jeep willys mb ford gpw manual

8/3/2019 Jeep Willys Mb Ford Gpw Manual

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WAR DEPARTMENT TECHNICAL MANUAL

TM 9-803

%-TON 4x4 TRUCK

(WILLYS-OVERLANDMODELMB and

FORDMODELGPW)

WAR DEPARTMENT . FEBRUARY 1944

W ashingt on : 1947


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WAR DE?ARTMENTWashington 25, D. C., 22 February 1944

TM 9-803, J /4-ton 4 x 4 Tru ck (Willys-Overlan d Model MB an d Ford

Model GPW), is pu blished for th e inform at ion an d guida nce of allconcerned.

[ A. G . 3 0 0 . 7 ( 1 7November 4 3 ) )

BY ORDEROFTHESECRETARYOFWAR:

G. C. MARSHALL,C h i e f o f S t a f f .

OFFICIAL:

J. A. ULTO,Major General,

T h e A d j u t a n t G en e r a l .

DISTRIBUTION:C&H (1).

(For explan at ion of symbols, see FM 2 l-6)

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TM 9-803

TRUCK (WILLYS-OVERLAND

and KbR0 MODEL GPW)

CONTENTS

%K!TION 1

II

IIIIV

V

. VIVII

Introduction. . . . . . . . . .

Dcacription and tabulated data.Driving control8 and operation. .

Operation under unusualconditiona..................

First echelon preventivemaintenance service. . . . . . .

Lubrication. . . . .Tools and equipment stowage on

the vehicle. . . . . . . . . .

pmmgraphr Pmges

1 5-92-3 10-124-6 13-20

7-11 21-27

12-16 28-36

17-18 37-48

19-21 49-5 1

CART TWO-VEHICLE MAI NTENA NCE INSTRUCTIONS

SICTION VIII

IX

XXI

XIIXIII

XIV

xvXVI

XVII

XVIII

XIX

Record of modifications. . . .

Second echelon preventive, maintenance. . . . . . . . .

New vehicle run-in test. . . .Organization tools and

equipment. . . . . . . . .

Trouble shooting. . . . . . . .

Engine-description, data,maintenance, and adjustmentin vehicle. . . . . . . . .

Engine-removal and installation

Ignition system. . . . . . . . . .Fuel and air intake and exhaust

systems....................cooling system . . . . . . .starting nystem . . . . . . . . . . . .

Generating system. . . . . . . . . . . .3

22 52

23 53-67

24-26 68-72

27-28 73

29-49 74-103

50-59 104-11560-61 116-117

62-69 118-125

70-78 126-13679-86 137-14387-90 144-14591-94 146-149


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TM 9-803

l / ,-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBan d FORD MODEL GPW)

SECTION XX

XXI

XXII

XXIII

XXIV

xxv

XXVI

XXVII

XXVIIIXXIX

xxx

xxx1

xxx11

REFERENCES. . .

Paragraphs

Bat tery an d lighting system. . 95-106

Clutch....................... 107-112

Transmission. . . . . . . . 113-116

Transfer case.. . . . . . . . 117-121

Propeller shafts and universaljoints...................... 122-125

Front axle.. . .!. . . . . 126-137

Rear axle.. . . . . . . . . . 138-145

Brakes....................... 146-152

Spr ings an d shock absorbers . 153-157Steering gear. . . . . . . . . 158-l 63

Body an d fra me.. . . . 164-175

Radio interference suppressionsystem..................... 176-179

Shipment an d tem pora ry storage 180-182

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pages

150-166

167-171

172-175

176-178

179-180

181-188

189-192

193-204

205-210211-215

216-220

221-227

228-232

233-234

INDEX............................................... 235

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TM

PART ONE-OPERATI NG IN STRUCTI ONS

Section I

9-8031

INTRODUCTIONParagraph

Scope . . . . . . . . . . . . . . . . . . . . . . . . .._....................... 1

1 . SCOPE.

a . This technical manual* is published for the information andguidance of the using arm personnel charged with the operation andmaintenance of this materiel,

b. In addition to a description of the I /4-tori 4 x 4 Truck (Willys-

Overland model MB and Ford GPW), this manual contains technicalinformation required for the identification, use, and care of the mate-riel. The manual is divided into two parts. Part One, sections Ithrough VII, contains vehicle operating instructions. Part Two, sec-Lf_-_ x1111 LL_^.._.l_ VVIT ^__L_:__ _._L:_,_ __:_e___,,, :_C....,.C:~^..LlrlS 111 rrlluyrl **All, C,,LIll,S C,,,CK ,,alllLcllaL,L.c lllDl.lULLlllJto using arm personnel charged with the responsibility of doingmaintenance work within their jurisdiction, including radio suppres-sion and shipment and temporary storage information.

c. In all cases where the nature of the repair, modification, oradjustment is beyond the scope of facilities of the unit, the respon-sible ordnance service should be informed so that trained personnelwith suitable tools and equipment may be provided, or proper in-structions issued.

d . This manual includes operating and organizational mainte-nance instructions from the following Quartermaster Corps lo-seriestechnical manuals. Together with TM g-180349 and TM 9-1803B,this manual supersedes them:

,.\ mrr .I\ ..nrl nr\ .___.._A .nn.(11 llvl IV-lllJ.3, LU fwlgusr 1YLtl.(2) TM 10-1207, 20 August 1941.

(3) TM 10-1349, 3 January 1942.(4) TM 10-1513, Change 1, 15 January 1943.

*To provide operating instructions with the materiel, this technical manual hasbeen published in advance of complete technical review. Any errors or omissionswill be corrected by changes or, if extensive, by an early revision.


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fRA PD 305251

Figure I--I/4-Ton 4 x 4 Truck-Left Front


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0,c00

TM 9-8031

INTRODUCTION


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TM 9-8031

l/,-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBand FORD MODEL GPW)

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TM 9-8031

INTRODUCTION


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TM 9-8032-3

l/i-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBand FORD MODEL GPW)

Section II

DESCRIPTION AND TABULATED DATAParagraph

Description . 2

Data _.._., .._.... . 3

2. DESCRIPTION.mm._._ m,~?_ _~ .,L_,_ .a. 1 YPe* ~nls vemcle is a generai purpose, personnei, or cargo

carrier especially adaptable for reconnaisance or command, anddesignated as I/d-ton 4 x 4 Truck. It is a four-wheel vehicle withfour-wheel drive. The engine is a 4-cylinder gasoline unit located inthe conventional place, under the hood at the front of the vehicle.A conventional three-speed transmission equipped with a transfercase provides additional speeds for traversing difficult terrain. Thebody is of the open type with an open drivers compartment. Thefolding top can be removed and stowed: and. the windshield tiltedforward on top of the hood, or opened upward and outward. A sparewheel equipped with a tire is mounted on thr rear of the body, and apintle hook is provided to haul trailed loads. Specifications of thevehicle are given under Data (par. 3). Genrral physical character-istics are shown in figures 1 through 4.

h. Identification. The manufacturers chassis serial number isstamped on a plate inside the left frame side member at the front end,and on the name plate (fig. 6). The engine serial number is stampedon the right side of the cylinder block. front upper corner. The U.S.A.registration number is painted on both sides of the hood.

3. DATA.a. Vehicle Specifirations.

Wheelbase 80 in.Length, over-all 1321/d in.Width, over-all .., 62 in.Height, over-all-top up 69$/4 in.

-top down 52 in.Wheel size combat 16 x 4.50 ETire size 16 x 6.00 in.

Tire pressure (front and rear) 35 lbTire type mud and snowTire plies 6Tread (center-to-center)-front 49 in.

-rear 49 in.Crew, operating 2Passenger capacity including crew 5

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TM 9-8033

DESCRIPTION AND TABULATED DATA

Weights:Road, including gas and water 2,453 lbGross (loaded) 3,253 lbShipping (less water and fuel) 2,337 lbBoxed gross 3,062 lbMaximum pay load 800 lbMaximum trailed load 1,000 lb

Ground clearance 8 in.Pintle height (loaded) 21 in.Kind and grade of fuel (octane rating) Gasoline (68 mm)Approach angle 45 degDeparture angle 35 degShipping dimensionscubic feet 331

square feet 57

b. Performance.

Maximum allowable speeds (mph) with transfer case in HIGH range:High gear (3rd) 65Intermediate gear (2nd) 41

Low gear (1st) 24Reverse gear . 18

Maximum allowable speeds (mph) with transfer case inLOW range:High gear (3rd) 33Intermediate gear (2nd) 21Low gear (1st) 12Reverse gear 9

Maximum grade ability 60 pct

Minimum turning radiusright 17 ftleft 171/2 ftMaximum fording depth. 21 in.Towing facilitiesfront none

rear pintle hook Maximum draw-bar pull 1,930 lbEngine idle speed 600 rpmMiles per gallon(high gearhigh range)average conditions 20

Cruising range(miles) average conditions 20

c. Capacities.Engine crankcase capacitydry 5 qt

refill 4 qtTransmission capacity % qtTransfer case capacity 1 I/I qt


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TM 9-8033

+TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBan d FORD MODEL GPW)

Front axle capacity (differential) . 1y4 qt

Rear axle capacity (differential) 1r/4 qtFront axle steering knuckle universal joint. j/4 qtSteering gear housing y4 qtAir cleaner (oil bath). . s/s qtFuel tank capacity 15 galCooling system capacity 11 qtBrake system (hydraulic brake fluid) j/4 qtShock absorbers--front 5 oz

-rear .., . __.. 53/4 02d. Communications.

(1) RADIO OUTLET Box. A radio outlet box is provided on thelater vehicles to use the vehicle battery (6-volt current supply). Thisoutlet is located against the body side panel at the right front seat.

(2) AUXILIARY GENERATOR. A 12-volt, 55ampere auxiliary gen-erator is furnished on some vehicles. The generator is driven by aV-belt from a power take-off unit on the rear of the transfer case.Instructions for operation and care accompany those vehicles.

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TM 9-8034

Sec t ion I I I

DRIVING CONTROLS AND OPERATIONParagraph

Instruments and controls . . , . . 4Use of instr um ent s an d cont rols in vehicular operat ion. . . 5Towing the veh icle....................................... 6

A B C

WVUTSRQPON ML K J I

AECDEF

GH

IJK1

MN0

;

4 .

