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• TECHNICAL MANUAL
• WARNING SUMMARY
• WARNING SUMMARY (Cont'd)
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE (cont)
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE (cont)
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE (Cont)
• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE (Cont)
• LIST OF EFFECTIVE PAGES
• LIST OF EFFECTIVE PAGES (Cont)
• LIST OF EFFECTIVE PAGES (Cont)
• LIST OF EFFECTIVE PAGES (Cont)
• Table of Contents
• Table of Contents (Cont)
• Table of Contents (Cont)
• HOW TO USE THIS MANUAL
• HOW TO USE THIS MANUAL (cont)
• HOW TO USE THIS MANUAL (cont)
• HOW TO USE THIS MANUAL (cont)
• HOW TO USE THIS MANUAL (cont)
• Chapter 1. INTRODUCTION
• DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
• Section II. EQUIPMENT DESCRIPTION AND DATA
• Table 1-1. Tabulated Data
• Table 1-1. Tabulated Data (Cont'd)
• Table 1-1. Tabulated Data (Cont'd)
• Chapter 2. GENERAL MAINTENANCE
• Section II. TROUBLESHOOTING
• TROUBLESHOOTING SYMPTOM INDEX
• Table 2-1. Mechanical Troubleshooting
• ENGINE KNOCKS (MECHANICAL NOISE)
• EXCESSIVE EXHAUST SMOKE
• LOSS OF COOLANT
• NO 1-2 UPSHIFT OR DELAYED UPSHIFT
• SHIFT FIRM OR ROUGH
• SHIFT SOFT OR SUPS
• NO DETENT DOWNSHIFTS
• TRANSMISSION NOISY
• ELECTRIC CHECK-OUT OF ELECTRONIC COMPONENTS IN 4L80-E TRANSMISSION AT TRANSMISSION ELECTRICAL CONNECTOR.
• TORQUE CONVERTER CLUTCH SOLENOID
• TRANSMISSION CONTROL MODULE (TCM) CODES ARE 59, 71, 75, 79, 81, 82, 83
• NO 1-2 UPSHIFT OR DELAYED UPSHIFT
• 1-2 SHIFT FIRM OR ROUGH
• NO 3-4 UPSHIFT OR DELAYED UPSHIFT
• NO ENGINE BRAKING - THIRD GEAR
• VEHICLE MOVES IN NEUTRAL
• DIFFERENTIAL NOISY
• Section III. AIR-CONDITIONING TROUBLESHOOTING
• Table 2-1.1. Normal Operating Temperatures and Pressures (FR-12).
• Table 2-2. Normal Operating Temperatures and Pressures (R-12).
• AIR-CONDITIONING TROUBLESHOOTING SYMPTOM INDEX
• INTERMITTENT COOLING
• INSUFFICIENT COOLING
• UNUSUAL NOISE WITH CLUTCH ENGAGED
• UNUSUAL NOISE WITH CLUTCH DISENGAGED
• SECTION IV. GENERAL MAINTENANCE INSTRUCTIONS
• INSPECTION
• REPAIR
• ASSEMBLY
• Chapter 3. ENGINE MAINTENANCE
• ENGINE MOUNT AND INSULATOR MAINTENANCE
• Removal
• Disassembly
• Assembly
• Installation
• Installation (cont)
• LEFT CYLINDER HEAD REPAIR
• Repair
• Installation
• Installation (cont)
• RIGHT CYLINDER HEAD REPLACEMENT
• Removal
• Installation
• Installation (cont)
• CRANKSHAFT PULLEY REPLACEMENT
• Installation
• TORSIONAL DAMPER REPLACEMENT
• Installation
• ROCKER ARM SHAFTS AND PUSHRODS REPLACEMENT
• HYDRAULIC VALVE LIFTER REPLACEMENT
• Installation
• TIMING CHAIN COVER, TIMING CHAIN, AND DRIVE SPROCKETS MAINTENANCE
• Inspection
• Installation
• Installation (cont)
• LEFT ROCKER ARM COVER MAINTENANCE
• Installation
• RIGHT ROCKER ARM COVER MAINTENANCE
• Installation
• FRONT COVER OIL SEAL REPLACEMENT
• FRONT COVER OIL SEAL REPLACEMENT
• REAR MAIN OIL SEAL REPLACEMENT
• Removal
• Installation
• Installation (cont)
• OIL PUMP MAINTENANCE
• Installation
• INTAKE MANIFOLD MAINTENANCE
• Installation
• GLOW PLUG TIP REMOVAL (DAMAGED OR BROKEN)
• Removal
• ENGINE INJECTION PUMP TIMING
• Timing Check
• Timing Check (cont)
• Timing Adjustment
• ENGINE RUN-IN
• Section II. ENGINE REPLACEMENT
• ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER
• Installation
• ENGINE REMOVAL (6.2 L AND 6.5 L [DETUNED])
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• ENGINE INSTALLATION (6.2 L AND 6.5 L [DETUNED])
• Installation
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• ENGINE REMOVAL (6.5 L)
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• ENGINE INSTALLATION (6.5 L)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE INSTALLATION (6.5 L) (Cont'd)
• ENGINE PREPARATION (6.2 L AND 6.5 L)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Assembly
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Chapter 4. FUEL SYSTEM MAINTENANCE
• FUEL INJECTION NOZZLE REPLACEMENT
• Installation
• FUEL INJECTION LINES MAINTENANCE
• Installation
• SERVO ADVANCE SEAL REPLACEMENT
• Installation
• FUEL INJECTION PUMP MAINTENANCE
• Removal
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• FUEL INJECTION PUMP COVER REPLACEMENT
• Installation
• FUEL INJECTION PUMP SHUTOFF SOLENOID MAINTENANCE
• Installation
• FUEL INJECTION PUMP COLD ADVANCE SOLENOID MAINTENANCE
• Installation
• ACCELERATOR CABLE MOUNTING BRACKET MAINTENANCE
• Installation
• Chapter 5: COOLING SYSTEM MAINTENANCE
• Chapter 6: ELECTRICAL SYSTEM MAINTENANCE
• 100 AMPERE ALTERNATOR (12340912) REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (cont)
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• AMPERE ALTERNATOR (12342944) TESTING AND REPAIR
• Table 6-A. No-Load Test.
