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CHAPTER 1. INTRODUCTION - TM-9-2320-266-340021
Tabulated Data.
Figure 1-5. Differences Between Grilles.
Table 1-1. Tabulated Data - TM-9-2320-266-340025
Table 1-1. Tabulated Data-continued - TM-9-2320-266-340026
Table 1-1. Tabulated Data-continued - TM-9-2320-266-340027
Table 1-2. Torque specifications
Table 1-2. Torque specifications-continued
Standard Torque Values.
Table 1-4. Standard Torque Values
CHAPTER 2. TROUBLESHOOTING
Figure 2-2. Troubleshooting the Engine (1 of 4).
Figure 2-2. Troubleshooting the Engine (2 of 4).
Figure 2-2. Troubleshooting the Engine (3 of 4)
Figure 2-2. Troubleshooting the Engine (4 of 4)
Figure 2-3. Troubleshooting Transmission
Figure 2-4. Troubleshooting the Steering and Suspension Systems.
PART TWO. REPAIRS ON THE VEHICLE
Intake Manifold.
Figure 3-4. Cylinder Head Assembly.
Hydraulic Tappets.
Timing Chain Cover, Oil Seal, and Chain.
Figure 3-10. Alinement of Timing Marks
Oil Pan Replacement.
Replacing the Front Motor Mounts.
CHAPTER 4. REPAIR OF THE TRANSMISSION
Figure 4-1. Transmission and Torque Converter (4X2 Models).
Figure 4-1.2. Park and Neutral,
Figure 4-2. Drive-Breakaway.
Figure 4-3. Drive-Second
Figure 4-4. Drive-Direct.
Figure 4-5. Drive-Pert Throttle kickdown.
Figure 4-6. Drive-Full Throttle Kickdown.
Figure 4-7. Selector Lever-Two.
Figure 4-8. Selector Lever One.
Figure 4-9. Reverse.
Testing the Transmission.
Hydraulic Pressure Tests.
Figure 4-11. Pressure Test Locations (Rear End of Case).
Converter Stall Test.
Clutch and Servo Air Pressure Tests.
Figure 4-14. Transmission Converter Area
Services.
Draining and Refilling Transmission Fluid.
Gear Selector Linkage Adjustment.
Band Adjustments,
Transmission Throttle Linkage Adjustment.
Transmission Throttle Rod Adjustment for Three-Section Throttle Rod
Hydraulic Control Pressure Tests.
Hydraulic Control Pressure Adjustments.
Speedometer Drive Pinion Gear Assembly (4X2 Models).
Removing the Transmission and Converter.
Figure 4-37. Alining Pump Rotors.
Figure 4-39. Converter and Drive Plate Markings.
Replacing the Pump Oil Seal.
CHAPTER 5. REPAIR OF THE TRANSFER ASSEMBLY
Replacing the Bearing and Seal.
Figure 5-5. Pressing In the Front Output Shaft Seal.
CHAPTER 6. AXLE ASSEMBLIES
Figure 6-2. Removing Inner Oil Seal from Steering Knuckle.
Assembly and Installation.
Section II. REAR AXLE ASSEMBLY
Figure 6-9. Rear Axle Assembly.
Section III. PROPELLER SHAFTS
Ball Socket.
CHAPTER 7. SUSPENSION AND STEERING
Lower Control Arm and Bushing.
Lower Ball Joint.
Upper Ball Joint.
Section II. MAINTENANCE OF THE SPRINGS
Rear Springs.
Section III. STEERING GEAR
Adjustments.
Section IV. STEERING COLUMN
Section V. WHEEL ALINEMENT
Figure 7-18. Positive Caster Angle.
Adjust Turning Angle
CHAPTER 8. REPAIR OF THE BODY AND SHEET METAL
Figure 8-3. Rear Window Removal.
Removing and Installing the Cargo Box.
CHAPTER 9. REPAIR OF FRAME STRUCTURES
Frame Inspection Procedures.
Servicing the Frame.
CHAPTER 10. REPAIR OF THE ELECTRICAL SYSTEM
Reassembling the Steering Colunm.
Figure 10-1. Wiring Diagram (1 of 5)
Figure 10-1. Wiring Diagram (2 of 5).
Figure 10-1. Wiring Diagram (3 of 5)
Figure 10-1. Wiring Diagram (4 of 5).