STEERING WHEEL RHORN BUTTON SWINDSHIELD WIPERS 1WINDSHIELD ADJUSTING ARMS UAMMETER VHAND BRAKE WWINDSHIELD CLAMPS XCAUTION PLATE YNAME PLATE ZSHIFT PLATE AATRAN SMISSION GEAR SHIFT LEVER ARTRANSFER CA SE SHIFT LEVER-FRONT AXLE DRIVE ACTRANSFER CA SE SHIFT LEVER-AUXILIARY RANGE ADSTARTING SWITCH AETEMPERATURE GA GE AFACCELERATOR FOO T REST ACSPEEDOMETER AH

ACCELERATOR ( FOO T THROTTLE)OIL PRESSURE G AGEFUEL GAGEBRAKE PEDALINSTRUMENT PANEL LIGHT SWITCHCLUTCH PEDA LFUEL TANKFIRE EXTINGUISHERSAFETY STRAPHEADLIGHT FOOT SWITCH (BEAM CO NTROL)BLACKOUT LIGHT SWITCHBLAC KOUT DRIVING LIGHT SWITCHREAR VISIO N MIRRORCHOKE CONTROLIGNITION SWITCHHA ND THROTTLERIFLE HOLDER

RA PD 334753

Figure 5-Ins t rum ent s and Cont ro ls

INSTRUMENTS AND CONTROLS.

a . I n s t r u m e n t s .(1) AMMETER (fig. ). The amm eter on the instrum ent panel

indicat es th e ra te of cur rent flow when the genera tor is cha rging th ebatt ery, an d also indicat es th e am oun t of cur rent being consu medwhen th e engine is idle.

(2) FUEL GAGE (fig. 5). The fuel gage on th e inst ru men t pan el

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TM 9-8034

/,-TON 4 x 4 TRUCK (WILL YS-OVERLA ND MODEL MBand FORD MODEL GPW)

Figure 6-Nam e PfafeRA PD 330838

RA PD 305162 RA PD 305161

Figure 7-Caut ion Plate Figure ( I -Shif t Pla te

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TM 9-8034

DRIVING CONTROLS AND OPERATION

is an electrical unit which indicates the fuel level in the tank, andonly registers while the ignition switch is turned on.

(3) OIL PRESSURE GAGE (fig. ). The oil pressure gage locatedon the instrument panel indicates the oil pressure when the engineis running.

(4) SPEEDOMETER (fig. ). The speedometer on the instrumentpanel indicates in miles per hour the speed at which the vehicle isbeing driven. The odometer (in upper part of speedometer face)registers the total number of miles the vehicle has been driven. Atrip indicator (in lower part of speedometer face) gives distancecovered on any trip. Set trip indicator by turning the knurled con-trol shaft extending through back of the speedometer.

(5) TEMPERATURE GAGE (fig. 5). The temperature gage registersthe temperature of the solution in the cooling system.

b. C o n t r o l s .(1) BLACKOUT DRIVING LIGHT SWITCH (fig. 5). The blackout

driving light switch (B.O. DRIVE) on the instrument panel controlsthe blackout driving light located on the left front fender, to furnishadditional light during blackout periods. To operate light, first pullthe blackout l i g h t switch button to the first position, then pull black-out d r i v i n g light switch knob. To switch off the light, push in black-out d r i v i n d light switch knob.

Fieure 9-Blackout Light Switch Operating ?ositions

(2) BLACKOUT LIGHT SWITCH (fig. 5). The knob on the instru-ment panel (LIGHTS) controls the entire lighting system, includingthe instrument panel lights, blackout driving light, and stop lights.A circuit-breaker type fuse, on the back of the switch, opens whena short circuit occurs, and closes when the thermostatic element cools.The light switch is a four-position push-pull type with a safety lock(fig. 9). When the control knob is pulled out to the first position, theblackout headlights and blackout stop and taillights are turned on.

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TM 9-8034

I/,-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBand FORD MODEL GPW)

The switch control knob travel is automatically locked in this positionby the lock-out button to prevent accidentally turning on of theservice (bright) lights in a blackout area. To obtain service lights,push in on lock-out control button on the left side of the switch, andpull out control knob to second position. When switch is in this posi-tion service headlights, service stop and taillights are turned on, andthe panel lights can be turned on by pulling out on the knob(PANEL LIGHTS). CAUTION: When driving during the day, pressin lock-out control button, and pull control knob out to the last orstop light position to cause only the regular stop light to function.

Figure IO- Gen e ra to r B rac eRA PD 305165

(3) PANEL LIGHT SWITCH (fig. 5). The panel light switch knob(PANEL LIGHTS), located on the instrument panel, controls thelights to illuminate the panel instruments and controls. The blackoutlight switch (subpar. b (2) above) must be in service (bright light)position for this switch to control the panel lights.

(4) FIRE EXTINGUISHER (fig. 5). The fire extinguisher is mountedinside the left cowl panel. To remove, pull outward on the clamprelease lever. To operate extinguisher, hold body in one hand andwith the other, turn handle to left one-quarter turn, which releasesplunger lock. Use pumping action to force liquid on base of fire. Readinstructions on fire extinguisher plate.

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TM 9-8034-5


(5 ) HAND BRAKE (fig. 5). The hand brake is applied by pullingout on the handle at the center of the instrument panel. Pull thehandle out in a vertical position when the vehicle is parked. The

brake is released by turning the handle one-quarter turn.(6 ) WINDSHIELD ADJUSTING ARMS (fig. 5). The windshield

adjustment arms are mounted on each end of the windshield frame.To open windshield, loosen knobs and push forward on lower part,then set by tightening the knobs.

(7) WINDSHIELD CLAMPS (fig. 5). The windshield clamps arelocated on the lower part of the windshield. Pull up on both clampsand unhook them, after which the windshield can be lowered on topof the hood. Be sure to hook down the windshield, using the hold-down catches on both sides of the hood.

(8) GENERATOR BRACE (fig. 10). The generator brace can bepulled up to release tension on the fan belt and stop the fan fromthrowing water over the engine when crossing a stream. Pull gen-erator out to running position as soon as possible thereafter, and itwill lock in place. CAUTION: B e s u r e f a n b e lt i s o n p u l l e ys .

(9) OTHER INSTRUMENTS AND CONTROLS. Other instruments andcontrols are of the conventional type, and are shown in figure 5.

5. USE OF INSTRUMENTS AND CONTROLS IN VEH ICULARO P E R AT I O N .

a . B e f or e -o p e r a t i o n S e r v i c e . Perform the services in paragraph13 before attempting to start the engine.

b . S t a r t i n g E n g i n e . To start the engine proceed as follows:(1) Put transmission gearshift lever in neutral position (fig. 8).(2) Pull out hand throttle button about 3/4 inch to 1 inch.(3) Pull out choke button all the way. NOTE: C h o k i n g i s not

n e ce ss a r y w h e n e n g i n e i s w a r m .(4 ) Turn ignition to ON position.(5) Depress clutch pedal to disengage clutch, and hold pedal

down while engine is started.(6) Step on starting switch to crank again. Release switch as

soon as engine starts.(7) Adjust choke and throttle control buttons to obtain proper

idling speed. As engine warms up, push choke button all the way in.(8) Check oil pressure gage reading; at idle speed the indicator

hand should show at least 10 on the gage.(9) Check ammeter for charge reading. Check fuel gage for

indication of fuel supply.

(10) After engine has operated a few minutes, check temperaturegage reading. Normal operating temperature is between 160F and185OF.

(11) In extremely cold weather refer to paragraph 7.

c. P l a c i n g Ve h i c le i n M o t i o n .(1) For daytime driving turn on service stop light (par. 4 b (2)).(2) Place transfer case right-hand shift lever in rear position to

soX!ri 0---48~~-2 17


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TM 9-8035

I/,-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MBand FORD MODEL GPW)

engage HIGH range, then place center shift lever in forward posi-tion to disengage front axle (fig. 8).

(3) Depress clutch pedal, and move transmission shift levertoward driver and backward to engage low (1st) gear (fig. 8).

(4) Release parking (hand) brake.(5) Slightly depress accelerator to increase engine speed, and at

the same time slowly release clutch pedal, increasing pressure onaccelerator as clutch engages and vehicle starts to move. NOTE:D u r i n g t h e f ol l ow i n g o p e r a t i on s p e r f or m p r o c ed u r e s o u t l i n e d i n p a r a -g r a p h 1 4 .

(6) Increase speed to approximately 10 miles per hour, depress

clutch pedal, and at the same time release pressure on accelerator.Move transmission shift lever out of low gear into neutral, and theninto second gear. No double clutching is required. Release clutchpedal and accelerate engine.

(7) After vehicle has attained a speed of approximately 20 milesper hour, follow the same procedure as outlined above in order toshift into high (3rd) gear, moving the gearshift lever straight back.

d . S h i ft i n g t o L o w e r G e a r s i n Tr a n s m i ss io n . Shift to a lowergear before engine begins to labor, as follows: Depress clutch pedalquickly, shift to next lower gear, increase engine speed, release clutchpedal slowly, and accelerate. When shifting to a lower gear at anyrate of vehicle speed, make sure that the engine speed is synchronizedwith vehicle speed before clutch is engaged.

e. S h i f t in g G e a r s i n Tr a n s f e r C a s e (fi g . 8). The transfer case isthe means by which power is applied to the front and rear axles. Inaddition, the low gear provided by the transfer case further increasesthe number of speeds provided by the transmission. The selection ofgear ratios depends upon the road and load conditions. Shift gearsin the transfer case in accordance with the shift plate (fig. S), andobserve the instructions on the caution plate (fig. 7). The transmis-sion gearshift does not in any way affect the selection or shifting ofthe transfer case gears. Vehicle may be driven by rear axle, or by bothfront and rear axles. The front axle cannot be driven independently.

(1) FRONT AXLE ENGAGEMENT. Front axle should be engagedonly in off-the-road operation, slippery roads, steep grades, or duringhard pulling. Disengage front axle when operating on average roadsunder normal conditions.

(a) E n & a g i n g F r on t A x l e w i t h Tr a n s f e r Ca s e i n H I G H R a n g e .With transfer case in HIGH range, move front axle drive shift lever

to IN position. Depressing the clutch pedal will facilitate shifting.( b ) D i s en g a g i n g F r o n t A x l e w i t h T r a n s f er C a s e i n H I G H

R a n g e . Move front axle drive shift lever to OUT position. Depressthe clutch pedal to facilitate shifting.

(c) D i s en g a g i n g F r o n t A x l e w h e n Tr a n s f e r Ca s e i s i n L O W.1. Depress clutch pedal, then shift transfer case lever into

HIGH.2. Shift front axle drive lever into OUT position.

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TM 9-8035-6


3. Release clutch pedal and accelerate engine to desired speed.(2) ENGAGING TRANSFER CASE LOW RANGE. Transfer case LOW

range cannot be engaged until front axle drive is engaged.(a) Engage front axle drive (subpar. e (1) above).(b) Depress clutch pedal and move transfer case shift lever into

IV (neutral) position.(c ) Ro1s .c .~~ r l t r t rh nm- la l anA nr r r l r=ca te ena ;ne*.b Ac .. L.YCC.. y-Cuu _...A Y..LL.L. ... . . . .b...L.

