TM-9-2320-211-34-2-1

• VOLUME 2 OF 2 PART 1 OF 4 MAINTENANCE DIRECT SUPPORT AND GENERAL SUPPORT LEVEL 5-TON, 6X6, M39 SERIES TRUCKS (MULTIFUEL)
• VOLUME 2 OF 2 PART 1 OF 4 MAINTENANCE DIRECT SUPPORT AND GENERAL SUPPORT LEVEL 5-TON, 6X6, M39 SERIES TRUCKS (MULTIFUEL)
• TABLE OF CONTENTS
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• TABLE OF CONTENTS-continued
• LIST OF TABLES
• LIST OF TABLES-continued
• WARNING
• WARNING-continued
• CHAPTER 1. GENERAL MAINTENANCE INFORMATION
• TORQUE VALUES
• Table 1-1. Standard Torque Specifications
• Table 1-2. Special Tools and Equipment
• Table 1-2. Special Tools and Equipment-continued
• Table 1-2. Special Tools and Equipment-continued
• REPORTING IMPROVEMENT RECOMMENDATIONS
• CHAPTER 2. ENGINE SYSTEM GROUP MAINTENANCE
• Removal.
• FRAME 2
• FRAME 3
• Inspection and Repair.
• Replacement.
• REAR ENGINE MOUNTS AND BRACKETS REMOVAL AND REPLACEMENT.
• FRAME 2
• FRAME 3
• Replacement.
• FRAME 2
• ENGINE ASSEMBLY, REMOVAL, AND REPLACEMENT.
• Removal.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• Section III. CRANKCASE, BLOCK, AND CYLINDER HEAD
• Removal.
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• Section IV. CRANKSHAFT
• Removal.
• Cleaning
• Replacement.
• Figure 2-1. Oil Seal Installation Adapter, Fabrication Instructions
• CRANKSHAFT REAR OIL SEAL REMOVAL AND REPLACEMENT.
• Cleaning, Inspection, and Repair.
• Replacement.
• FRAME 2
• CRANKSHAFT VIBRATION DAMPER REMOVAL AND REPLACEMENT.
• Removal.
• FRAME 2
• FRAME 3
• Cleaning
• Inspection and Repair.
• Replacement.
• Figure 2-2. Crankshaft Damper and Pulley Locator, Fabrication Instructions
• FRAME 2
• FRAME 3
• FRAME 4
• Section V. FLYWHEEL
• Removal.
• Figure 2-3. Pilot Bolt, Fabrication Instructions
• Inspection and Repair.
• Replacement.
• FLYWHEEL RING GEAR REMOVAL AND REPLACEMENT.
• FRAME 2
• Replacement.
• FLYWHEEL HOUSING REMOVAL, REPAIR, AND REPLACEMENT.
• Removal.
• Cleaning, Inspection, and Repair.
• Replacement.
• FRAME 2
• FRAME 3
• Final Inspection
• Flywheel housing inside rim.
• FRAME 2
• PILOT BEARING REMOVAL AND REPLACEMENT.
• Replacement.
• Section IV. VALVES, CAMSHAFT, AND TIMING SYSTEM
• Removal.
• Inspection.
• Replacement.
• ROCKER ARM ASSEMBLY, REMOVAL, REPAIR, REPLACEMENT, AND ADJUSTMENT
• Removal.
• Replacement.
• Adjustment.
• FRAME 2
• CRANKSHAFT GEAR AND CAMSHAFT GEAR REMOVAL, REPAIR, AND REPLACEMENT.
• Removal.
• FRAME 2
• Cleaning, Inspection, and Repair.
• Table 2-1. Camshaft Gear and Crankshaft Gear Tolerances
• Replacement.
• FRAME 2
• CAMSHAFT AND BUSHING TYPE BEARINGS REMOVAL AND REPLACEMENT.
• Removal.
• FRAME 2
• Cleaning.
• Replacement.
• FRAME 2
• FRAME 3
• TAPPET CHAMBER COVER REMOVAL, REPAIR, AND REPLACEMENT.
• Cleaning, Inspection, and Repair.
• Replacement.
• VALVE TAPPETS REMOVAL, REPAIR, AND REPLACEMENT.
• Removal.
• Inspection and Repair
• Replacement.
• Section VII. ENGINE LUBRICATING SYSTEM
• Removal.
• FRAME 2
• Disassembly.
• FRAME 2
• Assembly.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• Replacement.
• FRAME 2
• FRAME 3
• OIL PAN REMOVAL, REPAIR, AND REPLACEMENT.
• Model LDS465-1A.
• Model LDS465-2.
• Inspection and Repair
• Replacement.
• Model LDS-465-1A.
• Model LDS465-2.
• OIL COOLER ELEMENT AND HOUSING REMOVAL, REPAIR, AND REPLACEMENT.
• Removal.
• FRAME 2
• Oil cooler housing.
• Disassembly.
• Inspection and Repair.
• FRAME 2
• Assembly
• Replacement.
• Oil cooler radiator and cover.
• FRAME 2
• OIL PRESSURE REGULATOR, REMOVAL, AND REPLACEMENT.