Figure 10-1. Wiring Diagram (5 of 5).
Figure 10-1.1. Trailer Electrical Recepticle.
Figure 1O-1.2. Parking Light Circuit.
Figure 10-1.4. 100-Amp Wiring Diagram
Figure 10-2. Retainer and Turn Signal Switch.
Figure 10-2.1 Ignition Switch Connector
Figure 10-2.2 Replacement Ignition Switch Harness Installation
Figure 10-3. Removing the Steering Shaft Upper Snap Ring.
Figure 10-5. Removing the Lock Cylinder.
Blackout Lighting Repair.
Figure 10-7. Blackout Lighting Kit Wiring Diagram (Sheet 2 of 3)
Figure 10-7. Blackout Lighting Kit Wiring Diagram-Ambulance (Sheet 3 of 3)
PART THREE REPAIRS ON THE BENCH: CHAPTER 11. REBUILDING THE ENGINE
Table 11-1. Engine Specifications-continued - TM-9-2320-266-340136
Table 11-1. Engine Specifications-continued - TM-9-2320-266-340137
Section II. DISASSEMBLY AND CLEANING
Section III. INSPECTION AND MEASUREMENT
Figure 11-5. Measuring Cylinder Walls.
Servicing the Pistons, Pins, and Rings.
Figure 11-8. Piston Measurements.
Installing Piston Pins
Servicing the Cylinder Head Assemblies.
Inspecting the Valves.
Figure 11-21. Intake and Exhaust Valves.
Inspecting the Rocker Arm Assemblies.
Inspecting the Push Rods and Tappets.
Section IV. REASSEMBLY
Crankshaft
Timing Chain and Harmonic Balancer.
Oil Pump and Pan.
Remaining Components.
CHAPTER 12. REPAIR OF THE CARBURETOR
Figure 12-2. Removing the Step-Up Piston Cover Plate.
Figure 12-5. Removing or Installing the Air Horn.
Inspecting and Reassembling the Carburetor.
Adjusting the Carburetor.
Figure 12-12. Step-Up Piston.
Choke Unloader (Wide Open Kick).
CHAPTER 13. REPAIR OF THE DISTRIBUTOR
Removing the Pickup Coil.
Vacuum Diaphragm Leak Test.
CHAPTER 14. REPAIR OF THE ALTERNATOR
Figure 14-3. Rectifier End Shield and Stator Assembly.
Replacing the Rectifiers, Pulley, and Bearing.
Figure 14-10. Disengaging Bearing Retainer from End Shield.
Figure 14-14. Installing Rectifier End Shield Bearing.
Test Stand Operation.
CHAPTER 15. REPAIR OF THE STARTER
Figure 15-1. Removing Through Bolts and End Head Plate.
Figure 15-7. Removing Solenoid and Brush Plate Assembly.
Figure 15-12. Removing Return Spring.
Testing the Armature.
Servicing the Clutch Unit.
Figure 15-24. Installing Solenoid and Brush Plate Assembly.
Testing the Starter.
CHAPTER 16. REPAIR OF THE RADIATOR AND HEATER CORE
CHAPTER 17. REPAIR OF THE TRANSFER CASE ASSEMBLY
Figure 17-4. Positioning Transfer Case on Blocks
Disassembly of Range Selector Housing (Range Box)
Legend for Figure 17-9
Figure 17-10. Removing Input Shaft Bearing Retainer.
Reassembly and Installation of Subassemblies
Reassembly of the Transfer.
Figure 17-14. Transfer Assembly (Cross Section).
Figure 17-16 Shift Rail Installed Position
CHAPTER 18. REPAIR OF THE TRANSMISSION
Starter Ring Gear Replacement.
Flushing Oil Cooler and Tubas.
Figure 18-5. Transmission Installed in Repair Stand.
Reconditioning Subassemblies.
Figure 18-8. Oil Pump and Reaction Shaft Support.
Figure 18-10. Staking Pump Bushing.
Replacing the Front Clutch Retainer Bushing.
Rear Clutch.
Figure 18-18. Replacing Input Shaft Bushing.
Planetary Gear Train.
Figure 18-23. Planetary Gear Train and Output Shaft (4X4 Models).
Overrunning Clutch.
Kickdown Servo and Band.
Low-Reverse Servo and Band (Non-Controlled Load].