(d ) Depress clutch pedal again and move transfer case shift leverforward into LOW position.

(e> Release clutch pedal, and accelerate engine to desired speed.(3) ENGAGING TRANSFER CASE-LOW to HIGH. This shift

can be made regardless of vehicle speed.(a) Depress clutch pedal and move transfer case shift lever into

HIGH position.(b ) Release clutch pedal, and accelerate engine to desired speed.

f : S t o p p i n g t h e Ve h i c le . Remove foot from accelerator, andapply brakes by depressing brake pedal.

(1) When vehicle speed has been reduced to engine idle speed,depress clutch pedal and move transmission shift lever to N(neutral) position (fig. 8).

(2) When vehicle has come to a complete stop, apply parking(hand) brake, and release clutch and brake pedals.

g. R e v e r s i n g t h e Ve h i c le . To shift into reverse speed, first bringthe vehicle to a complete stop.

(1) Depress clutch pedal.(2) Move transmission shift lever to the left and forward into

R (reverse) position.(3) Release clutch pedal slowly. and accelerate as load is picked

up.

h . S t o p p i n g t h e E n g i n e . To stop the engine turn the ignitionswitch to OFF position. NOTE: Before a n e w o r r e c o n d i t i o n e dv eh i c l e i s f i r s t p u t i n t o s er v i c e: m a k e r u n -i n t e st s a s o u t l i n e d i n s ec -t ion 10 .

6 . TOWING THE VEH ICLE .

a . At t a c h i n g To w L i n e . To tow vehicle attach the chain, rope orcable to the front bumper bar at the frame side rail gusset (fig. 11).Do not tow from the middle of the bumper. To attach tow line, loopchain, rope, or cable over top of bumper, bring tow line up acrossfront of bumper, and back on opposite side of frame, then hook or tie.

h . To w i n g t o S t a r t Ve h i c l e . Place transfer case (aux. RANGE).h;ff la . , -v nf tn. . . .4 . . .ah.r l , en l a ram.. I UTr,U \ D1ms.a f-n-+ ow laL.IIIC SLL A I CVWL Ll A,C.x. L CA.C La, \ AAIU11 , . 1 AcIbC AI C a .%&

drive shift lever in OUT (forward) position. Depress clutch pedaland engage transmission in high (3rd) speed. Switch ignition ON,pull out choke control knob (if engine is cold), pull out throttle knobabout 1 inch, release parking (hand) brake, and tow vehicle. After

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TM 9-8036

l / ,-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBan d FORD MODEL GPW)

vehicle is under way, release clutch pedal slowly. As engine starts,regulate choke and throttle controls and disengage clutch, beingcareful to avoid overrunning towing vehicle or tow line.

c. Towing Disabled Vehicle. When towing a disabled vehicleexercise care so that no additional damage will occur.

(1) A. I XX,rrX7?7. _\I P_-r,rrr7r\X7L.L. ~l?rc.L3 IY UKIY.(a) If transfer case is not damaged, shift transmission and trans-

fer case into neutral position and follow steps (c) and (d) below.

(b) If transfer case is damaged, disconnect both propeller shaftsat the front and rear axles by removing the universal joint U-bolts,

being careful not to lose the bearing races and rollers. Securely fastenthe shafts to the frame with wire or remove dust cap and pull apartat the universal joint splines. Place bolts, nuts, rollers, and races inthe glove compartment.

(c) If the front axle differential or propeller shaft is damaged,remove front axle shaft driving flanges. Place front axle drive shiftlever in OUT (forward) position and drive vehicle under ownpower.

(d) If the rear axle differential is damaged, remove the rear axleshafts; remove rear propeller shaft at rear universal joint U-bolts andfront universal joint snap rings in forward flange, then drive outbearing cups. Place front axle drive shift lever in IN (rear) positionand this will allow front axle drive to propel vehicle under ownpower.

(e) If rear propeller shaft only is damaged, remove as describedin step (d) above.

(2) TOWING VEHICLE WITH FRONT OR REAR WHEELS OFFGROUND. If vehicle is to be towed in this manner be sure that transfercase shift lever is placed in N (neutral) position and front axledrive shift lever is placed in OUT (disengaged) position.

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TM 9-8037

Section I V

OPERAT ION UNDER UNU SUAL CONDITIONS

Paragraph

Operation in cold weather 7Operation in hot weather 8Operation in sand ,. 9Operation in ianding i0Decontamination 11

7. O P E R AT I O N I N C O L D WE AT H E R .

a . P u r p o s e . Operation of automotive equipment at subzerotemperatures presents problems that demand special precautions andextra careful servicing from both operation and maintenance person-nel, if poor performance and total functional failure are to be avoided.

b . G a s o l i n e . Winter grade of gasoline is designed to reduce cold. .._-&I___. ^L_._L:-- -1:cf-..Ic:,.-.wcaL,lrl YLill L111g UIIIICUILICS, tbleiefoie 4.l_ . . ..-c_- --_.l- __^L^^ c..,.,, LlC WllLCl g;lauc lllL ,UClshould be used in cold weather operation.

c. S t o r a g e a n d H a n d i n g o f G a s ol in e . Due to condensation ofmoisture from the air, water will accumulate in tanks, drums, andcontainers. At low temperatures, this water will form ice crystals thatwill clog fuel lines and carburetor jets, unless the following precau-tions are taken:

(1) Strain the fuel through filter paper, or any other type ofstrainer that will prevent the passage of water. CAUTION: Gasolinef l o w i n g o v er a s u r f a c e g e n e r a t e s s t a t i c el e ct r i c i t y t h a t w i N r e s u l t i n as p a r k , u n l e ss m e a n s a r e p r o v i d ed t o g r o u n d t h e e le ct r i c it y. A l w a y sp r o v id e a m e t a l l i c co n t a c t b e t w een t h e c on t a i n e r a n d t h e t a n k , t oa s s u r e a n e ff ec t i ve g r o u n d .

(2) Keep tank full, if possible. The more fuel there is in the tank,the smaller will be the volume of air from which moisture can becondensed.

(3) Add /z pint of denatured alcohol, Grade 3, to the fuel tankeach time it is filled. This will reduce the hazard of ice formation inthe fuel.

(4) Be sure that all containers are thoroughly clean and free fromrust before storing fuel in them.

(5) If possible, after filling or moving a container, allow the fuel

to settle before filling fuel tank from it.(6) Keep all closures of containers tight to prevent snow, ice, dirt,and other foreign matter from entering.

(7) Wipe all snow or i ce from dispensing equipment and fromaround fuel tank filler cap before removing cap to refuel vehicle.

d. L u b r i c a t i o n .(1) TRANSMISSION AND DIFFERENTIAL.

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(a ) Universal gear lubricant, SAE 80, where specified on figure 14,is suitable for use at temperatures as low as -20F. If consistenttemperature below OF is anticipated, drain the gear cases whilewarm, and refill with Grade 75 universal gear lubricant, which is suit-able for operation at all temperatures below +32F. If Grade 75universal gear lubricant is not available, SAE 80 universal gear lubri-cant diluted with the fuel used by the engine, in the proportion of onepart fuel to six parts universal gear lubricant, may be used. Dilutemake-up oil in the same proportion before it is added to gear cases.

(b ) After engine has been warmed up, engage clutch, and main-tain engine speed at fast idle for 5 minutes, or until gears can beengaged. Put transmission in low (first) gear, and drive vehicle for100 yards, being careful not to stall engine. This will heat gear lubri-cants to the point where normal operation can be expected.

(2) CHASSIS POINTS. Lubricate chassis points with generalpurpose grease, No. 0.

(3) STEERING GEAR HOUSING. Drain housing, if possible, or usesuction gun to remove as much lubricant as possible. Refill with uni-versal gear lubricant, Grade 75, or, if not available, SAE 80 universal

gear lubricant diluted with fuel used in the engine, in the proportionof one part fuel to six parts SAE 80 universal gear lubricant. Dilutemake-up oil in the same proportion before it is added to the housing.

(4) OILCAN POINTS. For oilcan points where engine oil is pre-scribed for above OF, use light lubricating, preservative oil.

e. P r o t e c t i o n o f C o o li n g S y s t e m s .

(1) USE ANTIFREEZE COMPOUND. Protect the system with anti-freeze compound (ethylene-glycol type) for operation below i 32F.

The following instructions apply to use of new antifreeze compound.(2) CLEAN COOLING SYSTEM. Before adding antifreeze compound,

clean the cooling system, and completely free it from rust. If the cool-ing system has been cleaned recently, it may be necessary only todrain, refill with clean water, and again drain. Otherwise the systemshould be cleaned with cleaning compound.

(3) REPAIR LEAKS. Inspect all hoses, and replace if deteriorated.Inspect all hose clamps, plugs, and pet cocks and tighten if necessary.Repair all radiator leaks before adding antifreeze compound. Correctall leakage of exhaust gas or air into the cooling system.

(4) ADD ANTIFREEZE COMPOUND. When the cooling system isclean and tight, fill the system with water to about one-third capacity.Then add antifreeze compound, using the proportion of antifreezecompound to the cooling system capacity indicated below. Protectthe system to at least lOoF below the lowest temperature expected tobe experienced during the winter season.

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ANTIFREEZE COMPOUND CHART(for 11 -q uart c ap ac ity c ooling system)

Tsmpera tur* Ant i f reeze Compound

(e thy lene-g lyco l type)

+lOF .,.,.. ._._........_._ 3 qtOF 33/4 qt

- 10F 4% nt,ri -I---20F 43/4 qt

-30F ._.... _. _. 5% qt-40F. ._.........._ 6 qt

(5) WARM THE EN GINE . Aft er ad ding an tifreeze compound , fill

with wa ter to slight ly below th e filler neck: th en sta rt an d war m th eengine to normal operat ing tempera tu re.

(6) TEST STRENGTH OF SOLUTION. Stop th e engine an d check th esolution with a hydr omet er, adding a nt ifreeze compound if requir ed.

(7) TwcDFrr Wurzu1IL..,1 x,L L . . YYLX 1 &&I YCI AL._,n .ZPPII;FP nrner+ the mnlan t w~~l r l , , mraYyLC._ L& 1.. ~vvIcI ssc . .LC...Jstr ength an d color. If ru sty, drain an d clean cooling system th or-oughly, and add new solution of th e requir ed str ength .

(8) CAUTIONS.

( a ) A n t i f r ee z e c o m p o u n d i s t h e o n l y a n t i f r ee z e m a t e r i a l a u t h o r -i z e d f o r o r d n a n c e m a t e r i e l .

