Dashboard Replacement

TM 9-2320-363-34-1 · Chapter 10 — Body, Cab, Hood, and Hull Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                      Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31                 Reference              Condition Description
Tool Kit, SC 5180-90-CL-N05
                                                  TM 9-2320-363-20       Batteries Disconnected
Materials/Parts:
                                                  TM 9-2320-363-20       Air System Drained
Nut, Lock (2)             P/N 420Z
                                                  TM 9-2320-363-20       Tachometer Cable
Washer, Lock (4)                                                         Removed
Compound, Sealing         Appendix B, Item 16     TM 9-2320-363-20       Speedometer Drive
                                                                         Shaft and Cable Removed
Nut, Lock (13)
                                                  TM 9-2320-363-20       Steering Wheel and
Personnel Required: (2)                                                  Column Removed
References:                                       TM 9-2320-363-20       Air Cleaner, Pre-Cleaner,
                                                                         and Duct Assembly
TM 9-2320-363-20                                                         Removed

TM page 10-4

Illustration from TM 9-2320-363-34-1 (PDF page 650)

DASHBOARD REPLACEMENT (CONT)

CAUTION Make sure all connectors are properly tagged. Failure to do so could result in electrical damage to equipment. **NOTE** Procedure is the same for both vehicles except as noted. Tag all connectors, cables, and air lines prior to removal to aid in installation. Quantity of tie wraps may vary from zero to several. Remove as necessary.

1. DISCONNECT CONNECTOR (1) FROM FIREWALL (2).

2. LOOSEN TWO SCREWS (3) AND DISCONNECT TWO CONNECTORS (4) FROM FIREWALL (2).

3. REMOVE TWO NUTS (5) AND DISCONNECT TWO CABLES (6).

TM page 10-5

Illustration from TM 9-2320-363-34-1 (PDF page 651)

4. REMOVE TWO SCREWS (7) AND TWO CLAMPS (8) FROM TWO AIR LINES (9).

5. REMOVE FOUR SCREWS (10) AND PULL WINDSHIELD WIPER MOTOR (11) FAR ENOUGH AWAY FROM FIREWALL (2) TO REMOVE TWO AIR LINES (12).

6. INSTALL WINDSHIELD WIPER MOTOR (11 ) AND FOUR SCREWS (10) HAND-TIGHT.

TM page 10-6

Illustration from TM 9-2320-363-34-1 (PDF page 652)

7. DISCONNECT SIX AIR LINES (13) AND OIL LINE (14) FROM JUNCTION BLOCK (15).

8. REMOVE SEALING COMPOUND (16) FROM FIREWALL (2).

9. ROTATE THREE FASTENERS (17) TO LEFT AND REMOVE COVER (18).

10. REMOVE TWO SCREWS (19) AND TWO WASHERS (20).

11. REMOVE LOCK NUT (21), WASHER (22), SPACER (23), SCREW (24), WASHER (25), AND COVER (26). DISCARD LOCK NUT.

TM page 10-7

Illustration from TM 9-2320-363-34-1 (PDF page 653)

12. REMOVE NINE SELF-TAPPING SCREWS (27) AND COVER (28).

13. REMOVE LOCK NUT (29), WASHER (30), SCREW (31 ), WASHER (32), AND SPACER (33). DISCARD LOCK NUT.

14. REMOVE SCREW (34) AND COVER (35).

15. REMOVE THREE LOCK NUTS (36), THREE WASHERS (37), THREE INSERTS (38), AND COMPARTMENT (39). DISCARD LOCK NUTS.

TM page 10-8

Illustration from TM 9-2320-363-34-1 (PDF page 654)

DASHBOARD REPLACEMENT (CONT)

16. REMOVE FOUR SCREWS (40), THREE TORX SCREWS (41), AND LOWER PANEL (42).

M915A2 M916A1

17. DISCONNECT CONNECTOR (43) FROM SIDE MARKER LIGHT CONNECTOR (44).

NOTE Perform step 18 on M916A1 only.

