Section I. Repair Parts, Special Tools; Test, Measurement, and Diagnostic
TM 9-2320-363-34-1
Equipment (TMDE); and Support Equipment . . . . . . . . . . . . . . . . . . . . . . 2-1
Section II .......,,..,.,..,.....,.................. 2-2 Approved for public release; distribution is unlimited.
TABLE OF CONTENTS (Cont)
Page
Section III General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
CHAPTER 3 ......................... 3-1
Section I Engine Assembly and Related Parts Removal and Installation ........ 3-2
Section II Transmission and Transfer Case Removal and Installation . . . . . . . . . . . 3-234
CHAPTER 4 ...................... 4-1
CHAPTER 5 .............................. 5-1
CHAPTER 6 ............................... 6-1
CHAPTER 7 ................................ 7-1
CHAPTER 8 ......... 8-1
CHAPTER 9 ............................. 9-1
CHAPTER 10 ............... 10-1
CHAPTER 11 ................................... 11-1
CHAPTER 11.1 ................. 11.1-1
VOLUME 2
ENGINE, FUEL, AND COOLING SYSTEM
CHAPTER 12 REPAIR INSTRUCTIONS .................... 12-1
Section I EngineRepair ............................................. 12-2
Section II Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-170
Section III Air lntake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-171
Section IV Cooling System Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-185
CHAPTER 13 13-1
Section I Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Section II Starter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
CHAPTER 14 . . . . . . . . . . . . . . . . . . 14-1
Section I Transmission Installation/Removal from Transmission Stand ......... 14-2
Section II Flywheel and Turbine Replacement and Repair . . . . . . . . . . . . . . . . . . . . 14-7
Section III Torque Convertor Stator Replacement and Repair . . . . . . . . . . . . . . . . . 14-22
Section IV Torque Convertor Pump Replacement and Repair . . . . . . . . . . . . . . . . . . 14-27
Section V Torque Convertor Housing and Front Support Replacement and Repair . 14-35
Section VI Forward Clutch and Housing Replacement and Repair . . . . . . . . . . . . . . 14-54
Section VII Lockup Cutoff Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-71
Section VIII Control Valve Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 14-74
Section IX Fourth Clutch Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 14-96
TABLE OF CONTENTS (Cont)
Page
Section X Third Clutch and Housing Replacement and Repair . . . . . . . . . . . . . . . . . 14-105
Section Xl Gear Unit and Main Shaft Replacement and Repair . . . . . . . . . . . . . . . . . 14-116
Section XII Rear Cover and First Clutch Replacement and Repair . . . . . . . . . . . . . . . 14-133
Section XIII Transmission Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-146
Section XIV Second Clutch Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 14-152
....................
CHAPTER 15 15-1
Section I Transfer Case Repair (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . . 15-2
Section II Input Shaft Repair (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
Section III Center Shaft Repair (All Except M915A2) ........................ 15-29
Section IV Lower Rear Output Shaft Repair (All Except M915A2) . . . . . . . . . . . . . . . 15-33
Section V Lower Front Output Shaft Repair (All Except M915A2) .............. 15-37
Section VI Lower Shift Rod Repair (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . 15-41
Section VII Upper Shift Rod Repair (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . 15-44
Section VIII Lubrication Pump Repair (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . 15-46
Section IX Air Shift Chamber Repair (All Except M915A2) .................... 15-51
. . . . . . . . . . . . . . . . . . . . 16-1
CHAPTER 16
CHAPTER 17 .............. 17-1
Section I Forward-Rear Axle Differential Carrier Repair . . . . . . . . . . . . . . . . . . . . . 17-2
Section II Rear-Rear Axle Differential Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . 17-47
Section III Rear Axle Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-72
CHAPTER 18 ........ 18-1
CHAPTER 19 . . . . . . . . . . . . . . 19-1
Section I Power Steering Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
Section II Steering Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
FRAME AND TOWING ATTACHMENTS REPAIR
CHAPTER 20 INSTRUCTIONS ........ ........ 20-1
Section I Fifth Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Section II Slide Bracket and Plate Repair (M915A2) . . . . . . . . . . . . . . . . . . . . . . . . 20-8
Section III Top Plate Replacement (M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Section IV Top Plate’ Repair (M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Section V Slide Bracket and Base Repair (M916A1 and M916A2) . . . . . . . . . . . . . . 20-20
Section VI Top Plate Replacement (M916A1 and M916A2) ................... 20-30
TABLE OF CONTENTS (Cont)
Page
Section VII Top Plate Repair (M916A1 and M916A2) . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Section VIII Ramp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
Section IX Frame Alinement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
CHAPTER 21 ...................... 21-1
CHAPTER 22 ....... 22-1
Section I Hood Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Section II Hood SMC Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
Section III Cab Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-12
Section IV Cab Door Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28
CHAPTER 23 . . . . . . . . . . .
