washers Remove four brush holders 19 insulation washers 20 and ground jumper 21 from commutator housing 10 Remove nut 22 four washers 23 insulator 24 and packing 25 from ground stud 26 Discard packing Remove ground stud 26 from commutator housing 10 Remove packing 27 insulation washer 28 and washer 29 from ground stud 26 Discard packing If damaged remove bushing 30 from commutator housing 10 Remove packing 31 pipe plug 32 and felt wick 33 from commutator housing 10 Discard packing If damaged remove bushing 34 from commutator housing 10 0054 00 2 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 DISASSEMBLY CONTINUED 342 546 0054 00 3 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 DISASSEMBLY CONTINUED NOTE Mark nose housing and shift housing prior to removing nose housing to aid in installation 13 Remove six screws 35 nose housing 36 packing 37 and washer 38 from shift housing 39 Discard packing NOTE Perform step 14 only if components are damaged 14 Remove bushing 40 plug 41 felt wick 42 and six plugs 43 from nose housing 36 342 547 15 Remove screw 44 washer 45 shaft 46 and packing 47 from shift housing 39 Discard packing 16 Remove armature 48 washer 49
321. ct and remove CWS wiring harness using illustration as a guide CENTRAL PROCESSING zu UNIT E E S SIDE SENSOR DISPLAY DRIVER DISPLAY UNIT TO ANTENNA ot ASSEMBLY INSTALLATION NOTE Wiring harness and leads are secured in place by clips new tiedown straps cushion clamps and screw termi nals Ensure harness is secure and all hardware is tight 1 Install connect and secure CWS wiring harness using illustration as a guide 2 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0066 00 2 TM 9 2320 302 34 TAILLIGHT WIRING HARNESS REPLACEMENT 0067 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE Note number and location of tiedown straps to aid in installation 1 Remove tiedown straps securing taillight wiring harness 1 Discard tiedown straps 2 Disconnect taillight wiring harness 1 from each taillight 2 342 538 INSTALLATION 1 Connect taillight wiring harness 1 to each taillight 2 2 Install same number of new tiedown straps as were removed to secure taillight wiring harness 1 3 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0067 00 1 TM 9 2320 302 34 This Page
322. cylinder head 17 Discard gaskets 0014 00 2 0014 00 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT CONTINUED 0014 00 REMOVAL CONTINUED 342 637 INSPECTION 1 Inspect air intake manifold for cracks particularly in mounting bolt boss areas If cracked discard intake manifold 2 Inspect all parts for wear or damage INSTALLATION 1 Install six guide studs in six bolt holes of cylinder head 17 NOTE Install gaskets with arrow pointing to front of engine 2 Install three new gaskets 16 over six guide studs NOTE Ensure all wires are clear of intake manifold connection points before installing manifold 3 Install air intake manifold 4 over six guide studs and against cylinder head 17 0014 00 3 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT CONTINUED 0014 00 INSTALLATION CONTINUED 4 Install one long bolt 14 in lower center position of air intake manifold 4 and hand tighten Remove six guide studs Install two short bolts 15 at ends of air intake manifold 4 Tighten by hand 5 6 Install remaining four long bolts 14 in air intake manifold 4 Tighten by hand 7 8 Tighten seven bolts 14 and 15 to 43 54 lb ft 58 73 Nm in sequence shown 342 639 Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in a well ventilated area If adhesive or se
323. d install new bushing using tool J37040 Install piston seal ring 37 on clutch hub 18 and piston seal ring 38 into C2 piston 33 Install clutch hub and piston seal ring 35 into C1 piston 32 With a mallet lightly tap C2 piston 33 into clutch hub 18 Align notch on C1 piston 32 with lubrication orifice on rotating drive hub With a mallet lightly tap C1 piston onto center of C2 piston 33 and over clutch hub 18 Install rotating drum 31 over clutch hub 18 and C1 C2 pistons 32 and 33 Install C2 spring assembly 29 Index spring assembly with drive hub tangs and splines on C2 piston 33 Ensure C2 spring assembly has made contact with bottom of slots in C2 piston If spring assembly did not reach bottom remove spring assembly and reannex in next spline on rotating drum Repeat this process until C2 spring is in proper position Install C2 spring plate 30 Index spring plate with drive hub tangs and splines on C2 piston 33 WARNING The rotating clutch piston springs are highly compressed and must be properly released Failure to follow this warning may result in personnel injury Place rotating clutch on tool base J37030 3 so that rotating drum is supported by tool tangs Install tool J37030 1 and J35923 2 that includes bearing washer and handle Tighten tool to compress C2 spring assembly 29 and install retaining ring 28 View B page 0072 00 24 Remove tools Install seal ring 27 onto bal
324. d international no 2 Item 13 WP 0125 00 Crankshaft removed WP 0033 00 Oil lubricating Item 25 WP 0125 00 Gear housing assembly removed WP 0035 00 0036 00 1 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 DISASSEMBLY NOTE Cylinder block repair conditions may warrant cylinder block pressure testing before complete block disas sembly Perform testing before removing cylinder liners cup plugs and pipe plugs Refer to Cylinder Block Pressure Testing WP 0040 00 1 Turn cylinder block so bottom side is up and remove six bolts 1 and oil spray nozzles 2 342 892 NOTE Determine left and right sides of cylinder block by viewing cylinder block from rear flywheel housing end 2 Position cylinder block to view right side NOTE Procedure is the same for round diamond or hollow dowels e Replace dowels and plugs only if necessary e Cover exposed areas to guard against welding sparks 3 If damaged remove dowels by fabricating a piece of sheet brass 3 with hole large enough to fit over dowel being removed 4 Tack weld flat washer 4 to top of sheet brass 3 as shown NOTE Ensure thread of nut matches thread of slide hammer shaft 5 Tack weld nut 5 to flat washer 4 6 Thread slide hammer shaft 6 into nut and remove dowel 0036 00 2 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 DISASSEMBLY CONTINUED 7 If damaged pierce five c
325. der head gasket 14 on deck of air compressor 6 NOTE Cylinder head should be positioned with air inlet and discharge flange on right side of air compressor when viewed from rear 53 Position cylinder head 13 on air compressor 6 54 Install six bolts 12 and tighten bolts to 25 30 Ib ft 34 41 Nm 0084 00 16 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 55 Attach drive hub 10 to drive gear 5 and secure with four bolts 11 Tighten bolts to 43 54 Ib ft 58 73 Nm 56 Position drive hub 10 and drive gear 5 on crankshaft and ball bearing 57 Engage teeth 3 of cover plate 4 with teeth in drive gear 5 Align spacer legs of cover plate with mounting bolt holes in flange face of air compressor 6 Secure cover plate to air compressor with two bolts 7 and nuts 8 342 987 0084 00 17 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 58 Secure air compressor 6 in soft jawed vise and install drive hub retaining bolt 9 Tighten bolt to 220 255 lb ft 298 346 Nm 59 Remove two nuts 8 bolts 7 and cover plate 4 342 988 60 Install two new gaskets 1 and 2 61 Install governor TM 9 2320 302 20 62 Install air compressor TM 9 2320 302 20 END OF WORK PACKAGE 0084 00 18 TM 9 2320 302 34 BRAKE DRUM REPAIR 0085 00 THIS WORK PACKAGE COVERS Repair INITIAL SETUP Maintenance Level Material
326. dial indicator Runout must not exceed 0 008 in 0 200 mm If runout is exceeded perform disassembly step 37 and 38 Inspect all ring gear subassembly 50 parts and differential carrier 1 for possible excessive runout causes Replace defective part s Repeat steps 45 through 55 342 1220 0080 00 25 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 59 60 61 62 63 64 65 Attach dial indicator on mounting flange of differential carrier 1 so plunger is against tooth surface on drive side of ring gear 2 Adjust dial indicator to zero NOTE Move ring gear only when adjusting backlash While holding drive pinion 3 in position rotate ring gear 2 slightly in both directions against drive pinion teeth Note measurement NOTE e If same ring gear and drive pinion has been installed adjust backlash to setting recorded in disassembly step 5 e If new ring gear and drive pinion has been installed adjust backlash to 0 01 in 0 25 mm If backlash measurement is less than specified loosen adjusting ring 48 on back surface of ring gear 2 and equally tighten adjusting ring on tooth side of ring gear Repeat step 60 If backlash measurement is more than specified loosen adjusting ring 48 on tooth side of ring gear 2 and equally tighten adjusting ring on back of surface of ring gear Repeat step 60 Repeat steps 59 through 62 until
327. ding should be obtained each time If there is no reading or ohmmeter reads zero replace stator 22 342 531 68 b Connect ohmmeter leads to stator leads 25 terminals as follows and note each reading 1 A and B 2 A and C 3 B and C 0052 00 7 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 TESTING CONTINUED c Each measurement in step b should be approximately equal If difference is great between any two readings replace stator 22 ASSEMBLY 1 If removed install new slidable bushing 64 CAUTION If either rotor half has been damaged both rotor halves must be replaced Failure to replace both will cause rotor to be out of balance and alternator will not operate properly 2 Install two woodruff keys 63 rotor half 61 hub 62 and rotor half 60 on shaft 50 3 Install inner bearing race 59 with chamfered edge facing away from rotor half 61 until gap of 0 141 in 3 6 mm is between inner bearing race and shaft 50 threads 4 Place rotor assembly 57 in soft jawed vise and install nut 58 Tighten nut to 110 Ib ft 149 Nm 64 342 532 5 Apply a light coating of sealing compound to shaft 50 where slip ring assembly 56 will be installed CAUTION Use extreme care not to damage two terminals located on end of slip ring assembly 6 Install slip ring assembly 56 on shaft 50 until end of slip ring assembly is against inner bearing race 59 7 Install beari
328. dling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0072 00 1 TM 9 2320 302 34 FRONT AXLE ASSEMBLY REPLACEMENT CONTINUED 0072 00 REMOVAL NOTE Procedure is same for both sides except where noted 1 On left side remove cotter pin 1 and castellated nut 2 and set drag link 3 aside Discard cotter pin 2 Remove two cotter pins 4 castellated nuts 5 and tie rod 6 Discard cotter pins 342 1115 WARNING Front axle weighs 1060 Ib 481 kg Support front axle with a suitable floor jack during removal to prevent possible injury to personnel NOTE Ensure front of vehicle is blocked up enough to allow removal of axle 3 Position suitable floor jack under center of axle 7 and secure axle to floor jack NOTE Note position of axle stops during removal to aid in installation Remove eight nuts 8 washers 9 four U bolts 10 and two axle stops 11 Lower axle 7 and remove from vehicle Remove spacer 12 and shim 13 Remove pin 14 from spacer 12 0072 00 2 TM 9 2320 302 34 FRONT AXLE ASSEMBLY REPLACEMENT CONTINUED 0072 00 REMOVAL CONTINUED 8 Using lifting device remove axle 7 from floor jack 11 3
329. drive assembly 50 insulator 51 shift lever 52 and two cams 53 NOTE Mark shift housing and field ring prior to removing shift housing to aid in installation 17 Remove five screws 54 lock washers 55 and shift housing 39 from field ring 13 0054 00 4 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 DISASSEMBLY CONTINUED 342 548 18 Remove seal 56 bushing 57 and packing 58 from shift housing 39 Discard seal and packing 342 549 0054 00 5 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 DISASSEMBLY CONTINUED 19 Remove nut 59 washer 60 insulator 61 and packing 62 from field ring 13 Discard packing CAUTION When removing stud terminal do not use hammer to tap stud out To do so could cause damage to compo nents 20 remove stud terminal 63 temporarily replace nut 59 flush with end of stud Using suitable pliers work stud out while supporting field coil 64 21 Remove insulator 65 and bushing 66 from field ring 13 22 Remove eight screws 67 four pole pieces 68 field coil 64 and insulator 69 from field ring 13 69 M ASSEMBLY 1 Install insulator 69 in field ring 13 2 Install field coil 64 in field ring 13 so that terminal stud holes in field coil and field ring 13 line up CAUTION Pole pieces must be installed so that slot clears field coil contact tab Failure to do so will cause damage to starter motor
330. dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0070 00 1 TM 9 2320 302 34 TRANSMISSION REPLACEMENT CONTINUED 0070 00 REMOVAL 1 Remove access plug 1 and drain plug 2 from engine flywheel housing 3 342 947 WARNING Do not place finger in hole of engine flywheel housing while engine is being barred over Failure to follow this warning could result in injury CAUTION e Step 2 must be followed in barring engine over Any other method may damage engine e If bolts are dropped in engine flywheel housing retrieve immediately Failure to do so could result in damage to equipment 2 Have an assistant bar engine 4 over using accessory drive 5 Locate and remove bolt 6 through hole in engine fly wheel housing 3 Repeat until 12 bolts have been removed 342 1141 0070 00 2 TM 9 2320 302 34 TRANSMISSION REPLACEMENT CONTINUED 0070 00 REMOVAL CONTINUED VA WARNING e Transmission weighs 900 lb 409 kg Always support transmission with transmission lift during removal to prevent injury to personnel Ensure transmission is properly positioned and secure on transmission lift to prevent injury to person nel or damage to equipment 3 Position transmission lift directly under transmission and centered Raise lift
331. e 24 Install beacon warning light bracket 25 Install cab air ducts WP 00 26 Install floor mats 27 Install radio mounting bracket TM 9 2320 302 20 28 Install windshield WP 0109 00 29 Install rear window WP 0110 00 0104 00 6 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 INSTALLATION CONTINUED 30 Install foot brake valve 31 Install starter regulator 32 Install dual voltage alternator control DUVAC 33 Install voltage regulator TM 9 2320 302 20 34 Install windshield wiper linkage TM 9 2320 302 20 35 Install clearance lights 36 Install utility lights 37 Install hood latches 38 Install fender extensions 39 Install exterior grabhandles 40 Install muffler and exhaust stack 41 Install cab doord WP 0107 00 END OF WORK PACKAGE 0104 00 7 TM 9 2320 302 34 This Page Intentionally Left Blank 0104 00 8 TM 9 2320 302 34 CAB BODY REPAIR 0105 00 THIS WORK PACKAGE COVERS General Inspection Rivet Replacement Aluminum Repair INITIAL SETUP Maintenance Level Materials Parts General Support Compound sealing Item 14 WP 0125 00 Tools and Special Tools Tool kit body and fender repair Item 39 WA 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Drill electric portable Item 31 WP 0126 00 Drill set twist Item 32 WP 0126 00 Riveter blind hand Item 109 WP 0126 00 GENERAL 1 The body is constructed from aluminum alloys that hav
332. e Blue Color 77220 PLASTIGAGEPBI GREASE Aircraft 81349 MIL G 4343 2 Ounce Tube 1 75 Pound Can GREASE Automotive and Artillery GAA 81349 M 10924 14 Ounce Cartridge M 10924 B 1 1 4 Ounce Tube M 10924 A 2 1 4 Pound Can M 10924 C 35 Pound Can M 10924 E 120 Pound Drum M10924 F LUBRIPLATE Lubricant 90536 ST40334 OIL Cutting 77247 22F 1 Gallon Can OIL Lubricating OE HDO 10 81349 MIL L 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum 18 Gage MILL2104 OIL Lubricating GO 85 140 81349 MIL PRF 2105 1 Quart Can 5 Gallon Can 55 Gallon Drum 0125 00 3 TM 9 2320 302 34 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0125 00 Table 1 Expendable and Durable Items List Continued 1 3 ITEM NUMBER NATIONAL 9150 01 410 8972 8010 01 329 6150 9150 00 250 0926 8040 01 024 6993 7920 00 205 1711 3439 00 555 4629 5975 00 984 6582 5975 00 935 5946 5975 00 903 2284 9905 00 537 8954 STOCK NUMBER 4 DESCRIPTION CAGEC AND PART NUMBER OIL Lubricating Refrigerant Compressor Synthetic Ester 59595 CAPELLA HFC 68NA 1 Quart Can PASTE Prussian Blue Bearing Surface Permatex 10670 35V 2 Ounce Tube PETROLATUM TECHNICAL 81348 VV P 236 1 75 Pound Can PRIMER Adhesive 05972 73656 6 Ounce Can RAG Wiping 64067 7920 00 205 1711 50 Pound Bale ROPE Nylon 2 Inch Diameter SOLDER Lead tin Alloy Rosin Core 81348 QQ S 57
333. e Forward Rear 0 0 0c cette nent eens 13 14 5 qt 12 3 13 7 1 Engine Manufacture ze ttp EIN Ea Waals ep ea Rees Detroit Diesel Ee EE RR eR LINE CERA DEUDA EE IL REED E DURER EEE REL 4 stroke in line turbocharged diesel B we ew Went mee e idm ues DDEC IV Cylinders 3 5 svo ert IPSE ES ERUNT 6 Displacement ue bekennen ardere vel tents 755 CID 12 7 1 Torque 1200 Tpmi oe Ex EU ERE ketal DUREE el ace se CERE ER 1400 Ib ft 1898 Nm Maximum Horsepower 2100 430 320 6 kW Maximum Governed 8 5 2100 rpm Oil Filter VY pesto sk cass AR ee See MESURES hoe du edes Sd ew hae hea 2 full flow replaceable elements Oil Filter Quantity ese eb edi pee ve eem ee 2 Fuel System ene Me iP Aula cre Re ern ST ea iy ME Greer arate diesel fuel injected Filter Py pe se ted edet etse te a e eic Sagi ite ht Sul primary 1 secondary replaceable element Air Cleaner fup E dry element QUABULCy oc recen e eae ete Baer toy Saco RI IERI RATE Me 1 0002 00 6 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Cooling System Radiator Working Pressure 00 eee eh 10 psi 69 kPa Coolant Inhibitor Filter ce
334. e minimum allowable thickness is 0 1109 in 2 818 mm b Backplate distortion maximum allowable distortion is 0 006 in 0 15 mm c Backplate step wear maximum allowable wear is 0 005 in 0 13 mm If replacement is necessary remove thrust plates 4 by drilling out rivets 5 Remove P1 ring gear 6 and inspect clutch splines of P1 ring gear Maximum allowable spline wear is 0 015 in 0 38 mm Remove and measure C3 clutch pack five friction plates 7 and four steel reaction plates 8 Perform the following measurements a Friction plate thickness minimum allowable thickness is 0 137 in 3 48 mm b Friction plate maximum allowable cone is 0 010 in 0 25 mm c Steel reaction plate thickness minimum allowable thickness is 0 095 in 2 41 mm d Steel reaction plate maximum allowable cone is 0 016 in 0 40 mm Remove piston return plate 9 with four return springs assemblies 10 attached Inspect and measure piston return plate 9 Minimum allowable thickness of plate is 2 162 in 54 91 mm If return spring assemblies 10 are damaged and require replacement remove them from piston return plate 9 by sep arating spring retainer 11 from piston 12 Remove seal rings 13 and 14 from piston 12 Discard seal rings Remove C3 clutch housing assembly 15 from C3 C4 clutch assembly 2 Inspect and measure four thrust plates 16 on C3 clutch housing 15 Perform the following measurements a Thrust plate thic
335. e Ee E eere 15 Telescoping Range rre rcr RE ERA UESTRE Nr A ERES 2 5 8 in 67 mm Suspension RH REEL BESSER UE ERES RUE ERU do et EMEN RAPI Single leaf spring w shock absorbers TufTrac w shock absorbers Towing Attachments Pintle Hook Manufacturer esses e hes Holland Model iae ERES eee eae ecd Ree no 760 Rated Capacity ise attach alert E Sa cd n e em e ere eae 30 tons 27 2 metric tons Towing Eyes Quantity i ees ee e RE NEN M aane Ac Eten ce be Eee ae m 2 front 2 rear Maximum Load Capacity Each een 60 000 1b 27 240 kg Up to 45 Angle Front Long Axis Fifth Wheel Manu fac tur OEC E Pp Holland n E 36 in 91 4 cm diameter 2 way oscillating low lube Capacity Le uk ERE ROCHE ERN CR ERU eua 30 000 Ib 13 620 kg Height Empty iuter t rtt ette t eerte n waste ubt 52 in 132 1 cm Pitch FWJ Af o Eo RN DRE S RR REN EE REG SERA GR 15 10 Kingpin Size ok te ate etes ebd e E ERE ada 2 in 5 1 cm Cab Manufacturer i s cms en c rece Te e ete CRUS Meo E Rea eap ee Dev S Freightliner CONSHMUCHON as FARR eee ls kA ge be bees a aluminum ose aer Rer Sa ae BY Seen ee ee ew ees 2 passenger tilt forward hood Aur D flectOE cde Recs ne ee GT He ER EV e Ls Sa CERRAR adjustable 0002 00 8 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Accessories Utility
336. e been heat treated to obtain high strength Welding cannot be used to make body repairs Heat generated in welding will reverse the heat treatment process and cause a great reduction in strength of material The hood is made of SMC sheet molding compound Cracks splits or holes may be repaired with a glass reinforced plastic laminate repair kit WP 0106 00 Solid 3 16 in diameter aluminum rivets are the primary method of joining body components Rivets are inserted into a hole through two pieces of metal A second head is formed by manual or pneumatic impacting or by squeezing the rivet A bucking bar is used to back up the rivet to form the rivet head When making repairs use blind rivets of the same size or oversize diameter with the appropriate grip length Blind structural aluminum rivets of 3 16 in diameter are used in applications where there is access from only one side of the part Blind rivets are installed using a tool that pulls on the rivet stem causing a bulbed head to form on the back side of the part Fastening is complete when the stem breaks off High strength is obtained in blind structural rivets by mechanically locking the remaining stem inside the rivet body Steel pull type lock bolt fasteners in 3 16 and 1 4 in diameters are used where tension or high shear loads exist Lock bolts are two piece unthreaded fasteners One part is a high strength steel headed bolt like part with serrations on its shank The mating part is a
337. e bolt 176 through hole in engine flywheel housing 155 Repeat until 12 bolts have been removed 342 952 V M WARNING Transmission weighs 900 Ib 409 kg Support transmission with transmission lift during removal to prevent possible injury to personnel 2 Support transmission 177 using transmission lift Remove 12 screws 178 lock washers 179 and two brackets 180 Discard lock washers 180 178 179 342 953 0010 00 15 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 POWER PACK SEPARATION CONTINUED CAUTION To avoid binding during removal check frequently to ensure proper alignment between engine and transmis sion Failure to do so could result in damage to components 3 Raise and adjust height of transmission lift to maintain support of transmission 177 4 Repeat step 3 until transmission 177 can be separated from engine 156 NOTE If engine is to be replaced perform steps 5 and 6 after repositioning engine on suitable stands 5 Remove two screws 181 washers 182 two screws 183 and right engine leg 184 6 Repeat step 5 for left engine leg 185 342 954 POWER PACK ASSEMBLY 1 Install right engine leg 184 with two screws 183 washers 182 and screws 181 2 Repeat step 1 for installation of left engine leg 185 CAUTION Transmission must be seated squarely against engine flywheel housing to prevent damage to equipment 3 Support transmissio
338. e distance between top side of axle and steering knuckle 10 342 1122 0077 00 3 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT CONTINUED 0077 00 INSTALLATION CONTINUED WARNING Shims are delicate and sharp Use extreme caution when aligning shims to prevent cutting fingers or bending inside diameter of shims Damage to shims will require complete disassembly and replacement of damaged parts 7 Install new shims 12 of thickness equal to measurement from step 6 CAUTION Ensure shim s is not blocking passage for pin installation to prevent damage to equipment NOTE e Ensure draw key slots align with draw key holes e If pin will not pass completely through steering knuckle but did pass through shim s lower jack to align thrust bearing and seal assembly to allow passage of pin 8 Install pin 9 in steering knuckle 10 9 Install two draw keys 8 and nuts 7 Tighten nuts to 30 40 Ib ft 41 54 Nm 342 1122 10 Position steering knuckle 10 in straight ahead position and install dial indicator on steering knuckle as shown 11 Pry up on steering knuckle 10 while observing dial indicator Vertical end play must be 0 001 0 025 in 0 03 0 64 mm If vertical end play is less than 0 001 in 0 03 mm remove shim s 12 to achieve vertical end play If vertical end play is more than 0 025 in 0 64 mm add shim s to reduce vertical end play 12 If shim s 12 is to be added or remo
339. e thread of nut matches thread of slide hammer shaft 27 27 Thread slide hammer shaft 27 into nut 26 and remove dowel 24 342 1011 NOTE Cylinder head repair conditions may warrant cylinder head pressure testing before complete head disassem bly Testing should be performed before injector tubes cup plugs and pipe plugs are removed Refer to Inspection steps 2 through 10 for pressure testing 28 If worn damaged or leaking replace injector tubes by placing injector tube installation removal tool 28 in injector tube Insert pilot 29 through small opening of injector tube and thread pilot into tapped hole in end of installation removal tool 29 Using brass hammer or fiber mallet tap on end of pilot 29 Carefully drive and lift injector tube installation removal tool 28 and pilot from cylinder head 2 If injector tube o ring seal is not removed with injector tube remove o ring seal from cylinder head casting at upper end of injector tube bore Discard injector tube and o ring seal 0032 00 8 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED 28 342 1012 30 Remove cup plugs by piercing with screwdriver or chisel and prying plug out of cylinder head 31 Unscrew pipe plugs and fuse plug CLEANING AND INSPECTION 1 Steam clean stripped cylinder head NOTE Ensure all cup plugs pipe plugs and injector tubes are installed before pressure testing cylinder head
340. ea Check torque reading on input shaft 2 Reading must not exceed 22 Ib in 2 5 Nm 20 Apply a light coat of lubricating oil to two new packings 23 and 24 and install packings in valve housing 20 ae a 23 EA zo P A ES ESE 32 342 851 33 21 Apply a light coat of lubricating oil to new packing 31 and new seal ring 30 Install packing and seal ring on rack pis ton 22 0089 00 14 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED WARNING Do not allow valve housing to contact poppet Such contact could cause steering problems or loss of steering resulting in possible injury to personnel 22 Place rack piston 22 with guide holes up on padded pedestal high enough so that valve housing 20 can rotate when assembled Insert worm end of input shaft 2 into rack piston 22 close to maximum depth Ensure valve housing does not contact poppet 54 Line up rack piston guide holes with worm track grooves on input shaft GUIDE 20 54 HOLES 342 866 2 3031 WARNING Do not force guide halves into place Force may damage guide halves which could cause loss of steering resulting in possible injury to personnel NOTE Rotate input shaft slightly if necessary to ensure guide halves are properly seated 0089 00 15 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 23 Install two new guide halves 28 by hand in rack
341. eal inserter base 7 0031 00 2 TM 9 2320 302 34 CRANKSHAFT FRONT OIL SEAL REPLACEMENT CONTINUED 0031 00 INSTALLATION CONTINUED 11 Remove seal inserter nut 13 thrust bearing 12 seal inserter housing 10 seal inserter collar 9 two guide studs 8 and seal inserter base 7 342 752 12 Install vibration dampet WP 0020 00 END OF WORK PACKAGE 0031 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0031 00 4 TM 9 2320 302 34 CYLINDER HEAD REPAIR 0032 00 THIS WORK PACKAGE COVERS Disassembly Cleaning and Inspection Assembly INITIAL SETUP Maintenance Level Tools and Special Tools Continued General Support Tester spring resiliency Item 128 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Adapter motor hoist Item 24 WP 0126 00 Materials Parts Bracket engine mounting Item 11 WP 0126 00 pula Valve Insert exhaust valve P N 8929126 12 Clamp material lift Item 20 WP 0126 00 12 Insert intake valve P N 8929127 12 Compressor spring Item 23 WP 0126 00 Key valve P N 0984 C 48 Compressor spring Item 24 WP 0126 00 Kit exhaust valve P N 23507504 12 Compressor spring Item 25 WP 0126 00 Kit intake valve P N 23501576 12 Inserter set dowel Item 55 WP 0126 00 Seal guide P N 85 0691 9 24 I
342. ear outs or cracks between rivets usually indicates partially failed or damaged rivets Complete repair of the joint will require replacement by the next larger size rivets Use the next 1 32 in larger diameter rivet to obtain a tight joint when original hole has been enlarged If original size rivet is installed rivet will not be able to carry its share of shear load and the joint will not meet its strength requirements Lock Bolt Failure Lock bolts are used to withstand tension loads and high shear loads These fasteners are installed in holes with an interference fit No looseness can be permitted Lock bolts showing evidence of being stretched broken loose in holes or having heads that do not set flat against the surface must be replaced Guidelines used in Rivet Failure above for detecting rivet failures also apply to lock bolts RIVET REPLACEMENT NOTE When removing rivets be careful not to enlarge rivet holes This will require use of an oversize or larger rivet for replacement Solid Rivet Removal a File flat surface on manufactured head if accessible It is always preferable to work on manufactured head rather than a head that is bucked over Manufactured head will always be more symmetrical around shank b Indent center of filed surface with center punch CAUTION Use drill slightly smaller than diameter of rivet shank to avoid making rivet hole oversized c Using drill slightly smaller than diameter of rivet shank dri
343. ear subassembly 50 342 1246 342 1247 43 Remove nut 7 and washer 56 from drive pinion 3 342 1248 0080 00 12 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 44 Using press remove drive pinion 3 from differential carrier 1 342 1249 45 Remove bearing cone 57 spacer 58 and gear 15 from differential carrier 1 46 Remove spacer 59 and bearing cone 60 from drive pinion 3 57 342 1250 0080 00 13 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED NOTE Perform steps 47 and 48 only if bearings are damaged or if pinion and ring gear are being replaced 47 Remove outer bearing cup 61 48 Remove inner bearing cup 62 and shim s 63 from differential carrier 1 Measure and record thickness of shim s 342 1251 49 Remove screen plug assembly 64 plug 65 washer 66 four cap screws 67 washers 68 and cover 69 from dif ferential carrier 1 69 342 1252 0080 00 14 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY Nn Boop m V WARNING Forward rear axle differential carrier weighs 1160 Ib 526 kg Attach suitable lifting device when lifting assembly to prevent possible injury to personnel NOTE e installing new ring gear and drive pinion perform steps 1
344. ecured by clips tiedown straps cushion clamps and screw terminals Only remove hardware securing harness or lead to be removed Tag wiring harness and leads prior to removal to aid in installation Disconnect and remove chassis wiring harness using illustration as a guide Discard tiedown straps INSTALLATION NOTE Wiring harness and leads are secured by clips new tiedown straps cushion clamps and screw terminals Ensure harness is secure and all hardware is tight 1 Install connect and secure chassis wiring harness using illustration s a guide 2 Connect battery cables TM 9 2320 302 20 0062 00 1 TM 9 2320 302 34 CHASSIS WIRING HARNESS REPLACEMENT CONTINUED 0062 00 INSTALLATION CONTINUED TABLE 34 pin Male Connector 3 pin Female Sealed Connector 3 pin Male Sealed Connector 2 pin Male Sealed Connector 1 pin Male Sealed Connector 1 pin Female Connector Male Cable Connector Female Cable Connector Ring Terminal 342 552 4 PN LP Ur WY Oo EH END OF WORK PACKAGE 0062 00 2 TM 9 2320 302 34 FRONT ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT 0063 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery
345. ed visibility to sides and front of truck 0002 00 3 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED 0002 00 31 19 20 21 L3 Sei 22 gt x C 23 ELA S 24 REP AM 25 342 002 COMPONENT DESCRIPTION Ramp Fifth Wheel Utility Lights Strobe Warning Light Intervehicular Receptacles Installation Antenna Mount Exhaust Muffler Hood Latch CWS Side Sensor Fuel Tank Storage Boxes Mud Flaps Sloped surface serves as an approach to fifth wheel and facilitates coupling of semitrailer Coupling device for semitrailers with kingpins Illuminate area in back of cab There is one light on each side of cab Strobe light alerts other vehicles of presence of truck Contains 12 volt commercial 24 volt military and trailer ABS receptacles Mount for radio antenna Deadens noise of engine exhaust Locks hood closed Located on both sides of hood Side looking collision warning system sensor Holds fuel Steps mounted to tank provide access to cab Provide stowage area for BII and other items Prevent water and debris from spraying up on passers by or towed semitrailer 0002 00 4 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED COMPONENT DESCRIPTION Blackout Lights Used during bl
346. ed with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death RECOVERY 1 Remove caps from suction and discharge valves Valves are located at firewall on passenger side of vehicle 2 Wearing protective goggles and non leather gloves attach recovery recycling station s hoses to valves NOTE Push down firmly on hose connectors until a clicking sound is heard This will ensure coupler is locked a Ensure recovery recycling station s valves are closed b Connect red high side hose to discharge service valve c Connect blue low side hose to suction service valve d Turn knob clockwise on each coupler to open shrader valves 0112 00 1 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE CONTINUED 0112 00 RECOVERY CONTINUED gt To Recovery Station Manifold Suction Hand Valve Open Low Side Gage High Side Gage Manifold Discharge Hand Valve Open Suction Service Valve 2 Discharge Service Valve a 342 561 RUP QN tA 3 Follow recovery recycling manufacturer s instructions and recover all refrigerant from system NOTE e Always comply with all local regulations regarding refrigerant disposal You may be subject to substan tial penalties for improper disposal Any time air conditioning system refrigerant is evacuated replace receiver drier 4 Replace receiver drigr WP 0118 00 N
347. efore assem bling camshaft bearing caps to cylinder head Failure to do so could result in equipment damage NOTE Ensure locating tangs are in correct position Apply thin bead of gasket forming compound to joint face surfaces A and B of camshaft bearing cap no 7 Apply thin bead of gasket forming compound to joint groove face surfaces C and D of camshaft bearing cap no 1 Cap no 1 i 342 701 Install new seal ring 25 in counterbore under camshaft bearing cap 23 position no 7 rear Install new racetrack seal ring 25 in counterbore under camshaft bearing cap 23 position no 1 Install two camshaft bearing caps 23 no 1 and no 7 with bearing shells in place Install two studs 21 two seals 22 and two cap bolts 20 Tighten two rocker shaft studs 21 and two camshaft cap bolts 20 on two camshaft bearing caps 23 no 1 and no 7 to 75 86 lb ft 102 117 Nm Use rocker stud socket to tighten studs 0026 00 18 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 12 Remove three bolts 15 and camshaft gear pilot 13 from camshaft drive gear access opening 14 CAUTION Clean rag may be inserted into gear housing assembly opening to trap bolts in case they are dropped DO NOT allow rag to drop into gear housing assembly Failure to follow this caution will result in equipment damage NOTE Ensure camshaft dowel is engaged before performing next ste
348. elbow fitting 2 at rear of cylinder head 3 2 Disconnect fuel return line 4 from elbow fitting 5 at rear of cylinder head 3 3 Place fuel lines 1 and 4 in a suitable container to collect drained fuel 342 633 2 WARNING Eye protection must be worn to prevent fuel from getting in eyes during fuel removal CAUTION All fuel must be removed from cylinder head before removing an injector to prevent fuel from entering cyl inder and causing hydrostatic lock or washdown 4 Apply low air pressure for 20 to 30 seconds into elbow fitting 2 to purge remaining fuel from cylinder head 3 NOTE Perform step 5 through 8 for each injector to be removed 5 Loosen two screws 6 and disconnect injector wiring harness terminals 7 0046 00 2 TM 9 2320 302 34 FUEL INJECTOR REPLACEMENT CONTINUED 0046 00 REMOVAL CONTINUED 6 Remove holddown bolt 8 washer 9 and holddown clamp 10 342 630 0046 00 3 TM 9 2320 302 34 FUEL INJECTOR REPLACEMENT CONTINUED 0046 00 REMOVAL CONTINUED CAUTION Use extreme care when handling injectors to avoid costly damage by dropping or mishandling 7 Lift injector 11 from seat in cylinder head 3 by inserting pry bar under injector as shown NOTE Use a clean rag in injector hole to keep foreign matter out of engine 8 Remove three o ring seals 12 and 13 from injector 11 Discard seals 342 632 0046 00 4 TM 9 2320 302 34
349. em 2 WP 0125 00 Refrigerant recovered WP 0112 00 SI gt Usecare to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death e NOT disconnect refrigerant lines from air conditioner compressor without first recovering refriger ant from system Failure to recover system could cause uncontrolled release of high pressure refrigerant which can freeze skin and eye tissue causing serious injury or blindness REMOVAL NOTE If air conditioner compressor is being removed as an equipment condition for engine replacement DO NOT disconnect refrigerant hoses and lines Perform ONLY the following four steps e Disconnect compressor clutch electrical lead e Cuttiedown straps securing refrigerant hoses e Remove compressor mounting bolts e Move compressor from mounting bracket to truck frame and secure in place to prevent damage 0117 00 1 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR REPLACEMENT CONTINUED 0117 00 REMOVAL CONTINUED 1 Disconnect compressor clutch electrical lead 1 from engine h
350. embly to aid in assembly Remove three screws 16 flange 17 and gasket 18 from pump body 9 Discard gasket Remove five screws 19 and rear cover 4 from pump body 9 Remove and discard large packing 20 and small packing 21 from pump body 9 eo noo Remove valve cap 22 packing 23 spring 24 and valve 25 from rear cover 4 Discard packing 10 If damaged remove and discard two guide pins 26 from rear cover 4 0087 00 2 TM 9 2320 302 34 POWER STEERING PUMP REPAIR CONTINUED 0087 00 DISASSEMBLY CONTINUED 342 800 0087 00 3 TM 9 2320 302 34 POWER STEERING PUMP REPAIR CONTINUED 0087 00 DISASSEMBLY CONTINUED 11 Remove shaft 13 from pump body 9 NOTE Ensure locating pin position is marked to aid in assembly 12 Remove ten rollers 27 cam 28 port plate 29 two seals 30 two O rings 31 locating pin 32 and end plate 33 from pump body 9 Discard rollers cam port plate seals o rings and locating pin 13 Remove two snap rings 34 carrier 35 and drive pin 36 from shaft 13 Discard carrier and drive pin 14 Remove and discard two seals 37 and 38 from pump body 9 LOCATING PIN LOCATION 342 801 INSPECTION 1 Inspect shaft for wear burning and scoring in areas of bushings oil seals and spline drive If found replace shaft 2 If pump has been disassembled because of hard steering and no other parts show any wear or damage repl
