Transmission Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

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

Tools and Special Equipment:                          Equipment Condition: (Cont)

Shop Equipment, SC 4910-95CL-A31                      Reference                 Condition Description
Tool Kit, SC 5180-90-CL-N05
Shop Equipment, SC 5180-95-CL-A62                     TM 9-2320-363-20          Air System Drained

                                                      TM 9-2320-363-20          Drivelines Removed
Materials/Parts:
Kit, Mounting             P/N 328170-101X             TM 9-2320-363-20          Transmission Fluid
                                                                                Drained
Gasket                    P/N 23016683
                                                      General Safety Instructions:
Nut, Lock (2)
Washer, Lock (2)                                                          WARNING
Washer, Lock (15)         P/N 103323                              Do not disconnect any air
                                                                  system lines or fittings unless
Washer, Lock
                                                                  vehicle engine is shut off and
Tag, Identification       Appendix B, Item 55                     air system pressure          is
                                                                  relieved. To do so could
Personnel Required: (2)                                           result in serious injury’ to
                                                                  personnel.
References:
                                                                   Transmission weighs 900 lb
TM 9-2320-363-10                                                  (409 kg). Support transmission
TM 9-2320-363-20                                                  with transmission jack during
                                                                  removal or installation to
Equipment Condition:                                              prevent possible injury to
                                                                  personnel.
Reference                  Condition Description
                                                               Do not place finger in hole of
TM 9-2320-363-10          Transfer Case Shift                  engine flywheel housing while
                          Selector Set to Neutral              engine is being barred over.
                          (M916A1)                             To do so could result in
TM 9-2320-363-10           Spare Tire Removed                  serious injury to personnel.

TM 9-2320-363-20          Transmission Dipstick                    Oil filter mounting bracket
                          Tube Removed                            assembly weighs 22 lb (10
                                                                  kg).    Support    mounting
TM 9-2320-363-20           Passenger Seal                         bracket assembly prior to
                           Removed                                removal to prevent injury to
TM 9-2320-363-20           Batteries Disconnected                 personnel.

TM 9-2320-363-20           Transmission Tunnel
                           Access Cover Removed
TM 9-2320-363-20           Transmission Shift
                           Control Removed

TM page 3-236 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 312)

WARNING Do not disconnect any air system lines or fittings unless vehicle engine is shut off and air system pressure is relieved. To do so could result in serious injury to personnel. **NOTE** Tag all fluid lines, air lines, and electrical connectors prior to removal to aid in installation.

If transmission is being replaced because of clutch or gear failure, external filter must be replaced and cooler hoses and cooler must be flushed and blown out.

Steps 1 thru 6 are for all except M915A2.

1. FROM INSIDE CAB, THRU ACCESS HOLE, DISCONNECT TWO AIR HOSES (1 AND 2) AND LUBRICATION HOSE (3).

TM page 3-237

Illustration from TM 9-2320-363-34-1 (PDF page 313)

2. REMOVE LOCK NUT (4), WASHER (5), SCREW (6), WASHER (7), AND CLAMP (8) FROM BRACKET (9). DISCARD LOCK NUT.

3. REMOVE FIVE NUTS (10), FIVE COPPER GASKETS (11), CAPSCREW (12), WASHER (13), AND HOSE (14). DISCARD NUTS AND GASKETS.

4. REMOVE TWO BOLTS (15), TWO LOCK WASHERS (16), TWO WASHERS (17), LOCK NUT (18), WASHER (19), BRACKET (20), AND THREE WASHERS (21). DISCARD LOCK WASHERS AND LOCK NUT.

5. LIFT AND SECURE PTO-HYDRAULIC PUMP COMBINATION (22).

6. REMOVE AND DISCARD PTO GASKET (23) AND FIVE STUDS (24).

TM page 3-238

Illustration from TM 9-2320-363-34-1 (PDF page 314)

TRANSMISSION REPLACEMENT (CONT)

7. DISCONNECT OIL COOLER HOSE (25).

8. DISCONNECT ELECTRICAL CABLE (26) FROM TEMPERATURE SENDING UNIT (27).

9. DISCONNECT AIR HOSE (28).

—

10. REMOVE BOLT (29) AND WASHER (30) AND DISCONNECT GROUND STRAP (31). INSTALL WASHER (30) AND BOLT (29).

TM page Change 1 3-239

Illustration from TM 9-2320-363-34-1 (PDF page 315)

11. REMOVE BOLT (32) AND LOCK WASHER (33) AND SET PRESSURE REGULATOR SOLENOID VALVE (34) ASIDE. NOTE BOLT (32) POSITION FOR LATER USE. DISCARD LOCK WASHER.