Figure 18-32. Kickdown Band and Linkage.
Figure 18-34. Accumulator Piston and Spring.
CHAPTER 19. REPAIR OF THE REAR DIFFERENTIAL ASSEMBLY
Figure 19-3. Spreading Rear Axle Housing.
Figure 19-5. Pinion Inner Bearing Cup Removal.
Figure 19-9. Removing Differential Bearings.
Drive Pinion Depth of Mesh Setting and Pinion Bearing Preload. - TM-9-2320-266-340215
Figure 19-14. Installing the Rear Pinion Bearing Cone.
Table 19-1. Pinion Setting Chart
Differential Bearing Preload and Drive Gear and Pinion Backlash. - TM-9-2320-266-340218
Gear Tooth Contact Pattern. - TM-9-2320-266-340219
Figure 19-24. Incorrect Tooth Contact Pattern (Decrease Shim Pack Thickness).
CHAPTER 20. REPAIR OF THE FRONT DIFFERENTIAL ASSEMBLY
Figure 20-3. Removing Companion Flange (Typical)
Figure 20-7. Removing Differential Bearings.
Figure 20-9. Front Differential.
Drive Pinion Depth of Mesh Setting and Pinion Bearing Preload. - TM-9-2320-266-340225
Figure 20-16. Determining Shim Pack Thickness for Drive Pinion Depth of Mesh.
Differential Bearing Preload and Drive Gear and Pinion Backlash. - TM-9-2320-266-340227
Gear Tooth Contact Pattern. - TM-9-2320-266-340228
CHAPTER 21. REPAIR OF THE STEERING BOX AND STEERING COLUMN ASSEMBLY
Ball Nut.
Figure 21-7. Steering Gear.
Section II. REPAIR OF THE STEERING COLUMN ASSEMBLY
Figure 21-10. Removing Steering Shaft Bearing Upper Snap Ring
Reassembling the Column.
Assembling the Bearing Housing.
CHAPTER 22. REPAIR OF THE BRAKE SYSTEM
Figure 22-5. Removing Rear Piston Assembly.
Wheel Cylinders.
Figure 22-11. Wheel Cylinder (Disassembled View).
CHAPTER 23. LITTER COMPARTMENT HEATER (AMBULANCE)
Fuel Pump.
Upset Switch.
CHAPTER 24. ARCTIC WINTERIZATION EQUIPMENT
Figure 24-1. Arctic Kit Components Location.
Section II. TROUBLESHOOTING - TM-9-2320-266-340247
Table 24-2. Personnel Heater Troubleshooting
Table 24-3. Cab Heavy-duty Heater
Section III. REPAIR
Mixing Chamber Air Valve.
Carburetor Assembly.
Personnel Heater, Cargo Area.
Disassembly - TM-9-2320-266-340254
Figure 24-4. Ventilating Blower Assembly Component Parts.
Assembly of igniter assembly.
Figure 24-5. Personnel Heater Test Wiring Setup.
Adjusting Flame Detector Switch
Personnel Heater Control Box.
Cargo Box Bow.
CHAPTER 25. MATERIEL USED IN CONJUNCTION WITH MAJOR ITEM
Figure 25-2. Blackout Lighting Kit Cab Harness.
Figure 25-4. Stoplight Switch Connection.
Figure 25-6. Bulkhead Connector.
Figure 25-7. Instrument Cluster Lamp Filter Locations.
Lamp Installation.
Figure 25-10. Blackout Marker Lights.
Figure 25-11. Tail/Stop Light Assembly Locotions
CHAPTER 26. REPLACEMENT OF THE RADIATOR CORE SUPPORT
APPENDIX A. REFERENCES - TM-9-2320-266-340271
APPENDIX A. REFERENCES-continued
INDEX - TM-9-2320-266-340273
INDEX-continued - TM-9-2320-266-340274
INDEX-continued - TM-9-2320-266-340275
INDEX-continued - TM-9-2320-266-340277
INDEX-continued - TM-9-2320-266-340278
INDEX-continued - TM-9-2320-266-340279
/.25ton/TM-9-2320-266-34 Truck Cargo; 1-1/4 Ton 4x4 4X2 Ambulance; 1-1/4 TON 4X4 4X2 Telephone Maintenance; 1-TON 4X4 M888 (NSN 2320-01-044-0333) Manual