( b ) I t i s e s se n t i a l t h a t a n t i f r e ez e so l u t i o n s b e k e p t c l ea n . U s e o n l yc on t a i n e r s a n d w a t e r t h a t a r e f r ee fr o m d i r t , r u s t , a n d o i l.

( c) U s e a n a c c u r a t e h y d r o m e t er. To t e st a h y d r o m e t er, u s e o n ep a r t a n t i f r ee z e co m p o u n d t o t w o p a r t s w a t e r. T h i s s ol u t i o n w i l l p r o -d u c e a h y d r o m e t er r e a d i n g o f O F.

(d ) D o n o t s p i l l a n t i f r ee z e c om p o u n d o n p a i n t e d s u r f a c es .

f. E l e t t r i c a l S y s t e m s .

(1) GENE RATOR AND CRANKING MOTOR. Check th e bru shes,commu ta tors, and bearings. See tha t th e commu ta tors ar e clean. Thelar ge sur ges of cur ren t which occur when st ar ting a cold enginerequir e good cont act between bru shes a nd comm ut at ors.

(2) WIRING. Check, clean , an d tigh ten all conn ections , especiallyth e batt ery terminals. Care should be tak en tha t no short circuits ar epresent .

(3) COIL. Check coil for pr oper fun ctionin g by notin g qua lity ofspark.

(4) DISTRIBUTOR. Clean th oroughly, an d clean or rep lace point s.Check t he points frequently. In cold weat her , slight ly pitt ed pointsmay prevent engine from starting.

(5) SPARK PLU GS. Clean an d adju st or rep lace, if necessa ry. Tf itis difficult to ma ke t he engin e fire, r edu ce th e gap t o 0.005 inch lessth an th at recomm ended for norma l opera tion (par . 67 1)). This willma ke ignition more effective at redu ced voltages likely t o prevail.

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(6 ) TIMING. Check carefully. Care should be taken that the sparkis not unduly advanced nor retarded.

(7) BATTERY.(a ) The efficiency of batteries decreases sharply with decreasing

temperatures, and becomes practically nil at -4OF. Do not try tostart the engine with the battery when it has been chilled to tem-peratures below -30F until battery has been heated, unless a warmslave battery is available. See that the battery is always fullycharged, with the hydrometer reading between 1.275 and 1.300. Afully charged battery will not freeze at temperatures likely to beencountered even in arctic climates, but a fully discharged battery

will freeze and rupture at +5F.(b ) Do not add water to a battery when it has been exposed to

subzero temperatures unless the battery is to be charged immediately.If water is added and the battery not put on charge, the layer of waterwill stay at the top and freeze before it has a chance to mix withthe acid.

(8) LIGHTS. Inspect the lights carefully. Check for short circuitsand presence of moisture around sockets.

(9) ICE. Before every start, see that the spark plugs, wiring, or

other electrical equipment is free from ice.g. Sta r t i ng a n d O p e r a t i n g E n g i n e .

(1) INSPECT CRANKING MOTOR MECHANISM. Be sure that noheavy grease or dirt has been left on the cranking motor throwoutmechanism. Heavy grease or dirt is liable to keep the gears from beingmeshed, or cause them to remain in mesh after the engine starts run-ning. The latter will ruin the cranking motor and necessitate repairs.

(2) USE OF CHOKE. A full choke is necessary to secure the richair-fuel mixture required for cold weather starting. Check the butter-fly valve to see that it closes all the way, and otherwise functionsproperly.

(3) CARBURETOR AND FUEL PUMP. The carburetor, which willgive no appreciable trouble at normal temperatures, is liable not tooperate satisfactorily at low temperatures. Be sure the fuel pump hasno leaky valves or diaphragm, as this will prevent the fuel pump fromdelivering the amount of fuel required to start the engine at lowtemperatures, when turning speeds are reduced to 30 to 60 revolu-tions per minute.

(4) AIR CLEANERS. At temperatures below OF do not use oil inair cleaners. The oil will congeal and prevent the easy flow of air.Wash screens in dry-cleaning solvent, dry, and replace. Ice and frostformations on the air cleaner screens can cause an abnormally highintake vacuum in the carburetor air horn hose, resulting in collapse.

(5) FUEL SYSTEM. Remove and clean sediment bulb, strainers,etc., daily. Also drain fuel tank sump daily to remove water and dirt.

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(6 ) STARTING THE ENGINE. Observe the following precautions inaddition to the normal starting procedure (par. 5 a and b ).

(4frost.

(h)(c)(d)

12).

(e)ffl

Clean ignition wires and outside of spark plugs of dirt and

Free distributor point arm on post and clean points.Be sure carburetor choke closes fully.Operate fuel pump hand lever to fill carburetor bowl (fig.

Free up engine with hand crank or use slave battery.Stop engine if no oil pressure shows on gage.

Figure I2-Fuel Pump, Hand Operation

(g) Engage clutch to warm up transmission oil before attemptingto move vehicle.

(h) Check engine operation for proper condition (par. 13 b (22)).

h . C h a s s i s .

(1) BRAKE BANDS. Brake bands, particularly on new vehicles,have a tendency to bind when they are very cold. Always have ablowtorch handy to warm up these parts, if they bind prior to mov-ing, or attempting to move, the vehicle. Parking the vehicle with thebrake released will eliminate most of the binding. Precaution must betaken, under these circumstances, to block the wheels or otherwiseprevent movement of the vehicle.

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(2) EFFECT OF Low TEMPERATURES ON METALS. Inspect the

vehicle frequently. Shock resistance of metals, or resistance againstbreaking, is greatly reduced at extremely low temperatures. Operationof vehicles on hard, frozen ground causes strain and jolting which willresult in screws breaking, or nuts jarring loose.

(3) SPEEDOMETER CABLE. Disconnect the oil-lubricated speed-ometer cable at the drive end when operating the vehicle at tempera-tures of -30F and below. The cable will often fail to work properlyat these temperatures, and sometimes will break, due to the excessivedrag caused by the high viscosity of the oil with which it is lubricated.

8 . OP ER ATION IN HOT WEATHER .

a . P r o t e c t i o n o f Ve h i c le . In extremely hot weather avoid thecontinuous use of low gear ratios whenever possible. Check andreplenish oil and water frequently. If a flooded condition of theengine is experienced in starting, pull the throttle control out, pushchoke control in, and use the cranking motor. When engine starts,adjust throttle control.

(1) COOLING SYSTEM. Rust formation occurs more rapidly dur-ing.high temperatures; therefore, add rust preventive solution to thecooling system, or clean and flush the system at frequent intervals.

(2) LUBRICATION. Lubricate the vehicle for hot weather operation(par. 8).

(3) ELECTRICAL SYSTEM. Check the battery solution level fre-quently during hot weather operation, and add water as required tokeep it above the top of the plates. If hard starting is experienced inhot, damp weather or quick changes in temperature, dry the sparkplugs, wires, and both inside and outside of distributor cap.

9. OP ER ATION IN SAND.

a . O p e r a t i o n . Reduce tire pressures in desert terrain if characterof sand demands this precaution. When operating in sand deepenough to cause the use of a lower gear, do not exceed the speedspecified on the caution plate for the particular gear ratio (fig. 7).

b . S t a r t i n g t h e Ve h i c l e . When starting the vehicle in sand,gravel, or soft terrain, engage the front wheel drive (par. 5 e (1)).Release clutch pedal slowly so the wheels will not spin and dig in,necessitating a tow or winch-out.

c. C l u t c h . Do not attempt to jump or rock the vehicle outwith a quick engagement of the clutch, particularly if a tow or winchis available. Racing the engine usually causes the wheels to dig infarther.

d . Ai r C l e a n e r . In sandy territory clean the carburetor air cleanermore often. The frequency of cleaning depends upon the severity ofthe sandy condition.

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e . R a d i a t o r . In desert operation check the radiator coolant supplyfrequently, and see that the air passages of the core do not becomeclogged.

f. For additional information on technique of operating thevehicle in sand, refer to FM 31-25.

10. OP ER ATION IN LANDING.

a . I n s p e c t i o n . As soon as possible after completing a landing oroperation in water, inspect the vehicle for water in the various units.

(1) ENGINE. Drain the engine crankcase oil. If water or sludgeis found, flush the engine, using a mixture of half engine oil SAE 10and half kerosene. Before putting in new oil, clean the valve chamber,

drain and clean the oil filter, and install a new filter element.(2) FUEL SYSTEM. Inspect the carburetor bowl, fuel strainers,fuel pump, filter, fuel tank, and lines. Clean the air cleaner andchange the oil.

(3) POWER TRAIN. Inspect the front and rear axle housings,wheel bearings, transmission, and transfer case lubricant for presenceof sludge. If sludge is found, renew the lubricant after cleaning theunits with a mixture of half engine oil SAE 10 and half kerosene.Lubricate the propeller shaft universal joints and spring shackles toforce out any water which might damage parts.

11. DECONTAMINATION.

a . P r o t e c t i o n . For protective measures against chemical attacksand decontamination refer to FM 17-59.

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Section V

FIRST ECHELON PREVENTIVE MAINTENANCE SERVICEParagraph

Purpose ................................................ 12Before-operation service .................................. i3During-operation service ............................... 14At-halt service ........................................ 15After-operation and weekly service ........................ 16

12. P U R P O S E .a. To ensure mechanical efficiency it is necessary that the vehicle

be systematically inspected at intervals each day it is operated, alsoweekly, so that defects may be discovered and corrected before theyresult in serious damage or failure. Certain scheduled maintenanceservices will be performed at these designated intervals. The servicesset forth in this section are those performed by driver or crew beforeoperation, during operation, at halt, and after operation and weekly.

b. Driver preventive maintenance services are listed on the back

of Drivers Trip Ticket and Preventive Maintenance ServiceRecord, W.D. Form No. 48, to cover vehicles of all types and models.Items peculiar to specific vehicles, but not listed on W.D. Form No.48, are covered in manual procedures under the items to which theyare related. Certain items listed on the form that do not pertain tothe vehicle involved are eliminated from the procedures as writteninto the manual. Every organization must thoroughly school eachdriver in performing the maintenance procedures set forth in manuals,whether they are listed specifically on W.D. Form No. 48 or not.

c. The items listed on W.D. Form No. 48 that apply to this

vehicle are expanded in this manual to provide specific proceduresfor accomplishment of the inspections and services. These services

rr +r\are arrange- fnAl; ta tn ;e .nnort ;r \ . . c .nA P.T~~P.-. .P the t ;m o nf theC IEIs,LAL~CL ,lK ?p~L._Lr r alI l l . .1* .TLl SL LllC Cll l lC 1 L& I. .driver, and are not necessarily in the same numerical order as shownon W.D. Form No. 48. The item numbers, however, are identical withthose shown on that form.

d. The general inspection of each item applies also to any sup-porting member or connection, and generally includes a check to seewhether the item is in good condition, correctly assembled, secure,

or excessively worn.(1) The inspection for good condition is usually an external

visual inspection to determine whether the unit is damaged beyondsafe or serviceable limits. The term good condition is explainedfurther by the following: not bent or twisted, not chafed or burned,not broken or cracked, not bare or frayed, not dented or collapsed,not torn or cut.