12. REMOVE BOLT (35) AND LOCK WASHER (36) AND SET BRACKET (37) ASIDE. NOTE BOLT (35) POSITION FOR LATER USE. DISCARD LOCK WASHER.

NOTE Steps 13 and 14 are for all except M915A2.

13. DISCONNECT HOSE (38).

14. REMOVE TWO BOLTS (39) AND TWO WASHERS (40) AND SET SWING BRACKET (41) ASIDE.

TM page 3-240

Illustration from TM 9-2320-363-34-1 (PDF page 316)

TRANSMISSION REPLACEMENT (CONT)

15. REMOVE BOLT (42) AND LOCK WASHER (43) AND SET BRACKET (44) ASIDE. NOTE BOLT (42) POSITION FOR LATER USE. DISCARD LOCK WASHER.

16. DISCONNECT HYDRAULIC HOSE (45).

TM page Change 1 3-241

Illustration from TM 9-2320-363-34-1 (PDF page 317)

17. DISCONNECT ELECTRICAL CONNECTOR (46).

NOTE Step 18 is for M915A2 only.

18. REMOVE BOLT (47) AND BRACKET (48). NOTE BOLT (47) POSITION FOR LATER USE.

19. DISCONNECT HYDRAULIC HOSE (49).

20. DISCONNECT OIL SAMPLE HOSE (50).

21. REMOVE TWO SCREWS (51) AND DISCONNECT TWO CABLES (52) FROM REVERSE SENDING UNIT (53).

NOTE Step 22 is for M915A2 only.

22. REMOVE TWO BOLTS (54), TWO WASHERS (55), AND OIL FILTER MOUNTING BRACKET (56).

23. REMOVE NUT (57), WASHER (58), BRACKET (59), BOLT (60), AND WASHER (61).

WARNING Oil filter mounting bracket assembly weighs 22 lb (10 kg). Support mounting bracket assembly prior to removal to prevent injury to personnel. **NOTE** Step 24 is for all except M915A2.

24. REMOVE TWO BOLTS (62), SPACER (63), AND OIL FILTER MOUNTING BRACKET (64).

TM page 3-242

Illustration from TM 9-2320-363-34-1 (PDF page 318)

25. DISCONNECT HOSE (65) FROM GOVERNOR (66).

26. DISCONNECT ELECTRICAL CONNECTOR (67).

27. REMOVE PLUG (66) FROM ENGINE FLYWHEEL HOUSING (69).

TM page 3-243

Illustration from TM 9-2320-363-34-1 (PDF page 319)

WARNING

Do not place finger in hole of engine flywheel housing while engine is being barred over. To do so could result in serious injury to personnel.

CAUTION

Step 28 must be followed in barring engine over. Any other method may damage equipment.

28. HAVE ASSISTANT BAR ENGINE (70) OVER USING ACCESSORY DRIVE (71). USING INSPECTION MIRROR, LOCATE BOLT (72). HAVE ASSISTANT STOP BARRING ENGINE OVER. REMOVE BOLT (72) THRU HOLE IN ENGINE FLYWHEEL HOUSING (69). REPEAT UNTIL 12 BOLTS (72) HAVE BEEN REMOVED.

NOTE Step 29 is for M915A2 only.

29. DISCONNECT SPEEDOMETER CABLE (73).

TM page 3-244 Change 1

WARNING Transmission weighs 900 lb (409 kg). Support transmission with transmission jack during removal to prevent possible injury to personnel. **NOTE** Step 30 is for all except M915A2. Step 31 is for M915A2.