18. DISCONNECT THREE AIR LINES (45).

TM page 10-9

Illustration from TM 9-2320-363-34-1 (PDF page 655)

NOTE Perform step 19 on M915A2 only.

19. DISCONNECT FOUR AIR LINES (46).

20. REMOVE LOCK NUT (47) AND WASHER (46) AND DISCONNECT GROUND CABLE (49). DISCARD LOCK NUT.

21. DISCONNECT ACCELERATOR CONNECTOR (50).

22. REMOVE TORX SCREW (51) AND RETAINER (52).

23. REMOVE TWO LOCK NUTS (53), TWO WASHERS (54), THREE CAPSCREWS (55), GROUND CABLE (49), THREE WASHERS (56), AND JUNCTION BLOCK (15) FROM FIREWALL (2). DISCARD LOCK NUTS.

24. CAREFULLY MOVE JUNCTION BLOCK (15) FROM BEHIND STEERING COLUMN BRACKET (57).

TM page 10-10

Illustration from TM 9-2320-363-34-1 (PDF page 656)

DASHBOARD REPLACEMENT (CONT)

25. REMOVE SEALING COMPOUND (16) FROM FIREWALL (2).

26. REMOVE FOUR TORX SCREWS (58), TWO BRACKETS (59), AND COVER (60).

TM page 10-11

Illustration from TM 9-2320-363-34-1 (PDF page 657)

27. REMOVE TWO TORX SCREWS (61), TWO WASHERS (62), AND COVER (63).

REMOVE FOUR SCREWS (64), FOUR WASHERS (65), AND WINDSHIELD SUPPORT (66). DISCONNECT CONNECTOR (67) FROM CEILING (66).

TM page 10-12

Illustration from TM 9-2320-363-34-1 (PDF page 658)

DASHBOARD REPLACEMENT (CONT)

30. REMOVE FOUR CAPSCREWS (69), FOUR WASHERS (70), FOUR LOCK WASHERS (71), AND FUSE, RELAY, AND CIRCUIT BREAKER PANEL (72). SET FUSE, RELAY, AND CIRCUIT BREAKER PANEL (72) ASIDE. DISCARD LOCK WASHERS.

31. DISCONNECT TRAILER CONNECTOR (73).

32. DISCONNECT FOUR CONNECTORS (74) FROM CHASSIS WIRING HARNESS (75).

33. DISCONNECT THREE CONNECTORS (76) FROM ABS WIRING HARNESS (77).

34. DISCONNECT CONNECTOR (78) FROM TRANSMISSION SELECTOR LAMP CONNECTOR (79).

TM page 10-13

Illustration from TM 9-2320-363-34-1 (PDF page 659)

35. DISCONNECT TWO CONNECTORS (80) FROM HEATER RESISTOR BLOCK (81).

36. DISCONNECT CONNECTOR (82) FROM HEATER FAN MOTOR CONNECTOR (83).

37. DISCONNECT CONNECTOR (84) FROM SIDE MARKER LIGHT CONNECTOR (85).

38. DISCONNECT AIR LINE (86) FROM AIR CYLINDER (87).

39. REMOVE RETAINER (88) AND SCREW (89) AND DISCONNECT HEATER CONTROL CABLE (90).

TM page 10-14

Illustration from TM 9-2320-363-34-1 (PDF page 660)

DASHBOARD REPLACEMENT (CONT)

40. REMOVE SCREW (91) AND DISCONNECT GROUND CABLE (92).

41. DISCONNECT CONNECTOR (93) FROM LOW COOLANT MODULE (94).

42. REMOVE SIX TORX SCREWS (95), LOW COOLANT MODULE (94), THREE GROUND CABLES (96). AND CONNECTOR PANEL (97). SET CONNECTOR PANEL (97) ASIDE.