• Removal.
• FRAME 2
• Cleaning and Inspection.
• Replacement.
• FRAME 2
• FRAME 3
• Section VIII. MANIFOLDS
• Removal.
• FRAME 2
• FRAME 3
• Disassembly.
• Intake manifold.
• FRAME 2
• Inspection and Repair.
• Assembly.
• FRAME 2
• Exhaust manifold.
• Replacement.
• FRAME 2
• FRAME 3
• CHAPTER 3. CLUTCH SYSTEM GROUP MAINTENANCE
• Removal.
• Cleaning.
• Inspection.
• FRAME 2
• FRAME 3
• Adjustment of Clutch
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• CHAPTER 4. FUEL SYSTEM GROUP MAINTENANCE
• Removal.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• Figure 4-1. Gear Hub Holding Wrench, Fabrication Data
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FUEL INJECTOR PUMP TIMING.
• Timing.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• Section IV. FUEL TANKS
• Disassembly.
• Cleaning.
• Inspection and Repair.
• Assembly.
• Section V. COLD START SYSTEM
• CHAPTER 5. COOLING SYSTEM GROUP MAINTENANCE
• Disassemble.
• Cleaning.
• Inspection.
• Repair.
• Assembly.
• Section IV. FAN ASSEMBLY
• Cleaning, Inspection, and Repair.
• CHAPTER 6. ELECTRICAL SYSTEM GROUP MAINTENANCE
• GENERATOR MOUNTING BRACKET REMOVAL, REPAIR, AND REPLACEMENT.
• Replacement.
• Section III. STARTING SYSTEM
• ENGINE STARTER SOLENOID REMOVAL AND REPLACEMENT.
• FRAME 2
• Replacement.
• FRAME 2
• STARTER RELAY HARNESS REMOVAL AND REPLACEMENT.
• Removal.
• FRAME 2
• Replacement.
• FRAME 2
• Section IV. INSTRUMENT PANEL
• ACCESSORY WIRING CIRCUIT BREAKERS REMOVAL AND REPLACEMENT.
• Replacement.
• Section V. LIGHTING SYSTEM
• Inspection and Repair.
• Section VI. HORN ASSEMBLY
• Cleaning.
• Inspection and Repair.
• Assembly.
• HORN CONTACT BRUSH ASSEMBLY REMOVAL AND REPLACEMENT.
• FRAME 2
• Replacement.
• FRAME 2
• Section VII. BATTERY SYSTEM
• Section VIII. CAB AND CHASSIS WIRING HARNESSES
• Replacement.
• FRONT WIRING HARNESS REMOVAL AND REPLACEMENT.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• TRAILER CONNECTOR CABLE HARNESS REMOVAL AND REPLACEMENT.
• Replacement.
• REAR WIRING HARNESS REMOVAL AND REPLACEMENT.
• Removal.
• Replacement.
• CHAPTER 7. TRANSMISSION SYSTEM GROUP MAINTENANCE
• Preliminary Procedures.
• Removal.
• FRAME 2
• FRAME 3
• Disassembly of Transmission into Subassemblies.
• FRAME 2
• FRAME 3
• FRAME 4
• Shifter housing assembly.
• FRAME 2
• Covers.
• Backlash check.
• FRAME 2
• FRAME 3
• FRAME 4
• Transmission gears and shafts.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• Disassembly of Transmission Subassemblies.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• Transmission gears and shafts.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• Clutch housing and transmission case.
• FRAME 2
• Cleaning.
• Inspection and Repair.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• FRAME 14
• FRAME 15
• FRAME 16
• FRAME 17
• Assembly of Transmission Subassemblies.
• FRAME 2
• Transmission gears and shafts.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• Shifter housing assembly.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• Assembly of Subassemblies into Transmission.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• Shifter housing assembly.
• FRAME 2
• Clutch release mechanism and housing.
• FRAME 2
• FRAME 3
• FRAME 4
• Covers.
• Replacement.
• FRAME 2
• TRANSMISSION POWER TEST.
• Test.
• TRANSMISSION INPUT SHAFT SEAL REMOVAL AND REPLACEMENT.
• Removal.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• TRANSMISSION OUTPUT SHAFT SEAL REMOVAL AND REPLACEMENT.
• Removal.
• FRAME 2
• Replacement.
• FRAME 2
• MAINTENANCE OF BEARINGS.
• Removal of Bearing from Shaft by Pulling.
• Removal of Bearing from Housing by Pressing.
• Removal of Bearing from Housing By Pulling.
• Cleaning of Bearings.
• Inspection.
• Replacement of Bearing onto Shaft.
• Replacement of Bearing into Housing.
• CHAPTER 8. TRANSMISSION TRANSFER SYSTEM GROUP MAINTENANCE
• Removal
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• TRANSMISSION TRANSFER ASSEMBLY REPAIR.
• MountingTransmission Transfer Assembly in Stand.
• FRAME 2
• Disassembly into Subassemblies.
• FRAME 2
• FRAME 3
• Input shaft cover (all trucks except M543A2).
• Handbrake brake drum and flange assembly.