30. REMOVE TWO NUTS (74), TWO WASHERS (75), TWO BOLTS (76), AND SUPPORT SPRING (77).

31. REMOVE TWO BOLTS (78), TWO WASHERS (79), AND SUPPORT SPRING (80).

TM page 3-245

Illustration from TM 9-2320-363-34-1 (PDF page 321)

32. USING TRANSMISSION JACK, SUPPORT TRANSMISSION (81) AND REMOVE 10 BOLTS (82) AND 10 LOCK WASHERS (83). DISCARD LOCK WASHERS.

NOTE It may be necessary to jack vehicle up so transmission will clear.

33. LOWER TRANSMISSION (81) AND ROLL FROM UNDER VEHICLE.

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

Inspect all parts for wear or damage.

TM page 3-246 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 322)

WARNING Transmission weighs 900 lb (409 kg). Support transmission with transmission jack during installation to prevent possible injury to personnel.

1. USING TRANSMISSION JACK, ROLL TRANSMISSION (1) INTO PLACE UNDER VEHICLE.

CAUTION Transmission must be seated squarely against flywheel housing to prevent damage to equipment.

2. INSTALL TRANSMISSION (1), 12 NEW LOCK WASHERS (2), AND 12 BOLTS (3). HAND-TIGHTEN BOLTS.

3. TIGHTEN FOUR BOLTS (3) 90 DEGREES APART TO 40 LB-FT (54 N.m).

4. TIGHTEN 12 BOLTS (3) TO 40 LB-FT (54 N.m).

NOTE Step 5 is for all except M915A2. Step 6 is for M915A2.

5. INSTALL TWO BOLTS (4), SUPPORT SPRING (5), TWO WASHERS (6), AND TWO NUTS (7).

TM page 3-247

Illustration from TM 9-2320-363-34-1 (PDF page 323)

6. INSTALL TWO BOLTS (8), TWO WASHERS (9), AND SUPPORT SPRING (10).

7. REMOVE PLUG (11) AND ROTATE TORQUE CONVERTOR TO ALINE HOLES IN FLEX PLATE WITH HOLES IN TORQUE CONVERTOR.

WARNING Do not place finger in hole of engine flywheel housing while engine is being barred over, To do so could result in serious injury to personnel. **CAUTION** Step 8 must be followed in barring engine over. Any other method may damage equipment. If bolts are dropped in engine flywheel housing, retrieve immediately. Failure to do so will result in damage to equipment.

8. HAVE ASSISTANT BAR ENGINE (12) OVER USING ACCESSORY DRIVE (13), USING INSPECTION MIRROR, LOCATE PLACEMENT AREA FOR BOLT (14). HAVE ASSISTANT STOP BARRING ENGINE OVER. INSTALL BOLT (14) THRU HOLE IN ENGINE BELL HOUSING (15). REPEAT UNTIL 12 BOLTS (14) HAVE BEEN INSTALLED HAND-TIGHT.

9. TIGHTEN 12 BOLTS (14) TO 96-115 LB-FT (131-156 N.m).

TM page 3-248

Illustration from TM 9-2320-363-34-1 (PDF page 324)

TRANSMISSION REPLACEMENT (CONT)

10. INSTALL PLUG (16) IN ENGINE BELL HOUSING (15).

11. INSTALL PLUG (11) IN ENGINE BELL HOUSING (15).

12. CONNECT ELECTRICAL CONNECTOR (17).

TM page Change 1 3-249

Illustration from TM 9-2320-363-34-1 (PDF page 325)

13. CONNECT HOSE (18) TO GOVERNOR (19).

NOTE Step 14 is for M915A2. Step 15 is for all except M915A2.

14. INSTALL OIL FILTER MOUNTING BRACKET (20), TWO WASHERS (21), AND TWO BOLTS (22).

15. INSTALL OIL FILTER MOUNTING BRACKET (23), SPACER (24), AND TWO BOLTS (25).

16. INSTALL WASHER (26), BOLT (27), BRACKET (28), WASHER (29), AND NUT (30).

TM page 3-250

Illustration from TM 9-2320-363-34-1 (PDF page 326)

17. CONNECT TWO CABLES (31) TO REVERSE SENDING UNIT (32) AND INSTALL TWO SCREWS (33).

18. CONNECT HYDRAULIC HOSE (34).

19. CONNECT OIL SAMPLE HOSE (35).

20. CONNECT ELECTRICAL CONNECTOR (36).

NOTE Steps 21 and 22 are for M915A2 only.