43. REMOVE FOUR SCREWS (98) AND TWO STUDS (99) FROM FIREWALL (2). SET STUDS (99) ASIDE.

TM page 10-15

Illustration from TM 9-2320-363-34-1 (PDF page 661)

44. DISCONNECT TWO AIR LINES (100) FROM AIR CYLINDER (101).

45. DISCONNECT AIR LINE (102) FROM AIR CYLINDER (103).

46. REMOVE TIE WRAP (104) AND DISCONNECT FLEX TUBE (105) FROM STEERING COLUMN BRACKET (57).

47. CAREFULLY REMOVE FLEX TUBE (105) FROM BRACKET (106).

TM page 10-16

Illustration from TM 9-2320-363-34-1 (PDF page 662)

NOTE Perform step 48 on M916A1 only.

48. DISCONNECT AIR LINE (107) FROM AIR JUNCTION BLOCK (108).

49. DISCONNECT WINDSHIELD WASHER AIR PRESSURE LINE (109).

TM page 10-17

Illustration from TM 9-2320-363-34-1 (PDF page 663)

50. REMOVE TWO SCREWS (110).

51. REMOVE TWO NUTS (111), TWO WASHERS (112), TWO TORX SCREWS (113), AND TWO WASHERS (114).

CAUTION

When performing step 52, use extreme caution to prevent damaging wiring harnesses and/or other items in dashboard assembly.

NOTE

Tag location of all lines removed thru firewall with dashboard assembly to aid in installation.

52. REMOVE NUT (115), TWO WASHERS (116), SCREW (117), AND DASHBOARD ASSEMBLY (118).

TM page 10-18

Illustration from TM 9-2320-363-34-1 (PDF page 664)

53. REMOVE LEFT GAGE PANEL (119) IN ACCORDANCE WITH REMOVAL, LEFT GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

54. REMOVE RIGHT GAGE PANEL (1 20) IN ACCORDANCE WITH REMOVAL, RIGHT GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

55. REMOVE CENTER GAGE PANEL (121) IN ACCORDANCE WITH REMOVAL, CENTER GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

56. REMOVE TACHOGRAPH PANEL (122) IN ACCORDANCE WITH REMOVAL, TACHOGRAPH PANEL, REPLACEMENT, TM 9-2320-363-20.

57. REMOVE RIGHT-HAND SWITCH PANEL (123) IN ACCORDANCE WITH REMOVAL, RIGHT-HAND SWITCH PANEL REPLACEMENT, TM 9-2320-363-20.

58. REMOVE LEFT-HAND SWITCH PANEL (124) IN ACCORDANCE WITH REMOVAL, LEFT-HAND SWITCH PANEL REPLACEMENT, TM 9-2320-363-20.

59. REMOVE HEATER CONTROL PANEL (125) IN ACCORDANCE WITH REMOVAL, HEATER CONTROL PANEL REPLACEMENT, TM 9-2320-363-20.

60. REMOVE CONTROL MODULE (126) IN ACCORDANCE WITH REMOVAL, CONTROL MODULE REPLACEMENT, TM 9-2320-363-20.

TM page 10-19

Illustration from TM 9-2320-363-34-1 (PDF page 665)

61. REMOVE TWO LOCK NUTS (127), TWO SCREWS (128), TWO WASHERS (129), AND AIR JUNCTION BLOCK (108). DISCARD LOCK NUTS.

62. REMOVE TWO LOCK NUTS (130), TWO SCREWS (131), TWO WASHERS (132), SCREW (133), AND RIGHT END PANEL (134). DISCARD LOCK NUTS.

63. REMOVE THREE LOCK NUTS (135), THREE SCREWS (136), AND THREE WASHERS (137) THAT JOIN LEFT DASHBOARD (138) TO RIGHT DASHBOARD (139). DISCARD LOCK NUTS.

Use general cleaning methods to clean all parts (page 2-30).