351. eners may have been stretched or holes elongated It is possible for this to happen and for fasteners to still appear to be tight in their holes In addition make a thorough inspection of adjacent areas to determine if high loads have been transmitted from the damaged area to other areas This can result in secondary dam age in the form of distorted panels or seams loosened or sheared fasteners elongated fastener holes and cracks Classification After extent of damage has been determined affected parts should be classified in one of the following categories Negligible Damage Damage Repairable by Patching Damage Repairable by Insertion Damage Necessitating Replacement of Parts Negligible Damage Minor dents nicks scores cracks and holes in body panels which are within or are brought within reasonable limits by a simple procedure without extensive rework These defects should be considered more serious if located in main structural members such as body side rails a pillar or floor crossmembers rather than in body panels such as cowls or rear wheelhouses Deep wrinkles of undetermined origin in body panels should not be classed as negligible until the source of wrinkles has been investigated and positively identified Damage other than small dents holes nicks and scratches will require repair or replacement of the part Refer to repair of negli gible damage below 1 Negligible Cracks Isolated cracks less than 0 50 in 1 27 cm lo
352. ent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 9 Leak test air conditioner system 9 2320 302 20 0114 00 3 TM 9 2320 302 34 AIR CONDITIONER EXPANSION VALVE REPLACEMENT CONTINUED 0114 00 INSTALLATION CONTINUED 10 Wipe expansion valve 3 and refrigerant line 4 connections clean Wrap line connections with insulation tape 11 Wrap expansion valve 3 with strip caulk 12 Install dash panel 2 and nine screws 1 END OF WORK PACKAGE 0114 00 4 TM 9 2320 302 34 AIR CONDITIONER EVAPORATOR COIL REPLACEMENT 0115 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Cap set Item 7 WP 0125 00 Tools and Special Tools Caulk strip Item 8 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Oil refrigerant Item 27 Crowfoot attachment set Item 28 WP 0126 00 Rags wiping Item 31 WP 0125 00 Gloves rubber Item 40 WP 0126 00 ping Goggles Item 42 WP 0126 00 Tags marker Item 35 WP 0125 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Tape insulation Item 36 WP 0125 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 References Materials Parts TM 92320 30220 Packing preformed P N 2 011C944 70 Packing preformed
353. ential carrier 1 so that plunger is against tooth surface on drive side of ring gear 2 and zero indicator NOTE Move ring gear only when adjusting backlash While holding drive pinion shaft 3 in position rotate ring gear 2 slightly in both directions against drive pinion shaft Note measurement NOTE e If same ring gear and drive pinion have been installed adjust backlash to setting recorded in disassem bly step 5 e If new ring gear and drive pinion have been installed adjust backlash to 0 012 in 0 305 mm If backlash measurement is less than specified loosen adjusting ring 9 on back surface of ring gear 2 and equally tighten adjusting ring 9 on tooth side of ring gear Repeat step 49 If backlash measurement is more than specified loosen adjusting ring 9 on tooth side of ring gear 2 and equally tighten adjusting ring 9 on back surface of ring gear Repeat step 49 Repeat steps 49 through 51 until backlash meets specification Record setting for use when adjusting pinion bearing pre load 0082 00 20 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 342 1197 NOTE Always check tooth contact pattern on drive side of ring gear teeth 53 Apply Prussian blue dye to approximately 12 teeth of ring gear 2 Rotate ring gear so marked gear teeth are next to drive pinion shaft 3 54 To get contact pattern rotate ring gear 2 forward and b
354. er 58 in front of gear 15 33 Install outer bearing cone 57 34 Using press apply two tons of pressure to outer bearing cone 57 Move differential carrier 1 in both directions while installing outer bearing cone 35 Relieve pressure and remove differential carrier 1 from press Install differential carrier on repair stand xmi DN SUED 0080 00 20 ROTATE CARRIER IN THESE DIRECTIONS AS CONE IS PRESSED ON PINION WOOD BLOCK MUST TOUCH HEAD OF DRIVE PINION 4421279 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED NOTE Drive pinion must be held in place with fixture holding gear teeth or with wood blocks between pinion gear and differential carrier case 36 Install washer 56 and nut 7 on drive pinion 3 and tighten to 1200 1500 Ib ft 1625 2035 Nm 37 Using inch pound torque wrench rotate drive pinion 3 Check reading on dial while turning torque wrench New drive pinion gear reading must be 5 45 Ib in 0 56 5 08 Nm Used drive pinion gear reading must be 10 30 Ib in 1 13 3 39 Nm 38 If preload is not within limits remove and replace spacers disassembly steps 45 and 46 Install thicker spacer to decrease preload or thinner spacer to increase preload Repeat steps 32 through 37 until correct preload is obtained 23 7 56 a 342 1260 CAUTION To prevent damage to case do not press cold ring gear on
355. er body 18 0083 00 4 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 DISASSEMBLY CONTINUED 39 342 198 ASSEMBLY NOTE e assist in assembly place foot brake valve in a soft jawed vise e Install new repair kit parts on assembly 1 Apply a light coating of grease to surfaces of preformed packings preformed packing grooves and piston bores of upper body 18 NOTE Perform step 2 to install valve assembly to upper body 2 Install valve 44 seat 43 spring 42 preformed packing 41 retainer 40 washer 39 and retaining clip 38 to upper body 18 with retaining ring 37 3 Install two preformed packings 35 and 36 to piston 22 Install retainer 34 spring 33 piston 22 and screw 23 to upper body 18 0083 00 5 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 ASSEMBLY CONTINUED 4 Install rubber spring 32 and spring seat 31 to primary piston 21 with sleeve nut 30 5 Install rubber washer 29 and preformed packing 28 to primary piston 21 Install spring 27 and primary piston to upper body 18 342 197 WARNING Internal components are under spring pressure Use care when assembling Failure to hold components in position may result in injury to personnel 6 While holding primary piston 21 and piston 22 compressed and using a screwdriver to prevent screw 23 from turn ing install spring 26 and retainer 2
356. er drier to expansion valve e Tube assembly on firewall to expansion valve 2 places 2 Remove insulation tape from each hose connection 0121 00 1 TM 9 2320 302 34 AIR CONDITIONER HOSE REPLACEMENT CONTINUED 0121 00 REMOVAL CONTINUED NOTE DO NOT disconnect or connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 3 Disconnect each end of hose connection CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid 4 Cap each opening where hose was disconnected 5 At firewall remove two screws 1 washers 2 tube assembly 3 and gasket 4 Discard gasket 342 522 INSTALLATION 1 Install gasket 4 on tube assembly 3 and tube assembly on firewall 2 Install two washers 2 and screws 1 3 Install and lubricate new preformed packing 5 with refrigerant oil 4 Apply loctite to male threads 6 and connect each end of hose 342 521 5 Tighten connections WP 0123 00 0121 00 2 TM 9 2320 302 34 AIR CONDITIONER HOSE REPLACEMENT CONTINUED 0121 00 INSTALLATION CONTINUED 6 Apply insulation tape at each end of hose connection 7 Wrap remainder of hose with strip caulk NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 8
357. erant breaks down into poisonous phosgene gas which if breathed causes severe respiratory irritation Do not breathe the fumes from an open flame leak detector 5 Even though refrigerant does not burn when it contacts extreme heat or flame poisonous phosgene gas is created This gas is also produced when an open flame leak detector is used Phosgene fumes have an acrid bitter smell 6 You must work in an area where there is a constant flow of fresh air when the system is discharged flushed charged and leak tested using an open flame leak detector 7 Changes in both federal and state laws will affect the way dealerships service air conditioning systems Under current federal laws refrigerant must be recovered and recycled by all users to protect the environment and not released into the atmosphere Many service operations not directly involving the air conditioning system require the release of the refrigerant charge Under the new regulations dealerships not having the required recovery and recycling equipment and properly trained and certified personnel will not be allowed to do any of this service work 8 Because of its very low boiling point refrigerant must be stored under pressure To prevent the refrigerant cans from exploding never expose them to temperatures higher than 125 F 52 C Never leave refrigerant cans in the sun and do not store them in sun exposed areas where heat can build up such as in gloveboxes automobile t
358. ering control valve WP 0089 00jor WP 0088 00 Check for steering gear control Repair or replace steering gear valve sticking WP 0089 00jor WP 0088 00 6 High Steering Effort in Both Directions Check for sufficient pump If pressure is less than 900 psi pressure Malfunction 2 step 62 07 bars repair or replace 2 power steering pump WP 0087 O00lor WP 0086 00 Check for sufficient pump flow Repair or replace power steering Malfunction 2 step 3 pump CWP 0087 00 or WP 0086 00 Check for defective teflon seals Repair or replace steering gear in steering control valve WP 0089 00jor WP 0088 00 Check for steering gear control Repair or replace steering gear valve sticking WP 0089 00j or WP 0088 00 High steering effort or replace steering gear direction WP 0089 O0 or WP 0088 00 0008 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0008 00 4 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING 0009 00 PRELIMINARY CHECKS Before testing the operation of the air conditioning system make the following checks 1 Ensure the refrigerant compressor s drive belt is not damaged and is correctly tensioned Also check the compressor mountings for tightness 2 Check for broken burst or cut hoses also check for loose fittings on all parts Check for road debris buildup on the condenser coil fins Using air pressure a
359. ers 12 screws 11 left front spring hanger 10 three washers 9 and new lock nuts 8 Install screw 7 washer 6 and new lock nut 5 Install threaded block 4 two screws 3 washers 2 and new lock nuts 1 Tighten 1 2 13 grade 8 lock nuts to 80 Ib ft 108 Nm Tighten 5 8 11 grade 8 lock nuts to 160 Ib ft 217 Nm Install steering gear left side only WP 0088 00 Install front sprind WP 0099 00 END OF WORK PACKAGE 0100 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0100 00 4 TM 9 2320 302 34 REAR SUSPENSION CENTER BEARING REPLACEMENT 0101 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Screw P N 23 12576 125 2 Adhesive loctite Item 2 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Personnel Required Jack hydraulic Item 73 WP 0126 00 Two Trestle hoist portable 2 Item 135 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 REMOVAL 1 Remove nut 1 screw 2 and rebound stop 3 from mounting bracket 4 2 Remove two screws 5 from center bearing 6 3 Using floor jack lift rear of vehicle and place trestle under each frame rail Lower vehicle onto trestles 4 Remove two screws 7 and center bearing 6 from top of spring assembly 8 Discard screws 342 973 0101 00 1 TM 9 2320 302 34 REAR SUSPENSION CENTER BEARING REPLAC
360. es for excessive wear or grooving If excessively worn replace crankshaft Check crankshaft timing gear for worn or chipped teeth Inspect timing wheel for bent or damaged teeth Replace as necessary Support crankshaft front and rear journals on V blocks or inverted engine block with only front and rear upper bearing shells in place Check intermediate main journals with dial indicator for runout when crankshaft is rotated Replace crankshaft if runout is greater than maximum shown in Table 1 Table 1 Intermediate Main Journals Runout MAXIMUM RUNOUT JOURNAL SUPPORTED ON JOURNALS MEASURED TOTAL INDICATOR READING No 1 and No 7 0 0030 in 0 076 mm 0 0051 in 0 130 mm men Measure all main bearing journals 19 and connecting rod bearing journals 20 as shown at several places on circum ference to determine taper out of round and journal diameter Replace crankshaft if not within specifications shown 0033 00 6 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED INSPECTION CONTINUED 4 921 in 125 00 mm 4 920 in 124 968 mm 1 954 in 49 65 mm 1 942 in 49 35 mm 8 Measure crankshaft thrust washer surfaces as shown 0033 00 2 199 in 65 87 mm 2 195 in 55 77 mm 342 1078 NO 6 MAIN BEARING JOURNAL 1 947 in 49 45 mm 1 950 in gt 49 53 mm 342 1079 0033 00 7 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSPECTION CONTINUED
361. ests squarely on pedestal flat 5 Mount dial indicator so stem of indicator rests on scribed line of pedestal flat 6 Remove bolt 14 and washer 15 10 2 342 1097 j Turn adjusting screw 16 clockwise to move adjustable idler gear toward camshaft drive gear 10 until there is zero lash 8 Insert screwdriver through access bolt hole 17 and engage adjustable idler gear tooth to determine gear lash 9 Apply pressure on screwdriver to hold adjustable idler gear in counterclockwise direction and attempt to move camshaft drive gear 10 by hand Watch dial indicator pointer If there is zero lash pointer will not move NOTE Gear lash reading obtained on cam idler lash pedestal is one half actual gear lash Reading on dial indicator must be doubled to determine if specification is met 10 When zero lash is obtained turn adjusting screw 16 approximately 1 1 2 turns counterclockwise or until correct gear lash is obtained 0038 00 4 TM 9 2320 302 34 ADJUSTABLE IDLER GEAR REPLACEMENT CONTINUED 0038 00 ADJUSTMENT CONTINUED 11 Bar engine to check adjustable idler gear lash on camshaft drive gear 10 at 3 6 9 and 12 o clock positions 12 When gear lash is 0 002 0 009 in 0 05 1 0 229 mm for new parts and a maximum of 0 012 in 0 305 mm for used parts at all four positions tighten two top nuts 1 to 42 49 lb ft 57 67 Nm 13 Remove cam idler lash adjuster 12 and tighten lower nut to 42 49 Ib ft 57 66 Nm
362. esult in damage to equipment 54 Install valve spring 11 and valve rotator 9 over valve stem 10 and against valve spring seat 15 342 1004 NOTE When compressing valve spring valve rotator should not contact valve stem seal 55 Using valve spring compressor 8 compress valve spring 11 only enough to install new valve keys 12 NOTE Ensure valve key is in place and engaged in valve stem groove before releasing valve spring compressor 56 Install new valve keys 12 57 Remove valve spring compressor 8 0032 00 28 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 342 1003 58 Using fiber or plastic mallet strike end of valve stems 10 sharply to seat valve keys 12 59 Install cylinder head WP 0018 00 END OF WORK PACKAGE 0032 00 29 TM 9 2320 302 34 This Page Intentionally Left Blank 0032 00 30 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT 0033 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Continued General Support Lubriplate Item 23 WP 0125 00 Tools and Special Tools Oil lubricating Item 25 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Rope 1 2 in nylon Item 32 WP 0125 00 Dial indicator set Item 29 WP 0126 00 Personnel Required Inserter and remover Item 52 WP 0126 00 Two Pump hydraulic ram Item 98 WP 0126 00 Wrench torque 15 75
363. evel Materials Parts Direct Support Oil refrigerant Item 27 WP 0125 00 Rags wiping Item 31 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 References Gage oil level Item 35 WP 0126 00 Gloves rubber Item 40 WP 0126 00 Equipment Condition Goggles Item 42 WP 0126 00 Refrigerant recovered gt y e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death GENERAL INFORMATION CAUTION e Always use correct refrigerant oil in R 134a air conditioning system Never mix oils If wrong oil is used or if oils are mixed compressor could seize due to improper lubrication e Refrigerant oil must be from a container that has not been opened or that has been tightly sealed since its last use Tubing funnels or other equipment used to transfer refrigerant oil should be very clean and dry Failure to follow this caution may result in contamination of system NOTE Replacing only the amount of refrigerant oil that was removed during evacuation may
364. event damage to equipment do not press shaft of drive pinion out of gear 28 Using press remove outer bearing cone 57 and lead pieces 0080 00 29 Measure thicknesses of compressed lead pieces Add measurements of two lead pieces and divide by two to determine average size of pieces Add 0 004 in 0 100 mm to average size Use this dimension to determine size of spacer removed in disassembly step 45 to be installed between gear 15 and outer bearing cone 57 ET VEDO TN ocn dnm WOOD BLOCK MUST TOUCH HEAD OF PINION 0080 00 19 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 30 Place wood block under head of drive pinion 3 so that inner bearing cone 60 touches inner bearing cup 62 Remove supports from under differential carrier 1 CAUTION To prevent damage to spacer do not apply pressure after gear touches spacer in front of inner bearing on drive pinion 31 Using press and sleeve that fits inside pinion bore of differential carrier 1 press gear 15 on drive pinion 3 until gear touches spacer 59 Do not remove wood block 15 WOOD BLOCK 62 eee 59 AND END OF ae DRIVE PINION j EIN MUST TOUCH 77 MT 60 Y iy WOOD BLOCK SUPPORT SUPPORT 342 1258 32 Install spac
365. f bearing retainer lock nut 2 Use tool J37035 1 to check turning torque Maximum turning torque is 27 Ib in 3 Nm J37035 1 342 1176 Control Valve Module Disassembly 9 ND un P ow m 10 NOTE The control valve module assembly springs and other parts can be mistakenly interchanged Tag each part with its item name as it is removed and use valve tray set 733163 to simplify correct valve reassembly Remove bolt 1 and two bolts 2 securing the suction filter housing 3 Remove suction filter housing 3 filter 4 face seal 5 and gasket 6 Discard filter and gasket Remove four bolts 7 and wiring harness cover plate 8 Tag and disconnect electrical connections Remove three bolts 9 and control harness assembly 10 Remove three bolts 11 and rotating clutch solenoid body assembly 12 Remove eight bolts 13 and stationary clutch solenoid assembly 14 Remove two bolts 15 and main valve body assembly 16 see page 0072 00 45 for illustration NOTE Rotating clutch solenoid body disassembly procedures are steps 9 through 14 Remove two bolts 17 and then remove C3 pressure switch 18 from rotating clutch solenoid body assembly 12 Check resistance of C3 pressure switch Maximum allowable resistance is 2 ohms when contacts are closed and must be 20 000 ohms minimum when contacts are open Check pressure at which switch opens and closes Both events must occur between 23 37 psi 159 255 kPa Test
366. f material thickness 0105 00 5 16 in or more 1 1 2 x diameter of rivet 5 16 in or more over 1 in 1 1 2 x diameter of rivet 1 16 in for every in of material thickness 7 Rivet Driving Practices and Precautions Riveting is the major means of joining body parts Proper procedures must be followed to maintain high quality workmanship Table 6 lists types of faulty rivet installations causes and corrective action to be taken Table 6 Correctly and Incorrectly Driven Rivet TOP VIEW A B C D E F DRIVEN UNSTEADY DRIVEN SEPARATION UNSTEADY EXCESSIVE CORRECTLY TOOL EXCESSIVELY OF SHEETS RIVETSET SHANK LENGTH DAMAGED HEAD SWELLED ES SHANK EAD CRACKS Ton BUCKLED SHANK BOTTOM VIEW IMPERFECTION CAUSE REMEDY ACTION None None None None Cut a ea held tools LN riveting tools firmly rivet against work Excessive flat head resultant Excessive driving too much Improve riveting technique Replace rivet head cracks pressure on bucking bar 0105 00 7 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 RIVET REPLACEMENT CONTINUED Table 6 Correctly and Incorrectly Driven Rivet Continued IMPERFECTION CAUSE REMEDY ACTION IM separation Work not firmly together Fasten work n 2308 together ME M rivet and rivet shank swelled to prevent slipping Sloping head a Bucking bar not held Hold bucking bar firmly Replace rive
367. for used parts 12 Measure gear lash between camshaft idler gear 17 to adjustable idler gear 18 Allowable lash is 0 002 0 009 in 0 051 0 229 mm for new parts and a maximum of 0 012 in 0 305 mm for used parts 342 911 0037 00 5 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT CONTINUED INSTALLATION CONTINUED 13 Install rocker arm assemblies WP 0027 00 14 Install gear case covet WP0019 00 END OF WORK PACKAGE 0037 00 6 0037 00 TM 9 2320 302 34 ADJUSTABLE IDLER GEAR REPLACEMENT 0038 00 THIS WORK PACKAGE COVERS Removal Inspection Installation Adjustment INITIAL SETUP Maintenance Level Materials Parts General Support Cloth abrasive Item 9 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 References Adjuster lash cam Item 5 WP 0126 00 Barring tool engine Item 8 WP 0126 00 Equipment Condition Dial indicator set Item 29 WP 0126 00 Rocker arm assemblies removed WP 0027 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Engine installed on repair stand Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Bull idler gear removed WP 0037 00 REMOVAL 1 Remove three nuts 1 and retaining plate 2 342 1092 0038 00 1 TM 9 2320 302 34 ADJUSTABLE IDLER GEAR REPLACEMENT CONTINUED 0038 00 REMOVAL 2 Remove adjustable idler gear 3 and hub 4 from gear housing assembly 5 342 1093
368. ft 24 30 Nm 9 Install wire 3 new lock washer 2 and nut 1 on starter solenoid 4 342 536 10 Install starter TM 9 2320 302 20 END OF WORK PACKAGE 0053 00 2 TM 9 2320 302 34 STARTER REPAIR THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Test stand automotive generator and starter Item 122 Materials Parts Packing P N 71038 Packing P N 71040 2 Packing P N 71041 Packing P N Z053095777 2 DISASSEMBLY 1 Remove two nuts 1 screws 2 and brush opening band 3 0054 00 1 0054 00 Materials Parts Continued Seal P N 97799 Washer lock P N 2434 4 Washer lock P N 2523 9 Adhesive silicone Item Equipment Condition Starter solenoid removed WP 0053 00 342 544 TM 9 2320 302 34 STARTER REPAIR CONTINUED 0054 00 DISASSEMBLY CONTINUED CAUTION Do not pull brush leads until spring tension is relieved to prevent damage to equipment Remove eight screws 4 and four lock plates 5 Pull two springs 6 upward and remove eight brushes 7 342 545 NOTE Mark commutator housing and field ring prior to removing commutator housing to aid in installation Remove four screws 8 lock washers 9 commutator housing 10 insulation washer 11 and washer 12 from field ring 13 Discard lock washers Remove four s
369. ft journals before installing bearings h Coat connecting rod bearing shells and journal with clean engine lubricating oil before assembly 342 1069 34 35 Place lower connecting rod bearing shell 6 in connecting rod cap 5 Index bearing tang with notch in connecting rod cap Lubricate bearing shell with clean engine lubricating oil CAUTION Number stamped on connecting rod cap indicates cylinder it should be installed in Number must be on oil cooler side of cylinder block when installing connecting rod cap to prevent damage to equipment 0041 00 21 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED 36 Install connecting rod cap 5 and lower connecting rod bearing shell 6 on connecting rod 12 CAUTION Ensure connecting rod bolt has not turned in connecting rod before connecting rod cap nut is tightened to prevent damage to equipment 37 Install two connecting rod cap nuts 4 Tighten cap nuts alternately to 118 137 lb ft 160 185 Nm Check connecting rod side clearance by moving connecting rod from crank neck If there is no clearance check bearing installation 342 1070 38 Install remaining piston and rod assemblies in same manner 39 Install oil pump WP0029 00 40 Install cylinder head WP 0018 00 END OF WORK PACKAGE 0041 00 22 TM 9 2320 302 34 TURBOCHARGER REPLACEMENT 0042 00 THIS WORK PACKAGE COVERS Removal Inspection
370. g 5 3 Remove and discard screw 6 washer 7 roller 8 and washer 9 4 Remove and discard lock nut 10 screw 11 washer 12 roller 13 cam plate 14 and washer 15 29 342 963 Remove primary lock handle 16 from top plate 17 Remove and discard washer 18 from primary lock handle 16 Remove roll pin 19 spring 20 lock bar 21 and handle 22 Discard roll pin spring and lock bar 0094 00 2 TM 9 2320 302 34 TOP PLATE REPAIR CONTINUED 0094 00 DISASSEMBLY CONTINUED 2 WARNING When removing spring compress spring slightly and relieve tension slowly Failure to do so could cause spring to fly off resulting in injury to personnel 8 Remove and discard shaft 23 spring 24 and yoke 25 from top plate 17 9 Remove two cotter pins 26 pin 27 spring 28 and lock guard 29 Discard cotter pins pin and lock guard 10 Remove two pins 30 pins 31 and locks 1 Discard cotter pins and pins 11 If damaged remove two grease fittings 32 from top plate 17 NOTE Lube plates must be replaced as a pair 12 Remove 18 lock nuts 33 washers 34 and two lube plates 35 from top plate 17 Discard lock nuts 35 jel 34 l4 de T 33 342 964 13 Remove two retaining clips 36 and two pocket inserts 37 from top plate 17 ASSEMBLY 1 Install two pocket inserts 37 on top plate 17 and secure with two
371. g caps parting line Coat lower main bearing shells with clean engine lubricating oil NOTE Journal numbers stamped on main bearing caps should be read from oil cooler side of cylinder block begin ning with front main bearing cap as no 1 Note journal number and position main bearing cap and bearing on correct main bearing Main bearing caps must be installed in their original positions j Install main bearing caps 12 in cylinder block 15 Apply a small amount of international compound no 2 on threads and undersides of heads of main bearing cap bolts 10 Install washer 11 on each main bearing cap bolt 8 Install main bearing cap bolts 10 hand tight 9 Using fiber or plastic mallet strike main bearing caps 12 sharply toward crankshaft 14 0033 00 12 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSTALLATION CONTINUED 342 1075 NOTE Crankshaft will turn freely if bearings are installed properly and all main bearing cap bolts are tightened properly 10 Tighten all main bearing cap bolts 10 to 30 50 lb ft 41 68 Nm Turn crankshaft 14 1 8 turn to ensure crankshaft is not binding within journals 11 Beginning at center main bearing cap 12 and working progressively toward each end tighten all main bearing cap bolts 10 to 173 195 Ib ft 235 264 Nm Turn crankshaft 14 1 8 turn to ensure crankshaft is not binding within jour nals 12 Repeat tightening sequence and tighten each main
372. g spanner wrench 35 install adjuster 33 in valve housing 20 Tighten adjuster to 132 180 Ib in 14 9 20 3 Nm to seat components then back off 1 4 to 1 2 turn 0089 00 12 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 342 862 13 Reverse valve housing 20 in vise 14 Using 19 mm deep well socket rotate input shaft 2 Note amount of torque required to rotate input shaft in each direc tion 15 Using spanner wrench 35 tighter adjuster 33 so that torque reading on input shaft 2 is 5 10 Ib in 0 56 1 13 Nm higher than noted in step 14 Maximum torque required to rotate input shaft must not exceed 22 Ib in 2 5 Nm 342 863 0089 00 13 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 16 Reverse valve housing 20 in vise 17 Apply a light coat of lubricating oil to new adjuster lock nut 32 18 Using spanner wrenches 34 and 35 install adjuster lock nut 32 while holding adjuster 33 in place Tighten adjuster lock nut to 101 122 Ib ft 137 165 Nm Check torque reading noted in step 14 If torque reading is not within 5 10 16 1 0 56 1 13 Nm higher remove adjuster lock nut back off adjuster 2 turn and repeat steps 13 through 18 342 864 32 33 20 19 Stake valve housing 20 in clockwise most corner of two opposing slots of adjuster lock nut 32 Stake adjuster lock nut on adjuster 33 in one place at threaded ar
373. grinder method cut head down until very thin but do not grind completely off or touch body part with grinding tool d Support head and use pin punch to pry off head or shear off with sharp chisel CAUTION Be careful not to distort lock bolt or lock bolt hole to prevent damage to equipment e Drive lock bolt out of hole with pin punch 4 Rivet Hole Drilling a Center punch all new rivet locations Center punch mark must be large enough to prevent drill from slipping out of position and must not dent surface of material To prevent denting place bucking bar behind material during punching b sure drill is correct size Tables 1 and 2 and point is properly ground Number 10 drill is used to install stan dard 3 16 in blind rivets Table 1 Drill Sizes for Solid Shank Rivets RIVET DRILL DIAMETER DIAMETER IN DRILL SIZE IN 0105 00 4 W TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 RIVET REPLACEMENT CONTINUED Table 2 Drill Sizes for Blind Rivets NOMINAL DIAMETER IN OVERSIZE DIAMETER IN RIVET DRILL RIVET DRILL DIAMETER SIZE MINIMUM MAXIMUM DIAMETER SIZE MINIMUM MAXIMUM 1 8 30 0 129 0 132 1 8 27 0 143 0 146 5 32 20 0 160 0 164 5 32 16 0 176 0 180 3 16 10 0 192 0 196 3 16 0 205 0 209 e While drilling hold drill at 90 degree angle to material surface Avoid letting drill wobble making oblong holes e Avoid excessive pressure Let drill bit do cutti
374. h set socket attachment torx Item 142 Maintenance Level Direct Support Tools and Special Tools 0126 00 Tool kit general mechanic s Item 132 WP 0126 00 0126 00 Adjusting tool Item 6 WP 0126 00 Materials Parts Caps vise jaw Item 17 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Handle drive 45 WP 0126 00 Inserter bearing Item 48 WP 0126 00 Installation tool seal Item 56 WP 0126 00 Bearing roller P N 071020 Fitting lubrication P N 037027 Retainer P N 062005 Seal kit P N TAS650006 Screw adjusting P N 062005 Installer output shaft Item 62 WP 0126 00 Socket socket wrench 19 mm deep well Item 117 Spanner attachment Item 119 WP 0126 00 Vise machinist s Item 136 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Grease GAA Item 22 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Tags marker Item 35 WP 0125 00 Tape masking Item 37 WP 0125 00 Equipment Condition Steering gear removed from vehicle WP 0088 00 0089 00 1 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY 1 Place steering gear assembly 1 in vise 2 Using 19 mm deep socket rotate input shaft 2 until timing marks on sector shaft 3 and housing 4 line up 3 Remove and discard seal 5 from housing 4 TIMING MARKS 342 840 4 Remove any paint or corrosion from sector shaft
375. h to 0 02 in 0 5 mm below bottom of oil seal coun terbore 0039 00 6 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 ASSEMBLY CONTINUED 4 Install new oil seal 12 in accessory drive assembly housing 1 Using service kit seal installer 17 and plastic hammer or fiber mallet install oil seal flush to 0 01 in 0 25 mm below face of accessory drive assembly housing 342 1109 5 Support service kit holding fixture 3 on two steel plates 14 and place accessory drive assembly housing 1 in service kit holding fixture hole Lubricate ball bearing assembly 15 with clean engine lubricating oil and install accessory drive shaft and bearing assembly 9 in accessory drive assembly housing o ee C Ep 0039 00 7 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 ASSEMBLY CONTINUED 6 Using wide end of service kit bearing installer 16 press on ball bearing assembly 15 outer race until ball bearing assembly is seated against shoulder of accessory drive assembly housing 1 342 1111 NOTE Ensure tapered side of snap ring is installed away from bearing Ensure snap ring is fully seated in groove of accessory drive assembly 7 Install snap ring 8 in groove of accessory drive assembly 1 8 Apply thin film of lubriplate to drive gear end of accessory drive shaft 9 342 1102 0039 00 8 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CO
376. haft Pilots Both Ends Minimum OD P1 PLANETARY MODULE p Um P1 Planetary Carrier Assembly Maximum Pinion End Play P1 Carrier Bushing Maximum ID P1 Pinion Trust Washer Maximum Step Wear P2 Ring Gear Spline Maximum Wear P2 PLANETARY MODULE P2 Planetary Carrier Assembly Maximum Pinion End Play 0 037 P2 Carrier Bushing Maximum ID P2 Pinion Thrust Washer Minimum Thickness P2 Pinion Thrust Washer Maximum Step Wear REARCOVERANDPEMODUEE Output Shaft Bushing Maximum ID 36 14 P3 Pinion Thrust Washer Minimum Thickness OUIPUTFTANGEANDYORE 000000 Journal Seal Maximum OD 0071 00 62 9 00 1 00 Table 3 Wear Limits and Spring Data APPROX LENGTH UNDERLOAD UNDER LOAD SPRING FREE PART COLOR NO OF WIREDIA OD LENGTH MM SPRING NUMBER CODE COILS MM n MM IN MM IN IN en Stator 29501300 No dd 17 8 5 7 0 9 pe eee am eze e Main Relief 29507709 No Code 3 25 17 96 52 4 40 7 474 sr m pee Eom a 0 0 C2 Return 29505719 No Code 11 5 2 04 19 06 70 76 28 2 5185 eed Reed eee ee diese C1 Return 29509453 No Code 2 10 16 0 57 53 34 8 4649 C3 Return 29506206 No Code 2 10 15 0 52 3 35 4 274 4 0 083 0 590 2 06 1 39 61 69 C3 Retainer 29507882 No Code 736 12 62 I2 93 16408 Se ee EJ C3 Retainer 29515628 No Code 236 12 62 ILi 10 40 15403 0 093 0 497 0 44 0 41 3463 C4 Return 29506206 No Code 2 10 15 0 52 3 35 4 274 4 ee ew ex
377. hermostatic switch Check all circuits for the cause and repair or replace the wiring or parts In all other cases where the compressor is not engaging and disengaging properly the thermostatic switch is the cause Replace it with a new switch TM 9 2320 302 20 6 Shut down the engine and to prevent accidental electric shock or shorting during dash assembling discon nect the batteries 7 Assemble the dash Line Restrictions a restricted suction line causes low suction pressure at the compressor and little or no cooling A restriction in a line between the compressor and the expansion valve can cause high discharge and low suction pressure and insufficient cooling b Usually areas of ice or frost buildup mean a blockage Parts that often freeze up are probably corroded or inopera tive and should be replaced Parts such as the expansion valve that freeze up once in a while may do so because of moisture in the system which will cause the moisture indicator s element to turn white or pink if this happens recover the refrigerant charge evacuate recycle the system refrigerant replace the receiver drier and install a new charge WP 0112 00 SAFETY PRECAUTIONS 1 Whenever repairs are made to any air conditioner parts that hold refrigerant you must discharge purge or flush if con taminated evacuate charge and leak test the system In a good system refrigerant lines are always under pressure and you should disc
378. hten to 160 180 Ib ft 217 244 Nm in sequence shown 342 873 45 Pack trunnion area of sector shaft 3 with grease Apply a light coat of grease to new seal 5 and install seal in sector shaft 342 874 46 Apply a light coat of grease to new seal 19 Using small end of input seal installer tap seal into valve housing 20 until shoulder of input seal installer rests against valve housing Clean off any seal material that may have shredded off 47 Install new retaining ring 44 and pack end of valve housing 20 with grease 48 Apply a light coat of grease to new seal 45 and install seal in valve housing 20 0089 00 20 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED INSTALLER 342 875 49 Install new grease fitting 18 two new packings 17 and plugs 16 in housing 4 342 846 16 0089 00 21 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 50 Ensure timing marks on sector shaft 3 and steering gear assembly 1 are aligned If not turn input shaft 2 with 19 mm deep well socket to align timing marks TIMING MARKS 342 840 WARNING Do not rotate input shaft more than 1 1 2 turns from center position Doing so will incorrectly set poppets causing steering problems resulting in possible injury to personnel 51 Loosen nut 7 52 Tighten adjusting screw 11 so that input shaft 2 requires torque of 45
379. i iced eeu eue quos Rie emda qat quoe ee que eie parie ede dulce nd Du RR Roe E e tied 0008 00 3 5 High Steering Effort in One Direction llle e ene 0008 00 3 6 High Steering Effort in Both Directions 00 cece eee eens 0008 00 3 AIR CONDITIONING SYSTEM 1 Warm Airflow When Air Conditioner Is hh 0009 00 7 2 Low Evaporator Coil Outlet Pressure Low Compressor Suction 0009 00 7 3 High Compressor Discharge Pressure 0 0 0 0 ccc ee T eiir 0009 00 7 4 Evaporator Outlet Air Temperature Increases as Compressor Discharge Pressure Drops 0009 00 7 5 Compressor Operates Too Often or Continuously llle 0009 00 8 6 Quick or Delayed Cycling of Compressor he 0005 00 1 TM 9 2320 302 34 This Page Intentionally Left Blank 0005 00 2 ENGINE TROUBLESHOOTING TM 9 2320 302 34 Table 1 Engine Troubleshooting Procedures 0006 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 Engine Fails to Crank 2 Engine Cranks But Does Not Start 3 Engine Runs Erratically 4 High Oil Consumption Using accessory drive attempt to rotate engine 1 Inspect engine gear train for correct timing mark alignment Inspect engine gear train for damaged or missing gear teeth Inspect engine gear train for correct timing mark alignment Inspect engine gear train for damaged or
380. in installation Tag wiring harness and leads prior to removal to aid in installation 1 Remove tiedown straps securing rear ABS wiring harness Discard tiedown straps 2 Disconnect rear ABS wiring harness connections using illustration as a guide TO R R TO R R SENSOR VALVE TO FRONT HARNESS SENSOR 342 511 0064 00 1 TM 9 2320 302 34 REAR ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT CONTINUED 0064 00 INSTALLATION 1 Connect rear ABS wiring harness connections using illustration as a guide 2 Install same number of new tiedown straps as were removed to secure rear ABS wiring harness R R SENSOR TO FRONT HARNESS VALVE VALVE 342 512 L R SENSOR 3 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0064 00 2 TM 9 2320 302 34 CAB ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT 0065 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Equipment Condition Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Note number and location of tiedown straps to aid in installation Tag wiring harness and leads prior to removal to aid in installation 1 Remove tiedown straps securing cab ABS wiring harness Discard tied
381. ing 23 Lift C5 clutch pack 41 containing eight friction plates 42 and nine steel reaction plates 43 from main housing 23 Measure tag and note thickness and cone of each friction plate 42 Minimum thickness is 0 137 in 3 48 mm Maxi mum allowable cone is 0 010 in 0 25 mm Measure tag and note thickness and cone of each steel reaction plate 43 Minimum thickness is 0 095 in 2 41 mm Maximum allowable cone is 0 010 in 0 25 mm Lift P1 planetary module 44 from main housing 23 342 1151 342 1152 Removal of Front Support and Charging Pump Module and Rotating Clutch Module NOTE Note size and position of 14 bolts securing front support and charging pump module to main housing to aid during assembly Remove seven bolts 45 and seven bolts 46 securing front support and charging pump module 47 to main housing 23 Lift front support and charging pump module 47 from main housing 23 Install an M16 lifting eye bolt into turbine shaft 48 Attach a suitable hoist to lifting eye Using hoist remove turbine shaft 48 and rotating clutch module 49 from main housing 23 0071 00 8 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 DISASSEMBLY CONTINUED Removal of Front Support and Charging Pump Module and Rotating Clutch Module Continued 342 1154 342 1153 Removal of C3 C4 Clutch Assembly 1 Remove 14 bolts 50 securing C3 C4 clutch assembly 51 in main housing