23-1
Section I Hydraulic Winch Repair (M916A1 and M916A2) ................... 23-2
Section II Hydraulic Motor Repair (M916A1 and M916A2) . . . . . . . . . . . . . . . . . . . . 23-9
Section III Hydraulic Pump Repair (M916A1 and M916A2 . . . . . . . . . . . . . . . . . . . . 23-12
Section IV Speed Control Valve Repair (M916A1 and M916A2) . . . . . . . . . . . . . . . . 23-18
Section V Direction Control Valve Repair (M916A1 and M916A2) . . . . . . . . . . . . . . 23-22
Section VI Gear End Repair (M916A1 and M916A2) . . . . . . . . . . . . . . . . . . . . . . . . . 23-26
Section VII Motor End Repair (M916A1 and M916A2) . . . . . . . . . . . . . . . . . . . . . . . . 23-34
CHAPTER 24 ............ 24-1
CHAPTER 25 ................. 25-1
Section I Vehicle Heater Repair (M915A2 and M916A1) . . . . . . . . . . . . . . . . . . . . . 25-2
Section II Arctic Personnel Heater Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10
Section III Vehicle Heater/Air Conditioner Unit Repair
(All Except M915A2 and M916A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-36
CHAPTER 26 AIR CONDITIONING SYSTEM REPAIR INSTRUCTIONS . . . . . . . . . . . . 26-1
APPENDIX A References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B Expendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
APPENDIX D Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
............................................... Index 1
How To Use This Manual
This manual has an edge index that will help you find specific information in a hurry. Simply spread the pages in the right edge of the manual until the printed blocks can be seen. Open the manual where the block on the edge of the page lines up with your selected topic printed in the front cover block.
OVERVIEW
This manual is organized by chapters, sections and appendices. A summary of the organization of this manual, by major divisions, follows:
Front cover index gives you a quick reference to chapters, sections, and appendices that you will use often.
WARNINGS - All warnings you should observe while working on or around the M915 family of vehicles are shown in this part of the manual. These are repeated in the parts of the manual where they apply.
Table of Contents - The contents of the chapters and appendices are listed here.
Chapter 1 - This chapter contains general information about the M915 family of vehicles.
Chapter 2 - This chapter outlines troubleshooting of the M915 family of vehicles, and their systems. It includes a troubleshooting index, by symptom and system, for troubleshooting. Other sections include information on tools, repair parts, and general maintenance instructions.
Chapters 3 thru 26 - These chapters contain step-by-step instructions for doing the maintenance tasks. Each system of the M915 family of vehicles has its own chapter, and any special tools, equipment, or supplies you may need for a task are listed.
Appendix A - This appendix lists the technical manuals and other publications you may have to refer to while working on the vehicle.
Appendix B -This appendix lists the expendable supplies and materials you will need while performing maintenance on the M915 family of vehicles.
Appendix C - This appendix describes any manufactured items you will need for performing maintenance on the M915 family of vehicles.
Appendix D - This appendix describes the proper method of tightening fasteners.
Index - The index is an alphabetical listing of the contents of this manual.
Back Cover - This inside back cover contains a metric conversion table.
USING THE MANUAL ON THE JOB
Find the task or component that needs repair by using the Index (page Index-l), then turn to the page listed for that task or component.
Read the INITIAL SETUP procedures, and gather the necessary items and personnel. Pay attention to the warnings. The INITIAL SETUP sheet is described on page vi.
Change 1 v
1. TITLE—This is the name of the task.
2. TASK COVERS—This lists all the tasks included in the module.
3. APPLICABLE CONFIGURATION—lf the task is applicable to only one of the vehicles, M915A2 or M916A1 (as appropriate) will be listed here.
4. TOOLS AND SPECIAL EQUIPMENT—These are the tools and equipment you will need to do the task.
5. MATERIALS/PARTS—These are the supplies you will need to do the task. If parts or materials are required, they are listed here or referenced to Appendix B.
6. PERSONNEL REQUIRED-Personnel required to perform a task will be identified if the task requires more than one.
7. REFERENCES—These are the other technical publications you will need to do the task.
8. EQUIPMENT CONDITION—This is the condition(s) the vehicle must be in before you start the task. Other tasks that must be done first are listed by page number or by technical manual number if another manual is required.
9. GENERAL SAFETY lNSTRUCTIONS—These are the safety precautions that must be observed while you are doing the task.
10. FOLLOW-ON MAINTENANCE—These are the tasks listed at the end of the procedure that must be completed to return the vehicle to an operational condition.