TM page 10-20

Illustration from TM 9-2320-363-34-1 (PDF page 666)

DASHBOARD REPLACEMENT (CONT)

Inspect all parts for wear or damage.

NOTE Procedure is the same for both vehicles except as noted. Quantity of tie wraps may vary from zero to several. Install as necessary.

1. INSTALL THREE WASHERS (1), THREE SCREWS (2), AND THREE NEW LOCK NUTS (3) THAT

TM page 10-21

Illustration from TM 9-2320-363-34-1 (PDF page 667)

2. INSTALL RIGHT END PANEL (6), SCREW (7), TWO WASHERS (8), TWO SCREWS (9), AND TWO NEW LOCK NUTS (10).

3. INSTALL AIR JUNCTION BLOCK (11), TWO WASHERS (12), TWO SCREWS (13), AND TWO NEW LOCK NUTS (14).

4. INSTALL CONTROL MODULE (15) IN ACCORDANCE WITH INSTALLATION, CONTROL MODULE REPLACEMENT, TM 9-2320-363-20.

5. INSTALL HEATER CONTROL PANEL (16) IN ACCORDANCE WITH INSTALLATION, HEATER CONTROL PANEL REPLACEMENT, TM 9-2320-363-20.

6. INSTALL LEFT-HAND SWITCH PANEL (17) IN ACCORDANCE WITH INSTALLATION, LEFT-HAND SWITCH PANEL REPLACEMENT, TM 9-2320-363-20.

7. INSTALL RIGHT-HAND SWITCH PANEL (18) IN ACCORDANCE WITH INSTALLATION, RIGHT-HAND SWITCH PANEL REPLACEMENT, TM 9-2320-363-20.

8. INSTALL TACHOGRAPH PANEL (19) IN ACCORDANCE WITH INSTALLATION, TACHOGRAPH PANEL REPLACEMENT, TM 9-2320-363-20.

9. INSTALL CENTER GAGE PANEL (20) IN ACCORDANCE WITH INSTALLATION, CENTER GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

10. INSTALL RIGHT GAGE PANEL (21) IN ACCORDANCE WITH INSTALLATION, RIGHT GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

11. INSTALL LEFf GAGE PANEL (22) IN ACCORDANCE WITH INSTALLATION, LEFT GAGE PANEL REPLACEMENT, TM 9-2320-363-20.

TM page 10-22

Illustration from TM 9-2320-363-34-1 (PDF page 668)

DASHBOARD REPLACEMENT (CONT)

CAUTION When performing step 12, use extreme caution to prevent damaging wiring harnesses and/or other items in dashboard assembly.

12. INSTALL (23), SCREW (24), TWO (25), AND NUT (26).

TM page 10-23

Illustration from TM 9-2320-363-34-1 (PDF page 669)

13. INSTALL TWO WASHERS (27), TWO TORX SCREWS (23), TWO WASHERS (29), AND TWO NUTS (30).

14. INSTALL TWO SCREWS (31).

15. CONNECT WINDSHIELD WASHER AIR PRESSURE LINE (32).

TM page 10-24

Illustration from TM 9-2320-363-34-1 (PDF page 670)

DASHBOARD REPLACEMENT (CONT)

NOTE Perform step 16 on M916A1 only.

16. CONNECT AIR LINE (33) TO AIR JUNCTION BLOCK (11).

17. CAREFULLY INSTALL FLEX TUBE (34) THRU BRACKET (35).

18. CONNECT FLEX TUBE (34) TO STEERING COLUMN BRACKET (36) AND INSTALL TIE WRAP (37).

TM page 10-25

Illustration from TM 9-2320-363-34-1 (PDF page 671)

19. CONNECT AIR LINE (38) TO AIR CYLINDER (39).

20. CONNECT TWO AIR LINES (40) TO AIR CYLINDER (41).

21. INSTALL TWO STUDS (42) AND FOUR SCREWS (43) IN FIREWALL (44).

TM page 10-26

Illustration from TM 9-2320-363-34-1 (PDF page 672)