382. ing If binding occurs or if ball is stuck in control valve replace control valve Install collar 20 in engine retarder 6 housing with long sleeve area up Install spring 19 in center of collar 20 Install spring 18 over top of collar Press washer 16 to compress springs 18 and 19 Install new retaining ring 17 Rotate retaining ring 90 degrees to ensure proper seating in groove 342 660 0022 00 7 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 ASSEMBLY CONTINUED 13 Install accumulator piston 15 spring 14 and washer 12 in engine retarder 6 housing 14 Press washer 12 to compress spring 14 and install new retaining ring 13 Rotate retaining ring 90 degrees to ensure proper seating in groove CAUTION Be careful not to twist seal rings while installing to prevent damage to equipment 15 Coat three new seal rings 9 10 and 11 with clean engine lubricating oil Install seal rings 9 and 10 on solenoid valve 3 16 Install seal ring 11 in bottom of engine retarder 6 housing 17 Thread solenoid valve 3 into engine retarder 6 housing Tighten solenoid valve to 60 Ib in 7 Nm 12 13 342 659 INSTALLATION 2 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person
383. ing may result in death or injury to personnel e Spilled gear oil is very slippery Wipe up any spilled oil immediately Failure to do so could result in serious injury to personnel 0079 00 1 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT CONTINUED 0079 00 REMOVAL 1 Disconnect air line 1 WA v WARNING Forward rear axle differential carrier weighs 1160 Ib 527 kg Support with suitable floor jack prior to removal to prevent possible injury to personnel 2 Remove ten cap screws 2 and washers 3 and two nuts 4 and washers 5 3 Loosen differential carrier 6 by tapping around flange 4 Remove differential carrier 6 from axle 7 and lower differential carrier 6 onto floor jack Roll differential carrier from under vehicle 342 1132 5 If damaged remove oil filter adapter 8 342 1131 0079 00 2 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT CONTINUED 0079 00 INSTALLATION 1 If removed install new oil filter adapter 8 N WARNING Forward rear axle differential carrier weighs 1160 lb 527 kg Support with suitable floor jack prior to installation to prevent possible injury to personnel CAUTION Ensure both mating surfaces have been completely cleaned to prevent damage to equipment 2 Position differential carrier 6 on floor jack and roll differential carrier into position under vehicle Adhesives and sealing compounds can b
384. ining ring 53 from bearing side of housing 4 HANDLE REMOVAL 342 856 ASSEMBLY 1 Install new retaining ring 53 in inside ring groove of housing 4 2 Install new roller bearing 52 using installation end of bearing inserter and drive handle HANDLE INSTALLATION 52 342 857 3 Install trunnion washer 51 in housing 4 with beveled side facing away from retaining ring 53 4 Place new seal 50 on installation end of bearing inserter with spring toward shoulder of tool 5 Install seal 50 0089 00 10 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 6 Install new seal 49 and new retaining ring 48 Pack roller bearing 52 with grease HANDLE 50 INSTALLATION 342 858 7 Place valve housing 20 in vise Apply a light coat of lubricating oil to two new packings 42 and 43 and two new seal rings 40 and 41 Install packings and seal rings 40 342 859 0089 00 11 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 8 Apply a light coat of lubricating oil to thrust bearing 37 and washer 36 Install thrust bearing and washer on input shaft 2 9 Install input shaft 2 in valve housing 20 10 Apply a light coat of grease to thrust bearing 37 and washer 36 Install thrust bearing and washer 342 860 11 Install new packing 39 and new seal ring 38 in adjuster 33 33 342 861 12 Usin
385. into position but do not attempt to lift transmission 4 Remove two bolts 7 washers 8 and rear support spring 9 from transmission 342 1142 5 Remove 12 bolts 10 and lock washers 11 securing transmission to engine flywheel housing 3 Discard lock wash ers 342 1143 6 With assistance lower transmission from engine and remove from under vehicle 0070 00 3 TM 9 2320 302 34 TRANSMISSION REPLACEMENT CONTINUED 0070 00 INSTALLATION v WARNING e Transmission weighs 900 Ib 409 kg Always support transmission with transmission lift during instal lation to prevent injury to personnel Ensure transmission is properly positioned and secure on transmission lift to prevent injury to person nel or damage to equipment 1 With assistance move transmission under vehicle and directly behind engine CAUTION Transmission must be seated squarely against engine flywheel housing to prevent damage to equipment 2 Lift and position transmission against engine flywheel housing 3 3 Install 12 new lock washers 11 and bolts 10 to secure transmission to engine flywheel housing 3 Hand tighten bolts 4 Tighten four transmission mounting bolts 90 degrees apart to 40 1b ft 54 Nm 5 Tighten remaining transmission mounting bolts to 40 Ib ft 54 Nm 6 342 1142 7 Remove transmission lift 0070 00 4 TM 9 2320 302 34 TRANSMISSION REPLACEMENT CONTINUED 0070 00 INSTALLATION CONTINUE
386. ions may warrant cylinder block pressure testing before complete block assem bly Perform testing after installing cylinder liners cup plugs and pipe plugs Refer to Cylinder Block Pres sure Testing WP_0040 00 9 Install air compressor oil supply line elbow 16 10 Install air compressor coolant supply elbow 17 NOTE If cylinder block is not being placed in service perform steps 11 through 15 11 Install 1 4 in pipe plugs in tapped holes for oil pressure sensor 23 and oil temperature sensor 24 12 Install 1 4 in pipe plug in place of air compressor oil supply line elbow 16 13 Install 1 2 in pipe plug in place of air compressor coolant supply elbow 17 14 Install six plastic weep hole plugs 18 342 895 15 Spray or dip cylinder block in corrosion preventive compound for extended storage CAUTION New cylinder blocks are supplied with cover plates in place of oil spray nozzles which are used to lubricate and cool down pistons Cover plates must be removed and oil spray nozzles installed in their place Failure to install nozzles will result in severe engine damage 16 cylinder block bottom side up and install six oil spray nozzles 2 and bolts 1 Tighten bolts to 22 28 lb ft 30 38 Nm 0036 00 8 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 ASSEMBLY CONTINUED 342 892 CAUTION Ensure that diamond dowels are correctly aligned Orientation is critical to co
387. ir conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death 0113 00 1 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 REMOVAL NOTE Tag all lines and wires prior to removal to aid in installation 1 Remove nine screws 1 and cover 2 2 Remove three screws 3 and cover 4 3 Remove two screws 5 and cover 6 5 NN RA 1 5 342 563 4 mee 342 564 0113 00 2 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 REMOVAL CONTINUED 5 Open glove box door 10 and remove two screws 11 and top panel 12 from compartment 13 6 Remove three nuts 14 spring washers 15 and compartment 13 from dash 9 11 12 342 565 14 15 7 Disconnect two flex hoses from ducts behind compartment 13 8 Disconnect blue air line from air cylinder behind compartment 13 9 Disconnect connectors for blower motor 16 resistor block 17 and thermostatic switch 18 342 566 0113 00 3 TM 9 2320 302 34 HVAC UNIT REPLACEMENT CONTINUED 0113 00 REMOVAL CONTINUED 10 Place rags on cab floor loosen two hose clamps 19 and remove heater core hoses 20 11 Loosen two hose clamps 21 and remove drain tubes 22 342 567 12 Oncab floor 23 remove sealant 24 from drain tubes 22
388. itting in place using a wrench and turn other fitting with a second wrench 6 Using wrenches tighten evaporator coil lines 7 to 216 Ib in 25 Nm 7 Tighten refrigerant lines 6 large hose to compressor to 24 Ib ft 33 Nm tighten small hose from receiver drier to 144 Ib in 16 Nm NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 8 Replace receiver dridr WP0118 00 9 Evacuate and charge system with refrigeran WP 0112 00 10 Add refrigerant oil to compressor to replace that which was lost during system discharge WP 0116 00 0115 00 3 TM 9 2320 302 34 AIR CONDITIONER EVAPORATOR COIL REPLACEMENT CONTINUED 0115 00 INSTALLATION CONTINUED 11 12 13 14 15 WARNING Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with compressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death Leak test air conditioner system TM 9 2320 302 20 Wipe expansion valve 3 and refrigerant line 6 connections clean Wrap line connections with insulation tape Wrap expansion valve 3 with strip caulk Install cover 5 and four screws 4 Install cover 2 and nine screws 1 END OF WORK PACKAGE 0115 00 4 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR SERVICE 0116 00 THIS WORK PACKAGE COVERS General Information Service INITIAL SETUP Maintenance L
389. ive the spring parking brakes automatically apply when air pressure drops to 35 45 psi 241 310 kPa 5 The vehicle has a four channel anti lock brake system ABS and cam operated service brakes with non asbestos brake shoes 6 The M915A3 has automatically adjusting slack adjusters On all axles brake chambers have a stroke alert indicator which allows the operator to monitor brakeshoe wear AIR CONTROLS TRAILER TRAILER AIR PARKING HAND BRAKE BRAKE BRAKE P CONTROL x REAR AXLE SPRING BRAKE CHAMBERS FRONT AXLE BRAKE CHAMBERS 342 008 AIR COMPRESSOR 0003 00 6 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 STEERING SYSTEM 1 The power steering system consists of an integral steering gear which includes a manual steering mechanism and hydraulic control valve hydraulic hoses power steering pump reservoir and other components The power steering pump driven by the engine provides the power assist for the steering system POWER STEERING PUMP STEERING GEAR RESERVOIR 342 009 TRACTION CONTROL SYSTEM The inter axle differential lock is controlled by the air operated lever labeled INTER AXLE DIFFERENTIAL on the driver s instrument panel Under normal driving conditions the control lever should be in the UNLOCKED position During poor driv ing conditions the control lever may be moved to the LOCKED position to improve tr
390. jector tube o ring seal 63 with lubricating oil Install o ring seal over new injector tube 64 until flush against lip 12 Install injector tube 64 on injector tube reconditioning set installer 28 0032 00 16 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 342 1024 NOTE If injector tube falls off installer during installation use injector tube reconditioning set tube remover pilot to retain injector tube on installer Remove pilot after hold down clamp is installed and tightened 13 Install injector tube reconditioning set installer 28 with injector tube in injector bore Ensure tip of injector tube goes through small hole in cylinder head 2 fire deck Tap lightly on end of installer if necessary to seat injector tube 14 Install injector hold down clamp 37 washer 38 and hold down bolt 39 over injector tube reconditioning set installer 28 Tighten bolt to 43 49 Ib ft 58 66 Nm gt 38 2 ZL Pe Ne 0 342 1025 AS ad NN 0032 00 17 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED 15 Insert injector tube reconditioning set flaring tool 65 through small hole in bottom of injector tube 64 and rotate flar ing tool to engage threads in injector tube reconditioning set installer 28 16 Using torque wrench and standard 9 16 in socket thread flaring tool 65 into injector tube reconditioning set installe
391. just caster alignment Failure to install shim s correctly will cause hard steering and could result in injury to personnel 1 With assistance install pin 37 shim s 2 shock absorber bracket 35 spacer 34 and spring 3 on front axle 2 NOTE Install pin so that grooves line up with holes in shackle allowing screws to be installed 0099 00 3 TM 9 2320 302 34 FRONT SPRING REPLACEMENT CONTINUED 0099 00 INSTALLATION CONTINUED 2 Install pin 33 and two washers 32 in spring 3 3 Using floor jack raise front axle 2 so that front end of spring 3 is positioned in front spring hanger 31 Install two saddle caps 30 four washers 29 screws 28 and grease fitting 27 Tighten screws to 50 Ib ft 68 Nm 37 4 Install pin 25 four shims 24 two wear plates 23 shackles 22 washers 21 screws 20 washers 19 nuts 18 and grease fitting 17 in rear spring hanger 26 5 Position spring 3 in two shackles 22 and install four shims 15 two wear plates 14 and pin 16 6 Align grooves in pin 16 with holes in two shackles 22 and check end play End play should be no more than 1 32 in 0 8 mm Add shims 15 to correct end play If possible add same number of shims on each side of pin Vs Install two washers 13 screws 12 washers 11 nuts 10 and grease fitting 9 CAUTION Incorrect installation of axle stop will cause damage to axle and frame during use 8
392. k nut Remove three lock nuts 8 washers 9 left front spring hanger 10 three screws 11 and washers 12 from frame 13 Discard lock nuts 17 14 15 RIGHT FRONT 342 967 NOTE Perform steps 4 and 5 on right front side of vehicle 4 Remove three lock nuts 14 washers 15 and screws 16 5 Remove three lock nuts 17 washers 18 right front spring hanger 19 three screws 20 and washers 21 from frame 13 Discard lock nuts NOTE Perform steps 6 and 7 for rear spring hangers 6 Remove four lock nuts 22 washers 23 screws 24 washers 25 and rear spring hanger 26 from frame 13 Dis card lock nuts 7 If damaged remove bushing 27 from rear spring hanger 26 0100 00 2 TM 9 2320 302 34 FRONT SPRING HANGERS REPLACEMENT CONTINUED 0100 00 INSTALLATION n oO 10 11 NOTE Perform steps 1 and 2 for rear spring hangers If removed install new bushing 27 in rear spring hanger 26 Install four washers 25 screws 24 rear spring hanger 26 four washers 23 and new lock nuts 22 on frame 13 NOTE Perform steps 3 and 4 on right front side of vehicle Install three washers 21 screws 20 right front spring hanger 19 three washers 18 and new lock nuts 17 on frame 13 Install three screws 16 washers 15 and new lock nuts 14 NOTE Perform steps 5 through 7 on left front side of vehicle Install three wash
393. kness at contact surface minimum allowable thickness is 0 1109 in 2 818 mm b Backplate distortion maximum allowable distortion is 0 006 in 0 15 mm c Backplate step wear maximum allowable wear is 0 005 in 0 13 mm d Clutch housing splines maximum allowable wear is 0 045 in 1 15 mm If replacement is necessary remove thrust plates 16 by drilling out 12 rivets 17 Remove and measure C4 clutch pack five friction plates 18 and five steel reaction plates 19 Perform the following measurements a Friction plate thickness minimum allowable thickness is 0 137 in 3 48 mm b Friction plate maximum allowable cone is 0 010 in 0 25 mm Steel reaction plate thickness minimum allowable thickness 15 0 095 in 2 41 mm d Steel reaction plate maximum allowable cone is 0 010 in 0 25 mm Remove piston return plate 20 with four return springs assemblies 21 attached Inspect and measure piston return plate 20 Minimum allowable thickness of plate is 2 162 in 54 91 mm 0071 00 28 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED C3 C4 Clutch Assembly and Main Housing Module Disassembly Continued 15 Ifreturn spring assemblies 21 are damaged and require replacement remove them from piston return plate 20 by sep arating spring retainer 22 from piston 23 16 Remove seal rings 24 and 25 from piston 23 Discard seal rings 17 Inspect and measure C4 clu
394. l cylinder head WP 0018 00 27 Install gear housing assembly WP 0035 00 28 Install oil cooler core and oil filter adapter 29 Install oil fill tube 30 Install oil dipstick and tube TM 9 2320 302 20 31 Install fuel pump and lines 32 Install fuel filter adapters 33 Install electronic control module TM 9 2320 302 20 34 Install engine injector wiring harnesq WP 0069 00 35 Install oil temperature and oil pressure sending units END OF WORK PACKAGE 0036 00 10 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT 0037 00 THIS WORK PACKAGE COVERS Removal Cleaning and Inspection Installation INITIAL SETUP Maintenance Level Tools and Special Tools Continued General Support Protector crankshaft Item 92 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Alignment stud set Item 7 WP 0126 00 Gear case cover removed Barring tool engine Item 8 WP 0126 00 Rocker arm assemblies removed WP 0027 00 Dial indicator set Item 29 WP 0126 00 Engine installed on repair stand REMOVAL 1 Install engine barring tool 1 on front end of crankshaft Bar engine over until four access holes 2 in bull idler gear line up with four bolts 3 in cylinder block 2 Remove two upper bolts 3 and install two guide studs 4 0037 00 1 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT CONTINUED 0037 00 REMO
395. l ring 21 and inner seal ring 22 from C5 clutch piston 18 Inspect bearing cup 23 If worn or damaged remove using tool 73940 Cover and P3 Planetary Module Assembly If removed install new bearing cup 23 using bearing tool J37033 and drive sleeve tool J37034 Install inner seal ring 22 and outer seal ring 21 onto C5 clutch piston 18 Align tang notch on rear of C5 clutch piston 18 with tang in rear cover 3 while installing C5 clutch piston into rear cover Install spring and retainer assembly 19 while aligning tab in spring and retainer assembly with notch in rear cover 3 WARNING Rear cover spring and retainer assembly contains highly compressed springs Be extremely careful during assembly Personal injury can occur if the spring force is not controlled Compress spring and retainer assembly 19 using J37030 3 tool base washer bearing handle and piston spring com pressor J37030 2 Install retaining ring 20 and slowly release spring force If removed install cone and roller bearing 8 Use driver sleeve tool J37034 and press bearing against shoulder on P3 planetary carrier 4 If removed press bushing 16 inside end of output shaft 17 using installer tool J37036 and a press Install output shaft 17 thrust washer 7 and retaining ring 6 Install two bearing assemblies 15 into center of pinion gear 12 Install thrust washers 13 and 14 inside P3 planetary carrier 4 alig
396. l valve WP 0089 00jor WP 0088 00 Check for steering gear control Repair or replace steering gear valve sticking WP 0089 00 or WP 0088 00 3 External Oil Leaks from Steering Gear NOTE External leakage is not acceptable from steering gear Check for leak at rubber relief Repair or replace steering gear plug on frame side of steering K WP 0089 00Jor WP 0088 00 gear Check for leak at shaft seals Repair or replace steering gear WP 0089 00 or WP 0088 00 0008 00 2 TM 9 2320 302 34 Table 1 Steering System Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4 Oversteer or Darting Disconnect lower steering 1 Replace defective tilt steering column from steering gear and column WP 0090 00 check steering column for binding 2 Replace defective universal joint TM 9 2320 302 20 Disconnect steering gear Replace defective components pitman arm and check front end 9 2320 302 20 components for binding 5 High Steering Effort in One Direction Check for sufficient pump If pressure is less than 900 psi pressure Malfunction 2 step 62 07 bars repair or replace 2 power steering pump WP 0087 00Jor WP 0086 00 Check for sufficient pump flow Repair or replace power steering Malfunction 2 step 3 0087 OO or WP 0086 00 Check for defective teflon seals Repair or replace steering gear in ste
397. lace defective rocker arm 4 Check side clearance between cam follower roller 20 and rocker arm If more than 0 015 in 0 040 mm maximum replace defective rocker arm 5 Ensure cam follower roller 20 turns freely on its pin If roller does not turn freely binds or if there is vertical move ment between roller and pin replace defective rocker arm 0 015 in 0 040 mm 342 711 0027 00 5 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSPECTION CONTINUED 6 Check rocker arm shaft stud for tightness Ensure rocker arm shaft studs are tightened to 75 86 lb ft 101 116 Nm INSTALLATION CAUTION Do not expand retaining clip more than 0 61 in 15 50 mm when installing retaining clip To do so could result in equipment damage NOTE Position concave dished side of intake valve button toward adjusting screw ball 1 Slide retaining clip 14 open end first onto adjusting screw 12 Spread retaining clip slightly if necessary so open end can pass over ball head of adjusting screw 2 Insert tips of retaining ring pliers 13 between legs of retaining clip 14 Expand clip enough to insert groove on intake valve button 15 onto leg arcs of retaining clip 342 706 e Adjusting screws with annular Allen wrench adjustment are used on intake short arm and injector rocker arms Hex head adjusting screws are used on exhaust long arm rocker arms e Only exhaust r
398. lanetary ring gear from planetary module 3 Check planetary carrier assembly 4 for pinion end play Pinion end play must not exceed 0 037 in 0 94 m Check all six pinion gears Remove retaining ring 5 and indexing ring 6 Remove six pinion spindles 7 from 1 planetary carrier 4 Remove pinion gear 8 thrust washers 9 and 11 and two bearing assemblies 10 from side of P1 planetary carrier 4 Repeat procedure for remaining pinion gears Measure thickness and step wear of thrust washers 9 and 11 Minimum thrust washer thickness allowed is 0 055 in 1 40 mm Maximum step wear allowed is 0 005 in 0 12 mm Remove thrust bearing 12 from P1 planetary carrier 4 Inspect and measure bushing 13 inside P1 planetary carrier 4 for wear or damage Maximum ID allowed is 3 516 in 89 32 mm If bushing is worn remove and replace Check spline wear of P1 planetary carrier 4 and P2 planetary ring gear 2 Maximum allowed spline wear is 3 015 in 0 38 mm 342 1173 0071 00 33 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED P1 Planetary Module Assembly 1 ONO dE If removed install bushing 13 into P1 planetary carrier 4 using a press and tool J37038 Press new bushing flush to 0 016 in 0 40 mm below surface Install two bearing assemblies 10 into center of pinion gear 8 Install thrust washers 9 and 11 inside P1 planetary carrier
399. late is located at 12 o clock position before installing camshaft dowel 27 in cam shaft drive gear hub 28 3 Lubricate camshaft lobes and journals with clean engine lubricating oil 0026 00 16 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED k N Nes WARNING Camshaft weighs 53 Ib 24 kg Attach suitable lifting device prior to installation to prevent possible injury to personnel 4 Using non metallic sling lower camshaft 5 into position and slide forward ensuring camshaft dowel 27 aligns with mating hole in camshaft drive gear hub 28 This will position camshaft bearing journals in lower camshaft bearing shells 0026 00 17 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 2 6 10 11 E WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in a well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION Be careful not to get gasket forming compound or sealing compound on camshaft bearing shell seats and bearing surfaces Keep time to minimum between installation of camshaft bearing caps no 1 and no 7 and tightening of camshaft cap bolts and nuts Ensure two seal rings are placed on cylinder head b
400. lb ft Item 138 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Oil 0029 00 Wrench torque 100 600 Ib ft Item 140 WP 012600 E d Eo Wrench set socket 3 4 in drive Item 141 WA 24 0126 00 Bull idler gear removed WP 0037 00 Equipment Condition Flywheel housing removed WP 0024 00 Materials Parts s Timing reference sensor TRS removed TM 9 2320 Compound international no 2 Item 13 WP 0125 00 302 20 Detergent Item 19 WP 0125 00 Synchronous reference sensor SRS removed TM 9 Gage bearing clearance Item 20 WP 0125 00 2320 302 20 V WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0033 00 1 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 REMOVAL 1 Using two crankshaft gear inserter remover bolts 1 secure crankshaft gear inserter remover base post 2 to end of crankshaft Tighten two bolts to 140 150 Ib ft 190 203 Nm 2 Thread three crankshaft gear inserter remover legs 3 into threaded holes in crankshaft timing gear 4 Tighten three inserter remover legs AS 5 S T SS 2 y 3 9 342 1071 3 Slide hydraulic ram and pump 5 over
401. linder wear patterns g Gouges nicks or burrs on machined surface of connecting rods at piston pin end 0041 00 8 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSPECTION CONTINUED 9 Check connecting rod bolts and connecting rod cap nuts for thread damage or fretting on underside of heads Replace rod bolts and connecting rod cap nuts if either condition is present 10 Measure connecting rod bore at points A B and C Average of bore readings must be within 3 594 3 595 in 91 288 91 313m 342 1055 NOTE e Replace rod and main bearings whenever crankshaft is replaced or engine is rebuilt e Overlay plated bearings may develop very small cracks or small isolated cavities checking on bearing surface during engine operation These are characteristics of and are not detrimental to this type of bearing Bearing should not be replaced for these minor surface imperfections 11 Inspect bearings for scoring pitting flaking chipping cracking loss of overlay or signs of overheating If any of these conditions are present discard bearings NOTE Upper connecting rod bearing shells will normally show signs of distress before lower connecting rod bear ing shells If overlay is worn to copper across connecting rod bearing shell replace all connecting rod bear ing shells 0041 00 9 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSPECTION CONTINUE
402. ll 14 bolts 1 into C3 C4 clutch assembly 2 Tighten bolts to 38 45 ft Ib 51 61 Nm 0071 00 30 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED C3 C4 Clutch Assembly and Main Housing Module Assembly Continued 0071 00 31 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Main Shaft Module Disassembly 1 Remove external spiral retaining ring 1 and P2 sun gear 2 from main shaft 3 2 Remove bearing spacer 4 thrust bearing 5 and selective shim 6 from main shaft 3 3 Inspect and measure main shaft 3 Inspect for evidence of wear chipped or cracked splines or teeth Measure main shaft in accordance with Table 2 Wear Limits Data located at the end of this work package AL EN 8 E Pa 4 35 92 ur 1 414 in t 52 98 mm 342 1172 342 1171 Main Shaft Module Assembly NOTE Do not install thrust bearing 5 and selective shim 6 until final transmission assembly Measurement for selective shim is performed during final buildup Install bearing spacer 4 on main shaft 3 2 Install P2 sun gear 2 and external spiral retaining ring 1 on main shaft 3 0071 00 32 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED 1 Planetary Module Disassembly 1 Remove internal retaining ring 1 from P2 planetary ring gear 2 and remove P2 p
403. ll through rivet head d Support back of rivet using sharp chisel Cut rivet head along direction of rivet line or panel edge to prevent distor tion of panel and shear off weakened rivet head e Support panel from opposite side and drive out shank with pin punch If rivet is unduly tight because of swelling between sheets drill rivet shank out with undersize drill Blind Rivet Removal File small flat on rivet head a b Center punch flat Support rivet backside if possible Using small drill about the size of rivet pin drill off tapered end of pin that forms lock d Shear lock using pin punch to drive out pin e Pry out remainder of locking collar f Using drill slightly smaller than rivet shank drill almost through rivet head 0105 00 3 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 RIVET REPLACEMENT CONTINUED g h Pry off rivet head with pin punch Tap out rivet shank with pin punch 3 Lock Bolt Removal NOTE If lock bolt head is inaccessible locking collar must be removed Remove collars by grinding or splitting collars axially with sharp chisel a Work from head side of lock bolt if accessible File small flat on head if rounded b Center punch head c Using hardened drill slightly smaller than bolt head drill through head In cases where lock bolts are too hard to be drilled with available drills grind head down using cutoff wheel or carbide bit in die grinder When using
404. lock nut 3 Remove accessory drive pulley 5 by tapping with rubber hammer or fiber mallet Remove service kit holding fixture 3 from vise 342 1100 4 Position accessory drive assembly 1 on press bed with service kit holding fixture 3 supported Using arbor press apply pressure through holding fixture access hole 6 and press accessory drive assembly 1 out of accessory drive gear 7 Remove three screws 2 and accessory drive gear 342 1101 0039 00 2 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 DISASSEMBLY CONTINUED 5 Remove snap ring 8 from accessory drive assembly 1 342 1102 6 Turn accessory drive assembly 1 over and support on machined surface Using press apply pressure to pulley end of accessory drive shaft and bearing assembly 9 Remove accessory drive shaft and bearing assembly from accessory drive assembly 342 1103 0039 00 3 TM 9 2320 302 34 ACCESSORY DRIVE REPAIR CONTINUED 0039 00 DISASSEMBLY CONTINUED NOTE Word INSTALL and an arrow are etched on needle bearing remover installer to aid in installation Place needle bearing identification numbers up against needle bearing remover installer 7 Turn accessory drive assembly 1 over and support on attaching bolt bosses Place long end of service kit needle bear ing remover installer 10 in accessory drive assembly against needle bearing 11 Apply pressure to needle bearing remover installer
405. lock nuts 18 in rear cab mount 23 3 Carefully install two wiring harnesses 16 and 17 in cab assembly 6 Secure with washer 15 screw 14 and new kep nut 12 12 14 15 X NS C TS d 6 alt SS t 342 887 4 Install two screws 10 resilient mounts 9 washers 8 and new lock nuts 7 in front cab mounts 11 342 886 0104 00 5 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 INSTALLATION CONTINUED 5 Remove sling and hoist from cab assembly 6 6 Swing three radiator support rods 5 into place and install two washers 4 bolts 3 washers 2 and nuts 1 342 884 7 Install Collision Warning System CWS wiring harnes WP 0066 00 8 Install cab anti lock brake system ABS wiring harness TM 9 2320 302 20 9 Install anti lock brake system ABS fuse and relay panel 9 2320 302 20 10 Install anti lock brake system ABS electronic control unit TM 9 2320 302 20 11 Install air tubes 12 Install chassis wiring harness TM 9 2320 302 20 13 Install cab overhead wiring harness 14 Install brake pedal TM 9 2320 302 20 15 Install steering column support bracket TM 9 2320 302 20 16 Install electronic throttle 17 Install cab liners 18 Install interior grabhandle 19 Install sunvisors TM 9 2320 302 20 20 Install head liners 21 Install arctic heater 22 Install transmission shift control 23 Install air horn and valv
406. low this warning may result in death or injury to personnel Improper use of lifting equipment and improper attachment of cables to vehicle can result in seri ous injury to personnel and equipment damage Observe all standard rules of safety ALWAYS install hood prop after opening hood Failure to follow this warning could result in severe injury to personnel TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 TECHNICAL MANUAL HEADQUARTERS TM 9 2320 302 34 DEPARTMENT OF THE ARMY Washington D C 28 May 2001 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A3 NSN 2320 01 432 4847 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or if you know of a way to improve the pro cedures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publications through the Internet on the Army Electronic Product Support AEPS website The Internet address is http aeps ria army mil If you need a password scroll down and click on ACCESS REQUEST FORM The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your com ments and better manage the DA Form 2028 program You may also mail fax or e mail your letter DA Form 2028 direct t
407. ls to crack or tear Sharp bends should not be attempted 0105 00 11 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 ALUMINUM REPAIR CONTINUED Table 8 Stop Drill Sizes for Negligible Cracks SHEET THICKNESS MINIMUM STOP DRILL IN SIZE NO 0 0 032 40 0 033 and thicker 30 hs Repair by Patching a Most body panel damage that exceeds limits of negligible damage may be repaired by patching This procedure involves removal of damaged area 3 and application of a patch 4 to cover the area The damaged area 3 is prepared by removal of the damage followed by rounding or smoothing of all corners and edges This helps ensure that cracks will not spread into undamaged areas In the case of a large crack 5 it may be desirable to stop drill crack rather than cut out a portion of a panel 6 or structural member Repair is completed by applying a large overlapping patch 7 over the area that was damaged The overlap must be sufficient to allow the observance of proper rivet edge distance 8 refer to Rivet Patterns on page 0105 00 10 342 584 0105 00 12 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 ALUMINUM REPAIR CONTINUED e Large areas of damage are best repaired using a patch that is attached with multiple rows of rivets refer to Rivet Patterns on page 0105 00 10 8 Repair by Insertion For damage larger or more severe in nature than crack or hole it is often desirable to remove
408. lts 9 and new lock nuts 8 on oil inlet tube bracket halves 10 Tighten bolts to 43 54 Ib ft 58 73 Nm 0029 00 14 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 INSTALLATION CONTINUED 10 342 724 0029 00 15 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 INSTALLATION CONTINUED 10 11 12 13 14 Gear lash measurements between crankshaft gear and oil pump drive gear must be taken with engine in run ning position With dial indicator tip resting on tooth of oil pump drive gear 23 measure gear lash between oil pump drive gear and crankshaft drive gear 34 Gear lash should be 0 002 0 009 in 0 05 1 0 229 mm If gear lash is not within specifications perform oil pump removal steps through 8 NOTE Same number of shims must be installed under each oil pump mounting leg so that oil pump will always be level on engine block Install required amount of shims 35 between oil pump assembly 5 and cylinder block 2 Repeat installation steps through 10 to reinstall oil pump assembly 5 and verify gear lash 342 740 Install oil WP 0028 00 END OF WORK PACKAGE 0029 00 16 TM 9 2320 302 34 OIL PRESSURE RELIEF AND REGULATOR VALVES REPLACEMENT THIS WORK PACKAGE COVERS Oil Pressure Regulator Valve Replacement Oil Pressure Relief Valve Replacement INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Ring se
409. m j Using wooden stir stick and measuring in spoonfuls mix equal volumes of magnolia 58 A and B epoxy resins on clean sheet of glass metal or section of scrap laminate Mix 15 seconds k Use stir stick to spread thin layer of mixed epoxy resins over scuffed area 6 0106 00 2 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED l Lay fiberglass cloth 7 on repair area centered over damage Using stir stick firmly press fiberglass cloth into epoxy to completely soak fiberglass cloth m Apply another layer of epoxy resins over fiberglass cloth 7 3 342 586 5 n Allow 2 5 minutes for epoxy to start gelling It may take more time in cool temperatures less in hot temperatures NOTE For smoother surface press piece of masking tape wider than repair directly over wet epoxy and smooth before epoxy hardens Tape can be removed when epoxy sets up after 15 minutes o Patch should be hard enough in 15 minutes to allow sanding to smooth flat surface if required p Repair damage on outside surface of hood and paint surface on both sides 2 Section Replacement Repair of Punctures and Large Fractures On large damaged areas for example structural damage on side surface of the hood covering a square foot area it may be easier to do a section replacement rather than to make a patch Fenders and headlight reinforcements are available for use in section replacements or a second dam aged ho
410. m 2D WP 0125 00 Retrigerant recovered WE 0112 00 Cap set Item 7 WP 0125 00 Fan cycling switch removed WP 0120 00 CBE See e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death REMOVAL CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid NOTE The receiver drier and moisture indicator are one unit and cannot be replaced separately fdesiccant cartridge inside receiver drier has fallen apart evacuate system and replace expansion valve and refrigerant compressor desiccant matter cannot be removed from these parts A desiccant car tridge may fall apart from too much moisture in system because of poor evacuation of system or lack of maintenance DO NOT disconnect or connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 0118 00 1 TM 9 2320 302 34 AIR CONDI
411. m differential carrier 1 20 Remove bearing cup 28 from differential carrier 1 0080 00 4 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 342 1232 342 1233 21 Remove bearing cone 25 from side gear 24 342 1234 0080 00 5 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 22 Remove and discard lock nut 8 from yoke 9 23 Using yoke puller remove yoke 9 from input shaft 13 342 1235 24 Remove and discard oil seal 29 342 1136 25 Remove snap ring 30 and pinion differential case 14 3423 1237 0080 00 6 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 26 Remove gear 31 and thrust washer 32 342 1238 CAUTION Use care when installing bearing puller If puller touches rivets oil pump could be damaged 27 Install bearing puller under pump 33 342 1239 0080 00 7 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED DISASSEMBLY CONTINUED 28 Using press with bearing puller down press input shaft 13 from oil pump 33 29 Remove and discard two packings 34 342 1240 0080 00 8 0080 00 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 DISASSEMBLY CONTINUED 30 Remove plug 35 w
412. mark 8 with diamond timing mark 9 on camshaft drive gear 10 and install adjustable idler gear 3 on hub 4 4 342 1095 Install retaining plate 2 on three studs 6 with relief portion of plate down 4 Install three nuts 1 on studs 6 Tighten nuts to 42 49 Ib ft 57 66 Nm 342 1096 5 Install bull idler gear WP 0037 00 6 Measure gear lash between adjustable idler gear 3 and bull idler gear Gear lash should be 0 002 0 009 in 0 051 0 0229 mm for new parts and a maximum of 0 012 in 0 305 mm for used parts 7 Install gear case cover without fan drive support WP 0013 00 0038 00 3 TM 9 2320 302 34 ADJUSTABLE IDLER GEAR REPLACEMENT CONTINUED 0038 00 INSTALLATION CONTINUED 8 Measure gear lash between adjustable idler gear and camshaft drive gear Using cam idler lash adjuster gear lash should be 0 002 0 009 in 0 051 0 229 mm for new parts and a maximum of 0 012 in 0 305 mm for used parts Reading is one half of actual measurement Multiply reading by 2 to determine specification ADJUSTMENT 1 Loosen three nuts 1 until hand tight 2 Insert dowel portion of cam idler lash adjuster 11 in center hole of retaining plate 2 3 Secure engine barring tool 12 to bottom of access cover opening with two access cover bolts 13 Tighten bolts to 20 Ib ft 27 Nm 4 Install cam idler lash pedestal in threaded hole in leg of camshaft drive gear 10 NOTE Ensure dial indicator r
413. meters 10 76 Sq Feet 1 Sq Kilometer 1 000 000 Sq Meters 0 0386 Sq Miles Cubic Measure 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet Temperature 5 9 F 32 C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 C 32 F APPROXIMATE CONVERSION FACTORS Cubic Yards 0 765 Pounds per Sq Kilopascals 6 895 Inch Miles per Gallon Kilometers per Liter 0 425 Miles per Hour Kilometers per Hour Cubic Meters 1 308 Newton Meters Pound Feet Kilopascals Pounds per Sq 0 145 Inch Kilometers per Liter Miles per Gallon 2 354 Kilometers per Hour Miles per Hour PIN 078100 000