21. REMOVE BOLT (37) FROM POSITION NOTED IN REMOVAL STEP 18.

22. POSITION BRACKET (38) AND INSTALL BOLT (37).

TM page Change 1 3-251

Illustration from TM 9-2320-363-34-1 (PDF page 327)

23. REMOVE BOLT (39) AND LOCK WASHER (40) FROM POSITION NOTED IN REMOVAL STEP 16. DISCARD LOCK WASHER.

24. CONNECT HYDRAULIC HOSE (41).

25. POSITION BRACKET (42) AND INSTALL NEW LOCK WASHER (40) AND BOLT (39). TIGHTEN BOLT TO 40 LB-FT (54 N.m).

NOTE Step 26 is for all except M915A2.

26. POSITION BRACKET (43) AND INSTALL TWO WASHERS (44) AND TWO BOLTS (45).

NOTE Step 27 is for all except M915A2.

27. CONNECT HOSE (46).

TM page 3-252

Illustration from TM 9-2320-363-34-1 (PDF page 328)

28. REMOVE BOLT (47) AND LOCK WASHER (48) FROM POSITION NOTED IN REMOVAL STEP 12. DISCARD LOCK WASHER.

29. POSITION BRACKET (49) AND INSTALL NEW LOCK WASHER (48) AND BOLT (47). TIGHTEN BOLT TO 40 LB-FT (54 N.m).

30. REMOVE BOLT (50) AND LOCK WASHER (51) FROM POSITION NOTED IN REMOVAL STEP 11. DISCARD LOCK WASHER.

31. POSITION PRESSURE REGULATOR SOLENOID VALVE (52) AND INSTALL NEW LOCK WASHER (51) AND BOLT (50). TIGHTEN BOLT TO 40 LB-FT (54 N.m).

32. CONNECT AIR HOSE (53).

33. REMOVE BOLT (54) AND WASHER (55) AND INSTALL GROUND STRAP (58). INSTALL WASHER (55) AND BOLT (54).

TM page Change 1 3-253

34. CONNECT ELECTRICAL CABLE (57) TO TEMPERATURE SENDING UNIT (58).

35. CONNECT OIL COOLER HOSE (59).

NOTE Steps 36 thru 40 are for all except M915A2.

36. INSTALL FIVE NEW STUDS (60) AND NEW PTO GASKET (61).

37. POSITION PTO-HYDRAULIC PUMP COMBINATION (62) AND INSTALL THREE WASHERS (63), BRACKET (64), WASHER (65), NEW LOCK NUT (66), TWO WASHERS (67), TWO NEW LOCK WASHERS (68), AND TWO BOLTS (69).

38. INSTALL WASHER (70), CAPSCREW (71), FIVE NEW COPPER GASKETS (72), FIVE NEW NUTS (73), AND HOSE (74).

TM page 3-254

Illustration from TM 9-2320-363-34-1 (PDF page 330)

39. INSTALL CLAMP (75), WASHER (76), SCREW (77), WASHER (78), AND NEW LOCK NUT (79) ON BRACKET (80).

40. CONNECT LUBRICATION HOSE (81) AND TWO AIR HOSES (82 AND 83).

TM page Change 1 3-255

NOTE Step 41 is for M915A2 only.

41. CONNECT SPEEDOMETER CABLE (84).

NOTE Follow-on Maintenance:

Install drivelines (TM 9-2320-363-20). Install transmission shift control (TM 9-2320-363-20). Adjust transmission shift linkage (TM 9-2320-363-20). Install transmission tunnel access cover (TM 9-2320-363-20). Install passenger seat (TM 9-2320-363-20). Connect batteries (TM 9-2320-363-20). Install transmission dipstick tube (TM 9-2320-363-20). Install spare tire (TM 9-2320-363-1 0). Fill transmission with fluid (TM 9-2320-363-20).

TM page 3-256