DASHBOARD REPLACEMENT (CONT)

22. INSTALL CONNECTOR PANEL (45), THREE GROUND CABLES (46), LOW COOLANT MODULE (47), AND SIX TORX SCREWS (48).

23. CONNECT CONNECTOR (49) TO LOW COOLANT MODULE (47).

24. CONNECT GROUND CABLE (50) AND INSTALL SCREW (51).

25. CONNECT HEATER CONTROL CABLE (52) AND INSTALL SCREW (53) AND RETAINER (54).

26. CONNECT AIR LINE (55) TO AIR CYLINDER (56).

27. CONNECT CONNECTOR (57) TO SIDE MARKER LIGHT CONNECTOR (58).

28. CONNECT CONNECTOR (59) TO HEATER FAN MOTOR CONNECTOR (60).

29. CONNECT TWO CONNECTORS (61) TO HEATER RESISTOR BLOCK (62).

TM page 10-27

Illustration from TM 9-2320-363-34-1 (PDF page 673)

30. CONNECT TRANSMISSION SELECTOR LAMP CONNECTOR (63) TO LAMP CONNECTOR (64).

31. CONNECT THREE CONNECTORS (65) TO ABS WIRING HARNESS (66).

32. CONNECT FOUR CONNECTORS (67) TO CHASSIS WIRING HARNESS (66).

33. CONNECT TRAILER CONNECTOR (69).

34. INSTA LL FUSE, RELAY, AND CIRCUIT BREAKER PANEL (70), FOUR NEW LOCK WASHERS (71), FOUR WASHERS (72), AND FOUR CAPSCREWS (73).

TM page 10-28

Illustration from TM 9-2320-363-34-1 (PDF page 674)

35. CONNECT CONNECTOR (74) TO CEILING (75).

36. INSTALL WINDSHIELD SUPPORT (76), FOUR WASHERS (77), AND FOUR SCREWS (78).

37. INSTALL COVER (79), TWO WASHERS (80), AND TWO TORX SCREWS (81).

TM page 10-29

Illustration from TM 9-2320-363-34-1 (PDF page 675)

38. INSTALL COVER (82), TWO BRACKETS (83), AND FOUR TORX SCREWS (84).

NOTE

Make sure all old sealing compound has been removed from firewall before applying new sealing compound.

39. APPLY NEW SEALING COMPOUND (85) ON FIREWALL (44).

TM page 10-30

Illustration from TM 9-2320-363-34-1 (PDF page 676)

DASHBOARD REPLACEMENT (CONT)

40. CAREFULLY MOVE JUNCTION BLOCK (86) INTO POSITION BEHIND STEERING COLUMN BRACKET (36).

41. INSTALL JUNCTION BLOCK (86), THREE WASHERS (87), GROUND CABLE (88), THREE CAPSCREWS (89), TWO WASHERS (90), AND TWO NEW LOCK NUTS (91) IN FIREWALL (44).

42. INSTALL RETAINER (92) AND TORX SCREW (93).

43. CONNECT ACCELERATOR CONNECTOR (94).

TM page 10-31

Illustration from TM 9-2320-363-34-1 (PDF page 677)

44. CONNECT GROUND CABLE (88) AND INSTALL WASHER (95) AND NEW LOCK NUT (96).

NOTE Perform step 45 on M915A2 only.

45. CONNECT FOUR AIR LINES (97).

NOTE Perform step 46 on M916A1 only.