414. move four cap screws 7 washers 8 two bearing caps 4 and 5 and two adjusting rings 9 342 1200 10 Attach lifting device to ring gear subassembly 10 NOTE Ring gear and assembled parts must be tilted to clear casting inside carrier 11 Remove ring gear subassembly 10 and two bearing cups 11 12 Place ring gear subassembly 10 on clean work surface and remove lifting device 342 1201 0082 00 4 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED 13 Remove two bearing cones 12 Noe Q T c z SESS Vue 342 1202 14 Remove 12 nuts 13 washers 14 and bolts 15 from ring gear 2 VA WARNING Ring gear is heavy and can injure personnel if dropped Do not put hands under ring gear 15 Remove ring gear 2 from ring gear assembly 10 13 14 15 342 1203 0082 00 5 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 DISASSEMBLY CONTINUED 16 Rotate differential carrier 1 so that yoke 16 is in horizontal position 17 Using yoke holder bar 17 to hold yoke 16 in place loosen lock nut 18 18 Rotate differential carrier 1 so that yoke 16 faces up 19 Remove lock nut 18 and yoke 16 Discard lock nut 342 1204 20 Matchmark bearing cage assembly 19 and differential carrier 1 Remove eight cap screws 20 washers 21
415. mp shaft must remain vertical and must not be rotated or moved to prevent damage to equipment Do not pressure test seal for at least four 4 hours 15 Apply one drop of sealing compound to water seal and water pump shaft contact area 25 Wipe off excess with a clean rag 16 Apply a small amount of lubricating oil to water seal and water pump shaft contact area 25 25 342 832 0049 00 9 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED 17 Install impeller 12 wide end up over square end of water pump shaft 5 Using impeller installation tool 26 press impeller on water pump shaft until installation tool is flush against water pump housing 4 Remove installation tool 342 833 18 Turn water pump housing 4 over impeller side down on holding fixture 16 CAUTION Water pump drive gear may be press fit onto water pump shaft Support water pump shaft when pressing drive gear onto shaft to prevent damage to bearing NOTE Water pump drive gear may be a slip fit This is due to manufacturing tolerances and is acceptable 19 Position drive gear 8 over water pump shaft 5 20 Using small end of bearing and seal installer 18 press drive gear 8 on water pump shaft 5 until drive gear is seated against bearing inner race 27 0049 00 10 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED 27 342 834 21 Install washer 7 and b
416. mponent alignment Failure to correctly align diamond dowels could result in engine failure NOTE If new cylinder block is being placed in service perform steps 17 through 22 17 Using dowel inserter set install diamond dowel 25 and round dowel 26 in cylinder block fire deck to height of 0 472 0 002 in 12 0 0 5 mm Angular orientation of diamond dowel must be perpendicular to centerline 27 through round and diamond dowels within 4 degrees 342 901 0036 00 9 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 ASSEMBLY CONTINUED 18 Using dowel inserter set install diamond dowel 28 and round dowel 29 in rear face of cylinder block to height of 0 472 0 002 in 12 0 0 5 mm Angular orientation of diamond dowel must be perpendicular to centerline 30 through round and diamond dowels within 4 degrees 19 Using dowel inserter set install diamond dowel 31 in front face of cylinder block to height of 0 472 0 002 in 12 0 0 5 mm Angular orientation of diamond dowel must be perpendicular to centerline 32 through bull gear pilot bore 33 and diamond dowel within 4 degrees 20 Install air compressor oil supply line elbow 21 Install air compressor coolant supply elbow 22 Perform cylinder block pressure testing WP 0040 00 23 Install six plastic weep hole plugs 24 Install crankshaf WP 0033 00 25 Install pistons and cylinder assemblies WP 0041 00 26 Instal
417. n 0 25 mm Backplate thickness minimum thickness allowed is 0 311 in 7 90 mm t c Backplate flatness maximum allowable distortion is 0 006 in 0 15 mm 8 Remove thrust bearing 17 from clutch hub assembly 18 Remove retaining ring 19 and turbine shaft 20 from clutch hub 18 10 Inspect and measure bushing 21 inside end of turbine shaft 20 Maximum ID allowed is 1 423 in 36 14 mm 11 Remove three seal rings 22 and o ring 23 from turbine shaft 20 Discard o ring 0071 00 23 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Disassembly Continued WARNING The rotating clutch piston springs are highly compressed and must be properly released Failure to follow this warning may result in personnel injury 12 Place rotating clutch 3 on tool base J37030 3 so rotating drum is supported by tool tangs View C 13 Install tool J35923 2 with bearing washer and handle Tighten tool compressing C1 balance piston 24 and Cl spring assembly 25 Remove retaining ring 26 View A J37030 3 HANDLE J37030 3 FLAT WASHER BEARING J35923 2 HANDLE FLAT WASHER BEARING J35923 2 J37030 1 ip ip d A Nt S TDI T J37030 3 VIEW D ALIGNMENT SLOTS 342 1169 14 Release spring tension by rotating handle in counterclockwise direction Remove tool J35923 2 with bea
418. n 177 using transmission lift Position transmission squarely against engine flywheel housing 155 4 Install two brackets 180 12 new lock washers 179 and screws 178 in transmission 177 Tighten screws hand tight 5 Tighten four screws 178 90 degrees apart to 40 Ib ft 54 Nm 0010 00 16 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 POWER PACK ASSEMBLY CONTINUED 6 7 8 9 Tighten remaining screws 178 to 40 Ib ft 54 Nm Remove plug 186 and rotate torque convertor to align holes in flex plate with holes in torque convertor 177 180 155 178 179 186 342 953 WARNING Do not place finger in hole of engine flywheel housing while engine is being barred over To do so could result in serious injury to personnel CAUTION e Step 8 must be followed for barring over engine Any other method could cause damage to equipment e f bolts are dropped in engine flywheel housing retrieve immediately Failure to do so could result in damage to equipment Have assistant bar engine 156 over using accessory drive 175 Locate and align holes and install bolt 176 through hole in engine flywheel housing 155 Repeat until 12 bolts have been installed hand tight Tighten 12 bolts 176 to 96 115 Ib ft 130 156 Nm 342 952 0010 00 17 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION M WARNING Power pack weighs 3750 Ib 1702 kg U
419. n be bonded in place A section of a part can be replaced as long as the section does not include a joint between two parts Fenders and headlight reinforcements are available as replacement parts or for use in section replacements If the dam age is such that parts cannot be replaced or a section replacement cannot be done replace the entire hood assembly 4 For repairing a small crack or hole refer to Crack or Small Hole Repair below 5 For repairing larger areas refer to Section Replacement Repair of Punctures and Large Fractures page 0106 00 3 6 For replacing or rebonding parts refer to Hood Component Rebonding page 0106 00 7 REPAIR 1 Crack or Small Hole Repair A crack fracture or small hole through the laminate requires repair with a fiberglass reinforced patch a Locate damage on hood Apply hand pressure all around damaged area to check for concealed damage 0106 00 1 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED Mh WARNING Solvents can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If solvent gets on skin or clothing wash immediately with soap and water b Clean area with xylene or equivalent solvent Inspect area closely c If sound absorbent liner is present on underside of damaged area remove panel s to provide adequate working area d
420. n thrust washer tangs with slots in planetary carrier and retain them with petrolatum Slide pinion gear and bearing assemblies into side of P3 planetary carrier between thrust washers Repeat procedure for remaining three pinion gears Install four pinion spindles 11 so that lower step is positioned for proper installation of indexing ring 10 0071 00 38 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rear Cover and P3 Planetary Module Assembly Continued 11 12 13 14 15 16 Install indexing ring 10 and retaining ring 9 Measure pinion end play Pinion end play must not exceed 0 037 in 0 94 mm Check all four pinions Place P3 planetary carrier assembly 4 on work bench with output shaft up Place rear cover 3 over output shaft If removed install cone and roller bearing 5 into rear cover assembly 3 using drive sleeve tool J37034 Install new lock nut retainer 1 CAUTION Over tightening bearing retainer lock nut will damage cone and roller bearing assembly Install bearing retainer lock nut 2 Tighten lock nut to 55 65 lb ft 74 88 Nm 342 1175 0071 00 39 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rear Cover and P3 Planetary Module Assembly Continued 17 Position and support rear cover assembly 3 so that turning torque of P3 planetary carrier assembly can be checked after installation o
421. n when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVAL 1 Remove three lock nuts 1 washers 2 screws 3 and washers 4 Discard lock nuts 2 Remove three lock nuts 5 washers 6 screws 7 and washers 8 Discard lock nuts 3 Remove ramp 9 from vehicle 342 962 0095 00 1 TM 9 2320 302 34 RAMP REPLACEMENT CONTINUED 0095 00 REMOVAL CONTINUED 4 Repeat steps through 3 to remove other ramp 9 INSTALLATION 1 Position ramp 9 to vehicle 2 Install ramp 9 with three washers 8 screws 7 washers 6 and new lock nuts 5 3 Install three washers 4 screws 3 washers 2 and new lock nuts 1 4 Repeat steps 1 through 3 to install other ramp 9 342 962 END OF WORK PACKAGE 0095 00 2 TM 9 2320 302 34 CROSSMEMBER REPLACEMENT 0096 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts General Support Nut lock P N 23 09901 116 12 Tools and Special Tools Nut lock P N MS51922 1 4 Tool kit general mechanic s Item 132 WP 0126 00 Nut lock P N MS51922 33 22 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Nut lock P N MS51922 49 12 T WP jo 100 6
422. nce holes in drive gear rim must face pump body to avoid possibility of installing drive gear back wards 18 Place end of internal oil pump drive gear and shaft assembly 22 on press support Press oil pump drive gear 23 on oil pump drive gear and shaft assembly Using feeler gage ensure that clearance of 0 033 0 044 in 0 84 1 12 mm is obtained between oil pump drive gear and oil pump body 20 342 739 0029 00 11 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY CONTINUED 19 Install shorter end of oil pump driven gear and shaft assembly 21 in left side bushing in oil pump body 20 as viewed from top rear 20 Lubricate bushings 24 in oil pump cover 19 with light engine lubricating oil 21 Install oil pump cover 19 on oil pump body 20 22 Install two shorter bolts 17 in upper two bolt holes and two longer bolts 18 in lower two bolt holes in oil pump cover 19 Tighten bolts to 22 28 Ib ft 30 38 Nm in crisscross pattern 17 18 342 727 23 Mount dial indicator on machined surface of right side oil pump body mounting leg 29 or on other suitable clamping surface 24 Measure gear face runout just inboard of oil pump drive gear 23 teeth while rotating gear by hand Gear face runout must not exceed 0 003 in 0 076 mm If gear face runout exceeds limits replace gear 342 740 INSTALLATION 1 Position oil pump assembly 5 on cylinder block 2 with oil pump drive gear 23 engaged wi
423. nch torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 DISASSEMBLY 1 2 Sod 55 Se Sd XS 0 J Q v od 0 Q2 e 52 X e 0 gt er 6747 QO NS e Ball bearing assembly P N 8929530 Plug cup P N 8929215 Roller bearing assembly P N 8929820 Seal oil P N V454136RR Adhesive loctite Item 3 WP 0125 00 Grease GAA ltem 22 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Equipment Condition Spindle and housing removed TM 9 2320 302 20 Secure fan spindle 1 in soft jawed vise and remove cup plug 2 Discard cup plug Remove spacer retaining bolt 3 and spacer 4 Remove fan spindle 1 from vise Big 342 805 0051 00 1 TM 9 2320 302 34 SPINDLE AND HOUSING REPAIR CONTINUED 0051 00 DISASSEMBLY CONTINUED CAUTION During handling ensure fan spindle does not drop free from spindle housing causing damage to equipment Support spindle housing 5 and press fan spindle 1 from housing 4 Remove inner roller bearing snap ring 6 from fan spindle 1 342 806 NOTE Roller bearing assembly must be replaced whenever inner race is removed from fan spindle or roller bearing is removed from spindle housing 5 Secure fan spindle 1 in vise Using puller 7 remove roller bearing inner race
424. nd antiseize Item 10 WP 0125 00 Compound pipe sealing Item 18 WP 0125 00 Tools and Special Tools Oil lubricating Item 25 WP 0125 00 General Support Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Turbocharger removed WP 0042 00 Wastegate removed from turbocharger WP 0044 00 Dial indicator set Item 29 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 WP 0045 00 DISASSEMBLY 1 Scribe match marks on compressor housing 1 center housing 2 and turbine housing 3 to aid in assembly 342 983 0043 00 1 TM 9 2320 302 34 TURBOCHARGER REPAIR CONTINUED 0043 00 DISASSEMBLY CONTINUED CAUTION Tilting or cocking turbine housing during disassembly could damage turbine wheel blades 2 Loosen coupling nut 4 and remove clamp 5 and turbine housing 3 from center housing 2 3 Loosen coupling nut 6 4 Remove compressor housing 1 and clamp 7 from center housing 2 If necessary loosen compressor housing by tap ping with soft mallet 342 983 ASSEMBLY 1 Slide clamp 7 over backplate 8 2 Position compressor housing 1 as marked in disassembly against backplate 8 Secure with clamp 7 Lubricate threads of clamp lightly with engine lubricating oil and tighten coupling nut 6 to 110 130 Ib in 12 15 Nm CAUTION Ensure coupling nuts are tightened enough to prevent turbine housing from contacting turbine wheel 3 Position turbine housi
425. nd a whiskbroom or a soapy spray of water carefully clean off the condenser be careful not to bend the fins 4 Check the color of the moisture indicator sight glass If the color is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contaminated with moisture Recover the refrigerant evacuate the system replace the receiver drier and add a full refrigerant charge WP 0112 00 5 If there is not enough airflow ensure leaves or other debris have not entered the fresh air ports under the windshield If debris has entered it could clog the fins of the evaporator core and block airflow Also be sure that all ducts are con nected to the dash louvers and that the air control flaps in the heater housing are moving properly this requires removal of the right and center dash panel PERFORMANCE TESTS Following is a brief description of symptoms or conditions that could exist if something goes wrong with a refrigerant part l Receiver Drier a Thereceiver drier is normally at outside temperature To the touch the entire length of the unit should be the same temperature If noticeable cool spots exist replace receiver drier WP 0118 00 b blockage at the inlet of the unit will cause high head pressures outlet blockages will cause low head pressures and little or no cooling c the moisture indicator is pink or white showing that the system 15 wet the receiver drier is saturated with mois
426. nd play must not exceed 0 037 in 0 94 mm Check all six pinion gears Remove internal retaining ring 6 indexing ring 7 and four pinion spindles 8 from P2 planetary carrier 5 Remove pinion gear 9 thrust washers 10 and 11 and two bearing assemblies 12 from side of P2 planetary carrier 5 Repeat procedure for remaining pinion gears Measure thickness and step wear of thrust washers 10 and 11 Minimum thrust washer thickness allowed is 0 055 in 1 40 mm Maximum step wear allowed is 0 005 in 0 12 mm Inspect and measure bushing 13 inside P2 planetary carrier 5 for wear or damage Maximum ID allowed is 2 096 in 53 23 mm If bushing is worn remove and replace Check spline wear of P2 planetary carrier 5 and P3 planetary ring gear 2 Maximum allowed spline wear is 0 015 in 0 38 mm 342 1174 0071 00 35 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED P2 Planetary Module Assembly 1 Nn rH Bo If removed replace bushing 13 into P2 planetary carrier 5 using a press and tool J37036 Press new bushing flush to 0 016 in 0 40 mm below surface Install two bearing assemblies 12 into center of pinion gear 9 Install thrust washers 10 and 11 inside P2 planetary carrier 5 align thrust washer tangs with slots in planetary and retain them with petrolatum Slide pinion gear and bear ing assemblies into side of P2 planetary carrier between thrust
427. nd resilient mounts 22 from rear cab mount 23 Discard lock nuts 342 888 V7 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel CAUTION Lift cab assembly slowly and check for parts that may still be connected to cab and vehicle structure Failure to do so may result in damage to equipment 7 Remove cab assembly 6 from frame structure INSTALLATION v WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0104 00 4 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 INSTALLATION CONTINUED CAUTION Check underside of cab assembly as it is lowered in place Make sure nothing is between cab and frame structure Failure to do so may result in damage to equipment 1 Attach sling and hoist to cab assembly 6 Position cab assembly on frame structure 2 Install two resilient mounts 22 washers 21 screws 20 washers 19 and new
428. nd secure with five clips 10 8 Connect duct 9 to face duct 26 and secure with two self tapping screws 8 9 Connect flex tubing 4 to duct 5 and secure with two self tapping screws 3 10 Install duct 5 to duct outlet 7 and secure with two screws 6 11 Install four air cylinders 2 and secure with eight retainers 1 12 Install dash panels TM 9 2320 302 20 END OF WORK PACKAGE 0111 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0111 00 4 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE 0112 00 THIS WORK PACKAGE COVERS Recovery Evacuating Recycling Purging Flushing Charging INITIAL SETUP Maintenance Level References Direct Support TM 9 2320 302 10 TM 9 2320 302 20 Tools and Special Tools Materials Parts Tool kit general mechanic s Item 132 WP 0126 00 Adhesive loctite Item 2 WP 0125 00 Gloves rubber Item 40 WP 0126 00 Cap set Item 7 WP 0125 00 Goggles Item 42 WP 0126 00 Oil refrigerant Item 27 WP 0125 00 Reclaimer refrigerant Item 99 WP 0126 00 Refrigerant R 134a Item 38 WP 0125 00 I gt e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak test
429. nd tighten to 175 228 16 1 20 25 Nm 342 993 0084 00 13 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 33 34 35 36 37 38 39 40 41 42 43 44 Support cylinder head 13 on bench deck side up and install new copper gasket 27 in bore Install inlet valve seat 26 in bore with raised side of valve seat toward deck of cylinder head 13 NOTE Ensure inlet valve is centered on inlet valve seat Install inlet valve 25 on top of inlet valve seat 26 NOTE Ensure inlet valve spring is centered on inlet valve Install inlet valve spring 24 on top of inlet valve 25 Thread inlet valve stop 23 carefully into cylinder head 13 until inlet valve spring 24 is seated on inlet valve stop Using insert inserter and remover tool 22 tighten inlet valve stop 23 to 70 90 lb ft 95 122 Nm Repeat step 33 through 38 for other cylinder head bore 342 991 Insert discharge valve spring 30 in discharge valve bore Place discharge valve 29 on top of discharge valve spring 30 and center in discharge valve bore Thread discharge valve seat 28 carefully into cylinder head 13 until discharge valve 29 is seated Tighten discharge valve seat 28 to 70 90 Ib ft 95 122 Nm Repeat step 40 through 43 for other discharge valve bore 0084 00 14 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 45 46 47
430. ndition Tool kit general support Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 NOTE Procedure is same for left and right side harnesses REMOVAL NOTE Wiring harness and leads are secured by clips tiedown straps cushion clamps and screw terminals Only remove hardware securing harness or lead to be removed Disconnect and remove turn signal thru deck wiring harness using illustration as a guide Discard tiedown straps INSTALLATION NOTE Wiring harness and leads are secured by clips new tiedown straps cushion clamps and screw terminals Ensure harness is secure and all hardware is tight 1 Install connect and secure turn signal thru deck wiring harness using illustration as a guide 2 Connect battery cables TM 9 2320 302 20 0060 00 1 TM 9 2320 302 34 TURN SIGNAL THRU DECK WIRING HARNESS REPLACEMENT CONTINUED 0060 00 INSTALLATION CONTINUED 342 539 TABLE QTY 1 2 pin Female Connector 2 2 2 pin Male Sealed Connector 2 END OF WORK PACKAGE 0060 00 2 TM 9 2320 302 34 OVERHEAD CAB WIRING HARNESS REPLACEMENT 0061 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tools and Special Tools Tags marker Item 35 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Head liners removed Battery cables disconnected TM 9 2320 302 20 R
431. never valve is removed 13 Remove valve stem oil seal 13 from top of valve guide 14 Discard oil seal 14 Remove valve spring seat 15 13 342 1006 0032 00 4 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED NOTE Procedure is the same for both intake and exhaust valve seat inserts except different collet is used in valve seat remover tool 15 Position cylinder head 2 fire deck side up 16 If valve seats are worn or damaged place valve seat remover handle 16 in vertical position so that no pressure is on internal spring Adjust valve seat collet 17 opening by turning tapered nut 18 to expand or reduce valve seat collet opening until it will slip through valve seat 343 1007 17 With valve seat remover handle 16 in vertical position insert valve seat collet portion of valve seat remover body 19 fully into valve seat 18 Hold valve seat remover body 19 square with surface of cylinder head fire deck 20 and pull valve seat remover han dle 16 until firm resistance is felt Hold handle in this position 342 1008 0032 00 5 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED 19 20 21 22 23 CAUTION Ensure valve seat remover body remains flat on cylinder head fire deck when moving collet handle to pre vent damage to collet and to correct engagement of valve seat insert Hold valve seat remover h
432. ng Do not push drill through material c Place drill in center mark for new rivet locations or align drill with old hole when replacing old rivets with oversize rivets When using power drill give bit a few turns with fingers before starting motor This will help ensure drill does not jump out of position when motor is started d Remove all burrs with metal countersink or file NOTE Ensure no chips are trapped between sheets of metal e Clean away all drill chips f Apply sealing compound to hole and surrounding area 5 Hole Countersinking NOTE Some rivet installations in body require that rivet head be flush with material surface In these instances countersunk or flush head rivets are used a When using countersunk rivets rivet holes must be countersunk with tool having 100 degree taper so rivet head will fit flush with surface b When using hand operated countersink hole must be tried with rivet so that recess will not be too deep or too shal low It is best to use countersink with stop so that depth of countersink can be controlled Typical countersinking dimensions for blind rivets are shown in Table 3 Minimum sheet thickness that can be machined for 100 degree countersink rivets is given in Table 4 c Do not remove edge of hole on blind side of joint 0105 00 5 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 RIVET REPLACEMENT CONTINUED Table 3 Countersinking Dimensions for 100 Degree Counter
433. ng 13 342 823 0049 00 3 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 DISASSEMBLY CONTINUED CAUTION Use care when removing oil seal or water seal to prevent damage to water pump housing seal bores Do not allow brass drift to score housing bores A scored bore will cause coolant leaks and can damage engine NOTE Oil seal and water seal must be replaced whenever water pump shaft is removed 8 Place water pump housing 4 on bench impeller side down and remove water seal 14 from housing Discard water seal 342 825 ASSEMBLY CAUTION Do not separate bearing components Bearing assembly is a matched set of parts and should be assembled as received Failure to do so could result in bearing misalinement 1 Place service kit holding fixture 16 on press bed Install drive shaft support tool 17 in holding fixture Install square end of water pump shaft 5 in support tool NOTE Ensure roller bearing identification numbers are against bearing and seal installer 2 Position new roller bearing 13 on water pump shaft 5 with roller bearing identification numbers up Using small end of bearing and seal installer 18 press roller bearing on water pump shaft until roller bearing is seated against shoulder of water pump shaft Remove assembled shaft and bearing from holding fixture 0049 00 4 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED 342 826 A
434. ng 3 as marked in disassembly against center housing 2 Coat threads of clamp 5 with anti seize compound Install clamp and tighten coupling nut 4 to 110 130 Ib in 12 15 Nm 4 Attach dial indicator 9 to turbine housing 3 so that dial indicator plunger 10 rests on hub end of turbine wheel assembly 5 Set dial indicator 9 for reading of zero 0043 00 2 TM 9 2320 302 34 TURBOCHARGER REPAIR CONTINUED 0043 00 ASSEMBLY CONTINUED 10 NOTE Bearing axial clearance must be 0 0020 0 0032 in 0 051 0 081 mm If bearing axial clearance does not meet specification replace turbocharger center housing assembly 6 Apply manual pressure to compressor wheel and turbine wheel assembly to move assembly as far as it will go away from turbine end of turbocharger toward dial indicator plunger 10 Note maximum shaft movement shown on dial indicator 9 7 Repeat steps 5 and 6 several times to ensure maximum bearing axial clearance as indicated by maximum turbine wheel assembly movement has been measured END OF WORK PACKAGE 0043 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0043 00 4 TM 9 2320 302 34 3K TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE 0044 00 THIS WORK PACKAGE COVERS Removal Installation Adjustment INITIAL SETUP Maintenance Level Materials Parts Direct Support Kit wastegate actuator P N 23523811 Tools and Special Tools Compound antiseize Item 10 WP 0125 00 T
435. ng 54 new seal 53 bearing retainer 52 and four screws 51 8 Install shaft 50 in rotor and drive end housing 21 0052 00 8 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 ASSEMBLY CONTINUED 9 10 11 12 13 14 15 16 17 18 Mount rotor and drive end housing 21 in soft jawed vise and using dial indicator gage with magnetic base check runout of slip ring assembly 56 Maximum allowable runout is 0 002 in 0 05 mm If runout is excessive mount assembly on lathe Dress slip ring assembly 56 using abrasive cloth Repeat steps 9 and 10 until proper runout is achieved Solder two leads 55 to terminals located on end of slip ring assembly 56 342 533 Install new seal 49 in rear of slip ring end housing 23 Install new bearing 48 and new inner seal 47 Install washer 46 and new tenz nut 45 on each of three terminal studs 43 Install insulator 44 three terminal studs 43 three insulators 42 insulator 41 three washers 40 and six nuts 39 Install two insulating bushings 38 in slip ring end housing 23 Install two insulating bushings 37 in negative rectifier 36 and positive rectifier 35 0052 00 9 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 ASSEMBLY CONTINUED 19 20 21 22 23 24 25 26 Install negative rectifier 36 positive rectifier 35 two insulating washers 34 washers 33 new lock washers 32
436. ng and Bearing Retainer Bushing Installer Rotating Clutch Bushing Installer Seal Input Installer Seal Output Installer Torque Converter Cover Bushing Installer Turbine Shaft Bushing Output Bushing P2 Carrier Bushing Installer Valve Guide Installer Valve Stem Seal Installer Wear Plate Installer Set Cup Plug Jack Hydraulic Hand 12 ton capacity 3 NATIONAL STOCK NUMBER 5120 01 338 7182 5120 01 322 2360 5120 01 322 6222 5120 01 388 5623 5120 01 322 3500 5120 01 354 0468 5120 01 333 4744 5120 01 054 4042 5120 01 322 3501 5120 01 322 2359 5120 00 224 7330 0126 00 4 4 PART NUMBER CAGEC J25447 B 33287 135642 33287 136310 33287 J35923 2 33287 136224 33287 J 37073 33287 139954 33287 136326 33287 J37041 33287 J37034 33287 J37033 33287 J 24202 1A 33287 J37038 33287 J37040 33287 J37032 33287 J37031 33287 J39949 33287 J37036 33287 J33191 A 33287 J39109 33287 J39534 33287 J35653 33287 67224 07505 0126 00 5 REFERENCE 9 2320 302 24P 9 2320 302 24P M 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24P 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24 9 2320 302 24P 9 2320 302 24
437. ng may be classified as negligible cracks provided they are stop drilled at each end to stop propagation 2 Negligible Holes Isolated holes no more than 0 50 in 1 27 cm diameter after they are made round with smooth edges are classified as negligible holes provided the distance from the edge of the hole to the near est line of rivets exceeds the diameter of the hole 3 Negligible Dents and Distortion Small dents and distorted areas may be classified as negligible if they can be repaired by hammering or bending without causing the material to crack Heat may not be used for reforming Damage Repairable by Patching Damage beyond negligible must be repaired or the section replaced Patches can often be applied over damaged body panels Damaged area must first be trimmed to remove sharp edges or notches that could cause start of new cracks Patch must then be sized to overlap the area to allow for attaching riv ets Refer to Repair by Patching on page 0105 00 12 Damage Repairable by Insertion In certain cases patch repairs may not be desirable because of impracticality or because a flush surface is desired In this case damaged area must be cut away and a partial replacement of equivalent material inserted flush with adjacent areas and backed up with a doubler Refer to Repair by Insertion on page 0105 00 Damage Necessitating Replacement of Parts Parts are too badly damaged for repair or replacement is easier than repair repair fo
438. nion drive gear preload must be 10 30 Ib in 1 13 3 39 Nm 12 If preload is not within limits install thicker spacer 26 to decrease preload or thinner spacer to increase preload 342 1207 13 Repeat steps 7 through 12 until correct preload is obtained 14 Coat outside of new oil seal 24 and bore of bearing cage 23 with GAA d e 24 342 1215 0082 00 12 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 15 Install oil seal 24 in bearing cage 23 342 1216 16 Using thickness gage check gap between oil seal 24 and bearing cage 23 at several points around oil seal Gap must be within 0 015 0 030 in 0 38 0 76 mm Difference between largest and smallest gap must not exceed 0 01 in 0 25 mm 0 015 0 030 IN 0 38 0 76 MM 342 1217 0082 00 13 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0082 00 ASSEMBLY CONTINUED 17 18 19 20 21 22 23 e If installing new ring gear and drive pinion perform steps 19 through 24 e Replace ring gear and drive pinion as matched set Gear set match number is on gear head of drive pin ion and front face or outer diameter of ring gear e Pinion cone variation number is used to adjust depth of pinion in differential carrier Pinion cone varia tion number is on end of gear head of drive pinion or outer diameter of ring gear Re
439. nsert 10 and install insert in oil pan 2 CAUTION Hold insert to prevent scoring of plastic oil pan Failure to prevent insert from spinning during installation could cause damage and result in equipment failure 4 Hold insert 10 and install nut 12 Tighten nut to 136 145 Ib ft 184 197 Nm L WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in a well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water 5 Coat threads of pipe plug 11 with pipe sealing compound and install pipe plug in insert 10 Hold insert while tighten ing pipe plug 0028 00 4 TM 9 2320 302 34 OIL PAN MAINTENANCE CONTINUED 0028 00 INSTALLATION NOTE To ease installation of oil pan gasket use a soapy water solution on gasket prior to installing in groove of oil pan 1 Place new oil pan gasket 6 on oil pan 2 with gasket lip toward oil pan groove 2 Press oil pan gasket 6 completely down into groove at each corner of oil pan 2 Repeat at points midway between corners halving distance between installed sections until oil pan gasket is completely installed 342 745 3 Apply a thin bead of gasket forming compound to pan rail joint faces of flywheel housing 7 gear housing 8 gear case cover 9 and cylinder block 3 342 746
440. nstall air cylinder 4 and connect air hose 8 2 Install plunger assembly 7 pin retainer 6 spring 2 and spring retainer 5 3 Install spring compressor tool 1 4 Compress spring 2 and place air cylinder 4 in position 5 Install pin 3 and release spring compressor tool 1 0092 00 2 TM 9 2320 302 34 SLIDE BRACKET AND PLATE REPAIR CONTINUED ASSEMBLY CONTINUED 6 Repeat steps 2 through 5 for opposite side plunger assembly 7 Install top plate WP 0093 00 8 Adjust fifth wheel TM 9 2320 302 20 END OF WORK PACKAGE 0092 00 3 0092 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0092 00 4 TOP PLATE REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools TM 9 2320 302 34 Tool kit general mechanic s Item 132 WP 0126 00 0093 00 Materials Parts Kit P N RK 04413 Compound antiseize Item 10 WP 0125 00 Personnel Required Two N WARNING e Use extreme caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel e plate weighs 320 Ib 145 kg Use hoist with lifting capacity of 500 Ib 227 kg to remove or install top
441. nstall lubrication regulator valve 54 spring 53 and stop 52 Install retention pin 51 Install converter flow valve 50 spring 49 and stop 48 Install retention pin 47 Install new small o ring 45 and new large o ring 46 on solenoid 44 Install solenoid Install solenoid retention pin 43 smooth side first from bottom of main valve body assembly 16 If removed install retention pin 42 in main valve body assembly 16 0071 00 46 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Assembly Continued 342 1178 0071 00 47 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Control Valve Module Assembly Continued 19 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 ST NOTE Stationary clutch solenoid body assembly procedures are steps 19 through 22 Install valve 40 spring 39 and stop 38 in stationary clutch solenoid body 14 Install retention pin 37 Install three springs 36 solenoid regulator valves 35 six new o rings 34 and three solenoids 33 As valve bores are filled install three solenoid retention pins 32 smooth end first from bottom of solenoid body Install two new seals 31 in stationary clutch solenoid body 14 NOTE Rotating clutch solenoid body assembly procedures are steps 23 through 27 Inst
442. nstall turn signal switch 2 to steering column 3 and tighten clamp screw 11 Install trailer brake control valve 1 and tighten clamp 12 Install steering column covers 13 Install steering wheel 14 Test drive vehicle TM 9 2320 302 10 and check steering END OF WORK PACKAGE 0090 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0090 00 4 TM 9 2320 302 34 FIFTH WHEEL REPLACEMENT 0091 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Personnel Required Direct Support Two Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Air system drained 9 2320 302 10 Materials Parts Nut lock P N MS51922 1 Nut lock P N MS51922 49 14 WARNING e Use extreme caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel e Fifth wheel weighs 550 Ib 249 7 kg Use hoist with lifting capacity of 800 Ib 363 2 kg to remove fifth wheel Failure to do so could result in injury to personnel 0091 00 1 TM 9 2320 302 34 FIFTH WHEEL REPLACEMENT CONTINUED 0091 00 REMOVAL 1 Disconnect air hose 1 from cylinder 2 2 Remove lock nut 3 screw 4 and clamp 5 Dis
443. nstaller valve guide Item 69 WP 0126 00 Adhesive loctite Item 3 WP 0125 00 Installer valve stem seal Item 70 WP 0126 00 Compound sealing pipe Item 18 WP 0125 00 Installer set cup plug Item 72 WP 0126 00 Oil cutting Item 2A WP 0125 00 Reconditioning set Item 100 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Remover valve guide Item 102 WP 0126 00 Paste Prussian blue Item 28 WP 0125 00 Remover valve seat Item 103 WP 0126 00 Tags marker Item 35 WP 0125 00 Remover valve seat Item 104 WP 0126 00 References Replacing tool engine Item 107 WP 0126 00 TM 9 237 Replacing tool engine Item 108 WP 0126 00 Equipment Condition Tester cylinder Item 124 WP 0126 00 Cylinder head removed WP 0018 00 N WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 0032 00 1 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 NOTE Remove and replace valves valve springs and valve guides as a matched set Ensured removed valves valve springs and valve guides are installed in same position from which they were removed DISASSEMBLY 1 Using hardware provided with material lift clamp 1 install material lift clam
444. nt 0118 00 0118 00 1 Air Conditioning System Refrigerant R 134a Maintenance 0112 00 0112 00 1 Theory of Operation 0 aa E EE KAE nh 0003 00 0003 00 9 Troubleshooting and Testing 0009 00 0009 00 1 Air System Theory of 0003 00 0003 00 5 Alternator ner ee eR Rue xe ee PAURA 0052 00 0052 00 1 Anti lock Brake System ABS Cab Wiring Harness Replacement 0065 00 0065 00 1 Front Wiring Harness Replacement 0063 00 0063 00 1 Rear Wiring Harness Replacement 0064 00 0064 00 1 Axle Assembly Replacement Front 0072 00 0072 00 1 Axle Caster Adjustment Front 0073 00 0073 00 1 Axle Replacement 0078 00 0078 00 1 B Body Repait Gab carece gender pet e e ate reni tree UR I TRIP RR REWA 0105 00 0105 00 1 Brake Dr m Repall senarna nE WERE EUER AOI Es 0085 00 0085 00 1 Index 1 TM 9 2320 302 34 INDEX Continued Subject Work Package Page B Continued Brake System Theory of Operation 0003 00 0003 00 5 Brake Valve Repair Foot 0 0000 c eee eee eee 0083 00 0083 00 1 Breather Tube Replacement
445. ntentionally Left Blank 0049 00 14 TM 9 2320 302 34 FAN CLUTCH REPAIR 0050 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts Direct Support Kit repair P N 1033 054335 02 Tools and Special Tools Seal dust P N 3018 01519 01 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Clamp 2 Item 19 WP 0126 00 Fan clutch removed from vehicle TM 9 2320 302 20 DISASSEMBLY 1 Remove nut 1 tab washer 2 cylinder 3 seal 4 packing 5 and dust seal 6 from clutch assembly 7 Discard nut tab washer seal packing and dust seal WARNING Housing is under spring tension Use suitable clamps to hold housing and shaft assembly in place while removing cylinder Failure to do so could result in injury to personnel 2 Install two clamps on opposite sides of clutch assembly 7 342 839 0050 00 1 TM 9 2320 302 34 FAN CLUTCH REPAIR CONTINUED 0050 00 DISASSEMBLY CONTINUED 3 Remove six screws 8 lock washers 9 three retaining plates 10 and lining 11 from shaft assembly 12 Discard screws lock washers and lining 4 Release C clamps slowly to relieve spring tension and remove housing 13 seal 14 end cap 15 and spring 16 from shaft assembly 12 Discard seal and spring 5 Remove retaining ring 17 and piston assembly 18 6 Remove two packings 19 and 20 and spring carrier