• Intermediate shaft bearing retainer cap and rear output shaft bearing retainer cap and seal.
• FRAME 2
• Input shaft companion flange and transfer case breather assembly.
• Front output shaft cover assembly.
• Transfer housing front cover.
• FRAME 2
• FRAME 3
• Backlash check.
• FRAME 2
• FRAME 3
• Shaft assemblies.
• FRAME 2
• FRAME 3
• Disassembly of Subassemblies.
• FRAME 2
• Intermediate shaft assembly.
• FRAME 2
• Rear output shaft.
• Front output shaft cover assembly.
• FRAME 2
• FRAME 3
• Front output shaft assembly.
• FRAME 2
• FRAME 3
• High and low range output shifter forks.
• Handbrake brake drum.
• Rear output bearing retainer cap and front cover.
• Inspection.
• FRAME 2
• FRAME 3
• FRAME 4
• Input shaft.
• FRAME 2
• FRAME 3
• Intermediate shaft.
• FRAME 2
• Front output shaft.
• FRAME 2
• Rear output shaft.
• FRAME 2
• Output shifter shaft.
• FRAME 2
• High and low range shifter fork.
• FRAME 2
• FRAME 3
• Sprag assembly.
• FRAME 2
• Shifter clutch collar.
• FRAME 2
• Repair.
• FRAME 2
• Assembly of Subassemblies.
• FRAME 1
• High and Iow range and output shifter forks.
• Front output shaft assembly.
• FRAME 2
• FRAME 3
• Front output shaft cover assembly.
• FRAME 2
• FRAME 3
• FRAME 4
• Rear output shaft.
• Intermediate shaft.
• FRAME 2
• Input shaft.
• FRAME 2
• Replacement of Subassemblies.
• FRAME 2
• FRAME 3
• Transfer housing front cover.
• FRAME 2
• FRAME 3
• Front output shaft cover assembly.
• TRANSMISSION TRANSFER ASSEMBLY REAR SEAL REMOVAL AND REPLACEMENT
• FRAME 2
• Replacement.
• FRAME 2
• TRANSMISSION TRANSFER CASE MOUNTING BRACKETS REMOVAL AND REPLACEMENT
• FRAME 2
• Cleaning and Inspection.
• Replacement.
• FRAME 2
• Section III. TRANSMISSION TRANSFER CONTROLS AND LINKAGES
• FRAME 2
• FRAME 3
• FRAME 4
• Disassembly.
• Inspection and Repair.
• Assembly.
• Replacement.
• FRAME 2
• FRAME 3
• TRANSMISSION TRANSFER CONTROLS AND LINKAGE REMOVAL, REPAIR, AND REPLACEMENT (TRUCKS WITH FRONT WINCH).
• FRAME 2
• FRAME 3
• Disassembly.
• Inspection and Repair.
• Assembly.
• Replacement.
• FRAME 2
• FRAME 3
• CHAPTER 9. FRONT AXLE GROUP MAINTENANCE
• Removal
• FRAME 1
• Disassembly.
• FRAME 2
• Cleaning.
• FRAME 2
• Assembly.
• FRAME 2
• Tests and Adjustments
• Replacement.
• FRAME 2
• FRAME 1
• Section III. DIFFERENTIAL CARRIER ASSEMBLY
• Removal.
• Disassembly.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• FRAME 14
• FRAME 15
• Inspection and Repair.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• Table 9-5. Differential Hypoid Drive Pinion Assembly Wear Limits
• Assembly and Adjustment.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• FRAME 7
• FRAME 8
• FRAME 9
• FRAME 10
• FRAME 11
• FRAME 12
• FRAME 13
• FRAME 14
• FRAME 15
• FRAME 16
• FRAME 17
• FRAME 18
• FRAME 19
• FRAME 20
• FRAME 21
• FRAME 22
• FRAME 23
• FRAME 24
• FRAME 25
• FRAME 26
• FRAME 27
• FRAME 28
• FRAME 29
• FRAME 30
• FRAME 31
• FRAME 32
• FRAME 33
• FRAME 34
• FRAME 35
• FRAME 36
• FRAME 37
• FRAME 38
• FRAME 39
• FRAME 40
• FRAME 41
• Replacement
• FRAME 2
• Section IV. STEERING MECHANISM
• Removal.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• Inspection and Repair.
• Table 9-6. Front Axle Assembly Wear Limits
• Replacement.
• FRAME 2
• FRAME 3
• FRAME 4
• FRAME 5
• FRAME 6
• Tests and Adjustments.
• FRAME 2
• FRAME 3
• Turning angle adjustment.
• Wheel alinement.
• CHAPTER 10. REAR AXLE GROUP MAINTENANCE
• Removal.
• Replacement.
• FRAME 2
• FORWARD-REAR AND REAR-REAR SUSPENSION AXLE ASSEMBLY REPAIR.
• Disassembly.
• Cleaning.
• Inspection and Repair.
• Assembly.
• FRAME 2
• THE METRIC SYSTEM AND EQUIVALENTS
• Distribution
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• TM-9-2320-211-34-2-1
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