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(2) The inspection of a unit to see that it is correctly assembledis usually an external visual inspection to see whether or not it is inits normal assembled position in the vehicle.

(3) The inspection of a unit to determine if it is secure isusually an external visual examination, a hand-feel, wrench, or pry-bar check for looseness. Such an inspection should include anybrackets, lock washers, lock nuts, locking wires, or cotter pins usedin assembly.

(4) Excessively worn will be understood to mean worn, closeto or beyond, serviceable limits, and likely to result in failure if notreplaced before the next scheduled inspection.

e. Any defects or unsatisfactory operating characteristics beyondthe scope of the first echelon to correct must be reported at theearliest opportunity to the designated individual in authority.

13. BEFORE-OP ERATION SERVICE.

a. This inspection schedule is designed primarily as a check tosee that the vehicle has not been tampered with or sabotaged sincethe After-operation Service was performed. Various combat condi-tions may have rendered the vehicle unsafe for operation, and it isthe duty of the driver to determine whether or not the vehicle is incondition to carry out any mission to which it is assigned. This

operation will not be entirely omitted, even in extreme tacticalsituations.

b. Procedures. Before-operation Service consists of inspectingitems listed below according to the procedure described, and correct-ing or reporting any deficiencies. Upon completion of the service,results should be reported promptly to the designated individual inauthority.

(1) ITEM 1, TAMPERING AND DAMAGE. Examine exterior ofvehicle, engine, wheels, brakes, and steering control for damage by

falling debris, shell fire, sabotage, or collision. If wet, dry the ignitionparts to ensure easy starting.

(2) ITEM 2, FIRE EXTINGUISHER. Be sure fire extinguisher is full,nozzle is clean, and mountings secure.

(3) ITEM 3, FUEL, OIL, AND WATER. Check fuel tank, crankcase,and radiator for leaks or tampering. Add fuel, oil, or water asneeded. Have value of antifreeze checked. If, during period whenantifreeze is used, it becomes necessary to replenish a considerableamount of water, report unusual losses.

(4) ITEM 4, ACCESSORIES AND DRIVES. Inspect carburetor, gener-ator, regulator, cranking motor, and water pump for loose connec-tions and security of mountings. Inspect carburetor and water pumpfor leaks.

(5) ITEM 6, LEAKS, GENERAL. Look on ground under vehicle forindications of fuel, oil, water, brake fluid, or gear oil leaks. Traceleaks to source, and correct or report to higher authority.

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(6 ) ITEM 7, EN GINE WARM-UP . St ar t engine, observe cra nk ingmotor action, listen for unusual noise, and note cranking speed. Idle

engine only fast enough to ru n smooth ly. Pr oceed imm ediately withfollowing ser vices while engin e is war min g up .(7) ITEM 8, CHOKE. As engine wa rm s, pu sh in choke as requ ired

for sm ooth opera tion, an d to pr event oil dilution.(8) ITEM 9, INSTRUME NTS.

(a ) Fue l Gage . Fu el gage should indicat e appr oxima te am oun tof fuel in tank.

(6) Oi l Pressu re Gag e. Norma l oil pr essur e should not be below10 with engine idling, an d should ra nge from 40 to 50 at ru nn ing

speeds (at n orm al operat ing tem perat ur e). If gage fails to registerwithin 30 second s, st op en gine, and correct or report to higherauthority.

(c) Te m p e r a t u r e I n d i c a t o r. Temperat ur e should rise slowly dur -ing warm -up. Norm al operat ing temper at ur e ra nge is 160F t o 185F.

(d) A m m e t e r. Ammeter should show high charge for short periodafter st ar tin g an d positive (plus) rea ding a bove 12 to 15 miles perhour with lights a nd accessories off. Zero read ing is norm al withlights and accessories on.

(9) ITE M 10, HORN AND WINDSHIELD WIPERS. Soun d horn, t acti-cal situ at ion perm itt ing, for pr oper opera tion an d tone. Check bothwipers for secur e at ta chm ent an d norma l full cont act operat ionthrough full stroke.

(10) ITE M 11, GLASS AND REAR VIEW MIRROR. Clean windsh ieldan d rear view mirr or an d inspect for cra cked, discolored, or brokenglass. Adjust mirr or.

(11) ITEM 12, LIGHTS AND REF LECTORS. Try switches in ea chposition an d see if light s respond. Light s a nd war ning r eflectors mu stbe secur ely m oun ted, clean , an d in good cond ition. Test foot con tr olof hea dlight beam s.

(12) ITEM 13, WHEE L AND FLANGE NUTS. Observe whet her or n otall wheel and flange nuts are present and tight.

(13) ITEM 14, TIRES. If time permits, test tires with gage, includ-ing spar e; n orm al pressu re is 35 poun ds with t ires cold. Inspect t rea dan d car cass for cut s an d bru ises. Remove imbedded objects fromtreads.

(14) ITEM 15, SP RINGS AND SUSP EN SION. In spect spr ings forsagged or broken leaves, shifted leaves, and loose or missing reboundclips.

(15) ITEM 16, STEE RING LINKAGE. Exam ine steer ing gear case,conn ectin g link s, an d Pit ma n ar m for secur ity an d good condit ion.Test st eering adjust ment , an d free motion of steering wheel.

(16) ITEM 17, FE NDERS AND BUMPE RS, Exam ine fend ers an dbum pers for secur e moun tin g an d serviceable condit ion.

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(17) ITEM 18, TOWING CONNECTIONS. Examine pintle hook forsecure mounting and serviceable condition. Be sure pintle latchesproperly and locks securely.

(18) ITEM 19, BODY AND LOAD. Examine body and load (if any)for damage. Be sure there is a cap on front drain hole under fueltank. See that rear drain hole cap is available in glove compartment.CAUTION: R e a r d r a i n h o l e c a p s h o u l d b e in s t a l l ed w h en a b o u t t op a s s t h r o u g h d e e p w a t e r.

(19) ITEM 20, DECONTAMINATOR. Examine decontaminator forfull charge and secure mountings.

(20) ITEM 21, TOOLS AND EQUIPMENT. See that tools and equip-ment are all present, properly stowed, and serviceable.

(21) ITEM 23, DRIVERS PERMIT AND FORM 26. Driver must havehis operators permit on his person. See that vehicle manuals, Lubri-cation Guide, Form No. 26 (accident report) and W.D. AGO FormNo. 478 (MWO and Major Unit Assembly Replacement Record) arepresent, legible, and properly stowed.

(22) ITEM 22, ENGINE OPERATION. Accelerate engine and observefor unusual noises indicating compression or exhaust leaks; worn,damaged, loose, and inadequately lubricated parts or misfiring.

(23) ITEM 25, DURING-OPERATION SERVICE. Begin the During-

operation Service immediately after the vehicle is put in motion.

a. While vehicle is in motion, listen for any sounds such as rattles,knocks, squeals, or hums that may indicate trouble. Look for indi-cations of trouble in cooling system, and smoke from any part of thevehicle. Be on the alert to detect any odor of overheated componentsor units such as generator, brakes, or clutch; check for fuel vaporfrom a leak in fuel system, exhaust gas, or other signs of trouble.Any time the brakes are used, gears shifted, or vehicle turned, con-sider this a test and notice any unsatisfactory or unusual perform-ance. Watch the instruments frequently. Notice promptly any un-usual instrument indication that may signify possible trouble insystem to which the instrument applies.

b. Procedures. During-operation Service consists of observingitems listed below according to the procedures following each item,and investigating any indications of serious trouble. Notice minordeficiencies to be corrected or reported at earliest opportunity, usuallyat next scheduled halt.

(1) ITEM 27, FOOT AND HAND BRAKES. Foot brakes must stopvehicle smoothly without side pull and within reasonable distance.There should be at least 5!< reserve brake pedal travel and %-inchfree travel. Hand brake must securely hold vehicle on reasonableincline with r${ reserve ratchet travel. There must be %-inch clear-ance (on cable) between relay crank and lower end of hand brakeconduit.

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(2) ITEM 28, CLUTCH. Clutch must operate smoothly withoutchatter, grabbing, or slipping. Free clutch pedal travel of three-

quarter inch is normal.(3) ITEM 29, TRANSMISSION. Gearshift mechanism must operate

smoothly, and not creep out of mesh.

(4) ITEM 29, TRANSFER CASE. Gearshift mechanism must operatesmoothly and not creep out of mesh.

(5) ITEM 31, ENGINE AND CONTROLS. Observe whether or notengine responds to controls, and has maximum pulling power withoutunusual noises, stalling, misfiring, overheating or unusual exhaustsmoke. If radio noise is reported during operation of the vehicle, the

driver will cooperate with the radio operator in locating the inter-ference. See paragraph 178.(6) ITEM 32, INSTRUMENTS. During operation observe the read-

ings of all instruments frequently to see if they are indicatingproperly.

(a) F u e l G a g e . Fuel gage must register approximate amount offuel in tank.

(b ) Oi l P ressu re Gage . Oil pressure gage should register 10 withengine running idle, and 40 to 50 at operating speeds.

(c) Te m p e r a t u r e I n d i c a t o r . Temperature indicator should showa temperature of 160F to 18SF after warm-up under normal con-ditions.

( d ) S p e e d o m e t e r. Speedometer should show speed of vehiclewithout noise or fluctuation of indicator needle. Odometer shouldregister accumulating trip and total mileage.

(e) A m m e t e r. Ammeter should show zero reading with lights on,zero or positive (plus) charge with lights off, and slightly higherpositive (plus) charge for short time immediately after starting.

(7) ITEM 33, STEERING GEAR. Observe steering for excessive pull-ing of vehicle to either side, wandering, or shimmy.

(8) ITEM 34, CHASSIS. Listen for unusual noises from wheel oraxles.

(9) ITEM 35, BODY. Observe body for sagging springs, loose ortorn top or windshield cover, if in use.

15. AT-HALT SERVICE.

a. At-halt Service may be regarded as the minimum mainte-nance procedure, and should be performed under all tactical condi-tions, even though more extensive maintenance services must beslighted or omitted altogether.

b. Procedures. At-halt Service consists of investigating anydeficiencies noted during operation, inspecting items listed belowaccording to the procedures following the items, and correcting anydeficiencies found. Deficiencies not corrected should be reportedpromptly to the designated individual in authority.