446. nting surface Top of dowel should be 0 197 in 5 0 mm from mounting surface when properly seated in bore 342 736 0029 00 9 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY CONTINUED NOTE Diamond shaped dowel must be oriented in relation to tubular shaped dowel before installing in pump body mounting surface 13 If removed loosely place diamond shaped dowel 26 in bore of pump body 20 mounting surface so that angular ori entation is perpendicular to center line through tubular shaped dowel 27 within 5 degrees 5 26 342 737 14 Install diamond shaped dowel 26 in bore of pump body 20 mounting surface Top of diamond shaped dowel should be 0 307 0 323 in 7 8 8 2 mm above surface when properly seated in bore 0 307 0 323 IN 7 8 8 2 mm ps 26 342 738 15 Place oil pump body 20 with cover side down on press support Lubricate two bushings 24 with clean engine lubri cating oil 16 Apply athin film of lubriplate to bore of oil pump drive gear 23 17 Install longer end of internal oil pump drive gear and shaft assembly 22 in right side bushing as view from top rear 0029 00 10 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY CONTINUED CAUTION Minimum press force of 1515 Ib 7 0 kN must be obtained to press oil pump drive gear onto oil pump drive gear and shaft assembly to prevent equipment damage e Bala
447. ntiseize compound 2 Position wastegate 3 on turbocharger 13 and hand tighten three bolts 12 3 Loosen jamnut 14 on actuator rod 9 4 While holding turbocharger lever 11 down closed turn end of actuator rod 9 until hole in rod aligns with stud 10 on turbocharger lever Secure actuator rod 9 end to stud 10 on turbocharger lever 11 with new retaining clip 8 Turn actuator rod 9 end five revolutions in direction of wastegate 3 and tighten jamnut 14 Tighten three bolts 12 to 180 Ib in 20 Nm Install elbow 7 Install hose 2 and hose clip 6 to elbow 7 10 Install hose 2 and hose clip 1 to wastegate 3 11 Install hose 2 hose clamp 5 and bolt 4 O Mw 0045 00 3 TM 9 2320 302 34 GARRETT TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0045 00 ADJUSTMENT 1 Disconnect hose 2 from wastegate 3 NOTE Dial indicator must have a minimum of 0 100 in 2 5 mm travel for measurement 2 Attach dial indicator 15 to wastegate actuator rod 9 to measure rod travel 3 Connect air supply through regulator valve 16 shutoff valve 17 pressure gage 18 and vent valve 19 to wastegate 3 4 Adjust regulator valve 16 to provide 31 psi 214 kPa of air pressure to actuator 3 5 Close air supply shutoff valve 17 and observe reading on pressure gage 18 NOTE If pressure drops check actuator hose and fitting connections for leaks If none
448. o AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The e mail address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 Table of Contents Page Number Warning Summary scere aie edes tested s dues segun elec e bu tede diced ess H How to Use This Manual lesse t M CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION WP 0001 00 GeneralInformation llle RII III 0001 00 1 WP 0002 00 Equipment Description and 0002 00 1 WP 0003 00 Theory of Operation 000 cette sadis 0003 00 1 CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT TROUBLESHOOTING WP 0004 00 Troubleshooting 0004 00 1 WP 0005 00 Troubleshooting Symptom 0005 00 1 WP 0006 00 Engine Troubleshooting sees 0006 00 1 WP 0007 00 Transmission Troubleshooting 0 cece eee RI 0007 00 1 WP 0008 00 Steering System Troubleshooting 0008 00 1 WP 0009 00 Air Conditioning System Troubleshooting and Testing 0009 00 1 CHAPTER 3 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS WP 0010 00 Power Pack 1 0010 00 1 WP 0011 00 Front Engine Mount Adapter and Support Replacement
449. o flow until there is no trace of refrigerant oil or solid bits of dirt or grit flowing from drain tube 9 Close nitrogen bottle control valve 1 and purging control valve 2 first then close supply line valve 3 10 Disconnect supply line valve 3 and drain line 4 Tightly cap both ends of part or line FLUSHING 1 Recover refrigerant system 2 Disconnect both ends of part or line being flushed Tightly cap lines to rest of system 3 Heat R 134a refrigerant in a dial a charge or pressurize refrigerant as recommended by manufacturer 4 Connect dial a charge outlet hose to outlet side of system this will ensure that R 134a will flow in reverse direction of normal flow 5 Connect a line from inlet side of system to a recovery recycling station NOTE If system is extremely contaminated install a receiver drier inline as a pre filter for recovery recycling sta tion 6 Turn on recovery recycling station and open outlet valve for dial a charge Allow about 2 pounds 1 kilogram of R 134a to flow through system 7 Close supply line valve and wait for recovery station to shut off 8 Disconnect supply line and drain line from dial a charge and recovery station Connect lines to nitrogen bottle 9 Purge system and check collection bottle for contaminants Repeat process if needed 10 Disconnect lines from part and tightly cap both ends of part CHARGING NOTE Before charging system must be recovered and evacuated with recovery and recycling st
450. o washers 21 one on each bonding surface Install nut 22 on clamping bolt There should be enough clamping bolts to hold hood in place and keep bonding surfaces together one bolt every 12 18 in 30 45 cm Remove part for application of adhesive e Using manufacturer s instructions mix enough Ashland Pliogrip 6600 6622 adhesive to bond parts together about 3 8 in 10 mm diameter bead at bonding surface 19 Adhesive will cure in 7 10 minutes f Put adhesive in standard caulking gun and cut nozzle so 3 8 in 10 mm diameter bead can be dispensed If parts could not be completely separated cut nozzle so adhesive can be injected between surfaces g Dispense 3 8 in 10 mm diameter bead of adhesive between all bonding surfaces 19 h Within 5 minutes of dispensing adhesive bead align part on hood and clamp firmly in place If a large part fender for example install clamping bolts Tighten clamps or clamping bolts just enough to ensure uniform amount of pressure is applied along seam Ideally adhesive should be compressed to form bondline 1 in 25 mm wide and 0 030 in 0 76 mm thick i Before adhesive cures remove excess adhesive that squeezes out edges of bond j Bond will be secure in about 1 hour Remove clamps k If holes were drilled for clamping bolts repair holes using instructions in Crack or Small Hole Repair on page 0106 00 1 END OF WORK PACKAGE 0106 00 7 TM 9 2320 302 34 This Page Intentionally Left
451. ocker arm is shown 3 Thread adjusting screw 12 into correct rocker arm 8 as noted during removal and loosely install jamnut 11 0027 00 6 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSTALLATION CONTINUED 11 12 342 712 4 Using cup plug installer 21 install new cup plug 16 in center oil passage 17 at each end of rocker arm shaft 7 342 713 0027 00 7 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSTALLATION CONTINUED NOTE If rocker arms are reused install in previously determined order with logo on rocker arm shaft facing out board front and rear when seated 5 Lubricate rocker arm bushing 19 with clean engine lubricating oil Install three rocker arm assembly sets 6 exhaust 8 injector 9 and intake 10 on rocker arm shaft 7 with logo stamped on end of shaft 342 714 6 Using rocker stud socket 22 check tightness of rocker arm shaft studs 23 in cam caps 24 no and no 7 Tighten studs to 75 86 lb ft 102 117 Nm 342 715 0027 00 8 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 INSTALLATION CONTINUED NOTE Position lifter fingers under cross arch of exhaust rocker arm assembly above center section of injector rocker assembly Lifter fingers fit between intake and injector rockers Using rocker arm lifter 5 on rocker arm assembly sets 6 from cam roller side
452. od must be available as scrap with the needed section intact CAUTION Piece of SMC laminate from another SMC laminate hood must be used for section replacement Use of any other material may not allow necessary bonding for repair a To determine extent of damage push in on area immediately surrounding and underneath damaged area 0106 00 3 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED R gii WARNING Solvents can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If solvent gets on skin or clothing wash immediately with soap and water Clean area with xylene or equivalent solvent Inspect area closely If sound absorbent liner is present on underside of damaged area remove panel s to provide adequate working area NOTE If damage extends to joint where part is bonded to another separate part with heat gun and putty knife before cutting Using saber saw cut out large straight sided panel 8 containing damaged area NOTE If damage is next to but does not include headlight reinforcement remove headlight reinforcement from replacement section not from hood From scrap hood 9 or new part cut patch 10 from same area slightly larger than original panel 8 Trim patch to fit both size and contour of original panel Sand patch 10 edges to allow 1 16 1 8 in 2 3 mm gap
453. of final value multiply final value by 0 7 then repeat the pattern until final value is reached c Tighten circular patterns using the circular torque pattern and straight patterns using the straight torque pattern CIRCULAR TORQUE PATTERN 9 7 5 31 2 4 6 8 STRAIGHT TORQUE PATTERN CAUTION If replacement cap screws are of higher grade than originally supplied use torque specifications for the orig inal This will prevent equipment damage due to overtorquing 0123 00 1 TM 9 2320 302 34 Table 1 Torque Limits CURRENT USAGE MUCH USED MUCH USED USED USED AT TIMES USED AT TIMES QUALITY OF aa MEDIUM BEST MATERIAL INDETERMINATE COMMERCIAL COMMERCIAL COMMERCIAL Cap screw Head Markings Manufacturer s marks may vary These are all SAE Grade 5 3 line O 6 CAP SCREW BODY SIZE TORQUE TORQUE TORQUE TORQUE INCHES THREAD LB FT NM LB FT NM LB FT NM LB FT NM 1 4 20 5 7 8 11 14 16 28 6 8 10 14 19 5 16 15 17 23 26 33 18 19 26 37 16 24 42 46 60 24 27 47 66 7 16 36 6 75 95 41 75 106 13 53 102 115 105 142 20 56 b 115 120 163 9 16 69 110 149 120 163 155 210 75 120 163 170 231 11 113 150 203 226 2 285 18 129 170 231 325 10 105 142 270 366 380 508 16 115 156 295 400 569 160 217 395 536 597 820 a 175 237 435 590 915 235 319 590 8
454. ogen gas is recommended for purging A pressure regulator is required to regulate between 0 to 200 psi 0 1379 kPa Commercial cylinders of nitrogen contain pressures in excess of 2000 psi 13 780 kPa this pressure must be reduced to 200 psi 1379 kPa for purging 1 Recover system refrigerant 2 Disconnect both ends of line or part being purged Tightly cap rest of system 3 Ensure valves 1 2 and 3 are closed NN aN te UN 0 T RN A Re MM i NUNN edd WONT TS ts NTN yt SRT SOR py Qr i nmm Dt 342 562 B A To Waste Container B To Recycling System Container 1 Nitrogen Bottle Control Valve 4 Drain Line 2 Purging Control Valve 5 Nitrogen Bottle Regulator Gage 3 Supply Line Valve 6 Nitrogen Bottle 4 Connect supply line valve 3 to outlet end of part or line 3 Connect drain line 4 to inlet end of part or line 6 Place outlet of drain line into a recycling system container 0112 00 4 TM 9 2320 302 34 AIR CONDITIONING SYSTEM REFRIGERANT R 134A MAINTENANCE CONTINUED 0112 00 PURGING CONTINUED 7 Adjust nitrogen bottle regulator 5 to 200 psi 1379 kPa Open nitrogen bottle control valve 1 and purging control valve 2 Then slowly open supply line valve 3 Check drain line 4 for gas flow 8 Let nitrogen flow at 200 psi 1379 kPa and let it flow for 1 to 2 minutes If part or line was very wet allow it t
455. olt 6 Hold square end of water pump shaft 5 and tighten bolt to 75 93 lb ft 102 126 Nm 0049 00 11 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 TEST AND INSPECTION 1 Turn water pump over gear side down Clamp drive gear 8 in soft jawed vise with water pump impeller 12 facing up 2 Install water pump impeller tester 28 in tapped holes provided in impeller 12 Tighten bolts to 156 204 Ib in 18 23Nm 3 Apply 50 Ib ft 68 Nm torque in either direction with torque wrench inserted in impeller tester 28 If impeller slippage is detected remove and discard impeller 12 Install new impeller and retest Remove impeller tester after testing se ae 342 836 4 Turn water pump over impeller side down 5 Attach dial indicator 29 to water pump housing 4 Measure gear face runout just inside of drive gear 8 teeth Rotate drive gear and measure runout in four places at 90 degree intervals Maximum allowable runout is 0 0025 in 0 0635 mm 6 If limit is exceeded remove drive gear 8 and check for burrs or foreign particles Install drive gear and recheck runout If runout still exceeds limits replace drive gear and or water pump shaft 5 as necessary 0049 00 12 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 TEST AND INSPECTION CONTINUED 342 837 7 342 838 8 Install water pump 9 2320 302 20 END OF WORK PACKAGE 0049 00 13 TM 9 2320 302 34 This Page I
456. on 0009 00 6 Expansion valve stuck open or switch not working Restriction DISCHARGE PRESSURE NORMAL HIGH Check moisture indicator for over charge or F DISCHARGE PRESSURE NORMAL DISCHARGE PRESSURE LOW NORMAL TO HIGH between 0009 00 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 AIR CONDITIONING SYSTEM TROUBLESHOOTING Table 1 Problem Warm Airflow When Air Conditioning Is On POSSIBLE CAUSE REMEDY There is no refrigerant charge in system Repair any leaks evacuate system WP 0112 00 replace receiver drier WP 0118 100 and add a full charge of refrigerant Moisture in system If moisture is in system ice crystals may form at expansion valve blocking the flow of refrigerant off and on Recover refrigerant charge replace receiver drier WP 0118 00 evacuate system and add a full charge of refrigerant Table 2 Problem Low Evaporator Coil Outlet Pressure Low Compressor Suction Pressure POSSIBLE CAUSE REMEDY The expansion valve is not working Replace expansion valve WP 0114 00 There are restrictions in line to expansion Remove line restrictions valve There is an insufficient refrigerant charge Locate leak Recover refrigerant charge WP 0112 00 replace receiver drier WP in system 0118 00 and add a full refrigerant charge WP 0112 00 Table 3 Problem High Compressor Discharge Pressure POSS
457. on upper main bearing shells 16 0033 00 8 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSPECTION CONTINUED 15 16 17 18 342 1081 Using strip of plastigauge 24 measure bearing clearances between crankshaft journals of main bearings Plastigauge type PG 1 green has clearance range of 0 001 0 003 in 0 0254 0 0762 mm Type PR 1 red has clearance range of 0 002 0 006 in 0 0508 0 01524 mm Type PB 1 blue has clearance range of 0 004 0 009 in 0 1016 0 2286 Place piece of plastigauge 24 along full width of each crankshaft main bearing journal about 1 4 in 6 35 mm off cen ter Install seven lower main bearing shells and main bearing caps 12 Install 14 washers 11 and main bearing cap bolts 10 Tighten main bearing cap bolts to 347 391 lb ft 470 530 Nm 342 1082 0033 00 9 TM 9 2320 302 34 CRANKSHAFT REPLACEMENT CONTINUED 0033 00 INSPECTION CONTINUED NOTE Flattened plastigauge will be found adhering to bearing shell or crankshaft 19 Remove 14 main bearing cap bolts 10 and washers 11 Remove seven main bearing caps 12 and lower main bear ing shells 13 NOTE If worn crankshaft maximum connecting rod bearing journal to bearing shell clearance with new shells exceeds 0 005 in 0 1270 mm or if maximum main bearing journal to bearing shell clearance with new shells exceeds 0 0056 in 0 1412 mm replace crankshaft Measurements of crankshaft sho
458. onent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC CI TECH PUBS TACOM RI 125th Transportation Company 1 Rock Island Arsenal ATTN Motor SGT SGT Wilson Rock Island IL 61299 7630 Ft Riley KA 78665 4000 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE rire Direct Support and General Support i 5 TM 9 2320 302 34 28 May 2001 ig ee Manual for M915A3 ractor Truck ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO 0035 00 1 Initial Item number for Oil Lubricating is not correct Setup Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION Johnny Wilson E 5 MOTOR SGT DSN 867 7967 DA K BM 2028 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC v1 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part I freverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is ODISC4 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE title Direct Support
459. onnect them only after the air conditioning system has been discharged to a refrigerant recovery unit through the service valves on the compressor WP 0112 00 2 L WARNING Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to the air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant Refrigerants are safe when used under the right conditions Always wear safety goggles and non leather gloves while discharging purging flushing evacuating charging and leak testing the system Do not wear leather gloves when refrigerant gas or liquid contacts leather the leather will stick to your skin Refrigerant splashed in the eyes should first be treated with a few drops of sterile mineral oil in the eyes then rinsed with a weak boric acid solution Do not rub the eyes Call a doctor right away Refrigerant splashed on the skin should be treated the same as for frostbite gently pour cool water on the area but do not rub the skin Keep the skin warm with layers of soft sterile cloth Call a doctor right away 0009 00 3 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 SAFETY PRECAUTIONS CONTINUED WARNING Do not work in an area where refrigerant may contact an open flame or any burning material such as a ciga rette When it contacts extreme heat refrig
460. ool kit general mechanic s Item 132 WP 0126 00 Dial indicator set Item 29 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 NOTE Turbocharger wastegate actuators are NOT interchangeable REMOVAL 1 Remove hose clamp 1 and hose 2 from wastegate 3 CAUTION Never remove actuator rod end from stud on turbocharger lever without applying light pressure to wastegate inlet port Failure to follow this caution could result in damage to wastegate diaphragm 2 Remove retaining ring 4 securing actuator rod 5 to stud 6 on turbocharger lever 7 3 Remove three bolts 8 and wastegate 3 from turbocharger 9 0044 00 1 TM 9 2320 302 34 3K TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0044 00 REMOVAL CONTINUED 4 Remove bolt 10 and hose clip 11 5 Remove bolt 12 two washers 13 and hose connector 14 from turbocharger 9 6 Remove hose clip 15 and hose 16 from hose connector 14 10 11 16 9 13 18 14 322 2019 12 INSTALLATION 1 Install hose 16 and hose clip 15 to hose connector 14 2 Install bolt 12 two washers 13 and hose connector 14 to turbocharger 9 3 Secure hose 16 to turbocharger 9 with hose clip 11 and bolt 10 4 Coat three bolts 8 with high temperature antiseize compound 5 Position wastegate 3 on turbocharger 9 and hand tighten three bolts 8 6 Secure hose 2 to wastegate 3 with hose clamp 1 7 Loosen jamnut 17 on actuator
461. ooting Procedures MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 Abnormal Noise If clicking noise is heard when Tighten or replace loose or initiating steering maneuver or defective components when changing directions of turn some linkage component is probably loose and shifting under load Check for excessive air in fluid Fill pump reservoir to proper level fluid is foamy and or low TM 9 2320 302 10 fluid level 2 No Recovery Disconnect lower steering 1 Replace defective tilt steering column from steering gear column WP 0090 00 check steering column for binding 2 Replace defective universal joint TM 9 2320 302 20 2 Check for sufficient pump pressure as follows a Disconnect pressure hose from power steering pump b Connect adapter hose from adapter kit Item 4 WP 0126 00 to power steering pump c Connect hose from dial end of power steering tester Item 127 WP 0126 00 to adapter hose d Connect hose from load valve end of power steering tester to pressure hose CAUTION Before performing step e ensure load valve is completely open to prevent damage to flow pressure valve e With engine idling rotate steering wheel to left and right for 5 minutes to warm power steering fluid CAUTION To prevent damage to power steering pump during perfor mance of step f do not allow load valve to be closed for more than 5 seconds 0008 00 1 TM 9 2320 30
462. oove of rear cover 48 NOTE Ensure oil supply to cover is on outboard side of air compressor Position rear cover 48 on crankshaft 34 against air compressor 6 Align bolt holes in rear cover 48 with holes in air compressor 6 Install four bolts 47 and tighten to 175 225 lb in 20 25 Nm in a crisscross pattern 0084 00 8 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 34 342 999 NOTE Oil control rings may be installed with either side up 13 With dome of piston 42 up install two oil control rings 45 in upper oil ring groove of piston 14 Install oil ring expander 46 in oil ring groove between oil control rings 45 342 995 0084 00 9 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 15 16 17 18 19 20 CAUTION Dot appearing on one side of second and top piston rings 30 degrees from ring gap indicates top of second and top piston rings Top of second and top piston rings must be installed facing piston dome to prevent damage to equipment Install second and top piston rings 44 in top two ring grooves of piston 42 CAUTION Dot appearing on one side of third piston ring 30 degrees from ring gap indicates top of third piston ring Top of third piston ring must be installed facing piston dome to prevent damage to equipment Install third piston ring 44 in top groove of lower ring groo
463. or 30 Place piston ring compressor 32 and connecting rod and piston assembly 9 over cylinder to be serviced Position pis ton ring compressor squarely on cylinder liner 3 flange A 9 342 1068 CAUTION Do not force connecting rod and piston assembly into cylinder liner as oil control ring expander applies con siderable force on oil control ring Use care to prevent ring breakage 31 Push connecting rod and piston assembly 9 into cylinder liner by hand until piston is free of piston ring compressor 32 32 Remove piston ring compressor 32 0041 00 19 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED CAUTION Failure to orient piston connecting rod properly during installation may result in connecting rod striking and damaging nozzle A damaged or loosed nozzle can cause a loss of main gallery pressure or lack of cooling to piston Severe engine damage would result e Use when loading piston into cylinder liner not to damage piston cooling nozzle installed at base of cylinder bore Before loading piston into liner turn connecting rod so that bearing end is offset approxi mately 10 15 degrees and is not perpendicular to crankshaft Once rod end is past nozzle turn rod so it is perpendicular with crankshaft NOTE Ensure two connecting rod bolts have not been unseated or turned 33 Push or tap connecting rod and piston assembly 9
464. ort Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Guide stud set Item 43 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 0014 00 Materials Parts Continued Compound sealing pipe Item 18 WP 0125 00 Oil lubricating Item 25 WP 0125 00 References TM 9 2320 302 10 Equipment Configuration Air intake manifold to intercooler tube removed Materials Parts Gasket P N 23517875 3 Bther atomizer and bushing removed TM 9 2320 Ring seal P N 5182977 302 20 REMOVAL 1 Loosen hose clamp 1 and disconnect air compressor inlet hose 2 from air supply connector 3 2 Remove air supply connector 3 from air intake manifold 4 0014 00 1 342 634 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT CONTINUED REMOVAL CONTINUED 3 Disconnect air line connector 5 from fitting 6 4 Remove fitting 6 check valve 7 and nipple 8 from air intake manifold 4 842 635 Disconnect engine wiring harness 9 from turbo boost sensor 10 and air temperature sensor 11 Remove air temperature sensor 11 from air intake manifold 4 Remove two retaining bolts 12 and turbo boost sensor 10 Remove and discard seal ring 13 O o nd Remove five long bolts 14 and two end short bolts 15 from air intake manifold 4 342 636 10 Remove air intake manifold 4 and three gaskets 16 from
465. osion preventive compound for extended storage 0036 00 6 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 CLEANING AND INSPECTION CONTINUED 10 Measure cylinder liner counterbore diameter A and depth B Diameter should be 6 186 6 191 in 157 15 157 25 mm Depth should be 0 3514 0 3533 in 8 9256 8 9746 mm ASSEMBLY 1 Coat outside sealing edge of five 1 1 2 in diameter cup plugs 7 with loctite adhesive Using single side plug installer and handle install five cup plugs to 0 098 0 118 in 2 5 3 0 mm below machined surfaces on right side of cylinder block 2 Coat outside sealing edge of 1 062 in cup plug 8 with loctite adhesive Using small end of double ended plug installer and driver handle install cup plug 0 098 0 118 in 2 5 3 0 mm below machined surface of rear of cylinder block 3 Install 3 8 in pipe plug 9 and pipe plug 12 4 Install four 1 4 in pipe plugs 10 and 11 5 Install stud 13 342 894 0036 00 7 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 ASSEMBLY CONTINUED 6 Position cylinder block to view left side 7 Coat outside sealing edge of 1 062 in cup plug 19 with loctite adhesive Using small end of double ended plug installer and handle install cup plug 0 098 0 118 in 2 5 3 0 mm below machined surface of front of cylinder block 8 Install two 3 8 in pipe plugs 14 and 1 4 in pipe plug 15 NOTE Cylinder block repair condit
466. ositive recti fier 2 Test negative rectifier 36 as follows a Connect negative lead of diode tester to negative rectifier 36 Touch negative lead to each of three diodes 66 High resistance should be indicated If any of three diodes show low resistance replace negative rectifier b Reverse test leads so that positive lead is connected to negative rectifier 36 Touch positive lead to each of three diodes 66 Low resistance should be indicated If any of three diodes show high resistance replace negative rec tifier 342 528 3 Check capacitor 30 using ohmmeter with positive and negative leads connected to terminals If resistance reading is low replace capacitor 342 529 0052 00 6 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 TESTING CONTINUED 4 Test rotor assembly 57 as follows a With ohmmeter connected between nut 58 and either of two slip rings 67 no reading should be obtained If any reading is obtained rotor coil 61 is grounded and rotor assembly 57 must be disassembled to repair short b Check rotor coil 61 resistance by connecting ohmmeter across both slip rings 67 Resistance should be 9 6 10 4 ohms If resistance is outside limits replace rotor coil 67 342 530 5 Test stator 22 as follows a Connect one ohmmeter lead to bare metal surface on stator lamination 68 Connect other lead to each of three sta tor leads 25 terminals High resistance rea
467. our clamps 135 and four hoses 132 133 134 and 136 130 Pow 131 i aN wee hr 132 i QU 136 M 124 N 131 133 122 13 132 134 342 944 0010 00 10 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 39 40 41 42 43 Remove screw 137 and washer 138 and rotate bracket 139 out of the way 342 945 Loosen four clamps 140 and remove pipe 141 and two hoses 142 Remove nut 143 washer 144 capscrew 145 and washer 146 from clamp 147 Loosen clamp 148 and disconnect hose 149 from transmission oil cooler 150 Loosen clamp 151 and remove hose and pipe assembly 152 342 946 0010 00 11 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 44 Remove two plugs 153 and 154 from engine flywheel housing 155 342 947 45 Attach suitable hoist and sling spreader to engine 156 Take up slack in lifting chains but do not lift engine 156 342 948 46 Remove two nuts 157 washers 158 screws 159 washers 160 isolators 161 and sleeves 162 from front engine mount 163 0010 00 12 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 REMOVAL CONTINUED 342 949 47 Right side only remove two nuts 164 washers 165 screws 166 washers 167 and bracket 168 from right engine mount 169 342 950 0010 00 13 TM 9 2320 302 34 POWER
468. out of adjustment If after doing the tests below the switch seems to be out of adjustment replace it TM 9 2320 302 20 the thermostatic switch cannot be recalibrated 1 Ensure the compressor clutch is operating correctly 2 Expose the evaporator coil 3 Start the engine Place the air conditioner control at its coldest setting turn on the air conditioner and the fan 4 Place an accurate thermometer in contact with a tube on the evaporator coil Ensure the thermometer is in good contact with the tube or you will get a wrong reading When the temperature drops below 31 F to 36 F 1 C to 2 C the compressor clutch should disengage and remain this way until the temperature rises to 39 F to 44 F 4 C to 7 C 5 If the compressor did not engage when the temperature was above the accepted high range do the follow ing test 0009 00 2 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 PERFORMANCE TESTS CONTINUED 8 a Connect a voltmeter or a test light from one of the terminals on the thermostatic switch to ground Repeat this test with the other terminal on the switch b With the engine running and the air conditioner and blower on both terminals will show voltage when the compressor should be engaged one terminal will show voltage when the compressor should be disengaged If there is no voltage there is a problem in the electrical system from the batteries to the t
469. ove adjuster lock nut 32 adjuster 33 input shaft 2 two washers 36 and two thrust bearings 37 from valve housing 20 36 37 l 2 8 36 _ ClD 342 852 25 Remove and discard seal ring 38 and packing 39 from adjuster 33 342 853 26 Remove and discard two seal rings 40 and 41 and two packings 42 and 43 from valve housing 20 27 Reverse valve housing 20 in vise and remove and discard retaining ring 44 28 Remove and discard seal 45 0089 00 8 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED 342 854 29 Remove screw 46 and washer 47 from housing 4 30 Remove and discard retaining ring 48 and seal 49 CAUTION Use care not to tap against housing bore when tapping seal and trunnion washer from housing Failure to do so will result in damage to housing 31 Tap seal 50 and trunnion washer 51 from housing 4 Discard seal 46 47 o o 49 342 855 0089 00 9 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 DISASSEMBLY CONTINUED CAUTION When using removal end of bearing and seal tool place tool only on roller bearing and not on retaining ring Failure to do so will result in damage to retaining ring and housing 32 Using removal end of bearing inserter and drive handle remove and discard roller bearing 52 33 Remove and discard reta
470. oving and discarding tiedown straps 9 Disconnect wiring harness connector 9 from compressor wiring harness connector 10 342 543 0068 00 2 TM 9 2320 302 34 AIR CONDITIONER BINARY SWITCH WIRING HARNESS REPLACEMENT CONTINUED 0068 00 INSTALLATION 1 Connect wiring harness connector 6 to binary switch 7 on receiver drier 5 2 Route one branch of wiring harness 4 to compressor 8 installing new tiedown straps in same place as removed 3 Connect wiring harness connector 9 to compressor wiring harness connector 10 4 Install grommet on branch of wiring harness 4 leading to circuit breaker panel 3 inside cab Route harness through firewall to circuit 98A on circuit breaker panel Install grommet into firewall and secure wiring harness 4 by installing new tiedown straps in same place as removed Connect wiring harness connector to circuit 98A on circuit breaker panel 3 342 541 7 Install fuse relay and circuit breaker panel TM 9 2320 302 20 8 Install access panel 2 and lock three fasteners 1 by turning clockwise 9 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0068 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0068 00 4 TM 9 2320 302 34 ENGINE INJECTOR AND ECM WIRING HARNESSES REPLACEMENT 0069 00 THIS WORK PACKAGE COVERS Engine Injector Wiring Harness Removal Engine Injector Wiring Harness Installation ECM Wiring Harness Removal ECM
471. own Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Equipment Condition Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Wiring harness and leads are secured in place by clips tiedown straps cushion clamps and screw termi nals Only remove hardware securing harness or lead to be removed Tag wiring harness and leads prior to removal to aid in installation Disconnect and remove engine wiring harness using illustrations as a guide 342 517 0056 00 1 TM 9 2320 302 34 ENGINE WIRING HARNESS REPLACEMENT CONTINUED 0056 00 REMOVAL CONTINUED 342 518 0056 00 2 TM 9 2320 302 34 ENGINE WIRING HARNESS REPLACEMENT CONTINUED REMOVAL CONTINUED 342 519 INSTALLATION NOTE Wiring harness and leads are secured in place by clips new tiedown straps cushion clamps and screw ter minals Ensure harness is secure and all hardware is tight 1 Install connect and secure engine wiring harness using illustrations as a guide 2 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0056 00 3 0056 00 TM 9 2320 302 34 This Page Intentionally Left Blank 0056 00 4 TM 9 2320 302 34 MAIN CAB WIRING HARNESS REPLACEMENT 0057 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 3
472. own straps 2 Disconnect ABS wiring harness connections using illustration as a guide TO ABS TO ECU DASH TO BULKHEAD CONNECTOR g BULKHEAD CONNECTOR 342 515 0065 00 1 TM 9 2320 302 34 CAB ANTI LOCK BRAKE SYSTEM ABS WIRING HARNESS REPLACEMENT CONTINUED 0065 00 INSTALLATION 1 Connect ABS wiring harness connections using illustration as a guide 2 Install same number of new tiedown straps as were removed to secure cab ABS wiring harness EC1 EC2 4 SWITCH FH1 BULKHEAD Ca CONNECTOR 342 516 3 Connect battery cables TM 9 2320 302 20 END OF WORK PACKAGE 0065 00 2 TM 9 2320 302 34 COLLISION WARNING SYSTEM CWS WIRING HARNESS REPLACEMENT 0066 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Straps tiedown Item 34 WP 0125 00 Tags marker Item 35 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Battery cables disconnected TM 9 2320 302 20 REMOVAL NOTE e Wiring harness and leads are secured in place by clips tiedown straps cushion clamps and screw termi nals Only remove hardware securing harness or lead to be removed Tag wiring harness and leads prior to removal to aid in installation 0066 00 1 TM 9 2320 302 34 COLLISION WARNING SYSTEM CWS WIRING HARNESS REPLACEMENT CONTINUED 0066 00 REMOVAL CONTINUED Disconne
473. p 0026 00 19 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 13 Install three new bolts 12 Tighten bolts alternately to draw thrust plate straight into gear housing assembly Tighten bolts to 22 28 lb ft 30 38 Nm 342 691 CAUTION Camshaft should be held in place while installing camshaft drive gear bolt to prevent disengaging camshaft dowel from drive gear hub 14 Coat threads and underside head of new camshaft drive gear bolt 11 with international compound no 2 and install bolt hand tight NOTE After inserting shoe of retaining plate through access hole of camshaft drive gear it may be necessary to bar engine over slightly to align bolt holes in retaining plate with bolt holes in drive gear access cover 15 Install retaining plate 6 on gear housing 7 engaging one access hole 8 in camshaft drive gear 9 Install two bolts 10 in retaining plate and gear housing 16 Tighten camshaft drive gear bolt 11 to 55 Ib ft 75 Nm Then turn bolt clockwise 120 degrees 17 Remove two bolts 10 and retaining plate 6 0026 00 20 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSTALLATION CONTINUED 342 690 18 Using dial indicator 3 place pointer in contact with side of camshaft lobe 4 19 Move camshaft 5 as far forward as possible Hold in position and zero dial indicator 3 20 Move camshaft 5 to rear as f
474. p body mounting legs are pressed in bores to specified depths Both dowels are extremely durable and should never need to be replaced 7 If removal of either dowel 26 or 27 is required place protective plate 28 on smooth surface of mounting leg 29 over dowel to be removed Tack weld washer 30 and nut 31 to dowel NOTE Secure pump body in soft jawed vise with machined smooth surfaces of mounting legs facing up 8 Attach slide hammer 32 to welded nut 31 on dowel 26 or 27 being removed and apply short upward shocking actions until dowel is freed from bore Discard dowel with welded nut and washer 342 731 INSPECTION 1 Inspect all parts for wear or damage 2 Discard pump body or pump cover if cracked or if evidence of spun bushings on bushing bores is visible 3 Inspect bushings in pump body and cover Shaft to pump body bushing clearance with new parts is 0 0016 0 0024 in 0 04 0 06 mm Maximum allowable shaft to pump cover bushing clearance with used parts is 0 0035 in 0 089 mm 0029 00 6 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 ASSEMBLY 1 Place oil pump body 20 cover side down on press support 2 Apply a thin film of lubriplate to bushing bores 33 3 Position bushings 24 loosely over pump body bushing bores 33 4 Rotate bushings 24 so split lines A and B are parallel with machined surface C of pump body 20 5 When properly aligned split line A should measure 0 46
475. p on cylinder head 2 2 Using hardware provided with engine stand adapter plate 3 bolt plate to engine stand 4 3 Using bolts provided with engine stand adapter plate 3 install engine mounting bracket 5 to cylinder head 2 4 U sing suitable lifting device lift and mount cylinder head 2 and engine mounting bracket 5 to engine stand adapter plate 3 by engaging slots 6 in engine mounting bracket to dowels 7 on engine stand adapter plate 5 Using six bolts and nuts provided with engine stand adapter plate 3 secure adapter plate and engine mounting bracket 5 together 6 Remove material lift clamp 1 7 Position cylinder head 2 in vertical position 342 1002 8 With legs of valve spring compressor 8 jaw on valve rotator 9 surrounding stem of valve 10 and with bottom of spring compressor against face of valve compress valve spring 11 9 Remove and discard valve keys 12 0032 00 2 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED 342 1003 NOTE Tag parts prior to removal for possible reuse 10 Release and remove valve spring compressor 8 11 Remove valve rotator 9 and valve spring 11 342 1004 0032 00 3 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 DISASSEMBLY CONTINUED 12 Remove valve 10 from fire deck side of cylinder head 2 10 342 1005 NOTE Remove and discard valve stem oil seal whe
476. pe assembly 152 and tighten clamp 151 10 Connect hose 149 to transmission oil cooler 150 and tighten clamp 148 11 Install washer 146 capscrew 145 clamp 147 washer 144 and nut 143 342 946 12 Rotate bracket 139 into position and install washer 138 and screw 137 0010 00 20 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 342 945 13 Install four hoses 136 134 132 and 133 and four clamps 135 14 Connect three hoses 134 132 and 133 and install four clamps 131 15 Install two clamps 123 bolts 122 and new tiedown strap 124 16 Install clamps 127 and 130 with washer 129 screw 128 washer 126 and new lock nut 125 on bracket gt 2 X 132 qu x y 136 124 N 131 133 122 13 132 134 342 944 0010 00 21 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 17 Unplug and connect oil pressure hose 121 to engine 156 342 943 18 Install drive coupler 119 and power steering pump 120 with six new lock washers 118 and screws 117 19 Install clamp 115 and screw 114 in gear case 116 114 117 118 EY 1 52 GE SES lt 5 lt 120 SS 342 942 119 116 20 Unplug and connect fuel hose 112 to primary fuel filter 113 0010 00 22 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 21 22 23