46. CONNECT THREE AIR LINES (98).

47. CONNECT CONNECTOR (99) TO SIDE MARKER LIGHT CONNECTOR (100).

48. INSTALL LOWER PANEL (101), THREE TORX SCREWS (102), AND FOUR SCREWS (103).

TM page 10-32

Illustration from TM 9-2320-363-34-1 (PDF page 678)

DASHBOARD REPLACEMENT (CONT)

49. INSTALL COMPARTMENT (104), THREE INSERTS (105), THREE WASHERS (106), AND THREE NEW LOCK NUTS (107).

50. INSTALL COVER (108) AND SCREW (109).

51. INSTALL SPACER (110), WASHER (111), SCREW (112), WASHER (113), AND NEW LOCK NUT (114).

52. INSTALL COVER (115) AND NINE SELF-TAPPING SCREWS (116).

TM page 10-33

Illustration from TM 9-2320-363-34-1 (PDF page 679)

53. INSTALL COVER (117), WASHER (118), SCREW (119), SPACER (120), WASHER (121), AND NEW LOCK NUT (122).

54. INSTALL TWO WASHERS (1 23) AND TWO SCREWS (1 24).

55. INSTALL COVER (125) AND ROTATE THREE FASTENERS (126) TO RIGHT.

Make sure all old sealing compound has been removed from firewall before applying new sealing compound.

56. APPLY NEW SEALING COMPOUND (85) ON FIR EWALL (44).

57. CONNECT OIL LINE (127) AND SIX AIR LINES (128) TO JUNCTION BLOCK (86).

TM page 10-34

Illustration from TM 9-2320-363-34-1 (PDF page 680)

DASHBOARD REPLACEMENT (CONT)

58. REMOVE FOUR SCREWS (129) AND PULL WINDSHIELD WIPER MOTOR (130) FAR ENOUGH AWAY FROM FIREWALL (44) TO CONNECT TWO AIR LINES (131).

59. INSTALL WINDSHIELD WIPER MOTOR (130) AND FOUR SCREWS (129).

60. INSTALL TWO CLAMPS (132) AND TWO SCREWS (133) ON TWO AIR LINES (134).

TM page 10-35

61. CONNECT TWO CABLES (135) AND INSTALL TWO NUTS (136).

62. CONNECT TWO CONNECTORS (137) AND TIGHTEN TWO SCREWS (138) TO FIREWALL (44).

63. CONNECT CONNECTOR (139) TO FIREWALL (44).

NOTE Follow-on Maintenance:

Install speedometer drive shaft and cable (TM 9-2320-363-20). Install tachometer cable (TM 9-2320-363-20). Install steering wheel and column (TM 9-2320-363-20). Connect batteries (TM 9-2320-363-20). Install air cleaner, pre-cleaner, and duct assembly (TM 9-2320-363-20).

TM page 10-36 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 682)

AIR     DUCTS       REPLACEMENT

This task covers:     a. Removal   b. Cleaning   c. Inspection d. Installation

Applicable Configuration: Equipment Condition:

M915A2 and M916A1                                   Reference              Condition Description
Tools and Special Equipment:                        Page 10-3              Dashboard Removed

Tool Kit, SC 5180-90-CL-N05

TM page 10-37

Illustration from TM 9-2320-363-34-1 (PDF page 683)

1. REMOVE TIE WRAP (1), DUCT (2), AND FLEX HOSE (3).

2. REMOVE TWO SELF-TAPPING SCREWS (4) AND DUCT (5).

3. REMOVE FIVE CLIPS (6) AND FLEX HOSE (7) FROM DUCT (5).

4. REMOVE TIE WRAP (8) AND FLEX HOSE (9).

5. REMOVE THREE SELF-TAPPING SCREWS (10) AND MAIN DUCT ASSEMBLY (11).

6. REMOVE TWO SCREWS (12) AND COVER (13).

7. REMOVE TWO RETAINERS (14) AND AIR CYLINDER (15).

8. REMOVE TWO RETAINERS (16) AND AIR CYLINDER (17).

9. REMOVE TWO SCREWS (18) AND DUCT (19).

10. REMOVE RETAINER (20), SHAFT (21), AND DOOR (22).

Use general cleaning methods to clean all parts (page 2-30).

Inspect all parts for wear or damage.

TM page 10-38

Illustration from TM 9-2320-363-34-1 (PDF page 684)