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(1) ITEM 38, FU EL, OIL AND WATER. Ch eck fuel supply, oil, an dcoolan t; add , as requ ired, for comp lete opera tion of vehicle t o th enext refueling point. If, dur ing period when an tifreeze is used, an

abnorma l am oun t of wat er is requir ed to refill ra diator, ha ve coolanttested with hydrometer , and add antifreeze if required.

(2) ITEM 39, TEMPE RATURES. Feel each bra ke dru m an d wheelhu b, tra nsm ission, tr an sfer case, an d front a nd rea r axles for over-hea tin g. Exa min e gear cas es for excessive oil leaks .

(3) ITEM 40, AXLE AND TRANSF ER CASE VENTS. Obser ve whet heraxle and tra nsfer case vents ar e present, and see tha t th ey are notda ma ged or clogged.

(4) ITEM 41, PROP ELLE R SHAFT. In spect pr opeller sha ft for loose-ness , dam age, or oil leaks .

(5) ITEM 42, SPRI NGS. Look for broken spr ing leaves or looseclips and U-bolts.

(6) ITEM 43, STEE RING LINKAGE. Exa min e st eerin g cont rolmechanism an d iinkage for dam age or iooseness. investigate an yirregular ities noted dur ing opera tion.

(7) ITEM 44, WHEEL AND FLANGE NUTS. Observe whet her or notall wheel a nd a xle flange nu ts ar e present and tight.

(8) ITEM 45, TIRES. In spect tir es, including spa re, for flat s ordam age, an d for cut s or foreign ma terial imbedded in tr ead.

(9) ITEM 46, LEAKS, GEN ERAL. Check ar oun d engine a nd onground beneat h th e vehicle for excessive leaks. Tra ce t o sour ce, an dcorr ect cause or report to higher aut hority.

(10) ITEM 47, ACCESSORIES AND BELTS. See th at fan, wat er pum pand generat or ar e securely mounted, tha t fan belt is adjusted tol-inch deflection, an d is not badly frayed. If ra dio noise du rin gopera tion of th e engine was observed, examine all ra dio noise sup-

pression capa citors, at coil, ignition an d sta rt ing switches, genera tor,regulat or, an d ra dio term inal box; suppressors at spark plugs anddistribut or, an d all bond str aps for dam age, an d loose moun tings orconnections.

(11) ITEM 48, AIR CLEANER. If dus ty or san dy cond itions ha vebeen encoun t ered , exam ine oil sum p for excessive dirt . Ser vice ifrequ ired. CAUTION : Do not apply oil to element after cleaning.

(12) ITEM 49, FE NDERS AND BUMPERS. Inspect fender s an dbumper s for looseness or dam age.

(13) ITEM 50, TOWING CONN ECTION S. In spect pint le h ook an dtrailer light socket for serviceability.

(14) ITEM 51, BODY LOAD AND TARPAULIN. Inspect vehicle an dtr ailed vehicle loads for shifting; see th at ta rpa ulins ar e properlysecur ed and not dama ged.

(15) ITEM 52, APPE ARANCE AND GLASS. Clean windsh ield, mir ror,light lenses, an d inspect vehicle for dam age.

802011 O-48--3 33


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l/,-TON 4 x 4 TRUCK (WILLYS-OVERLAN D MODEL M Ban d FORD MODEL GPW)

16 . AFTER-O P ERATIO N AND WEEKLY SER VICE.

a. After -opera tion Service is par ticular ly import an t becau se atth is time th e driver inspects his vehicle to detect an y deficiencies th atmay ha ve developed, an d corrects th ose he is permit ted to han dle.He should report prompt ly, to th e designa ted individual in au th ority,th e resu lts of his inspection. If th is schedule is per form ed th oroughly,th e vehicle should be rea dy to roll again on sh ort n otice. The Before-operat ion Ser vice, with a few except ions , is th en necessar y only t oascert ain wheth er th e vehicle is in th e same condition in which it wasleft up on completion of th e After-operat ion Ser vice. The After -opera tion Service sh ould never be ent irely omitted, even in extrem e

ta ctical situa tions, but may be redu ced, if necessar y, to th e barefun damen ta l services out lined for th e At-halt Service.

b. Procedures. When perform ing th e After -opera tion Service th edriver mu st remem ber an d consider an y irregular ities noticed du ringth e day in th e Before-opera tion, Durin g-operat ion, and At-halt Serv-ices. The After-operat ion Ser vice consists of inspecting an d servicingth e following items. Those items of th e After -oper at ion Ser vice th atar e ma rk ed by an ast erisk (*) requir e additiona l Weekly Service, th eprocedur es for which ar e indicat ed in step (b) of each applicableitem,

(1) ITEM 54, FU EL, OIL, AND WATER. Ch eck coolan t an d oillevels, a nd add a s need ed. Fill fuel ta nk . Refill sp ar e can s. Dur ingperiod when an tifreeze is used, have hydr ometer test made of coolantif loss from boiling or oth er cause has been considera ble. Add an ti-freeze with water if required.

(2) ITEM 55, EN GINE OPE RATION. Listen for miss, backfire, noise,or vibrat ion th at might indicate worn part s, loose mount ings, fau ltyfuel mixtu re, or fau lty ignition.

(3) ITEM 56, INSTRUMENTS. Inspect all instr umen ts to see th at

th ey ar e secur ely connected, an d not dam aged.(4) ITEM 57, HORN AND WINDSHIE LD WIPE RS. Test horn for

soun d, if ta ctical situat ion permits. See th at horn is secur ely mount edan d properly connected. Operat e both windshield wipers. See th atblades cont act th e glass effectively th rough out full st roke.

(5) ITEM 58, GLASS AND RE AR VIEW MIRROR. Clea n glass ofwindshield an d rea r view mirr or. Examine for secur e mount ing an ddamage.

(6) ITEM 59, LIGHTS AND REF LECTORS. Observe whet her or not

light s opera te pr operly with th e switch in ON positions, an d go outwhen switch is off. See th at stop light opera tes properly. Clean lensesand warn ing reflectors.

(7) ITEM 60, FIRE EXTINGUISH ER. Be su re fire extingu isher isfull, nozzle is clean, an d th at extinguisher is mount ed secur ely.

(8) ITEM 61, DECONTAMINATOR. Exa min e decont am ina tor forgood condition an d secur e mount ing.

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FIRST ECHELON PREVENT IV E MAI NTENA NCE SERVICE

(9 ) ITEM 62, *BATTERY.

(a) See th at bat ter y is clean, secur ely m oun ted, an d not leaking.In spect elect rolyte level, which s hould be /z inch above plat es withcaps in place an d vents open. Clean cables as requir ed.

(b) Weekly. Clean t op of bat ter y. Remove bat ter y caps, an d addwat er t o r/z inch above plat es. (Use distilled wat er if available; if notuse clean, drinka ble wat er.) CAUTION: Do no t over f i l l . Clean postsan d ter min als if corr oded, an d apply light coat of grea se. Tight enterm inals as needed. Tight en hold-down assembly. Clean bat ter ycarr ier if corr oded.

(10) ITEM 63, *ACCESSORIES AND BELTS.(a) Test fan belt for deflection of 1 inch. Exam ine belt for good

condit ion; it mu st n ot be frayed. Timing hole cover m ust be closedand tightened.(b) Weekly. Tight en all accessories such as car bur etor, gener-

at or, regulat or, cra nkin g motor, fan, wat er pump, an d hose conn ec-tions; exam ine fan belt for fraying, wear , cra cking, or pr esen ce of oil.

(11) ITEM 64, *ELECTRICAL WIRING.

(a) See th at all ignition wiring an d accessible low volta ge wir ingis in good condition, clean , cor rect ly an d secur ely a ssem bled an dmounted.

(b) Weekly. Tighten all loose wiring connections or electr icalunit mount ings. Pa y par ticular at ten tion to ra dio noise suppr essionunit s such as: capa citors, bond str aps, an d spar k plug and distribut orsuppressors.

(12) ITEM 65, *AIR CLEANER.(a) Examin e oil in air cleaner oil cup t o see th at it is at proper

level, an d not excessively dirt y. Clean elemen t an d refill oil cup asrequired. CAUTION: D o n o t a p p l y o i l t o el em e n t a f t e r cl ea n i n g .

(b) Weekly. Remove, clean, an d dry air cleaner element and oilcup. Fill cup t o indicated oil level (appr oxima tely 5/s qt). Do notapp ly oil to elemen t after cleanin g.

(13) ITEM 66, *FUE L FILTE RS.

(a ) Exa min e fuel filter for leaks .(b) Weekly. Remove plug from bottom of das h-moun ted fuel

filter. Allow wat er an d sediment to dra in out. Be sur e plug is replacedtightly, an d does not leak. *

(14) ITEM 67, EN GINE CONTROLS. Exa min e engine contr ols forwear or disconn ected linkage.

(15) ITEM 68, *TIRES.

(a ) Inspect tires for cut s or abnorma l tr ead wear ; rem ove foreignbodies from tr ead; inflate to 35 poun ds when t ires ar e cold.(b) Weekly. Replace badly worn or oth erwise un serviceable tires.(16) ITEM 69, *SPRIN GS.(a ) Exam ine spr ings for sag, broken or shifted leaves, loose or

missing reboun d clips, or sha ckles.(b) Weekly. Aline springs, and tight en U -bolts an d sha ckles as

required.

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(17) ITEM 70, STEERING LINKAGE. Examine steering wheelcolumn, gear case, Pitm an ar m, dra g link, tie rod, an d steering ar mto see if th ey a re bent , loose, or ina dequa tely lubricated.

(18) ITEM 71, PROPE LLER SHAFT. Inspect propeller sha ft an dun iversa l joint s for loose conn ections, lubrication leaks, or dam age.

(19) ITE M 72, *AXLE AND TRANSF ER VENTS.(a) See th at a xle an d tr an sfer case vents ar e in good condit ion,

clean, and secure.(b) We e k l y. Remove, clean, an d repla ce vents.(20) ITEM 73, LEAKS, GENE RAL. Check un der hood an d benea th

the vehicle for indicat ions of fuel, oil, wa ter, or bra ke fluid leaks .(21) ITE M 74, GEAR OIL LEVELS. After un its ha ve cooled, inspect

different ial tr an smission an d tr an sfer unit lubrican t levels. Lubrican tsh ould be level with bott om of filler hole. Obser ve gear case s forleaks.

(22) ITEM 76, FENDERS AND BUMPERS. Fen ders an d bumper smu st be in good condit ion an d secure.