477. pe eee ee eae tee WSR Se CS 1 replaceable element Electrical System WY Peres usce xc EU I RE SEE RO AGAR ee A ees Cae ade dual 12 24 volt Batteries Quantity ee E s er RU E E ERR REN RE ERE eI Sh 4 Pes Wr RD eU tele Set e 12 volt Transmission Manufacturer o dE RR AREE RARO ER ER OPERE ARA ERROR Allison Mode dE CR AE ORE CE PCR SEU HD 4560P diy RTT 6 speed automatic ShiftSelect t zs dais VESPERE ea AS Da Sos pushbutton Front Axle Manufacturer sess e ete eq tw ed ie dee UEBER 44 we aa ea Rockwell Types cu ees hee ere ue rre etre ep eei Rien DLS Ee ate UU LX e EISE ame I beam FF961 Rated Capacity et Fades RR reb RIS EEUU E E ee 12 000 Ib 5448 kg Maximum Steering Angle 0 2 eh 32 Rear Axle Tandem Manufacturer x22 rA AIRE EDEN CR MEE ER ARCEM Rockwell RT 40 145P XPRESS ERE Beat n pd COP 38 000 Ib 17 252 kg cone Pp 4 44 1 Intersaxle Differehti l corr QUERN REG VERRE bevel gear Traction Control cc ete ee REO eR P EPA AE air controlled Brake System o croce ER RN e E ER Qe pi eso sop bees air mechanical Press re Range a eoo r EA REA RR I dey Dia Gola ee ec he erre qe 60 120 psi 414 827 kPa Airbrake Chambers SEVICE EO ed Mec me aod easter ein p QE ad Roe A RC UE 2 on front axle Failsate4Spring s oec hit os XV xp ur
478. pecial Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is ODISC4 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE title Direct Support and General Support TM 9 2320 302 34 28 May 2001 Maintenance Manual for M915A3 Tractor Truck ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA n RM 2028 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V1 00 THE METRIC SYSTEM AND EQUIVALENTS Linear Measure 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0 621 Miles Weights 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Pounds 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons Liquid Measure 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces Square Measure 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Sq Meter 10 000 Sq Centi
479. placement Rear 0102 00 0102 00 1 Hangers Replacement Front 0100 00 0100 00 1 Replacement peed eg dpe Abeta ees 0099 00 0099 00 1 Starter 4 1x cnni te beach eee poet eie ppd deel ee 0054 00 0054 00 1 Solenoid Replacement 0053 00 0053 00 1 Steering Arm Replacement Front 0076 00 0076 00 1 Column Replacement eee ANA 0090 00 0090 00 1 Gear Blepall dessus Ante ee ix eR ERN BEEN Ad 0089 00 0089 00 1 Gear Replacement 0088 00 0088 00 1 Knuckle Replacement Front 0077 00 0077 00 1 Pump Repair Power 0 00 eee eee eee 0087 00 0087 00 1 Pump Replacement Power 0086 00 0086 00 1 Steering System Theory of Operation 0 0 0 eee eee 0003 00 0003 00 7 Troubleshooting Mea et Re dia Rem eem 0008 00 0008 00 1 Storage or Shipment Preparation for 0001 00 0001 00 1 Suspension System Rear Theory of 0003 00 0003 00 8 Suspension Rear Center Bearing Replacement 0101 00 0101 00 1 Control Rod Replacement oret oreca cece eae 0103
480. plate Failure to do so could result in injury to personnel 0093 00 1 TM 9 2320 302 34 TOP PLATE REPLACEMENT CONTINUED 0093 00 REMOVAL 1 Using suitable lifting device support top plate 1 and remove two roll pins 2 Discard roll pins 2 Remove two pivot pins 3 and top plate 1 Discard pivot pins 3 Remove and discard two cushion supports 4 from slide bracket 5 342 966 INSTALLATION Install two new cushion supports 4 in slide bracket 5 2 Coat two new pivot pins 3 with antiseize compound 3 Using suitable lifting device align top plate 1 with slide bracket 5 and install two new pivot pins 3 and two new roll pins 2 END OF WORK PACKAGE 0093 00 2 TM 9 2320 302 34 TOP PLATE REPAIR 0094 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Personnel Required Direct Support Ted Tools and Special Tools References Tool kit general mechanic s Item 132 WP 0126 00 Tester kingpin lock Item 126 WP 0126 00 TM 9 2320 302 10 Wrench torque 0 300 16 Item 137 WP 0126 00 TM 9 2320 302 20 Materials Parts TM 9 237 Kit P N RK 65015 Kit P N RK 65017 Equipment Condition Compound antiseize Item 10 WP 0125 00 Top plate removed WP 0093 00 0094 00 1 TM 9 2320 302 34 TOP PLATE REPAIR CONTINUED 0094 00 DISASSEMBLY 1 Ensure locks 1 are in closed position 2 Remove and discard nut 2 washer 3 rubber washer 4 and lock adjust ta
481. plosion which could cause personnel injury or death 9 Leak test air conditioning system TM 9 2320 302 20 END OF WORK PACKAGE 0119 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0119 00 4 TM 9 2320 302 34 AIR CONDITIONER FAN CYCLING SWITCH REPLACEMENT 0120 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Oil refrigerant Item 27 WP 0125 00 Rags wiping Item 31 WP 0125 00 Tools and Special Tools Equipment Condition Tool kit general mechanic s Item 132 WP 0126 00 Refrigerant recovered WP 0112 00 Crowfoot attachment set Item 28 WP 0126 00 References Wrench torque 15 75 Ib ft Item 138 WP 0126 00 TM 9 2320 302 20 FS WARNING y Usecare to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death REMOVAL CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid N
482. pment Condition Plate cover Oil pan removed WP 0028 00 REMOVAL 1 Remove two bolts 1 from cylinder block 2 Remove oil pressure relief valve outlet tube elbow assembly 3 and oil outlet tube 4 from oil pump assembly 5 Remove oil outlet tube 4 from tube elbow assembly 3 Remove and discard two seal rings 6 and 7 342 723 0029 00 1 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 REMOVAL CONTINUED 5 Remove two lock nuts 8 and two bolts 9 from inlet oil tube bracket halves 10 Discard lock nuts 6 Remove two bolts 11 and inlet oil tube bracket halves 10 from cylinder block 2 342 724 CAUTION Oil pump must be adequately supported to prevent pump from dropping when retaining bolts are removed 7 Remove two bolts 12 oil inlet tube 13 and gasket 14 from oil pump assembly 5 Discard gasket 0029 00 2 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 REMOVAL CONTINUED 342 725 8 Remove two long bolts 15 two short bolts 16 and oil pump assembly 5 342 726 0029 00 3 3 4 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED DISASSEMBLY 1 Remove two short bolts 17 and two long bolts 18 from oil pump cover 19 and pump body 20 CAUTION Use care when removing oil pump cover to prevent damage to equipment Oil pump driven gear and shaft assembly is retained in oil pump assembly only by co
483. pply thin film of clean engine lubricating oil to outside diameter of new oil seal 15 and water pump housing bore 19 4 Support water pump housing 4 on press bed impeller side down Using small end of bearing and seal installer 18 press oil seal 15 in water pump housing bore 19 342 827 0049 00 5 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEMBLY CONTINUED 5 Apply a thin film of clean engine lubricating oil to sealing lip of oil seal Lubricate roller bearing 13 assembly Care fully install square end of water pump shaft 5 through oil seal and position roller bearing assembly in water pump housing bore 19 Using large end of bearing and seal installer 18 press roller bearing and shaft assembly 11 in water pump housing bore 19 until roller bearing 13 is seated against shoulder of water pump housing bore Install retaining ring 10 in ring groove 20 of water pump housing bore 19 10 342 828 NOTE Ensure retaining ring is fully seated in ring groove Place holding fixture 16 on press bed Install extension tool 21 in holding fixture in contact with adjusting wheel 22 NOTE Ensure water pump shaft is supported while components are being assembled Turn water pump housing 4 gear side down and position water pump shaft 5 over extension tool 21 in holding fix ture 16 0049 00 6 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 ASSEM
484. q Apply another layer of epoxy resins over fiberglass cloth 18 r After 2 5 minutes epoxy will start gelling It may take more time in cool temperatures less in hot temperatures NOTE For smoother surface press piece of masking tape wider than repair directly over wet epoxy and smooth before epoxy hardens Tape can be removed when epoxy sets up after 15 minutes s After body filler has hardened sand unexposed side of repair area to smooth flat surface if required 0106 00 6 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED t Repair damage on outside surface of hood and paint surface on both sides 10 342 589 3 Hood Component Rebonding NOTE If parts cannot be separated work folded medium grit sandpaper or section of steel hacksaw blade between two surfaces to remove old adhesive a rebonding joint that has separated or replacing damaged part completely separate part or parts using heat gun and putty knife Remove as much of old adhesive as possible Heat gun will soften adhesive and allow it to be peeled off SMC b Scuff surfaces with 100 220 grit sandpaper c Clean surfaces are to be bonded with Ashland 6036 primer or methylene chloride Inspect area closely to be sure all old adhesive is removed d If replacing large part such as fender align part on hood and clamp in place Drill hole through bonding surfaces 19 and install clamping bolt 20 in hole Install tw
485. quare and outer edge chamfer must be approximately 0 015 in 0 381 mm 12 Measure compression ring gap of top ring as shown Remove ring 16 from cylinder liner after measurement is com pleted Repeat this procedure for each ring and record measurement Allowable ring end gap is as follows a Fire ring 0 016 0 024 in 0 40 0 87 mm b Compression ring 0 32 0 051 in 0 81 1 30 mm c Oil control ring 0 016 0 032 in 0 40 0 81 mm 0041 00 14 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED CAUTION Do not spread rings more than necessary to slip them over piston dome This will prevent damage to equip ment NOTE e Do not overlap oil control ring expander ends Ensure oil control ring expander is fully seated inside oil control ring groove 13 Install new oil control ring expander 17 in oil control ring groove of piston dome 14 14 Install new oil control ring 16 by hand Oil control ring gap must be positioned 180 degrees from oil control ring expander 17 spring gap 15 With piston ring pliers install new second middle compression ring 15 with vendor s mark dimple or color dot located 30 degrees from ring gap toward piston dome 14 top 16 With piston ring pliers install new fire top compression ring 15 with vendor s mark dimple or color dot located 30 degrees from ring gap toward piston dome 14 top 342 1047 0041 00 15 TM 9 2320
486. quipment Condition Press arbor Item 90 WP 0126 00 Puller kit mechanical Item 95 WP 0126 00 Service kit water pump Item 112 WP 0126 00 i WP 0126 00 Tester impeller Item 1251 WP 0126 00 Water pump removed from engine TM 9 2320 302 Vise machinist s Item 136LWP 0126 00 20 DISASSEMBLY Z WARNING Due to size and tension of water pump cover snap ring wear adequate face and eye protection during disas sembly to prevent personal injury 0049 00 1 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 DISASSEMBLY 1 Remove snap ring 1 cover 2 and seal ring 3 from water pump housing 4 Discard seal ring 2 Hold square end of water pump shaft 5 and remove retaining bolt 6 and washer 7 342 820 3 Remove drive gear 8 with two jaw puller 9 Z WARNING Due to tension of water pump shaft bearing retaining ring wear adequate face and eye protection during removal to prevent personal injury 4 Remove retaining ring 10 342 821 0049 00 2 TM 9 2320 302 34 WATER PUMP REPAIR CONTINUED 0049 00 DISASSEMBLY CONTINUED 5 Support water pump housing 4 impeller side up and press roller bearing and shaft assembly 11 from water pump housing 4 6 Remove impeller 12 from water pump housing 4 342 822 7 Support roller bearing and shaft assembly 11 with square end of water pump shaft down Press shaft 5 from roller bearing 13 Discard roller beari
487. r 28 until it flares injector tube 64 17 Rotate flaring tool 65 and apply pressure to flare end of injector tube firmly against cylinder head 2 Do not exceed 30 Ib ft 41 Nm 18 Remove flaring and installer tools Ensure proper flare 342 1026 NOTE Turn reamer in clockwise direction only when inserting and withdrawing reamer 19 Insert injector tube reconditioning set seat reamer pilot 66 into injector bore until it contacts cylinder head Insert reconditioning set seat tip reamer pilot 67 into seat reamer until it bottoms 20 Apply a few drops of cutting oil on cutting edges of injector tube reconditioning set tube tip reamer 68 and install in pilot 67 21 Use speed handle with 7 16 in socket to turn tube tip reamer 68 in clockwise direction Use light pressure until reamer goes completely through end of injector tube WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel 22 Remove reamer and pilot Use compressed air to clear out injector tube and tip 0032 00 18 TM 9 2320 302 34 0032 00 CYLINDER HEAD REPAIR CONTINUED ASSEMBLY CONTINUED B CY Que ie 342 1027 68 Install injector tube reconditioning set stop block 69 on cylinder head fire deck 20 using two cylinder head bolts
488. r new C 5 118 5 120 130 00 130 05 Inside diameter used C 5 122 130 100 Out of round inside diameter 0 001 0 025 Taper inside diameter 0 001 0 025 CAUTION If liners are not to be installed at this time oil them lightly with clean engine lubricating oil and store them upright in a clean dry area To prevent damage do not allow liners to rest on sides or store anything on top of liners NOTE e Do not hone used liners Series 60 cylinder liners are honed at the factory with a process that cannot be duplicated in the field e When installing used liners in proper bores of cylinder block measure inside diameter at points shown in liner diagram Maximum diameter of used liner is 5 122 in 130 100 mm at any measurement loca tion Check liner taper and out of round Inside diameter of new service liner is 5 118 5 120 in 130 00 130 05 mm 17 Coat bore of liner with clean engine lubricating oil and allow liner to sit for 10 minutes to allow oil to work into surface finish Wipe inside of liner with clean white paper towels If dark residue appears on towels repeat oiling and wiping until residue no longer appears INSTALLATION CAUTION Ensure cylinder block is rotated so that cylinder block deck is up and level Failure to do so could result in damage to seal rings and crevice seal NOTE Ensure block counter bores and cylinder liner flange are free of foreign material or damage 0041 00 11 TM 9
489. r bottoms 35 Check protrusion of valve guide 14 from cylinder head 2 Height should be 1 486 in 37 75 mm 342 1033 0032 00 22 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED NOTE Procedure is the same for both intake and exhaust valve seat inserts except different tools are used 36 Position cylinder head fire deck 20 side up 37 Ensure valve seat insert counterbore 76 is clean and free of carbon deposits burrs or damage 38 Seat new valve seat insert 77 squarely in counterbore with valve seat facing up 342 1034 39 Seat valve seat installer 78 on valve seat insert 77 40 Install valve seat insert 77 solidly in valve seat in cylinder head 2 342 1035 0032 00 23 TM 9 2320 302 34 CYLINDER HEAD REPAIR CONTINUED 0032 00 ASSEMBLY CONTINUED NOTE New valve seat inserts are preground Check for concentricity after installation Do not grind new valve seat insert unless concentricity exceeds 0 002 in 0 05 mm 41 Ensure valve seat insert angle 51 is 31 degrees 42 Ensure valve seat width 52 is 0 084 in 2 14 mm for intake valves and 0 105 in 2 66 mm for exhaust valves 51 EN 7 257 mm 0 286 in 7 155 mm 0 282 in 6 363 mm 0 2505 in 45 6 261 mm 0 2465 in 342 1021 43 Grind valve seat 79 lightly for full 360 degrees only enough to true it up 342 1036 0032 00 24 TM 9 2320 302 34 CYLINDER
490. r case over gear case indexing plate 9 Index hole in gear housing assembly 5 left leg with diamond dowel 11 in lower left corner of cylinder block 7 Seat gear housing assembly firmly against cylinder block 342 926 0035 00 5 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 INSTALLATION CONTINUED 6 Install three shorter bolts in locations E F and I 7 Install nine longer bolts in locations A through D G and J through L 8 Tighten bolts to 43 54 Ib ft 58 73 Nm in letter sequence shown 342 922 TIGHTENING SEQUENCE 9 Remove gear case indexing plate 9 10 Install bolt 1 and new washer 2 in adjustable idler gear oil supply hole Tighten bolt to 15 19 Ib ft 20 26 Nm 11 Install bolt 3 and new washer 4 in adjustable idler gear holding access hole Tighten bolt to 43 54 Ib ft 58 73 Nm 0035 00 6 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 INSTALLATION CONTINUED B DLL distins AM 12 Install camshaft drive geat WP0034 00 13 Install adjustable idler gear WP0038 00 14 Install bull idler geaf WP 0037 00 15 Install synchronous reference sensor SRS TM 9 2320 302 20 16 Install timing reference sensor TRS 17 Install camshaft and bearing WP 0026 00 END OF WORK PACKAGE 0035 00 7 TM 9 2320 302 34 This Page Intentionally Left Blank 0035 00 8 TM 9 2320 302
491. r end of oil outlet tube 6 until tube bottoms in bore Position oil pressure relief valve outlet tube elbow assembly 5 on cylinder block 2 Install two bolts 4 and tighten to 22 24 Ib ft 30 33 Nm Install oil pan WP 0028 00 END OF WORK PACKAGE 0030 00 2 TM 9 2320 302 34 CRANKSHAFT FRONT OIL SEAL REPLACEMENT 0031 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support Seal P N 23518355 Cloth abrasive Item 9 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Inserter seal Item 50 WP 0126 00 Equipment Condition Remover seal Item 101 WP 0126 00 Vibration damper removed WP 0020 00 REMOVAL 1 Install seal remover 1 over end of crankshaft and against gear case cover 2 Install six self tapping screws 3 2 Install three bolts 4 in seal remover 1 until bolts contact gear case cover 2 NOTE If self tapping screws strip out of seal case remove six self tapping screws and three bolts Rotate seal remover one half distance between existing screw holes in seal case and repeat steps 1 and 2 3 Work clockwise and turn three bolts 4 one at a time one full turn until oil seal is removed Discard oil seal 342 750 0031 00 1 TM 9 2320 302 34 CRANKSHAFT FRONT OIL SEAL REPLACEMENT CONTINUED 0031 00 INSPECTION NOTE Minor wear line on crank
492. r seal ring 25 on hub of cover assembly 3 Install lockup clutch piston outer seal ring 26 on outside diameter of lockup clutch piston 24 Install lockup clutch piston 24 Install lockup clutch damper assembly 23 in cover assembly 3 Install lockup clutch backup plate 22 Secure backup plate with 44 bolts 21 Tighten bolts to 22 26 lb ft 30 35 Nm Install turbine 7 into cover assembly 3 aligning balance mark on turbine with balance mark on lockup clutch damper assembly 23 Install stator assembly 8 in cover assembly 3 Install 36 T headed bolts 4 into flange of pump assembly 5 Install thrust bearing race 9 into pump assembly 5 Install o ring 6 onto cover assembly 3 With balance marks aligned position pump assembly 5 over cover assembly 3 Install four nuts 2 evenly spaced around cover assembly 3 onto T headed bolts 4 Tighten nuts to 22 26 lb ft 30 35 Nm 0071 00 12 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Torque Converter Module Assembly Continued 342 1156 0071 00 13 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Torque Converter Module Assembly Continued NOTE Perform steps 22 through 27 to determine torque converter selective shim dimensions 22 Using a depth micrometer measure from top of torque converter drive tang surface to thrust surface of turbine hub
493. r strips could deform curves 2 On engine side of hood 12 use 220 grit sandpaper to scuff sand areas on hood and patch 10 where strips 17 will be bonded 0106 00 5 TM 9 2320 302 34 HOOD SMC REPAIR CONTINUED 0106 00 REPAIR CONTINUED NOTE If joint between parts was separated for repair rebond joint Refer to Hood Component Rebonding on page 0106 00 7 3 Hold patch 10 in place and bond strips 17 to hood 12 and patch where scuffed Use Lord Fuser 320 322 to bond strips 4 Apply light pressure and heat from heat gun to area for 3 5 minutes 5 After Lord Fuser 320 322 has hardened use 100 220 grit sandpaper to scuff strips 6 Blow dust away with compressed air and wipe area with clean cloth SS 10 e TA 342 588 m Using razor knife cut sections of woven fiberglass cloth 18 to fully cover gap 11 between hood 12 and patch 10 all around patch Fiberglass cloth should overlay about 3 4 in 19 mm on both sides of gap n Using wooden stir stick and measuring in spoonfuls mix equal volumes of Magnolia 58 A and B epoxy resins on clean sheet of glass metal or section of scrap laminate Mix 15 seconds o Use stir stick to spread thin layer of mixed epoxy resins over scuffed area on unexposed side of repair p Lay cut sections of fiberglass cloth 18 on repair area centered over gap 11 Using stir stick firmly press fiber glass cloth into epoxy to completely soak fiberglass cloth
494. r support rod TM 9 2320 302 20 END OF WORK PACKAGE 0016 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0016 00 6 TM 9 2320 302 34 BREATHER TUBE REPLACEMENT 0017 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Tools and Special Tools Direct Support Tool kit general mechanic s Item 132 WP 0126 00 REMOVAL 1 Loosen hose clamp 1 and disconnect hose 2 from rocker arm cover 3 2 Remove two bolts 4 and spacer 5 from engine block 6 3 Remove breather tube 7 and two clamps 8 4 Loosen hose clamp 9 and remove hose 2 from breather tube 7 342 649 INSTALLATION 1 Install hose 2 on breather tube 7 and tighten hose clamp 9 2 Install breather tube 7 and two clamps 9 3 Install spacer 5 and two bolts 4 on engine block 6 4 Connect hose 2 to rocker arm cover 3 and tighten hose clamp 1 END OF WORK PACKAGE 0017 00 1 TM 9 2320 302 34 This Page Intentionally Left Blank 0017 00 2 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT 0018 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Equipment Condition Direct Support Alternator removed Tools and Special Tools Air conditioner compressor removed Tool kit general mechanic s Item 132 WP 0126 00 Thermostat and thermostat housing cover removed Clamp material lift Item 20 WP 0126 00 Wrench torque 15 75 Ib ft Item 138
495. r welded assemblies such as body mounts Welded assemblies cannot be rewelded without destroying their strength and must be replaced 0105 00 2 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED 0105 00 INSPECTION CONTINUED 3 Rivet Failure Signs of rivet failure include tipped heads looseness and chipped or cracked paint If heads are tipped in the same direction and rivets are loose in consecutive groups the joint has undergone excessive load Rivet heads that are tipped in different directions and are not in groups may be improperly installed With chipped or cracked paint it may be necessary to remove paint to check true condition of rivets Rivets subjected to critical loads but showing no distortion should be inspected if failure is suspected The head should be drilled off and the shank should be carefully punched out Failure is indicated by notched rivet shank and misaligned holes Flush rivets showing head slippage within the dimple or countersink indicate either sheet bearing or rivet shear failure and must be removed for inspection and replacement If failure of rivets cannot be detected by visual inspection the joint can be checked by drilling and punching out several rivets If rivet shanks are notched rivets should be replaced with next larger size rivets If rivet holes show elongation due to local failure in tearing of the sheet next larger size rivet must be used in replacement Any deformation of the sheet around rivet t
496. ransmission oil cooler lines disconnected TM 9 Washer lock P N MS35333 42 2320 302 20 Straps tiedown Item 34 WP 0125 00 Transmission wiring harness disconnected TM 9 Tags marker Item 35 WP 0125 00 2320 302 20 Transmission oil fill tube removed TM 9 2320 302 Personnel Required 20 Two Transmission rear mount removed WP 0070 00 WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel Washer lock P N 103323 12 0010 00 1 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 NOTE Tag all wires cables connectors hoses and tubes prior to removal to aid in installation REMOVAL Remove nut 1 and washer 2 and disconnect cable 3 ground strap 4 and three wires 5 from starter 6 Remove nut 7 and washer 8 and disconnect cable 9 and four wires 10 from starter solenoid 11 Remove nut 12 and washer 13 and disconnect two wires 14 from starter solenoid 11 Remove nut 15 and washer 16 and disconnect cable 17 and two wires 18 from plate 19 Remove screw 20 washer 21 bracket 22 and plate 19 dS 342 929 6 Remove screw 23 bracket 24 and spacer 2
497. relay panel removed TM 9 2320 302 20 Cab anti lock brake system ABS wiring harness removed TM 9 2320 302 20 Collision Warning System CWS wiring harness removed WP 0066 00 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 WA y WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel REMOVAL 1 2 Remove two nuts 1 washers 2 bolts 3 and washers 4 and swing three radiator support rods 5 out of the way 1 2 3 4 342 884 Attach sling and hoist to cab assembly 6 Remove all slack from chain 6 S N ett 5 342 885 0104 00 2 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 REMOVAL CONTINUED 3 Remove two lock nuts 7 washers 8 resilient mounts 9 and screws 10 from front cab mounts 11 Discard lock nuts 342 886 4 Remove kep nut 12 clamps 13 screw 14 and washer 15 Discard kep nut 5 Carefully pull two wiring harnesses 16 and 17 from cab assembly 6 12 14 15 342 887 0104 00 3 TM 9 2320 302 34 CAB REPLACEMENT CONTINUED 0104 00 REMOVAL CONTINUED 6 Remove two lock nuts 18 washers 19 screws 20 washers 21 a
498. removed WP 0038 00 Rope 1 2 in nylon Item 32 WP 0125 00 Camshaft drive gear removed WP 0034 00 0035 00 1 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 REMOVAL 1 Remove bolt 1 and washer 2 from adjustable idler gear oil supply hole Discard washer 7 Remove bolt 3 and washer 4 from adjustable idler gear holding access hole Discard washer 342 921 lt WARNING Use extreme caution when handling heavy parts Provide adequate support and use assistance during proce dure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel 3 Using suitable lifting device and 1 2 in nylon rope through camshaft thrust plate opening support gear housing assem bly 5 and remove 12 bolts 6 342 922 0035 00 2 TM 9 2320 302 34 GEAR HOUSING ASSEMBLY REPLACEMENT CONTINUED 0035 00 REMOVAL CONTINUED 4 Using fiber or plastic mallet tap rear face of gear housing assembly 5 to loosen gear housing assembly from cylinder block 7 Remove gear housing assembly 5 342 924 CLEANING AND INSPECTION 1 Use general cleaning methods to clean all parts Remove all old gasket forming compound from mating surfaces of gear housing assembly and cylinder block 2 Inspect all parts for wear or damage 0035 00 3
499. remover base post threaded rod Tighten stop nut CAUTION Ensure timing gear is indexed with woodruff key Failure to do so could result in damage to equipment NOTE Ensure timing wheel is firmly seated against crankshaft flange 24 Operate hydraulic ram and pump 5 to press crankshaft timing gear 4 on crankshaft until timing gear is firmly seated against timing wheel 8 Obtain maximum force of 3 37 tons 30 KN when pressing crankshaft timing gear on crank shaft 342 1091 25 Remove crankshaft gear inserter remover tool 26 Measure gearlash between crankshaft timing gear and bull gear assembly Gearlash must 0 002 0 009 in 0 05 1 0 229 mm for new parts and a maximum of 0 012 in 0 305 mm for used parts 27 Install bull idler WP 0037 00 28 Install flywheel housing WP 0024 00 29 Install pistons and cylinder assemblies WP 0041 00 30 Install oil pump WP0029 00 31 Install timing reference sensor TRS TM 9 2320 302 20 32 Install synchronous reference sensor SRS TM 9 2320 302 20 END OF WORK PACKAGE 0033 00 16 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE 0034 00 THIS WORK PACKAGE COVERS Removal Disassembly Cleaning and Inspection Assembly Installation INITIAL SETUP Maintenance Level Materials Parts Continued General Support Ring seal P N 8929318 Tools and Special Tools Adhesive Item 1 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Detergent
500. rench 3 Tag and disconnect refrigerant lines 4 and evaporator coil inlet and outlet lines 5 from expansion valve 3 Install plugs in refrigerant lines evaporator coil inlet and outlet lines and expansion valve Discard preformed packings 0114 00 2 TM 9 2320 302 34 AIR CONDITIONER EXPANSION VALVE REPLACEMENT CONTINUED 0114 00 REMOVAL CONTINUED 342 575 4 Remove expansion valve 3 INSTALLATION 1 Remove plugs from refrigerant lines 4 evaporator coil inlet and outlet lines 5 and expansion valve 3 2 Install new preformed packings and lubricate with refrigerant oil 3 Apply loctite to male fitting threads and connect refrigerant lines 4 and evaporator coil inlet and outlet lines 5 to expansion valve 3 NOTE DO NOT connect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 4 Using wrenches tighten evaporator coil lines 5 to 216 Ib in 25 Nm 5 Tighten refrigerant lines 4 tighten large hose to compressor to 24 Ib ft 33 Nm tighten small hose from receiver drier to 144 Ib in 16 Nm NOTE Any time air conditioning system refrigerant is evacuated replace receiver drier 6 Replace receiver driqr WP 0118 00 T Evacuate and charge system with refrigerant WP 0112 00 8 Add refrigerant oil to compressor to replace that which was lost during system discharge WP 0116 00 WARNING Use care to prev
501. repeat steps 21 through 27 0089 00 16 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED 29 30 31 32 2 5 342 867 Place housing 4 in vise Install washer 47 and screw 46 in housing and tighten screw to 38 42 Ib ft 52 57 Nm Apply a light coat of lubricating oil to bore of housing Apply a light coat of lubricating oil to seal ring 23 Install rack piston 22 and valve housing 20 assembly in housing 4 Apply a light coat of lubricating oil to four torx head screws 21 Using torx socket install torx head screws in housing 4 Tighten screws alternately to 75 85 lb ft 102 115 Nm 342 868 0089 00 17 TM 9 2320 302 34 STEERING GEAR REPAIR CONTINUED 0089 00 ASSEMBLY CONTINUED NOTE If adjusting screw was removed perform steps 33 through 36 33 Place sector shaft 3 in soft jawed vise apply a light coat of grease to new adjusting screw 11 and install adjusting screw and new retainer 15 34 Tighten adjusting screw 11 so that end play is 0 0 002 in 0 0 05 mm but adjusting screw can still be turned by hand Check end play by hand with dial indicator 35 Stake retainer 15 into two slots in sector shaft 3 36 Ensure adjusting screw 11 can still be turned by hand and end play is still 0 0 002 in 0 0 05 mm If not repeat disas sembly step 13 and installation steps 32 through 35 342 869 37 Apply a light coat of lubricating oil
502. result in serious injury or death to personnel Also included are explanations of safety and hazardous materials icons used within the technical manual BIOLOGICAL abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health CHEMICAL drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue EAR PROTECTION headphones over ears shows that noise level will harm ears ELECTRICAL electrical wire to arm with electricity symbol running through human body shows that shock hazard is present EYE PROTECTION person with goggles shows that the material will injure the eyes FIRE flame shows that a material may ignite and cause burns FLYING PARTICLES arrows bouncing off face with face shield shows that particles flying through the air will harm face HEAVY OBJECT human figure stooping over heavy object shows physical injury potential from improper lifting technique TM 9 2320 302 34 HEAVY PARTS hand with heavy object on top shows that heavy parts can crush and harm HEAVY PARTS heavy object on human figure shows that heavy parts present a danger to life or limb HOT AREA hand over object radiating heat shows that part is hot and can burn VAPOR human figure in a cloud shows that material vapors present a danger to life or health TM 9 2320 302 34 FOR INFORMATION ON FIRST AID REFER TO FM 21
503. result in wrong oil charge oil charge may have been incorrect prior to evacuation The only way to ensure proper oil charge is to check oil level in compressor with an oil level gage 1 When handling refrigerant oil a Oil should be free of water dust metal powder and other foreign substances b DO NOT mix refrigerant oil with other types or viscosities of oil c Quickly seal oil container after use Refrigerant oil absorbs moisture when exposed to air for any period of time 0116 00 1 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR SERVICE CONTINUED 0116 00 GENERAL INFORMATION CONTINUED 2 Air conditioning system should have approximately 14 fl oz 414 ml of refrigerant oil There should be 10 fl 296 ml in compressor 3 Each major component has approximately 2 fl oz 59 ml of refrigerant oil Therefore additional oil must be added to compressor when a major component is replaced EXAMPLE If condenser and receiver drier are to be replaced first check oil level in compressor Compressor should have 10 fl oz 296 ml Add oil if needed Then after replacing condenser and receiver drier add an additional 4 fl oz 118 ml of oil to compressor Entire system should then have approximately 14 fl oz 414 ml SERVICE WARNING DO NOT remove air conditioner compressor oil fill plug without first recovering refrigerant from sys tem Failure to recover system could cause uncontrolled release of high pressure refrigerant
504. rging Oil Pump Module Assembly 1 Install ball 16 and spring 14 into front support 2 Compress spring using tool J41462 until dowel pin 15 can be inserted to retain spring Remove tool Install ground sleeve 13 on front support 2 press sleeve into front support with machined surface at base of sleeve aligned with arrow cast on front support Total runout of spline OD may not exceed 0 005 in 0 13 mm If removed install dowel pins 11 and 12 in front support 2 Press pins to a height of 0 57 in 14 5 mm from surface of front support Install front support sleeve 10 into front support 2 with lubrication hole aligned with relief valve bore Using a press and tools J37041 and J37034 install wear plate 8 to front support 2 with 14 bolts 7 Tighten bolts to 38 45 lb ft 51 61 Nm If removed install roller bearing 9 to front support 2 using a press and tools J37038 Press roller bearing flush to 0 010 in 0 25 mm below surface Install gear pump bushing 6 into inner gear of gear set 5 Align staking in pre staked bushing with slots inside gear of gear set using tool 739954 Lubricate gear set 5 with transmission oil and install gear set in pump housing 4 0071 00 20 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Front Support and Charging Oil Pump Module Assembly Continued 9 10 11 Secure pump housing 4 to front support 2 wi
505. ric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may result in death or serious injury to personnel Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately Skin Flush with large amounts of cold water until all acid is removed Seek medical attention as required Internal If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegetable oil Seek medical attention immediately Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia TM 9 2320 302 34 WARNING 2 COMPRESSED AIR Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel m rai DIESEL FUEL HANDLING e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury or death to personnel and damage to vehicle e Fuel vapors are toxic Avoid prolonged exposure or breathing of fumes Work in a well ventilated area Failure to follow this warning could result in serious injury to personnel
506. rier 5 and tighten four screws 2 in crisscross pattern Repeat step 4 until differential carrier 5 is completely seated Tighten four screws 2 to 150 230 Ib ft 203 312 Nm Install eight flat washers 3 and screws 1 Tighten screws in crisscross pattern to 150 230 Ib ft 203 312 Nm Connect intermediate driveline TM 9 2320 302 20 Install axle shafts TM 9 2320 302 20 Fill axle with oil TM 9 2320 302 20 eo en nn RB END OF WORK PACKAGE 0081 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0081 00 4 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPAIR 0082 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts Nut lock P N 40X 1026 Seal oil P N A 1205 H 2426 General Support Tools and Special Tools Adhesive silicone rubber Item 5 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Grease GAA Item 22 WP 0125 00 Oil lubricating Item 26 WP 0125 00 Dial indicator set Item 29 WP 0126 00 Paste Prussian blue Item 28 WP 0125 00 Holding bar pinion Item 47 WP 0126 00 Rags wiping Item 31 WP 0125 00 Multiplier torque wrench Item 79 WP 0126 00 Wire 14 gage Item 411 WP 0125 00 Press arbor Item 90 WP 0126 00 Personnel Required Two Scale Item 110 WP 0126 00 Equi t Conditi Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Rear rear axle differential carrier removed Wrench torque 10
507. ring washer and handle 15 Remove C1 balance piston 24 seal ring 27 and C1 spring assembly 25 16 Install tools J37030 3 J37030 1 and J35923 bearing washer and handle Tighten tool and remove retaining ring 28 Remove tools after relieving spring tension Remove spring assembly 29 and spring plate 30 View B 0071 00 24 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Disassembly Continued 17 18 19 20 21 Lift rotating drum 31 from clutch hub 18 and C1 C2 pistons 32 and 33 Inspect clutch splines of rotating drum Maximum spline wear allowed is 0 015 in 0 38 mm Remove C1 C2 pistons 32 and 33 and seal rings 34 and 35 from clutch hub 18 by rocking pistons from side to side Inspect and measure ID of rotating clutch hub housing bushing 36 Maximum allowable ID of bushing is 4 735 in 120 27 mm Remove bushing from clutch hub 18 if replacement is necessary Avoid damaging bushing bore Remove piston seal rings 37 and 38 from clutch hub 18 Separate C1 piston 32 and seal ring 35 from C2 piston 33 and seal ring 34 by lightly tapping on C1 piston 342 1168 0071 00 25 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Assembly 1 2 10 11 12 13 14 15 16 If rotating clutch hub bushing 36 was remove
508. ring gear subassembly e maintain temper of metal and reliability of part do not use open flame to heat ring gear 39 Expand ring gear 2 in tank of water heated to 160 180 F 71 82 C for 10 15 minutes 24 WARNING Hot gear can cause burns Wear heat resistant gloves 40 Remove ring gear 2 from tank and install on ring gear subassembly 50 If ring gear does not fit easily reheat and install again 41 Install 12 bolts 55 washers 54 and nuts 53 Tighten nuts to 190 225 Ib ft 260 350 Nm 55 342 1261 0080 00 21 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 42 Install two bearing cones 52 CAPE 342 1262 WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION Ensure all old adhesive has been removed from differential carrier and bearing caps to prevent damage to equipment 43 Set two bearing caps 44 and 45 on differential carrier 1 and apply a continuous bead of adhesive around entire smooth ground surfaces on both sides Do not apply adhesive to threaded areas 44 Remove two bearing caps 44 and 45 342 1219 0080 00 22 TM 9 2320 302 34 FORWARD REAR AXLE
509. rod 5 8 While holding turbocharger lever 7 down closed turn end of actuator rod 5 until hole in rod aligns with stud 6 on turbocharger lever 9 Secure actuator rod 5 end to stud 6 on turbocharger lever 7 with retaining ring 4 10 Turn actuator rod 5 end five revolutions in direction of wastegate 3 and tighten jamnut 17 11 Tighten three bolts 8 to 180 Ib in 20 Nm 0044 00 2 TM 9 2320 302 34 3K TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0044 00 INSTALLATION CONTINUED ADJUSTMENT 1 Disconnect hose 2 from wastegate 3 NOTE Dial indicator must have a minimum of 0 100 in 2 5 mm travel for measurement 0044 00 3 TM 9 2320 302 34 3K TURBOCHARGER WASTEGATE ACTUATOR MAINTENANCE CONTINUED 0044 00 ADJUSTMENT CONTINUED 2 10 11 Attach dial indicator 18 to wastegate actuator rod 5 to measure rod travel Connect air supply through regulator valve 19 shutoff valve 20 pressure gage 21 and vent valve 22 to wastegate 3 Adjust regulator valve 19 to provide 34 psi 234 kPa of air pressure to wastegate 3 Close air supply at shutoff valve 20 and observe reading on pressure gage 21 NOTE If pressure drops check actuator hose and fitting connections for leaks If none are found replace wastegate actuator Open vent valve 22 to relieve pressure and observe pressure gage 21 for zero indication Adjust regulator valve 19 to zero
510. rom the pressure drop freezes the water forming a block of ice in the valve After the system shuts down and the valve warms up the ice melts and the valve operates again only to freeze up when the moisture returns c On and off operation of the expansion valve means that the receiver drier is not removing moisture from the sys tem These contaminants should cause the moisture indicator s element to turn white and then pink 0009 00 1 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 PERFORMANCE TESTS CONTINUED 4 Refrigerant Compressor a b Compressor problems usually show in one of four ways abnormal noise seizure leakage or low suction and dis charge pressures Resonant compressor noises are not causes for alarm irregular noise or rattles are likely to be caused by broken parts 5 Evaporator a The evaporator coils are basically trouble free when airflow over the fins is not blocked External or less often internal blockages will cause low suction pressure as well as little or no cooling b Ifa leak exists in the system and it cannot be traced to other parts or fittings suspect damage to one of the evapo rator coils 6 Condenser a The condenser is usually trouble free Normally the temperature of the condenser outlet line is noticeably cooler than the inlet line However when road debris such as leaves or dirt buildup cakes up airflow over the condenser
511. ross sequence shown to 180 190 lb ft 244 258 Nm 6 342 682 TIGHTENING SEQUENCE 0025 00 6 TM 9 2320 302 34 FLEX PLATE MAINTENANCE CONTINUED 0025 00 INSTALLATION CONTINUED 8 Tighten 12 outer bolts in crisscross sequence shown to 95 115 lb ft 129 156 Nm 342 683 TIGHTENING SEQUENCE END OF WORK PACKAGE 0025 00 7 TM 9 2320 302 34 This Page Intentionally Left Blank 0025 00 8 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT 0026 00 THIS WORK PACKAGE COVERS Removal Cleaning Inspection Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Compound gasket forming Item 12 WP 0125 00 Tools and Special Tools Compound international no 2 Item 13 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Compound sealing Item 16 WP 0125 00 WP 0125 00 Dispenser sealant Item 30 WP 0126 00 Detergent Item 19 WE 0125 QU Gage bearing clearance Item 20 WP 0125 00 Oil lubricating Item 25 WP 0125 00 Rags wiping Item 31 WP 0125 00 Tags marker Item 35 WP 0125 00 Pilot cam gear Item 81 WP 0126 00 Plate retaining Item 84 WP 0126 00 Socket socket wrench Item 116 WP 0126 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Personnel Required Two Materials Parts Bolt P N 8929206 References Bolt P N 11504822 3 WP 0034 00 Ring seal P N 8929410 Equipment Condition
512. rs 17 and lower body 7 from upper body 18 Remove preformed packing 19 from lower body ds Remove primary piston retainer 20 from upper body 18 0083 00 2 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 DISASSEMBLY CONTINUED 342 196 0083 00 3 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 DISASSEMBLY CONTINUED 10 11 12 13 WARNING Internal components are under spring pressure Use care when disassembling Failure to hold components in position may result in injury to personnel While holding primary piston 21 and piston 22 in position in upper body 18 use a screwdriver in head of screw 23 to prevent screw from turning Remove lock nut 24 retainer 25 and spring 26 from screw 23 Remove screwdriver and gradually release pri mary piston 21 and piston 22 Remove primary piston 21 and spring 27 from upper body 18 Remove preformed packing 28 and rubber washer 29 from primary piston Remove sleeve nut 30 spring seat 31 and rubber spring 32 from primary piston 21 342 197 Remove screw 23 piston 22 spring 33 and retainer 34 from upper body 18 Remove two preformed packings 35 and 36 from piston NOTE Step 13 removes valve assembly from upper body Remove retaining ring 37 retaining clip 38 washer 39 retainer 40 preformed packing 41 spring 42 seat 43 and valve 44 from upp
513. rs and Breather 1 Install 12 bolts 1 two filter covers 2 new o rings 3 new square cut seals 4 and new filters 5 in control module z Install transmission breather vent 6 in torque converter housing 342 1144 0071 00 58 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED ASSEMBLY CONTINUED Installation of Output Shaft and Oil Seal 1 3 4 Install new oil seal 12 in rear cover Install output yoke 11 and new o ring 10 0071 00 Insert bolt 7 through retainer plug 8 Install a new o ring 9 on bolt so that o ring seats against retainer plug Install retainer plug 8 into yoke 11 Tighten bolt 7 to 38 45 Ib ft 51 61 Nm ie EGE 2 2 GEE Sy SLL i Ji SERE E y MMW e KN b HEM Mees Vin NY pes RO A ML SUL gt Al x e a EK 1 aille oe Ji ine AME Install engine turbine and output speed sensors 9 2320 302 20 0071 00 59 342 1145 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 TABULATED DATA Table 1 Torque Converter Selective Shims 1 9049 1 9733 mm 0 0750 0 0776 in Table 2 Wear Limits Data 1 0159 1 1938 mm 0 0400 0 0469 in 29505683 4 559 mm 0 179 in e 5e WEAR LIMIT DESCRIPTION INCHES TORQUE CONVERTER MODULE Converter Cover Bushing Maximum ID 66 91 2 634 Lockup Piston Assembly Minimum Thicknes
514. rudes from bottom of adjusting screw 23 4 Ensure plunger 35 has light spring pressure when pressed and moves freely ASSEMBLY NOTE e Procedure is the same for all three engine retarder housings e Steps 1 through 12 are for right side of engine retarder housing The same procedures to be repeated to assemble the left side 1 Install adjusting screw 23 and lock nut 22 in slave piston bridge 31 2 Install slave piston 32 in engine retarder 6 NOTE Locate part number on slave piston bridge away from engine retarder housing 3 Install slave piston bridge 31 with adjusting screw 23 toward center of engine retarder 6 housing 4 Install torsion spring 30 with ends over slave piston bridge 31 5 Install screw 28 and washer 29 over center part of torsion spring 30 on engine retarder 6 housing Tighten screw to 180 Ib in 20 Nm DE 28 29 30 342 662 0022 00 6 TM 9 2320 302 34 ENGINE RETARDER MAINTENANCE CONTINUED 0022 00 ASSEMBLY CONTINUED 10 11 12 Ensure flat spring legs are centered around master piston boss Install master piston 27 flat spring 26 washer 25 and screw 24 in engine retarder 6 housing Tighten screw to 100 Ib in 11 Nm 342 661 Turn engine retarder 6 housing over Install adjusting screw 23 and lock nut 22 in engine retarder 6 housing Hold control valve 21 by stem and drop into engine retarder 6 hous
515. runks etc 0009 00 4 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED 0009 00 AIR CONDITIONING SYSTEM COMPONENTS F A To resistor block D Toengine fan thermal switch B To blower motor E From a c clutch relay C From engine fan thermal switch F clutch 1 Compressor 9 Ignition Switch 17 Circuit Breaker 15A 2 Condenser 10 Start Button 18 A C clutch Relay 3 Receiver drier 11 Circuit Breaker 10A 19 Diode 4 Binary Switch 12 Circuit Breaker 30A 20 Compressor Clutch 5 Moisture Indicator 13 Power Relay 21 High speed Relay 6 High Pressure Relief Valve 14 Blower Switch 22 Fan Cycling Switch 7 Expansion Valve 15 On Off Microsoft 23 Discharger Service Valve 8 Evaporator 16 Thermostatic Switch 24 Suction Service Valve 0009 00 5 TM 9 2320 302 34 AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING CONTINUED AIR CONDITIONING SYSTEM TROUBLESHOOTING LOGIC TREE INSUFFICIENT CHECK COOLING AIR FLOW NORMAL AIR FLOW Inspect system for visual defects temperature Low refrigerant ICE BLOCKING EVAPORATOR Check for low suction pressure Check thermo static switch BLOWER NOT OPERATING Check for blown circuit breaker defective blower s proren wiar NORMAL BLOWER OPERATION HIGH SUCTION PRESSURE LOW Check compressor NORMA SUCTION PRESSURE HIGH AIR TEMPERATURE LOW SUCTION PRESSURE Low charge expansi
516. s 6 and cover 7 0109 00 2 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED REMOVAL CONTINUED 6 Remove torx screw 8 and defroster vent 9 7 Remove two torx screws 10 washers 11 and cover 12 8 Remove four screws 13 washers 14 and windshield support 15 342 614 13 14 0109 00 3 0109 00 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 REMOVAL CONTINUED 9 Cut away portion of seal 2 molded around cab flange 16 10 Remove each windshield glass 1 and seal 2 as an assembly from cab 4 11 Remove seal 2 from each windshield glass 1 342 616 CLEANING AND INSPECTION Use general cleaning methods to clean all parts TM 9 2320 302 20 2 If windshield is removed due to criteria outlined in Removal step 1 inspect channel of seal where marked for foreign objects and inspect mounting flange of cab for irregularities 3 Inspect all parts for wear or damage 0109 00 4 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION WARNING Wear protective gloves when handling glass Failure to do so could result in injury to personnel CAUTION e When handling windshield glass be careful not to nick or splinter edges of glass Chipped edges could cause cracking later Do not use windshield sealant Windshield sealant compounds not needed and if applied unevenly can cause leaks resulting in water damage
517. s and Technical Documents oce cate CEREREM se wie acere HE dodo Ma CERE ed MIL STD 12D Army Medical Department Expendable Durable Items 0 0 0 0 I CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items CTA 50 970 Vehicle Wheeled Preparation for Shipment and Limited Storage of MIL V 62038D 0124 00 2 TM 9 2320 302 34 EXPENDABLE AND DURABLE ITEMS LIST 0125 00 SCOPE This work package lists expendable and durable items you will need to maintain the M915A3 Truck Tractor This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items EXPLANATION OF COLUMNS 1 Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the item e g Use adhesive Item 1 WP 0125 00 J 2 Column 2 Level This column identifies the lowest level of maintenance that requires the listed item F Direct Support Maintenance H General Support Maintenance 3 Column 3 National Stock Number This is the National Stock Number assigned to the item which you can use to requisition it 4 Column 4 Description CAGEC and Part Number
518. s 0 257 Damper Assembly Plate Maximum Distortion 0 020 Damper Assembly Plate Minimum Thickness 0 335 Turbine to damper Maximum Spline Wear 0 015 Backplate Maximum Distortion 0 006 Backplate Minimum Wear Surface Thickness 11 79 0 464 Turbine Hub Minimum OD 66 69 2 626 Stator Thrust Plate Minimum Thickness 0 372 Converter Pump Hub Minimum OD 88 99 3 504 to Oil Pump Drive Hub Maximum Tank Wear 0071 00 60 TORQUE CONVERTER HOUSING MODULE PTO EQUIPPED TM 9 2320 302 34 Table 2 Wear Limits Data WEAR LIMIT DESCRIPTION Turbine Shaft Bushing Maximum ID Turbine Seal Minimum End Gap 7 S C2 Backplate Minimum Thickness Backplate Maximum Step Wear 0 005 Backplate Maximum Distortion 0 006 P1 Ring Thrust Plate Minimum Thickness at Wear Point 0 111 0071 00 61 C1 C2 Friction Plate Minimum Thickness TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 Table 2 Wear Limits Data Continued WEAR LIMIT DESCRIPTION INCHES MAIN HOUSING MODULE CONTINUED 1 Ring Gear Spline Maximum Wear C3 C4 C5 Friction Plate Minimum Thickness C3 C4 C5 Reaction Steel Plate Maximum Cone C3 C4 C5 Reaction Steel Plate Minimum Thickness Main Housing Maximum Spline Wear MAIN SHAFT MODULE WIDE RATIO AND CLOSE RATIO EE ERES Main Shaft Bearing Journal Minimum OD Main S
519. s Parts Direct Support Cloth abrasive Item 9 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Brake drum removed from vehicle TM 9 2320 302 Lathe brake drum Item 74 WP 0126 00 20 REPAIR CAUTION If maximum inside diameter is exceeded to prevent damage to equipment brake drum must be replaced 1 Check brake drum inside diameter Refer to Table 1 for diameter 2 Brake drum 1 must be round within 0 003 in 0 076 mm If brake drum is out of round machine brake drum Refer to Table 1 for machining specifications 342 985 3 Check brake drum surface 2 for cracks or badly scored finish If brake drum is cracked or scored machine brake drum Refer to Table 1 for machining specifications 4 Check brake drum surface 2 for glossy or heat spots If glossy or heat spots are visible clean brake drum surface with abrasive cloth 5 Check brake drum 1 for external or mating surface cracks If cracks are visible replace brake drum 6 Check brake drum 1 for balance weight If balance weight is missing replace brake drum 0085 00 1 TM 9 2320 302 34 BRAKE DRUM REPAIR CONTINUED REPAIR CONTINUED Table 1 Machining Specifications INSIDE DIAMETER NEW MACHINE BRAKE DRUM IN MM IN MM M915A3 FRONT 15 0 381 0 0 12 4 00 M915A3 REAR 16 5 419 1 0 12 4 00 7 Install brake drum 9 2320 302 20 END OF WORK PACKAGE 0085 00
520. s not expanded Install seal ring 13 into seal ring bore of torque converter pump housing and measure end gap with feeler gage Seal ring end gap must be 0 047 0 065 in 1 19 1 65 mm If seal ring is not within tolerance ring has expanded and must be replaced Remove seal ring 13 from pump housing seal ring bore and install onto PTO gear 6 If removed install bearing retainer bushing 11 using press and tools 737038 and 18092 Install new seal ring 9 onto bearing retainer 5 and install new oil seal 10 using press and tools J37032 and J37034 Install new seal ring 8 into seal ring bore in PTO gear 6 and measure end gap with thickens gage Seal ring 8 end gap must be 0 047 0 065 in 1 19 1 65 mm If seal ring is not within tolerance ring has expanded and must be replaced Remove seal ring 8 from seal ring bore in PTO gear 6 and install seal ring onto bearing retainer 5 Using a mallet lightly tap PTO gear 6 assembly into converter housing 7 until gear assembly is seated Use guide bolts to install bearing retainer assembly 5 rocking retainer while installing into converter housing 7 Install 11 bolts 4 to secure bearing retainer assembly 5 and PTO gear 6 assembly into converter housing 7 Tighten bolts to 38 45 Ib ft 51 61 Nm Install PTO cover 2 and new gasket 3 with ten bolts 1 Tighten bolts to 38 45 Ib ft 51 61 Nm 0071 00 16 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUE
521. s wet humid NOTE DO NOT disconnect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with a second wrench 4 Tag and disconnect refrigerant lines 6 and evaporator coil inlet and outlet lines 7 from expansion valve 3 Install plugs in refrigerant lines evaporator coil inlet and outlet lines and expansion valve Discard preformed packings 0115 00 2 TM 9 2320 302 34 AIR CONDITIONER EVAPORATOR COIL REPLACEMENT CONTINUED 0115 00 REMOVAL CONTINUED 342 575 5 Remove thermostatic switch and sensor tube from evaporator coil TM 9 2320 302 20 WARNING Failure to wear protective gloves could result in serious skin cuts due to sharp edges on evaporator coil fins 6 Wearing protective gloves slide evaporator coil up and out of housing INSTALLATION l Wearing protective gloves slide evaporator coil into housing 2 Insert thermostatic switch and sensor tube Tip of sensor tube must be in direct contact with a fin and be inserted at least 4 inches 10 cm into evaporator 3 Remove plugs from refrigerant lines 6 evaporator coil inlet and outlet lines 7 and expansion valve 3 4 Install new preformed packings and lubricate with refrigerant oil 5 Apply loctite to male fitting threads and connect refrigerant lines 6 and evaporator coil inlet and outlet lines 7 to expansion valve 3 NOTE DO NOT connect refrigerant fittings using only one wrench Hold one f
522. se With engine running open low side and high side hose valves to recover refrigerant from lines 4 Shut down engine 5 Leak test air conditioning system TM 9 2320 302 20 6 Check operation of air conditioning system TM 9 2320 302 10 END OF WORK PACKAGE 0112 00 6 TM 9 2320 302 34 HVAC UNIT REPLACEMENT 0113 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Cap set Item 7 WP 0125 00 Compound gasket forming Item 12 WP 0125 00 Oil refrigerant Item 27 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Rags wiping Item 31 WP 0125 00 Dispenser sealant Item 30 WP 0126 00 Tags marker Item 35 WP 0125 00 Gloves rubber Item 40 WP 0126 00 Tape insulation Item 36 WP 0125 00 Goggles Item 42 WP 0126 00 Personnel Required Wrench torque 15 75 Ib ft Item 138 WP 0126 00 is References Materials Parts Packing preformed P N 2 011C944 70 Equipment Condition Packing preformed P N 2 015C944 70 Cooling system drained TM 9 2320 302 20 Adhesive loctite Item 2 WP 0125 00 Refrigerant recovered WP 0112 00 Dy Kx PS y e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a a
523. se hoist with lifting capacity of 5000 Ib 2270 kg to lift and support power pack Failure to do so could result in injury to personnel CAUTION e Ensure all harnesses tubes and hoses are clear of power pack prior to installation Failure to do so could result in damage to equipment e Keep power pack clear of frame Failure to do so could result in damage to equipment l Using suitable hoist and sling spreader maneuver power pack into vehicle 2 Alternately lower hoist in small increments until power pack is in place 3 Right side only install bracket 168 two washers 167 screws 166 washers 165 and nuts 164 in right engine mount 169 Do not tighten nuts 342 950 0010 00 18 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 4 Left side only install two washers 173 screws 172 washers 171 and nuts 170 in left engine mount 174 Do not tighten nuts 342 951 5 Install two sleeves 162 isolators 161 washers 160 screws 159 washers 158 and nuts 157 in front engine mount 163 0010 00 19 TM 9 2320 302 34 POWER PACK REPLACEMENT CONTINUED 0010 00 INSTALLATION CONTINUED 6 Tighten four nuts 164 and 170 on two rear engine mounts 169 and 174 7 Install two plugs 153 and 154 in engine flywheel housing 155 342 947 8 Install two hoses 142 and pipe 141 and tighten four clamps 140 9 Install hose and pi
524. se shim pack removed in Disassembly step 48 9 Install shim pack 63 Using press install inner bearing cup 62 in differential carrier 1 until bottom of inner bearing cup touches shim pack 342 1254 10 Turn differential carrier 1 over and install supports so that differential carrier is level on press 11 Using press install outer bearing cup 61 until bottom of outer bearing cup touches bottom of bore 342 1255 12 Install drive pinion 3 from bottom of differential carrier 1 Install support under head of drive pinion 0080 00 16 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 13 14 15 NOTE Apply no more than two tons of pressure to seat bearing cups Install outer bearing cone 57 on shaft of drive pinion 3 Using press seat two bearing cups 61and 62 Using press remove drive pinion 3 Remove outer bearing cone 57 61 62 m SUPPORT 0222 3 SUPPORT 342 1256 WOOD BLOCK 0080 00 17 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR CONTINUED 0080 00 ASSEMBLY CONTINUED 16 17 18 19 20 21 22 23 24 Install differential carrier 1 on press with legs of differential carrier toward top of press Install gear 15 with splines toward front of differential carrier 1 Install large diameter spacer 59 on top of gear 15 with spacer toward inner bearing cup 62
525. seal contact surface Oil leaks may result if this surface is scratched 4 Install bull idler gear 6 on two guide studs 4 Slide assembly toward engine but do not engage any gears 5 Align timing mark 12 on bull idler gear 6 with timing mark 9 on crankshaft timing gear Engage bull idler gear and crankshaft timing gear only enough to prevent rotation of bull idler gear NOTE Slight rotation of adjustable idler gear may be necessary to align timing marks 6 Looking through viewing hole 13 in bull idler gear 6 align timing mark 14 on adjustable idler gear with timing mark 15 on camshaft idler gear 7 Slide bull idler gear 6 toward engine engaging adjustable gear and seat assembly in recess of gear case and cylinder block 3 Q 10 2 N 14 13 4 4 6 12 9 342 909 8 Working through two access holes 2 in bull idler gear 6 install two mounting bolts 3 through hub and into cylinder block Tighten bolts hand tight 9 Remove two guide studs 4 and install two remaining mounting bolts 3 Tighten four bolts to 75 86 Ib ft 102 117 Nm 10 Remove crankshaft protector 5 and engine barring tool 1 0037 00 4 TM 9 2320 302 34 BULL IDLER GEAR REPLACEMENT CONTINUED 0037 00 INSTALLATION CONTINUED 342 910 11 Measure gear lash between crankshaft timing gear 16 to bull idler gear 6 Allowable lash is 0 002 0 009 in 0 051 0 229 mm for new parts and a maximum of 0 012 in 0 305 mm
526. shaft surface should be evident where contact was made with oil seal This is nor mal 1 Inspect oil seal contact surface of crankshaft for dirt burrs or rough surfaces 2 If necessary clean crankshaft surface with abrasive cloth INSTALLATION 1 Coat outside diameter of new oil seal 5 with a light film of clean engine lubricating oil 2 Coat outside of crankshaft 6 with a light film of clean engine lubricating oil 342 751 NOTE Ensure butt end of crankshaft both sides of seal inserter base and inside of seal inserter housing are clean smooth and free of foreign material or damage 3 Position seal inserter base 7 on front of crankshaft 6 Install two guide studs 8 through two holes in seal inserter base 7 and into two crankshaft pulley vibration damper mounting bolt holes 180 degrees apart Hand tighten two guide studs 8 until seal inserter base 7 is tight against end of crankshaft 6 Install oil seal 5 onto crankshaft 6 as far as it will go by hand Position seal inserter collar 9 against oil seal 5 Install seal inserter housing 10 over center screw 11 of seal inserter base 7 and two guide studs 8 and against oil seal 5 9 Install thrust bearing 12 on center screw 11 with case side of thrust bearing against seal inserter housing 10 10 Install and tighten seal inserter nut 13 until inside surface of seal inserter housing 10 is firmly seated against s
527. sket installation lightly spray a solution of soapy water into seal groove of rocker arm cover 3 Position rocker arm cover gasket 9 in rocker arm cover 5 4 Install rocker arm cover gasket 9 beginning at corners 7 of saddle arch 8 on each end of rocker arm cover 5 Work back into saddle arch equally from each corner 7 pushing gasket firmly into rocker arm cover groove 5 Beginning at center of rocker arm cover 5 install long runs of rocker arm cover gasket 9 toward corners 7 of saddle arches 8 and continue until gasket installation is completed 342 646 6 Apply a thin bead of gasket forming compound in front and rear corners 12 of cylinder head 6 where front and rear cam caps are located T Position rocker arm cover 5 on cylinder head 6 8 Install ten bolt assemblies 4 in rocker arm cover 5 6 R S Of m Jo 4 Ug d HE EDI wy 0016 00 4 TM 9 2320 302 34 ROCKER ARM COVER REPLACEMENT CONTINUED 0016 00 INSTALLATION CONTINUED 9 In sequence shown tighten ten bolt assemblies to 22 28 lb ft 30 38 Nm 9 8 10 5 342 648 TIGHTENING SEQUENCE 10 Install crankcase breather tube 2 over rocker arm cover neck 3 and secure with hose clamp 1 342 642 11 Install air cleaner pre cleaner and duct assembly TM 9 2320 302 20 12 Install thermostat to radiator coolant tube TM 9 2320 302 20 13 Install radiato
528. ss bottoms out in channel of seal 342 611 0109 00 6 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION CONTINUED 11 Using windshield pick go all the way around between each windshield glass 1 and seal 2 to make sure seal is prop erly seated 342 618 12 Install two cords in outside groove in seal 2 and leave safety loops in center 13 Using soap and water solution lubricate cord channel of seal 2 342 619 0109 00 7 TM 9 2320 302 34 WINDSHIELD REPLACEMENT CONTINUED 0109 00 INSTALLATION CONTINUED 14 Wet mounting flange of cab 4 with clear water 15 Place windshield glass 1 assembly into windshield opening of cab 4 16 With assistant pushing lightly on bottom center of windshield glass 1 assembly pull one end of lower cord around cor ner of windshield glass assembly go to other side and pull lower cord around other corner of windshield glass assembly Have assistant push lightly at top center of windshield assembly Repeat for top cord NOTE e If cord binds or starts to tear seal use safety loop at center and pull back toward point where cord is bound If safety loop is not needed it will pull out when cord is pulled to seat final portion of seal 17 With assistant applying light pressure to center of windshield glass 1 assembly pull both ends of either top or bottom cord alternately until only a few inches from center pull both ends at
529. ss hole 12 and position fan support bracket 3 on gear case cover 10 342 978 0013 00 3 TM 9 2320 302 34 FAN DRIVE SUPPORT REPLACEMENT CONTINUED 0013 00 INSTALLATION CONTINUED 2 Install five adjustable idler gear cover bolts 9 hand tight 342 9 3 Install short bolt 7 through bottom hole in fan support bracket 3 and long bolt 8 through right hand bolt hole Tighten bolts to 118 148 Ib ft 160 200 Nm 4 Install two bolts 6 through bolt holes at top of fan support bracket 3 Tighten bolts to 43 54 Ib ft 58 73 Nm 342 976 5 Tighten five adjustable idler gear cover bolts 9 to 22 28 lb ft 30 38 Nm 6 Install bolt 5 through top left hand bolt hole in fan support bracket 3 and through gear housing stabilizer bracket 7 Install nut 4 and tighten bolt 5 to 43 54 lb ft 58 73 Nm 0013 00 4 TM 9 2320 302 34 FAN DRIVE SUPPORT REPLACEMENT CONTINUED 0013 00 INSTALLATION CONTINUED 342 975 8 Position front engine lifting bracket 2 on fan support bracket 3 and install two bolts 1 Tighten bolts to 75 93 Ib ft 102 126 Nm 342 974 9 Install spindle and housing assembly TM 9 2320 302 20 END OF WORK PACKAGE 0013 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0013 00 6 TM 9 2320 302 34 AIR INTAKE MANIFOLD REPLACEMENT THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Direct Supp
530. ssory drive pulley retaining nut to align access hole 6 Install retaining plate 6 on gear housing 7 engaging one access hole 8 in camshaft drive gear 9 Install two bolts 10 in retaining plate 6 and gear housing 7 7 Remove camshaft drive gear bolt 11 Discard bolt 8 Remove two bolts 10 and retaining plate 6 from gear housing 7 er 342 690 0026 00 3 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED CAUTION Clean rag may be inserted into gear housing assembly opening to trap bolts in case they are dropped DO NOT allow rag to drop into gear housing assembly to prevent damage to equipment NOTE It may be necessary to bar engine over to align access holes in camshaft drive gear with mounting bolts in camshaft thrust plate 9 Remove and discard three bolts 12 342 691 NOTE Performing step 10 will move camshaft drive gear hub and thrust plate forward approximately in 6 7 mm until thrust plate seal is clear of camshaft front bearing cap and cylinder head 10 Install cam gear pilot 13 on camshaft drive gear access opening 14 and install three bolts 15 Thread pilot puller screw 16 into end of camshaft drive gear hub until puller screw bottoms out 342 692 0026 00 4 TM 9 2320 302 34 0026 00 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED REMOVAL CONTINUED If there is doubt of camshaft acceptability determine ex
531. stall 38 washers 16 and cylinder head bolts 15 in cylinder head 3 15 342 653 12 Initially tighten 38 cylinder head bolts 15 to 185 210 lb ft 251 285 Nm in sequence shown 342 656 31 24 23 316 151 21 55 6 27 28 9 TIGHTENING SEQUENCE 0018 00 6 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 INSTALLATION CONTINUED 13 Finally tighten 38 cylinder head bolts 15 to same torque and sequence as in step 12 14 Install bracket 14 on cylinder head 3 and install two bolts 11 Tighten bolts to 43 54 Ib ft 58 73 Nm 15 Install bolt 13 through gear case cover and housing assembly and install nut 12 Tighten nut to 43 54 lb ft 58 73 Nm 16 Connect air compressor hose 9 with clamp 10 to cylinder head 3 0 0000000 WG 097 e dn S o S 23 4 SR SS Ol py 2 gt 10 342 652 17 Position wiring harness 8 in place and install two washers 7 and bolts 6 18 Position bracket 5 in place and install bolt 4 0018 00 7 TM 9 2320 302 34 CYLINDER HEAD REPLACEMENT CONTINUED 0018 00 INSTALLATION CONTINUED 19 Connect two fuel lines 1 and 2 to cylinder head 3 it CCU KU su 342 650 20 Install injector wiring harnes WP 0069 00 21 Install fuel injector WP0046 00 22 Install camshaft and bearing WP 0026 00 23 Connect air compressor cooling
532. sting 0040 00 0040 00 1 Cylinder Head Rapal S used at pied 0032 00 0032 00 1 Replacement ede eR ee e ee de ened CH e ete 0018 00 0018 00 1 D Damper Replacement Vibration 0020 00 0020 00 1 Data Equipment lcm eere ye X Hager se A ee a bond 0002 00 0002 00 6 Destruction of Army Materiel to Prevent Enemy Use 0001 00 0001 00 1 Differential Carrier Repair Forward rear Axle Rer eer eor T c pel a Bees 0080 00 0080 00 1 Rearsrear Axle ot Pest SEX ee dae ae TE 0082 00 0082 00 1 Differential Carrier Replacement Forward rear Axle sure re Er EE Era E mee ER Be 0079 00 0079 00 1 Rear rear Axle coss s es exea ex REA RES DE 0081 00 0081 00 1 Door Cab eaten Stent nade oan ded wee DEM ESAE 0108 00 0108 00 1 Replacement di dein ga ates May ala big Genie TERI D ana A 0107 00 0107 00 1 Drive Gear Maintenance Camshaft 0034 00 0034 00 1 Drive Repair Accessory 0039 00 0039 00 1 Drive Replacement Accessory 0021 00 0021 00 1 Drive Support Fan 0013 00 0013 00 1 Drive Train Theory of Operation 0003 00 0003 00 1 Dr m Repair Brake
533. sunk Blind Rivets COUNTERSINKING DIMENSIONS 100 C 842 580 01 OR MIN RIVET Table 4 Minimum Sheet Gage for 100 Degree Machine Countersink RIVET SIZE IN 3 32 5 32 3 16 GAGE IN 6 Solid Rivet Installation NOTE When replacing rivets during repair use same rivet size and type if possible If hole has been damaged it will be necessary to drill hole oversize and use next larger rivet or oversize blind rivet a After drilling and prior to driving rivets parts to be joined must be secured to prevent slipping during riveting C clamps may be used or any of several varieties of skin fasteners may be inserted in previously drilled holes CAUTION When riveting thin gage materials be careful handling rivet tools to avoid damaging material b Solid rivets are available in various lengths Correct length rivet must be chosen so bucked head is not too small or too large to form tight fit Use Table 5 to determine proper rivet length c Three common methods of driving or setting rivets are hand squeeze and pneumatic gun All three methods use principle of upsetting or heading rivet shank against bucking bar 0105 00 6 TM 9 2320 302 34 CAB BODY REPAIR CONTINUED RIVET REPLACEMENT CONTINUED Table 5 Calculating Correct Solid Rivet Length RIVET DIAMETER MATERIAL THICKNESS 1 4 in or less 1 1 2 x diameter of rivet 1 4 in or less over 2 in 1 1 2 x diameter of rivet 1 16 in for every 2 in o
534. t firmly without too much pressure Bucking bar permitted to slide and bounce over rivet Buckled shank Improper rivet length and E E above and rivet of proper Replace rivet above length 9 Blind Rivet Driving Practices and Precautions a Rivets should be inspected for proper installation Grip length of each rivet is marked on top of rivet head to pro vide positive identification Use of proper grip length will produce rivet installation where locking collar is flush with top surface of rivet head Tolerance limit on flushness is 0 020 in 0 5 mm b For proper rivet installation it is imperative that holes be properly prepared tools be in good working order and rivets be properly applied When problems occur source of trouble could be in any of these areas Blind Rivet Installation CAUTION e Proper length rivet must be selected for each application to prevent damage to equipment Rivet lengths are sized by range of material thickness that rivet will grip e Rivets can tolerate only 1 16 in variation in material thickness for each particular rivet length to prevent damage to equipment Rivet grip lengths are called out as dash number at end of manufacturers part number e For double dimpled sheets add countersunk head height to materials thickness to prevent damage to equipment NOTE e Prior to installing blind rivets hole must be prepared and parts must be aligned and clamped firmly in place
535. t Packing preformed P N J200AR11 Tools and Special Tools Packing preformed P N 2 013C557 70 Tool kit general mechanic s Item 132 WP 0126 00 Adhesive loctite Item 2 WP 0125 00 Crowfoot attachment set Item 28 WP 0126 00 Cap set Item 7 WP 0125 00 Gloves rubber Item 40 WP 0126 00 Oil refrigerant Item 27 WP 0125 00 Goggles Item 42 WP 0126 00 Rags wiping Item 31 WP 0125 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Tags marker Item 35 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 References TM 9 2320 302 20 Equipment Condition Refrigerant recovered WP 0112 00 gt e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant e Refrigerant R 134a air conditioning systems should not be pressure tested or leak tested with com pressed air Combustible mixtures of air and R 134a may form resulting in a fire or explosion which could cause personnel injury or death REMOVAL CAUTION Water and dirt can damage refrigerant system Five minutes of not being capped is the limit for any hose or component DO NOT blow shop air through refrigerant hoses Shop air is wet humid NOTE DO NOT disconnect refrigerant fittings using only one wrench Hold one fitting in place using a wrench and turn other fitting with
536. t injector per cylinder a transfer pump low pressure fuel lines and primary and secondary fuel filters The engine is governed by an electronic control system The system controls idle speed and limits engine maximum speed The driver controls engine speed through the position of the electronic throttle position sensor foot pedal Fuel filters are spin on types The primary fuel filter has a hand fuel primer pump and a water drain Fuel may be drained from the tank through the drain port located on the bottom of the tank There is a computer controlled ether quick start system for use in cold weather 0003 00 1 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 FUEL SYSTEM CONTINUED CYLINDER HEAD RESTRICTED X FITTING UPPER ITTING FUEL PUMP PRIMARY FUEL FILTER WITH HAND PRIMER Suc FUEL TANK 342 004 EXHAUST SYSTEM The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger The gases flow into exhaust pipes and a muffler to the atmosphere above the cab EXHAUST MANIFOLD TURBOCHARGER MUFFLER EXHAUST PIPES 342 005 0003 00 2 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 COOLING SYSTEM The cooling system consists of one circulating pump a remote mounted coolant filter two 180 F 82 C thermostats for con trolling fluid flow a transmission oil cooler a radiator and a belt driven fan The cooling system cools the engine b
537. tall new valves If valve faces are warped or valve stem is bent replace valves Minimum valve stem diameter is 0 342 in 8 679 mm for intake valve and 0 343 in 8 714 mm for exhaust valve 19 Inspect guides for cracks chipping scoring and excessive wear 20 Measure valve guide bore with small hole gage or gage pin and measure valve stem diameter with micrometer Com pare measurements to determine valve stem clearance If clearance is greater than 0 006 in 0 152 mm valve guide must be replaced NOTE New valve seat inserts are preground Check for concentricity after installation Do not grind new valve seat insert unless concentricity exceeds 0 002 in 0 05 mm 21 Ensure valve seat insert angle 51 is 31 degrees 22 Ensure valve seat width 52 is 0 084 in 2 14 mm for intake valves and 0 105 in 2 66 mm for exhaust valves Sx ra 7 257 mm 0 286 in ANS 7 155 mm 0 282 in NM ee 6 363 mm 0 2505 in B 6 261 mm 0 2465 in 342 1021 1 If removed install seven hollow dowels 53 on cylinder head 2 to height of 0 197 0 010 in 5 0 0 5 mm 52 ASSEMBLY CAUTION Ensure diamond dowels are correctly aligned Failure to do so could result in engine failure 2 If removed install three diamond dowels 54 to height of 0 240 0 010 in 6 1 0 5 mm Angular orientation of dia mond dowels must be parallel to centerline through dowel holes within 4 degrees as shown 0032 00 14 TM 9 2320 302 34 C
538. talling rear window glass only perform steps 1 through 4 If installing rear window glass and seal per form steps through 6 1 Lubricate rear window channel of rubber extrusion 2 with detergent and water solution 2 Slide rear window glass 1 into window channel of rubber extrusion 2 as far as it will go without forcing 3 Using windshield pick alternate between top and bottom or rear window glass 1 and work rubber extrusion 2 over edge of rear window glass 0110 00 2 TM 9 2320 302 34 REAR WINDOW REPLACEMENT CONTINUED 0110 00 INSTALLATION CONTINUED 4 Using windshield pick install locking strip 3 in rubber extrusion 2 342 880 0110 00 3 TM 9 2320 302 34 REAR WINDOW REPLACEMENT CONTINUED 0110 00 INSTALLATION CONTINUED 5 With locking strip 3 facing out install rubber extrusion 2 over mounting flange 5 of cab 4 3 342 881 6 Apply sealing compound ONLY at point where both ends of rubber extrusion 2 meet 342 882 END OF WORK PACKAGE 0110 00 4 TM 9 2320 302 34 AIR DUCTS REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 REMOVAL 1 Remove eight retainers 1 and four air cylinders 2 0111 00 Equipment Condition Air system drained TM 9 2320 302 10 Dash panels removed for access TM 9 2320 302 20 01
539. tch housing 26 Maximum spline wear allowed is 0 045 in 1 15 mm C3 C4 Clutch Assembly and Main Housing Module Assembly Install new seal rings 24 and 25 on piston 23 Install piston with seal rings into C4 housing 26 Install spring retainer 22 on piston 23 and in C4 housing 26 If removed install new return spring assemblies 21 and attach them securely to piston return plate 20 Install piston return plate 20 with return spring assemblies 21 into C4 clutch housing 26 WP orn Install C4 clutch pack starting with a friction plate 18 Alternately install five friction plates 18 and five steel reac tion plates 19 0071 00 29 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED C3 C4 Clutch Assembly and Main Housing Module Assembly Continued 10 11 12 13 14 15 16 Perform step 6 only if C3 clutch housing was disassembled If clutch housing was not disassembled proceed to step 7 Install four thrust plates 16 using 12 rivets 17 into C3 clutch housing 15 Use tool J39534 to cold form rivets Insert rivet from front so that preformed head is below active surface of thrust plate Use cold forming tool to upset rivet at rear of clutch housing to complete riveted joint A correctly formed rivet upset will be 0 157 in 4 00 mm in diameter and no more than 0 039 in 1 00 mm above surface of clutch housing Thrust plate must be