(23) ITE M 77, *TOWING CONNECTIONS.(a ) In spect pint le hook and towed-load conn ections for loosenes s

or damage.(b) We ek ly. Tight en pint le hook m oun tin g bolts, an d lubricate

pintle h ook as required.(24) ITE M 78, BODY AND TARPAULINS. In spect body, t op, and

windsh ield cover for dam age a nd proper st owage. Make su re rea rdra in below fuel ta nk is open, an d th at cap is in glove compa rt ment .

(25) ITE M 82, *TIGHTE N.(a) Tighten an y loose wheel, axle dr ive flan ge, and spr ing U-bolt

nu ts .(b) We ek ly.

Tight en all vehicle a ssem bly or mount ing nu ts orscrews that inspection indicates require tightening.

(26) ITEM 83, *LUBRICATE AS NEE DED.(a) Lubricat e sprin g sha ckles an d st eering linkage, if lubrication

is needed.(b) We e k l y. Lubricat e point s indicat ed on cur ren t vehicle Lubri-

cat ion Guide as requir ing weekly at ten tion, also point s tha t experi-ence an d opera tin g condit ions indicat e need lubrication. Observelat est lubrication directives.

(27) ITEM 84, *CLEAN ENGINE AND VEH ICLE.(a ) Clean dirt and trash from inside of body. Keep sump under

fuel ta nk cleaned of dirt an d wat er. Remove excessive dirt or greas efrom exterior of the engine.

(b) We ek ly. Wash vehicle if possible. If not possible, wipe offth oroughly; clean engine.

(28) ITEM 85, TOOLS AND EQUI PME NT. Check to see th at all toolsan d equipment assigned to vehicle ar e present an d secur e.

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TM 9-80317-18

Sect ion VI

LUBRICATIONParagraph

Lubrication Guide 17Detailed lubrication instructions 18

17. LUBRICATION GUIDE.

a . War Department Lubrication Guide No. 501 (figs. 13 and 14)prescribes lubrication maintenance for the ye-ton 4 x 4 truck.

b. A Lubrication Guide is placed on or is issued with each vehicleand is to be carried with it at all times. In the event the vehicle isreceived without a Guide, the using arm shall immediately requisi-tion a replacement from the Commanding Officer, Fort Wayne Ord-nance Depot, Detroit 32, Mich.

c. Lubrication instructions on the Guide are binding on allechelons of maintenance and there shall be no deviations from theseinstructions.

d . Service intervals specified on the Guide are for normal oper-ation conditions. Reduce these intervals under extreme conditionssuch as excessively high or low temperatures, prolonged periods ofhigh speed, continued operation in sand or dust, immersion in water,or exposure to moisture, any one of which may quickly destroy theprotective qualities of the lubricant and require servicing in orderto prevent malfunctioning or damage to the materiel.

e. Lubricants are prescribed in the Key in accordance withthree temperature ranges; above +32F, +32OF to OF, and belowOF. Determine the time to change grades of lubricants by maintain-ing a close check on operation of the vehicle during the approach tochange-over periods. Be particularly observant when starting theengine. Sluggish starting is an indication of thickened lubricants and

the signal to change to grades prescribed for the next lower tempera-ture range. Ordinarily it will be necessary to change grades of lubri-cants only when air temperatures are consistently in the next higheror lower range, unless malfunctioning occurs sooner due to lubricantsbeing too thin or too heavy.

18. DETAILED LUBRICATION INSTRUCTIONS.

a . L u b r i ca t i o n E q u i p m e n t . Each piece of materiel is suppliedwith lubrication equipment adequate to maintain the materiel. Besure to clean this equipment both before and after use. Operatelubricating guns carefully and in such manner as to insure a properdistribution of the lubricant.

b . P o in t s o f Ap p l ic a t i on .

(1) Red circles surrounding lubrication fittings, grease cups,oilers and oil holes make them readily identifiable on the vehicle.Wipe clean such lubricators and the surrounding surface before lubri-cant is applied.

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D, tlg. 18

A, fig. 17

A, fig. 19

WAR DEPARTMENT 0 LUBRICATIONGUiiiORDNANCE DEPARTMENT

TRUCK, /ia TON, 4x4 (FORD-WILLYS)

TABLE OF CAPACITES ANO LUBRCANTS TO II,! USED

LOWEST EXPECTED AIR TEMPERATURE

Spring Shackle CG I -.___Front Axle Differential GO 6 -.___

D&n .nd .BII

Te Rods (Inner) CC I

,

Universal Joint and See ring CC I

- c, fig.15

- 4 fig. 15- 8, fig. 15

- E, fig. 15

- F, fig. 15

-D,fig. 15

- F,fIg.17

RA PD 305160


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A. fig.B, ig.

E, ig.F, fig.A, 8s.

A, fig.

8. fig.

E. ig.h fig.

A, fig.

A, fig.

D, fig.

Knuck le ea rings N... I,

18

1 8

n we r s a loint CG181818

16

16

1817

19

17

18

Shock Absorbers SA(Sm. mod.l,,

,NOh 15 and b,r Axle Differential GO

Dr.innd ,M,k..lr..& ,N0f.I,Sprina Shack le CG

B,.,:,.,s_t;,$inder .:k ; A , I,R.m*. ow.nto.b...d,

I . CC - ;,flg: 16

I CC - D, fig. 166 GO - C, tlg. 16

I CG-E,fig.16- F, flg. 16

lubricants

_ LNOTES Add itional Lubrication and Service Instructions on Individual Units and Parts NOTES

COLDWEAITEk For Lubriration end s.rrir. b&W OF.. r.1.r to OFI. .I I.I. FITTINGS-Clean before applyi ng lubri cant.

Lubricate unt il new lubricant is forced frometc.. reduce interval by /3 or /1, or more if fill oil reservoir to bead level with usedconditions warrant.

the bearing. unl ess othenvire specified.crankc are oil or OE. Every 1,000 n&r.

CAUTION: Lubri cate cha,ri. points after 3. CLEANING-SOLVENT. dry-cl eaning. ordaily under extreme dust condition,. re-

wsrhing truck and trailer. OIL. fuel. diesel. will be used to clean ormove and wash all parts. Fmm 0-F. t o

wash all partr. Use ,,f gav&e for this -40F.. use SA. Below -4OF., remove2. INTERVALS indi cated are for no,m.,l rervbe. purpose is

Brohibited. All parts will be oil and operate dry.

For extreme conditionr of speed, heat, thoroughly ry before relubrication.water. sand, mud. inox. roug h roads, dust, 4. AIR CLEANER--Daily. check level and re-

5. CRANKCASE--D,& only when engine is,Hot.. ronti n..d 0, I.*,,* lid.,

10 No.501

Figure 13-lubric at i on Guide-Truck , I /4-Ton, 4 x 4 (Ford-WilIys ) RA PD 3051608


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TM 9-80318

I/,-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL MBand FORD MODEL GPW)

42


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TM 9-80318

LUBRICATION

RA PD 305167

Figure 16-Pedal Shaf t s and Pow er l ra in Lubr ic a t ion Poin ts

43


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TM 9-80318

l/,-TON 4 x 4 TRUCK (WILLY S-OVERLAND MODEL MBan d FORD MODEL GPW)

Figure I7-Ax le , Wheel , Pi& e, and Steer ing Gear Hous ingLubr i ca t ion Po in t s

44


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TM 9-80318

LUBRICATION

Figure 18 Steer ing Gear and Spr ing

45

RA PD 305169

Lubr i ca t ion Po in t s


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TM 9-80318

I/& TON 4 x 4 TRUCK (WILL YS-OVERLAN D MODEL M Ban d FORD MODEL GPW)

Figure 19-Shock Absorber, Mas te r Cyl inder, and Bat te r yLubr i ca t i on Po in t s

(2 ) Where relief valves are provided, apply new lubricant untilthe old lubricant is forced from the vent. Exceptions are specifiedin notes on the Lubrication Guide.

c. C l e a n i n g . U s e S O LVE N T, dry-cleaning, or OIL, fuel, Diesel,to clean or wash all parts. Use of gasoline for this purpose is pro-hibited. After washing, dry all parts thoroughly before applyinglubricant.

d. L u b r i c a t io n N ot e s on I n d i v id u a l U n i t s a n d P a r t s . The fol-lowing instructions supplement those notes on the Lubrication Guidewhich pertain to lubrication and service of individual units and parts.All note references in the Guide itself are to the paragraph belowhaving the corresponding number.

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LUBRICATION

(1) FITTINGS. Clean before applying lubrican t. Lubr icat e un tilnew lubrican t is forced from t he bearing, un less oth erwise specified.CAUTION: Lubricate chassis points after washing truck and trailer.

(2) INTE RVALS. Int ervals indicat ed ar e for norma l service. F orextr eme conditions of speed, heat, wat er, sand, mud, snow, roughroads, du st, etc., redu ce inter val by one-thir d or one-half, or moreif conditions war ra nt .

(3) CLEANIN G. SOLVENT, dr y-clean ing, or OIL, fuel, Diesel,will be used to clean or wash all par ts. Use of gasoline for th is pur -pose is pr ohibited. All pa rt s will be th oroughly dr y befor e relu bri-cation.

(4) AIR CLE ANER. Daily, check level and refill oil r eser voir to

bead level with u sed cr an kcase oil or OIL, en gine, S AE 30 above+32F or SAE 10 from +32F to 0F. E ver y 1,000 miles, da ilyun der extr eme dust conditions, rem ove and wash all part s. Fr omOF to -40F, us e FLU ID, sh ock-absorber , light . Below -4OF,rem ove oil an d opera te dry.

(5) CRANKCASE . Dra in only when en gine is hot. Refill t o FU LLma rk on gage. Run engine a few minu tes an d recheck oil level.CAUTION: Be sure pressure gage indicates oil is circulating.

(6) OIL FILTE R. Ever y 1,000 miles, dra in sediment . Ever y 6,000miles or mor e often if filter becomes clogged, dr ain filter , clean inside

an d ren ew element. Run engine a few minut es, check cran kcase level,add OIL, engin e, to FU LL ma rk on gage. (SAE 30 above f32OF;SAE 10 from.+32F to OF; below OOF, r efer to OFS B 6-11.)

(7) GEAR CASES. Weekly, check level with tr uck on level groun dan d, if necessa ry, add lubr ican t to plug level. Check only beforeopera tion while lubrican t is cold. Dr ain an d refill at inter vals indi-cat ed on Guide. Dra in only after opera tion. On ear ly Willys models,skid plate mu st be rem oved to rea ch dr ain plug.