540. ted within the structure Technical instructions include metric units in addition to standard units A metric conversion chart is provided on the inside back cover An alphabetical index is provided at the end of the manual to assist in locating information not readily found in the Table of Contents FOLLOW THESE GUIDELINES WHEN YOU THIS MANUAL Read through this manual and become familiar with its contents before attempting to maintain the vehicle A Warning Summary is provided at the beginning of this manual and should be read before attempt ing to maintain the vehicle TM 9 2320 302 34 This Page Intentionally Left Blank vi TM 9 2320 302 34 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION TM 9 2320 302 34 This Page Intentionally Left Blank TM 9 2320 302 34 GENERAL INFORMATION 0001 00 SCOPE 1 Type of Manual This manual is for use in performing Direct Support and General Support Maintenance on the M915A3 Tractor Truck 2 Equipment Name and Model Number Truck Tractor Line Haul 52 000 GVWR 6 X 4 M915A3 3 Purpose of Equipment The M915A3 Tractor Truck is a 6 X 4 prime mover of semitrailers used primarily to transport containers bulk cargo and petroleum products over primary and secondary roads under worldwide climatic conditions in a military environment MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be
541. teners fastener is loaded in shear Fastener is loaded in tension when load is along axis of fastener causing pull on each end of fastener Rivets 1 are designed to be loaded in shear Do not create new joints during repairs that cause rivets to be used in tension application Bolts 2 should be used for tension applications or substituted for rivets in very high shear load applications lx RIVETS LOADED IN SHEAR 2 2 ww BOLTS REPLACING RIVETS LOADED IN TENSION 342 583 5 Repair Parts Preparation d Paint repair parts or patches with epoxy primer before installation Apply sealing compound to mating surfaces to prevent corrosion Install part or patch as detailed in Repair by Patching and Repair by Insertion on pages 0105 00 12 and 0105 00 13 Paint repaired area with epoxy primer Paint repaired area with polyurethane as required 6 Repair of Negligible Damage a Negligible cracks as defined in classification above are repaired by drilling small hole at each end of crack to stop crack propagation This is called stop drilling Table 8 gives proper drill sizes for stop drilling cracks Negligible holes are repaired by rounding and smoothing edges of hole to alleviate stress risers caused by sharp notches CAUTION Never use heat to reform parts Heat greatly reduces part strength Small dents and distorted areas may be repaired by bending or hammering as long as operation does not cause materia
542. tent of camshaft lobe wear as follows Using set of 0 0015 0 010 in 0 038 0 254 mm thickness gages 17 and piece of square hard material 18 mea a sure flats on injector rise side 19 of camshaft lobes 4 If flats measure less than 0 003 in 0 076 mm in depth but there are no other camshaft defects camshaft is satis 11 factory na a CP DER eS SS 6 1 o B 0 N AS t7 Nw AG SG lt 7 AS REAR VIEW 342 693 18 0026 00 5 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 REMOVAL CONTINUED 12 Remove four camshaft cap bolts 20 13 Using rocker stud socket remove two rocker shaft studs 21 and seals 22 from camshaft bearing caps 23 no 1 and no 7 Discard seals CAUTION Camshaft bearing caps are numbered and must be kept in sequence and reinstalled in original positions to prevent damage to equipment Camshaft bearing caps cannot be interchanged or transferred to another cylin der head NOTE If camshaft bearing shells are to be reused tag all parts Shell must be kept with same camshaft bearing cap 14 Remove seven camshaft bearing caps 23 and seven upper camshaft bearing shells 24 together as units 15 Remove and discard racetrack seal ring 25 between camshaft bearing cap 23 no 1 front and seal ring between cam shaft bearing cap 23 no 7 rear and cylinder head 26 2
543. tention pin 56 Carefully release spring force by rotating tool handle counterclockwise Remove spring compressor tool J35924 342 1179 Remove stop 57 spring 55 and main regulator valve 58 Push against stop 59 to compress spring 60 and remove valve retention pin 61 Slowly release pressure against stop 59 and remove stop spring and main control valve 62 Remove valve retention pin 63 stop 64 spring 65 and C2 latch valve 66 Remove retention pin 67 stop 68 spring 69 and exhaust back pressure valve 70 0071 00 44 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED MODULE OVERHAUL CONTINUED Control Valve Module Disassembly Continued 32 33 34 35 36 37 Remove retention pin 71 stop 72 spring 73 and C1 latching valve 74 Remove retention pin 75 stop 76 spring 77 and converter regulator valve 78 342 1178 Remove gaskets 79 and 80 and separator plate 81 from channel plate assembly 82 Discard gaskets NOTE Channel plate disassembly procedures are steps 35 through 37 If damaged remove two pins 83 from channel plate assembly 82 Remove drain plug 84 and o ring 85 from channel plate assembly 82 Discard o ring Remove eight pressure tap plugs 86 and o rings 87 from channel plate assembly 82 Discard o ring 0071 00 45 0071 00 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODUL
544. test ring retaining strips 3 and six test rings 2 Remove bolt 10 and water manifold cover 8 Clear out all passages and bolt holes with compressed air END OF WORK PACKAGE 0040 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0040 00 4 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE 0041 00 THIS WORK PACKAGE COVERS Removal Inspection Installation INITIAL SETUP Maintenance Level Materials Parts General Support Cylinder liner set P N 23523948 Piston ring kit P N 23525553 Cloth abrasive Item 9 WP 0125 00 Compound international no 2 Item 13 WP 0125 00 Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Compressor piston ring 22 WP 0126 00 Gage bearing clearance Item 20 WP 0125 00 Gage profile Item 36 WP 0126 00 Oil lubricating Item 25 WP 0125 00 Gage profile Item 38 WP 0126 00 Rags wiping Item 31LWP 0125 00 Guides connecting rod Item 44 WP 0126 00 Referenc s Pliers piston ring Item 85 0126 00 Press cylinder liner Item 91 WP 0126 00 Equipment Condition Protector piston Item 93 Engine installed on repair stand Puller mechanical Item 94 WP 0126 00 Cylinder head removed WP 0018 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 Oil pump removed WP 0029 00 REMOVAL 1 Rotate engine on stand so engine gear case is up 2 Bar engine over until connecting rod 1 of cylinder being serviced is at bottom
545. th crankshaft gear 34 Ensure tubular shaped dowel and diamond shaped dowel are fully seated in cylinder block 2 Install two long bolts 15 in front bolt holes and two short bolts 16 in rear bolt holes in oil pump assembly 5 Tighten bolts to 43 54 lb ft 58 73 Nm in crisscross pattern 0029 00 12 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 INSTALLATION CONTINUED 342 726 3 Coat two new seal rings 6 and 7 with light engine lubricating oil Install smaller seal ring 6 on elbow end of oil outlet tube 4 Install larger seal ring 7 on pump end of oil outlet tube 4 Install larger diameter end of oil outlet tube 4 in outlet neck of oil pump assembly 5 until oil outlet tube bottoms in bore 5 Install smaller diameter end of oil outlet tube 4 in oil relief valve outlet tube elbow assembly 3 until oil outlet tube bottoms in bore 6 Position oil pressure relief valve outlet tube elbow assembly 3 on cylinder block 2 Install two bolts 1 and tighten to 22 24 lb ft 30 33 Nm 342 723 0029 00 13 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 INSTALLATION CONTINUED 7 Install new gasket 14 and oil inlet tube 13 on oil pump assembly 5 Install two bolts 12 and tighten to 22 24 lb ft 30 33 Nm 342 725 8 Install two oil inlet tube bracket halves 10 and bolts 11 on cylinder block 2 Tighten bolts to 43 54 Ib ft 58 73 Nm 9 Install two bo
546. th eight bolts 3 Tighten bolts to 38 45 Ib ft 51 61 Nm NOTE Butt joint seal rings require special handling during assembly Seal rings contain materials that absorb mois ture from atmosphere causing them to expand Check seal ring end clearance before installation to ensure seal ring has not expanded Measure end gap of three rotating seal rings 1 before installation Insert seal rings into the rotating clutch hub bore of front support 2 and measure end gap with a thickness gage Seal ring end gap must be 0 040 0 057 in 1 00 1 44 mm Install three rotating seal rings 1 on front support hub FRONT SUPPORT DOWEL PIN GROUND SLEEVE Da Ta REMOVE INSTALL E SPLINE OD T I R 0 13 mm 0 005 in E RELIEF VALVE SECTION E E BORE VIEW A BOTTOM VIEW B TO INSTALL ALIGN FLAT ON GROUND SLEEVE WITH ARROW ON FRONT SUPPORT GROUND SLEEVE VIEW C 342 1167 0071 00 21 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rotating Clutch Module Disassembly 1 Remove thrust bearing 1 and retaining ring 2 from rotating clutch module 3 Inspect thrust bearing If worn dis card 2 Remove 1 sun gear assembly 4 and thrust bearing 5 from rotating clutch module 3 3 Remove C2 retaining ring 6 and backplate 7 4 Measure wear surface thickness of C2 backplate 7
547. the cab and engine cooling system The arctic heater may be operated prior to starting the engine to provide preheating of engine block 0002 00 1 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Marker Clearance Lights Side Mirrors Heated Grabhandles Utility Power Receptacle Air Horn Master Battery Switch Spare Wheel and Tire Battery Box and Steps Front Service Lights Bumper Extensions Blackout Lights Towing Eyes 342 001 Indicate outline of truck Provide driver with a view of sides of truck and semitrailer if towing Provide a hand hold for personnel climbing on truck Supplies power for work lights Located on both sides of truck Provides an audible alert Provides battery power to truck Extra wheel and tire used in case of a flat tire Holds vehicle batteries and provides steps to access cab Include headlights and turn signals Provide adjustable attachment point for slings Used during blackout conditions Include marker and drive lights Provide attachment points for towing device 0002 00 2 TM 9 2320 302 34 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED COMPONENT DESCRIPTION CWS Antenna Forward looking collision warning system antenna Brush Guard Protects front of hood and components under hood from damage Spotting Mirrors Provide add
548. the valve overlap period VALVE OVERLAP PERIOD EXHAUST VALVE ROCKER ARM ASSEMBLY B 1 EXHAUST VALVE CLOSING FUEL INJECTOR OS ROCKER ARM ASSEMBLY CAMSHAFT ROCKER CYLINDER am ARM SHAFT HEAD dici DET INTAKE VALVE ROCKER ARM ASSEMBLY INTAKE VALVE STARTS TO OPEN 342 719 0027 00 11 TM 9 2320 302 34 ROCKER ARM ASSEMBLIES MAINTENANCE CONTINUED 0027 00 ADJUSTMENT CONTINUED c Stop engine rotation at time of valve overlap Note which cylinder this is and follow sequence listed in Table 1 to correctly set valves and injector heights The timing can be started with any cylinder in valve overlap Table 1 Valve Lash and Injector Height Adjustment Sequence CYLINDER WITH VALVE SET VALVES ON SET INJECTOR HEIGHT OVERLAP CYLINDER NO ON CYLINDER NO d Insert 0 008 in 0 203 mm thickness gage 27 between tip of intake valve stem 28 and intake valve button 15 at end of rocker arm e Loosen jamnut 11 and turn adjusting screw 12 until thickness gage 27 produces even or smooth pull between intake valve stem 28 and intake valve button 15 f Tighten jamnut 11 to 30 35 lb ft 41 47 Nm and remove feeler gage 27 g Insert thickness gage 27 again to ensure adjustment did not change when jamnut 11 was tightened Readjust as necessary h Using 0 026 in 0 660 mm thickness gage adjust exhaust valves in same manner as intake valves 27 12 11 15 28 342 720
549. thin film of lubriplate to bore of camshaft drive gear 3 Ge od ot pn Support drive gear hub 7 from engine side Align keyway 9 of camshaft drive gear 3 with woodruff key 8 in drive gear hub Press camshaft drive gear onto drive gear hub until gear is firmly seated against hub shoulder 342 917 6 Support camshaft drive gear thrust plate 6 as shown With dial indicator measure camshaft drive gear face runout just inboard of drive gear teeth Zero dial indictor Rotate drive gear two full rotations Maximum allowable total indicated runout is 0 0045 in 0 114 mm 0034 00 4 TM 9 2320 302 34 CAMSHAFT DRIVE GEAR MAINTENANCE CONTINUED 0034 00 INSTALLATION 1 Lubricate new camshaft thrust plate seal ring 4 with clean engine lubricating oil Install seal ring on thrust plate 6 Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION Apply adhesive on racetrack shaped seal only not on face of thrust plate Failure to do so could result in damage to equipment 2 Apply a thin coat of adhesive on one side of new racetrack shaped seal 5 Install seal on engine side of thrust plate 6 3 Install camshaft drive gear assembly 3 in gear housing opening 10
550. ting rings 9 342 1226 61 Install rear rear axle differential carrier WP 0081 00 END OF WORK PACKAGE 0082 00 23 TM 9 2320 302 34 This Page Intentionally Left Blank 0082 00 24 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR 0083 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Tools and Special Tools Materials Parts Tool kit general mechanic s Item 132 WP 0126 00 Kit repair P N 82TV196 Caps vise jaw Item 17 WP 0126 00 Washer lock P N 202981 4 Vise machinist s Item 136 WP 0126 00 Grease aircraft Item 21 WP 0125 00 Equipment Condition Foot brake valve removed TM 9 2320 302 20 DISASSEMBLY NOTE e assist in disassembly place foot brake valve in a soft jawed vise e Discard all components of repair kit Remove screw 1 washer 2 and diaphragm 3 from cover 4 A Remove four screws 5 lock washers 6 and cover 4 from lower body 7 3 Remove valve 8 assembly from lower body 7 342 195 0083 00 1 TM 9 2320 302 34 FOOT BRAKE VALVE REPAIR CONTINUED 0083 00 DISASSEMBLY CONTINUED NOTE Perform steps 4 and 5 to disassemble valve assembly 4 While holding valve 8 assembly in collapsed position remove retaining ring 9 from valve 5 Release washer 10 and remove washer retainer 11 spring 12 and seat 13 from valve 8 Remove two preformed packings 14 and 15 from retainer 342 195 6 Remove four screws 16 lock washe
551. tion and Control Including Rustproofing Procedures for Tactical Vehicles and Trailers TB 43 0213 Solder and S olderin ss soe Le RENE BR IN PEN ERI PRU REUS paca ER TB SIG 222 Warranty Bulletin for M915A3 Tractor Truck 0 0 ccc cette TECHNICAL MANUALS Administrative Storage of 8 e TM 740 90 1 Cooling Systems Tactical Vehicles l l cette earren TM 750 254 Inspection Care and Maintenance of Antifriction Bearings 0 cece eects T 9 214 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals 0 0 cece eect eh TM 9 247 Operator s Manual for M915A3 Tractor Truck 0 0 ee III Operator s Manual for Welding Theory and Application 0 0 00 cee eee eee TM 9 237 Painting Instruction for Field Use ccc eae TM 43 0139 Procedures for Destruction of Tank automotive Equipment to Prevent Enemy TM 750 244 6 0124 00 1 TM 9 2320 302 34 REFERENCES CONTINUED 0124 00 TECHNICAL MANUALS CONTINUED Repair Parts and Special Tools Lists for M915A3 Tractor 9 2320 302 24P Unit Maintenance Manual for M915A3 Tractor Truck 0 0 0 0c cee teens M 9 2320 302 20 OTHER PUBLICATIONS Abbreviations for Use on Drawings and in Specifications Standard
552. tor rod 9 Disconnect hose 2 from regulated air source and reconnect hose to wastegate 3 342 755 END OF WORK PACKAGE 0045 00 5 TM 9 2320 302 34 This Page Intentionally Left Blank 0045 00 6 TM 9 2320 302 34 FUEL INJECTOR REPLACEMENT 0046 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Direct Support O ring P N 5234669 2 O ring P N 5234702 Tools and Special Tools Antifreeze ethylene glycol Item 6 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Rags wiping Item 31 WP 0125 00 Tags marker Item 35 WP 0125 00 Equipment Condition Pan drain Item 80 WP 0126 00 Wrench torque 0 300 Ib in Item 137 WP 0126 00 Rocker arm ooverz amp movedl WP 0016 00 Wrench torque 15 75 Ib ft Item 138 WP 0126 00 Rocker arm assemblies removed WP 0027 00 WARNING e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury or death to personnel or damage to equipment e Fuel vapors are toxic Avoid prolonged exposure or breathing of fumes Work in a well ventilated area Failure to do so could result in serious injury to personnel 0046 00 1 TM 9 2320 302 34 FUEL INJECTOR REPLACEMENT CONTINUED 0046 00 REMOVAL NOTE Tag fuel lines wire terminals and injectors prior to removal to aid in installation 1 Disconnect fuel supply hose 1 from
553. tuds 43 Discard tenz nuts Remove inner seal 47 and bearing 48 Discard seal and bearing Remove seal 49 from rear of slip ring end housing 23 by tapping equally in all five holes on outside of slip ring end housing Discard seal 29 342 525 Remove rotor and drive end housing 21 from shaft 50 Remove four screws 51 bearing retainer 52 seal 53 and bearing 54 Discard seal 0052 00 4 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 DISASSEMBLY CONTINUED 20 21 22 23 24 25 342 526 Unsolder two leads 55 from slip ring assembly 56 Remove slip ring assembly 56 Place rotor assembly 57 in soft jawed vise and remove nut 58 Remove inner bearing race 59 Remove two rotor halves 60 and 61 hub 62 and two woodruff keys 63 from shaft 50 If damaged remove slidable housing 64 342 527 0052 00 5 TM 9 2320 302 34 ALTERNATOR REPAIR CONTINUED 0052 00 TESTING 1 Test positive rectifier 35 as follows a Connect positive lead of diode tester to positive rectifier 35 Touch negative lead to each of three diodes 65 High resistance should be indicated If any of three diodes show low resistance replace positive rectifier b Reverse test leads so that negative lead is connected to positive rectifier 35 Touch positive lead to each of three diodes 65 Low resistance should be indicated If any of three diodes show high resistance replace p
554. uds 14 with exhaust outlet side facing toward rear 4 Install four washers 11 and nuts 10 on mounting studs 14 Tighten nuts to 43 54 Ib ft 58 73 Nm 0042 00 3 TM 9 2320 302 34 TURBOCHARGER REPLACEMENT 0042 00 INSTALLATION CONTINUED 5 Install new gasket 9 and connect oil drain line 8 to bottom of turbocharger 3 with two bolts 7 Tighten bolts to 22 28 lb ft 30 38 Nm CAUTION Do not use lubricant on inside of air inlet hose or hose contact surfaces of turbocharger compressor housing intercooler intercooler ducting or intake manifold Use of lubricant can cause hose to blow off turbocharger Failure to lubricate turbocharger will result in premature failure 6 Pour approximately half pint of engine lubricating oil into turbocharger 3 through oil inlet port fitting 2 at top of tur bocharger 3 while manually rotating compressor wheel 7 Connect oil supply line 1 to oil inlet port fitting 2 Wipe spilled oil from turbocharger 3 and exhaust manifold 8 Install oil supply line clip 6 on oil filter adapter and secure with top mounting bolt 4 and washer 5 Tighten bolt to 43 54 lb ft 58 73 Nm 9 Install air intake tubes and hoses TM 9 2320 302 20 10 Install exhaust pipes TM 9 2320 302 20 END OF WORK PACKAGE 0042 00 4 TM 9 2320 302 34 TURBOCHARGER REPAIR 0043 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts Compou
555. uld be accurate to nearest 0 0001 in 0 0025 mm If main bearing journal taper of used crankshaft exceeds 0 0015 in 0 0381 mm or if out of round clearance is greater than 0 001 in 0 0254 mm replace crankshaft 20 Compare width of flattened plastigauge 24 at widest point with graduations on envelope 25 as shown Number in graduation on envelope indicates bearing clearance in thousandths of an inch Multiply reading obtained in thou sandths by 25 4 to obtain metric specifications Measure each end of plastigauge Difference between two readings is approximate amount of taper 342 1083 INSTALLATION NOTE e When new crankshaft is installed all new main and connecting rod upper and lower bearing shells and thrust washers must also be installed e f new crankshaft is to be installed clean it to remove rust preventative and clear out oil passages with compressed air e Replace vibration damper at time of normal overhaul or if crankshaft breakage is experienced l Install notched upper main bearing shell 16 in main bearing saddle no 6 18 with tang of main bearing shell in notch at parting line of main bearing saddle no 6 2 Coat backs of two thrust washers 17 on side without oil grooves with a thin film of clean engine lubricating oil Install two thrust washers in counterbore on each side of main bearing saddle no 6 Engage tangs on ends of thrust washers with notches on ends of notched upper main bearing shell
556. until upper connecting rod bearing shell is firmly seated on crank shaft journal Remove two connecting rod guides 7 342 1044 NOTE Perform step 34 only if performing plastigauge check If not performing plastigauge check go to step 35 34 Check clearance between connecting rod bearing shells and crankshaft journal at time of connecting rod and piston assembly installation as follows a With upper and lower bearing shells 6 installed in connecting rod and connecting rod cap wipe any oil from bearing shells and connecting rod journal b Place piece of plastigauge 33 along full width of lower connecting rod bearing shell 6 about in 6 35 mm off center c Install connecting rod rod bolts on crankshaft bearing journal in its corresponding cylinder 0041 00 20 TM 9 2320 302 34 PISTON AND CYLINDER ASSEMBLY MAINTENANCE CONTINUED 0041 00 INSTALLATION CONTINUED d Install connecting rod cap and cap nuts on connecting rod and tighten connecting rod cap nuts to 118 137 lb ft 160 185 Nm e Remove connecting rod cap 5 and bearing shell 6 f Flattened plastiguage 33 will adhere to either bearing shell or connecting rod journal Compare width of plasti gauge at widest point with graduations scale 34 on plastigauge envelope to determine connecting rod bearing clearance Maximum connecting rod bearing to connecting rod journal clearance with used parts is 0 006 in 0 152 mm g Inspect cranksha
557. up plug s 7 and cup plug 8 with screwdriver or chisel Remove and discard plug s 8 Remove seven pipe plugs 9 10 11 and 12 and stud 13 342 894 0036 00 3 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 DISASSEMBLY CONTINUED 9 10 11 12 13 14 Position cylinder block to view left side Remove two pipe plugs 14 and pipe plug 15 Remove air compressor oil supply line elbow 16 If installed remove air compressor coolant supply elbow 17 Remove six weep hole plugs 18 Pierce cup plug 19 with screwdriver or chisel Remove and discard plug cy 342 895 CLEANING AND INSPECTION Use general cleaning methods to clean all parts Measure each cylinder bore 20 using inside micrometer Measure each cylinder bore for following dimensions at locations A B and C on axis 90 degrees apart Dimensions are average gage readings at each location Table 1 Taper and out of round should not exceed 0 001 in 0 0253 mm Table 1 Cylinder Bore Dimensions DIMENSION 5 868 5 871 in 149 050 149 120 mm 5 750 5 753 in 146 050 146 120 mm 5 750 5 753 in 146 050 146 120 mm 0036 00 4 TM 9 2320 302 34 CYLINDER BLOCK ASSEMBLY REPAIR CONTINUED 0036 00 CLEANING AND INSPECTION CONTINUED 342 896 4 If any of above measurements are exceeded replace cylinder block NOTE Perform step 5 before gaging main bearing bores 5 Install main bearing
558. urn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water Apply sealing compound around mating surface of axle 7 Attach suitable hoist and install differential carrier 6 with two washers 5 and nuts 4 Install ten washers 3 and cap screws 2 Tighten cap screws and two nuts 4 to 150 230 lb ft 203 312 Nm Connect air line 1 Install axle oil filter TM 9 2320 302 20 Connect drivelines TM 9 2320 302 20 Install axle shafts TM 9 2320 302 20 10 axle with oil TM 9 2320 302 20 O Bo END OF WORK PACKAGE 0079 00 3 TM 9 2320 302 34 This Page Intentionally Left Blank 0079 00 4 TM 9 2320 302 34 FORWARD REAR AXLE DIFFERENTIAL CARRIER REPAIR 0080 00 THIS WORK PACKAGE COVERS Disassembly Assembly INITIAL SETUP Maintenance Level Materials Parts Continued General Support Seal oil P N A 1205 W 1895 Tools and Special Tools Seal o ring P N 5X 1034 2 Tool kit general mechanic s Item 132 WP 0126 00 Adhesive silicone rubber Item 5 WP 0125 00 Dial indicator set Item 29 WP 0126 00 Grease GAA Item 22 WP 0125 00 Gloves welder s leather Item 41 WP 0126 00 Oil lubricating Item 26 WP 0125 00 Holding bar pinion Item 47 WP 0126 00 Paste Prussian blue Item 28 W
559. ved perform removal steps 3 through 7 and installation steps 1 through 11 until correct vertical end play is achieved 0077 00 4 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT CONTINUED 0077 00 INSTALLATION CONTINUED 342 1125 13 Install two new seal assemblies 6 new gaskets 5 caps 4 six flat washers 3 and cap screws 2 Tighten cap screws to 20 30 Ib ft 27 41 Nm 14 If removed install two new lubrication fittings 1 b gt 342 1126 0077 00 5 TM 9 2320 302 34 FRONT STEERING KNUCKLE REPLACEMENT CONTINUED INSTALLATION CONTINUED 15 16 17 18 Install front steering arm WP 0076 00 Install front cross tube arn WP0075 00 Install tie rod WP 0074 00 Lubricate steering knuckle TM 9 2320 302 10 END OF WORK PACKAGE 0077 00 6 0077 00 TM 9 2320 302 34 REAR AXLE REPLACEMENT THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Direct Support Tools and Special Tools Tool kit general mechanic s Item 132 WP 0126 00 Jack hydraulic Item 73 WP 0126 00 Wrench torque 50 250 Ib ft Item 139 WP 0126 00 0078 00 Personnel Required Two Equipment Condition Air system drained TM 9 2320 302 10 Rear brakeshoes removed TM 9 2320 302 20 Drivelines removed TM 9 2320 302 20 Rear ABS sensors removed TM 9 2320 302 20 Axle oil drained TM 9 2320 302 20 Rear shock absorbers removed TM 9 2320 302 20 Materials
560. ven bearing shells 24 342 697 0026 00 11 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSPECTION CONTINUED NOTE Flattened plastigauge will adhere to either bearing shell or camshaft journal 12 Compare width of plastigauge 30 at widest point with graduation scale 35 on plastigauge envelope to determine bearing clearance NOTE Maximum camshaft journal to bearing clearance is 0 0035 0 65 in 0 09 0 166 mm maximum with used parts is 0 0075 in 191 mm 342 698 17 lt WARNING Camshaft weighs 53 Ib 24 kg Attach suitable lifting device prior to removal to prevent possible injury to personnel e Remove camshaft 5 NOTE Ensure locating tangs are correctly positioned f Remove lower half of bearing shells 29 g Lubricate two upper and lower camshaft bearing shells 24 and 29 for no 1 and no 7 with clean engine lubricat ing oil and install in two respective camshaft bearing caps 23 n WARNING Camshaft weighs 53 Ib 24 kg Attach suitable lifting device prior to installation to prevent possible injury to personnel h Install camshaft 5 0026 00 12 TM 9 2320 302 34 CAMSHAFT AND BEARINGS REPLACEMENT CONTINUED 0026 00 INSPECTION CONTINUED i Install two camshaft bearing caps 23 no 1 and no 7 in cylinder head 26 and install two camshaft cap bolts 20 and two rocker shaft studs 21 in two camshaft bearing caps 23 no 1 and
561. ver 2 Remove oil pump cover 19 and oil pump driven gear and shaft assembly 21 from oil pump body 20 18 342 727 CAUTION Do not allow press support to interfere with oil pump drive gear and shaft assembly being pressed out To do so will result in damage to shaft assembly from oil pump drive gear 23 Remove oil pump drive gear 23 from oil pump body 20 342 728 0029 00 4 0029 00 Place oil pump body 20 pump cover side down on press support Press oil pump drive gear and shaft assembly 22 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 DISASSEMBLY CONTINUED NOTE When one or more bushings require replacing replace all bushings in pump body and pump cover 5 If bushings are damaged or worn place oil pump body 20 pump cover side up on press support Press two bushings 24 from pump body 342 728 6 Place oil pump cover 19 pump body side up on press support Press out two bushings 24 from bushing bores 25 24 342 730 CAUTION Extreme care should be taken to protect surfaces of mounting legs from electric arc welding slag Use fabri cated protective plate for this purpose Failure to do so could result in damage to surfaces of mounting legs 0029 00 5 TM 9 2320 302 34 OIL PUMP MAINTENANCE CONTINUED 0029 00 DISASSEMBLY CONTINUED NOTE Two steel locating dowels one solid diamond shaped dowel and one tubular shaped dowel installed on pum
562. ver WP 0016 00 END OF WORK PACKAGE 0046 00 6 TM 9 2320 302 34 FUEL INJECTOR SOLENOID REPLACEMENT 0047 00 THIS WORK PACKAGE COVERS Removal Installation INITIAL SETUP Maintenance Level Materials Parts Continued Direct Support Screw P N 5235586 4 Tools and Special Tools Tags marker Item 35 WP 0125 00 Tool kit general mechanic s Item 132 WP 0126 00 Equipment Condition Wrench torque 0 300 Ib in Item 137 WP 0126 00 Rocker arm cover removed WP 0016 00 Materials Parts Seal P N 5234224 2 REMOVAL NOTE e Solenoid may be removed and replaced without removing fuel injector Ensure fuel injector wiring harness lead connectors are tagged prior to removal to aid in installation 1 Loosen two screws 1 and disconnect fuel injector harness wiring terminals 2 0047 00 1 TM 9 2320 302 34 FUEL INJECTOR SOLENOID REPLACEMENT 0047 00 REMOVAL CONTINUED NOTE Load plate and spacer plate are matched to injector and must be retained for new solenoid 2 Remove four screws 3 load plate 4 and follower retainer 5 from solenoid 6 Discard screws 3 Remove solenoid 6 from fuel injector body 7 4 Remove spacer 8 and two seals 9 from fuel injector body 7 Discard seals and retain spacer D JO a O_o TIGHTENING SEQUENCE 342 627 INSTALLATION 1 Install two new seals 9 and spacer 8 on fuel injector body 7 2 Position solenoid 6 on spacer 8 and fuel injector body
563. ves on piston 42 Install two oil control rings 45 in bottom oil ring groove on piston 42 Install oil ring expander 46 in groove between oil control rings 45 Position connecting rod 40 and insert wrist pin 41 through piston 42 to connecting rod bore in opposite side of pis ton Center wrist pin 41 and push plastic wrist pin button 43 in each end of wrist pin 342 995 0084 00 10 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED CAUTION Tangs on one end of connecting rod upper bearing insert must be installed in corresponding notches on side of connecting rod bearing saddle to prevent damage to equipment 21 Install new upper bearing insert 39 in connecting rod 40 bearing saddle 342 994 22 Stagger piston ring gap two oil control ring gaps and oil expander ring gap 90 degrees from each other as shown OIL CONTROL RING PISTON OIL RING EXPANDER OIL 342 1000 CONTROL RING 0084 00 11 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 23 Coat connecting rod and piston assembly 35 liberally with clean engine lubricating oil and insert in ring compressor 55 24 Apply a film of clean engine lubricating oil to surface of connecting rod upper bearing insert 39 and insert connecting rod and piston assembly 35 in cylinder bore 25 Position crankshaft 34 with journal at bottom of its travel
564. void possible hand injury Remove retaining ring 6 and thrust washer 7 from P3 planetary carrier assembly 4 Inspect planetary carrier cone and roller bearing 8 If worn or damaged remove Remove retaining ring 9 indexing ring 10 and four pinion spindles 11 from P3 planetary carrier 4 Remove pinion gear 12 thrust washers 13 and 14 and two bearing assemblies 15 from side of planetary rier 4 Repeat procedures for remaining pinion gears Measure thickness and step wear of thrust washers Minimum thrust washer thickness allowed is 0 055 in 1 40 mm Maximum step wear allowed is 0 005 in 0 12 mm 0071 00 37 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rear 8 10 11 10 Cover Planetary Module Disassembly Continued Inspect and measure bushing 16 inside end of output shaft 17 for damage or wear The maximum ID of bushing is 1 423 in 36 14 mm WARNING Rear cover spring and retainer assembly contains highly compressed springs Be extremely careful during disassembly Personal injury can occur if spring force is not controlled Remove C5 clutch piston 18 from rear cover 3 by compressing spring and retainer assembly 19 using tool J37030 3 tool base washer bearing handle and piston compressor J37030 2 Remove retaining ring 20 and slowly release spring force Remove outer sea
565. washers Repeat procedure for remaining five pinion gears Install four pinion spindles 8 so that lower step is positioned for proper installation of indexing ring 7 Install indexing ring 7 and retaining 6 to secure pinion gears in place Measure pinion end play Pinion end play must not exceed 0 037 in 0 94 mm Check all four pinion gears Install P3 planetary ring gear 2 over P2 planetary carrier assembly 5 Install retaining ring 1 into P3 planetary ring gear 2 so that P2 planetary carrier and P3 planetary ring gear are assem bled Install thrust bearing 4 on planetary module 3 342 1174 0071 00 36 TM 9 2320 302 34 TRANSMISSION OVERHAUL CONTINUED 0071 00 MODULE OVERHAUL CONTINUED Rear Cover and P3 Planetary Module Disassembly 1 Straighten tangs of lock nut retainer 1 to allow removal of bearing retainer lock nut 2 Remove bearing retainer lock nut using tool J37035 Remove lock nut retainer 2 Support rear cover assembly 3 so that P3 planetary carrier assembly 4 be removed Place tool J37035 1 over output shaft splines and against threaded shoulder of P3 planetary carrier Using a hydraulic press or a mallet press on tool J37035 1 to separate planetary carrier from rear cover 3 Inspect rear cover cone and roller bearing 5 If worn or damaged remove using tool J3940 8 342 1175 EE WARNING Place P3 planetary carrier assembly on its side during disassembly to a
566. which can freeze skin and eye tissue causing serious injury or blindness e Use care to prevent refrigerant from touching your skin or eyes Liquid refrigerant when exposed to air quickly evaporates and will freeze skin or eye tissue Serious injury or blindness may result if you come in contact with liquid refrigerant 1 Remove oil fill plug 1 and preformed packing from compressor 2 Retain preformed packing if not damaged or if there are no signs of leaks 2 Use oil level gage to check oil level in compressor 2 a If gage bottoms out before going in more than 3 in 7 6 cm it is hitting compressor crankshaft Rotate drive plate by hand and insert gage until it contacts bottom of sump 0116 00 2 TM 9 2320 302 34 AIR CONDITIONER COMPRESSOR SERVICE CONTINUED 0116 00 SERVICE CONTINUED b Use Table 1 to determine oil quantity in compressor 2 Table 1 Determination of Compressor Capacity OIL LEVEL GAGE DEPTH IN INCHES MM OIL QUANTITY IN FLUID OZ ML 7 8 in 22 2 mm 6 fl oz 177 ml 1 in 25 4 mm 8 fl oz 237 ml 1 7 16 in 36 5 mm 12 fl oz 355 ml 1 11 16 in 43 mm 14 fl oz 414 ml 3 Add or remove oil from compressor 2 so that oil charge in compressor is 10 fl oz 296 ml 1 1 8 in 28 6 mm 10 fl oz 296 ml 4 Add additional oil to compressor 2 based on number of air conditioning components replaced Total charge should be 14 fl oz 414 ml 5 Ensure preformed packing and threads of oil fill
567. wo nuts 1 washers 2 screws 3 and washers 4 from rear engine mount 5 2 On right side remove nut 6 clamp 7 screw 8 washer 9 and clamp 10 from bracket 11 3 On right side remove two nuts 12 washers 13 screws 14 bracket 11 and washer 15 from rear engine mount 5 342 1134 LEFT SIDE RIGHT SIDE 0012 00 1 TM 9 2320 302 34 REAR ENGINE MOUNTS REPLACEMENT CONTINUED 0012 00 REMOVAL CONTINUED VA WARNING Engine weighs 2850 16 1294 kg Use hoist with lifting capacity of 5000 Ib 2270 kg to lift and support engine Failure to do so could result in injury to personnel CAUTION Lift engine only enough to take weight off engine mounts If engine is lifted too far wiring harness may be crushed by crossmember 4 Using suitable lifting device lift engine 16 slightly NOTE Steps 5 through 8 are for left side 5 Remove two screws 17 two washers 18 two screws 19 and rear engine leg 20 from flywheel housing 21 6 Remove two washers 22 and two isolators 23 from rear engine mount 5 9 10 28 342 1134 LEFT SIDE RIGHT SIDE M WARNING Cab weighs 1100 Ib 499 kg Use suitable jack stands to support cab Failure to do so could result in serious injury to personnel 7 Using suitable jack stands support cab at cab mounts 24 as close to frame rail 25 as possible 0012 00 2 TM 9 2320 302 34 REAR ENGINE MOUNTS REPLACEMENT CONTINUED 0012 0
568. ws 1 and 2 and flat washers 3 and 4 2 Loosen differential carrier 5 by tapping around flange 3 Remove differential carrier 5 from axle 6 4 Lower differential carrier 5 onto floor jack and roll differential carrier from under vehicle 342 1133 2 4 INSTALLATION 4 WARNING Rear rear differential carrier weighs 860 Ib 390 kg Support with suitable floor jack prior to installation to prevent injury to personnel NOTE If axle assembly has been removed from vehicle perform steps 3 through 5 only 1 Position differential carrier 5 on floor jack and roll differential carrier into position under vehicle 0081 00 2 TM 9 2320 302 34 REAR REAR AXLE DIFFERENTIAL CARRIER REPLACEMENT CONTINUED 0081 00 INSTALLATION CONTINUED D 9 WARNING Adhesives and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION Ensure both mating surfaces have been completely cleaned to prevent damage to equipment Apply sealing compound around mating surface of axle 6 w Attach suitable hoist and install differential carrier 5 to axle 6 with four flat washers 4 and screws 2 in four corner locations around differential carrier Hand tighten screws Seat differential car
569. y circulat ing pressurized ethylene glycol based coolant through the engine and radiator TWO THERMOSTATS CIRCULATING PUMP INLET FROM RADIATOR 342 006 DDEC IV ENGINE ELECTRICAL SYSTEM 1 Four 12 volt batteries connected in series parallel supply the 12 volt electrical system and provide 24 volts for the starter motor blackout lights accessories and trailer connectors 2 The Dual Voltage Alternator Control DUVAC mounted on the firewall in the engine compartment regulates the dis tribution of 12 and 24 volts 0003 00 3 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 ELECTRICAL SYSTEM CONTINUED VOLTAGE REGULATOR ALTERNATOR TO ENGINE ECU TO TRANS ECU MASTER BATTERY SWITCH BATTERY EQUALIZER STARTER 12 VOLT 12 VOLT Fm BATTERY F sm BATTERY 12 VOLT 12VOLT BATTERY BATTERY aia 324 2016 0003 00 4 TM 9 2320 302 34 THEORY OF OPERATION CONTINUED 0003 00 AIR SYSTEM The air system consists of the air compressor air dryer air reservoirs and various air lines Also included in the air system are air pressure gages located on the instrument panel for monitoring air pressure for safe operation of all air operated compo nents of the vehicle AIR GAGES PRIMARY SECONDARY D xD HOLDING TANKS AIR COMPRESSOR 342 008
570. y tapping around inside edge of sleeve and driving sleeve bearing away from rear cover 48 0084 00 6 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 DISASSEMBLY CONTINUED 342 996 INSPECTION Inspect crankshaft for galling pitting cracks or other damage Replace if damaged ASSEMBLY 1 Position rear cover 48 face down on press bed NOTE Ensure slot in bearing is lined up with oil passage in rear cover 2 Position crankshaft rear sleeve bearing 53 in bore of rear cover 48 with slot in bearing lined up with oil passage 3 Press crankshaft rear sleeve bearing 53 in bore of rear cover 48 until flush 53 342 997 0084 00 7 TM 9 2320 302 34 AIR COMPRESSOR REPAIR CONTINUED 0084 00 ASSEMBLY CONTINUED 4 5 6 10 11 12 Position air compressor mounting flange 52 face up on press bed Position ball bearing 50 in bore of air compressor mounting flange 52 Press ball bearing 50 into bore of air compressor mounting flange 52 until outer race of bearing bottoms out in flange bore Install retaining ring 51 in ring groove 342 998 Position air compressor mounting flange 52 face down on press bed Support inner race of ball bearing 50 with sleeve 54 Insert crankshaft 34 through air compressor 6 into ball bearing 50 Press crankshaft into inner race of ball bearing until inner race bottoms out on shoulder of crankshaft Install seal ring 49 in gr

TM 9-2320-302-34

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