(8) UNIVERSAL J OINT AND STEE RING KNUCKLE BEARINGS. Ever y

1,000 miles, rem ove plug at rea r an d add GREASE, genera l pur -nose. No; 1 above +32OF or No; 0 below +32OF. t o level of fillermm-. -7 --plug h ole. E very 6,000 miles, rem ove, clean , dry, inspect an d refill toplug level.

(a) Remove bra ke tube an d bra ke backing plate screws. Thisperm its th e rem oval of th e axle spindle, th e complete axle sha ft, a ndth e un iversa 1 joint assembly. Car e should be ta ken n ot to injure t heouter oil seal assembly in th e housing.

(b) Wash th e axle sha ft and un iversa l joint t horoughly in SOL-VEN T, dry-cleaning, an d dry.

(c) Clean and repa ck upper an d lower steer ing spindle bearingswithin th e universal housing and reassemble entire unit .

(9) UNIVERSAL J OINTS AND SLIP J OINTS. Apply GREASE, gen-era l pu rp ose, No. 1, above +32F, or No. 0 below $32OF, to joint sun til it shows at joint cross, an d to slip joint un til it shows at th eend of spline. Use han d gun only,

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l/,-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL M Ban d FORD MODEL GPW)

(10) DISTRIBU TOR. E very 6,000 miles, wipe dist ribu tor br eak ercam lightly with GREASE , gener al pu rp ose, N o. 1, above +32F or

No. 0, below +32F, an d lubricat e brea ker ar m pivot a nd wick underrot or with 1 to 2 dr ops of OIL, engin e, SAE 30 above +32F; SAE10 from +32OF to OF; OIL, lubr icat ing, pr eser vat ive, special, belowOF.

(11) TRAILER BRAKE CABLES . Ever y 6,000 miles, slide cable con-duit forward , clean an d coat with GREASE, genera l pur pose, No. 1above i-32OF an d No. 0 below f32OF.

(12) SP EE DOMETE R CABLE. E very 6,000 miles, remove cor e an dcoat lightly with GREASE, genera l pur pose, No. 0.

(13) RUBBER BUSHIN GS. Ever y 1,000 miles, apply FLUID, bra ke,hydra ulic, to shock absorber linkage. CAUTION: D o n o t u s e o i l .

(14) OILCAN POIN TS. Ever y 1,000 miles, lubr icat e all carbu ret or,clutch, brak e and th rottle linka ges, pintle hook and han d brak ecable with OIL, engine, SAE 30, above +32OF; SAE 10, +32F toOF; OIL, lubr icat ing, pr eser vat ive, special, below OF.

(15) POINTS REQUIRING No LUBRICATION SERVICE. These ar e th eclutch release bearing, wat er pum p, fan , shock absorbers an d linkageon all F ord an d ear ly Willys models, gener at or (lat e models),speedometer cable.

(i6) POI NTS TO BE SERVICED AND/OR LUBRICATED BY ORDNANCEMAINTEN ANCE PE RSONNE L ONLY. These ar e th e shock absorbers(lat e Willys). E very 6,000 miles, rem ove an d disassem ble th e sh ockabsorbers. Un screw link age eye an d refill with FLUID, shock-absorber, light.

(17) WHE EL BEARINGS. Remove bear ing cone assem blies fromhu b an d wash spindle an d inside of hu b. Inspect bearin g ra ces an dreplace if necessar y. Wet t he spindle an d inside of hu b and hub capwith GREASE, genera l pur pose, No. 2, to a maximum th ickn ess ofl/is inch only to ret ar d ru st. Wash bearing cones and grea se seals.Inspect an d replace if necessary. Lubr icat e bearings with GREASE,genera l pur pose, No. 2, with a packer or by ha nd, k nea ding lubrican tinto all spaces in th e bearing. Use extr eme car e to pr otect bearingsfrom dirt an d immediat ely reass emble an d replace wheel. The lubri-can t in th e bearings is sufficient to provide lubricat ion un til th e nextser vice per iod. Do not fill hu b or hu b cap. Any excess m ight resu ltin leaka ge into the brake drum .

R e p o r t s a n d R e c or d s . If lubr icat ion inst ru cdons ar e closelyfoibwed, pr oper lubrican ts used, an d sat isfactory resu lts ar e notobta ined, ma ke a report to th e ordn an ce officer r esponsible for th ema inten an ce of th e ma teriel. A complete record of lubricat ion servic-ing ma y be kep t in th e Dut y Roster (W.D., A.G.0 For m No. 6).

f . Loca l ized Views . The localized views of lubr icat ion points(figs. 15, 16, 17, 18, an d 19) su pplemen t th e inst ru ctions on th e Guideand in the notes.

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TM 9-80320-2 1

I/I-TON 4 x 4 TRUCK (WILLYS-OVERLAND MODEL M Band FORD MODEL GPW)

20. VEHICLE EQUIPMENT.

a . Un less vehicle is equipp ed with special equipm ent , t he follow-ing ar e supplied (one of each un less other wise specified) :Federal

Tool Stock No.

ADAPTE R, lubr . gun .....................APP ARATUS, decont am ina ting,

1ya qt ...............................

Ax, chopping, single-bit. .... 41-A-1277BAG, tool ................ 41-B-15CATALOG, ord. st d. nom. list . SNL-G-503

CHAINS, tir e, 6.00 x 16. ...... 8-C-2358

CONTAINER, S-gallon ....................COVER, headlight .......................

COVER, windsh ield ......................CRANK, starting ........................EXTINGUISHER, fire ......... 58-E-202GAGE, tire press ur e. ......... 8-G-615GUN, lubr., hand-type. ...... 41-G-1330-60MANUAL, technical ......... TM 9-803

NOZZLE, flexible tube ....................OILER, st ra ight spout , /2-pt. 13-o-1530PUMP, tire, w/chuck. ........ 8-P-5000

RIFLE ................................SHOVEL, D-ha ndle, rd. pt ..... 41-S-3170TAPE , friction, roll .......... 17-T-805WIRE, iron, roll. ............ 22-W-650

21. VEHICLE SP ARE P ARTS .

WhereCarried

Tool bag

Drivers compart-ment

Body left sideTool compartmentGlove compart-

mentTool compartment

(4)Bracket on rearUnder right seat

(2)Under right seatUnder rear seatInside cowl, leftTool compartmentTool compartmentGlove compart-

ment.,..__........Front of dashBehind rear seat

On dashBody, left sideParts bagParts bag

a. Unless t he vehicle is equipped with a special a ssortm ent ofpar ts , th e following ar e supplied (one of each un less oth erwisespecified) :

Federal WhereName of Spore Port Stoc k No. Carried

BAG, spare parts. ~ . 8-B-l 1 Glove compart-ment

BELT, fan . 33-B-76 Parts bagCAPS, t ire valve (boxed). 8-C-650 Parts bag (5)CORE S, t ire valve (boxed). 8-C-6750 Parts bag (5)

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TM 9-80321

TOOLS AN D EQUIPMENT STOWAGE ON TH E VEHI CLE

FederalNome of Spare Pert Stock No.

LAMP, elec. incan d. 6-W sing-tun g-fil., 3 cp (MZ63). 17-L-5215

LAMP-UNIT, blackout , st op,sea led, one opng., 6-W, 3 cp 8-L-421

LAMP-UNIT, blackout, tail,sea led, 4 opngs ., 6-W, 3 cp 8-L-415

LAMP-UNIT, service ta il a ndst op, sea led, 6-W, 21-3 cp 8-L-419

PIN , cott er, split, s. type Bboxed ass?. 42-P-5347

PLUG, spar k, with gasket. 17-P-5365

WhereCarried

Parts bag

Parts bag

Parts bag

Parts bag

Parts bagParts bag

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TM 9-80322


PART TWO

VEHICLE MAINTENANCE INSTRUCTIONS

Section VIII

RECORD OF MODIFICATIONSParagraph

MWO and major unit assembly replacement record 22

22. MWO AND MAJ OR UNIT ASSE MBLY RE P LACEME NT

R E C O R D .a. D e s c r i p t i o n . Every vehicle is supplied with a copy of A.G.O.

Form No. 478 which provides a means of keeping a record of eachMWO completed or major unit assembly replaced. This form in-cludes spaces for the vehicle name and U.S.A. registration number,instructions for use, and information pertinent to the work accom-plished. It is very important that the form be used as directed, andthat it remain with the vehicle until the vehicle is removed fromservice.

b. I n s t r u c t i on s fo r U s e. Personnel performing modifications ormajor unit assembly replacements must record clearly on the forma description of the work completed, and must initial the formYinthe columns provided. When each modification is completed, recordthe date, hours and/or mileage, and MWO number. When majorunit assemblies, such as engines, transmissions, transfer cases, arereplaced, record the date, hours and/or mileage, and nomenclatureof the unit assembly. Minor repairs and minor parts and accessoryreplacements need not be recorded.

c. E a r l y M o d i i f i c a t i o n s . Upon receipt by a third or fourth

echelon repair facility of a vehicle for modification or repair, main-tenance personnel will record the MWO numbers of modificationsapplied prior to the date of A.G.O. Form No. 478.

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Section IX

TM 9-80323

SECOND ECHELON PREVENTIVE MAINTENANCEParagraph

Second echelon preventive maintenance services. 23

23. SECOND ECH ELON PRE VEN TIVE MAINTEN ANCESERVICES.

a. Regular scheduled maintenance inspections and services area preventive maintenance function of the using arms and are theresponsibility of commanders of operating organizations.

(1) FREQUENCY. The frequency of the preventive maintenanceservices outlined herein is considered a minimum requirement fornormal operation of vehicles. Under unusual operating conditionssuch as extreme temperatures, and dusty or sandy terrain, it may benecessary to perform certain maintenance services more frequently.

(2) .F IRST ECH ELON P ARTICIP ATION. The drivers should ac-company their vehicles and assist the mechanics while periodic sec-ond echelon preventive maintenance services are performed. Ordi-narily the driver should present the vehicle for a scheduled preven-t ive maintenance service in a reasonably clean condition: that is,it should be dry and not caked with mud or grease to such anextent that inspection and servicing will be seriously hampered;

however, the vehicle should not be washed or wiped thoroughlyclean, since certain types of defects, such as cracks, leaks, and looseor shifted parts or assemblies are more evident if the surfaces areslightly soiled or dusty.

(3) INSTRUCTIONS. If instructions other than those which arecontained in the general procedures in step (4), or in the specificprocedures in step (5) which follow, are required for the correctperformance of a preventive maintenance service or for correctionof a deficiency, other sections of the vehicle operators manual pertain-ing to the item involved, or a designated individual in authorityshould be consulted.

(4) G E N E R AL P R O C E DU R E S . T h e s e g e n e r a l p r o c e d u r e s a

jeep willys mb ford gpw manual

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