• Table 6-A.1. Full-Load Test.
• Table 6-A.2. Regulator Bypass Test.
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Static Testing
• Cleaning
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• AMPERE DUAL VOLTAGE ALTERNATOR (12447110) TESTING AND REPAIR
• Alternator Output Testing
• Table 6-A.3. No-Load Test.
• Table 6-A.5. Alternator Speed and Current Tracking.
• Disassembly
• Disassembly (cont)
• Static Testing
• Cleaning
• Assembly
• Assembly (cont)
• AMPERE ALTERNATOR (A0013036AA) TESTING AND REPAIR
• Disassembly/Testing
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Disassembly/Testing (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• AMPERE ALTERNATOR (12338796-1) TESTING AND REPAIR
• Table 6-A.7. No-Load Test.
• Disassembly
• Disassembly (cont)
• Static Testing
• Cleaning
• Assembly
• Assembly (cont)
• AMPERE DUAL VOLTAGE ALTERNATOR (12447109) TESTING AND REPAIR
• Alternator Output Testing
• Table 6-D. No-Load Test.
• Table 6-F. Alternator Speed and Current Tracking.
• Disassembly
• Disassembly (cont)
• Static Testing
• Cleaning
• Assembly
• Assembly (cont)
• AMPERE DUAL VOLTAGE ALTERNATOR (12469057) TESTING AND REPAIR
• Alternator Output Testing
• Alternator Output Testing (cont)
• Table 6-H. No-Load Test.
• Table 6-I. Full-Load Test.
• Table 6-K. Regulator Bypass Test.
• Disassembly
• Disassembly (cont)
• Static Testing
• Assembly
• Assembly (cont)
• Assembly (cont)
• STARTER REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Bench Testing and Adjustment
• Bench Testing and Adjustment (cont)
• Bench Testing and Adjustment (cont)
• Bench Testing and Adjustment (cont)
• STE/ICE-R WIRING HARNESS REPLACEMENT
• Removal
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• ENGINE WIRING HARNESS REPLACEMENT
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• BODY WIRING HARNESS REPLACEMENT
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Removal (cont)
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• 60/100 AMPERE ALTERNATOR BRACKET MODIFICATION
• Modification
• Chapter 7. TRANSMISSION MAINTENANCE
• GOVERNOR MAINTENANCE (3L80)
• Installation
• TRANSMISSION OIL PUMP SEAL REPLACEMENT (3L80)
• Installation
• Section II. TRANSMISSION REPLACEMENT
• TRANSMISSION/TRANSFER CASE ASSEMBLY REMOVAL (3L80)
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• TRANSMISSION/TRANSFER CASE ASSEMBLY INSTALLATION (3L80)
• Installation
• Installation (cont)
• Installation (cont)
• TRANSMISSION/TRANSFER CASE ASSEMBLY REMOVAL (4L80-E)
• Removal
• Removal (cont)
• Removal (cont)
• Removal (cont)
• TRANSMISSION/TRANSFER CASE ASSEMBLY INSTALLATION (4L80-E)
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• Installation (cont)
• TRANSMISSION PREPARATION
• Assembly
• Chapter 8. TRANSFER CASE MAINTENANCE
• TRANSFER CASE REPLACEMENT
• Removal
• Installation
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• TRANSFER CASE GUIDE CABLE REPLACEMENT
• Installation
• Chapter 9. PROPELLER SHAFTS, AXLES, AND SUSPENSION MAINTENANCE
• DIFFERENTIAL OUTPUT SHAFT SEAL REPLACEMENT
• Installation
• PINION SEAL REPLACEMENT
• Installation
• DIFFERENTIAL REPLACEMENT
• Removal
• Installation
• Installation (cont)
• GEARED HUB REPAIR
• Disassembly
• Disassembly (cont)
• Inspection
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• CONTROL ARM BUSHING RE PLA CEMENT
• FRONT PROPELLER SHAFT REPAIR
• REAR DIFFERENTIAL AND PARKING BRAKE MOUNTING BRACKET REPLACEMENT
• DIFFERENTIAL AND AXLE FREE PLAY TOLERANCE INSPECTION
• Chapter 10. SERVICE BRAKE SYSTEM MAINTENANCE
• BRAKE ROTOR REPAIR
• Refinishing
• DISC BRAKE CALIPER REPAIR
• Inspection
• Assembly
• Assembly (cont)
• REAR PARKING BRAKE CALIPER REPAIR
• Inspection
• Assembly
• Assembly (cont)
• Chapter 11. STEERING SYSTEM MAINTENANCE
• POWER STEERING PUMP AND STEERING GEAR LEAK TEST
• STEERING GEAR REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Housing Group Inspection and Repair
• Pitman Shaft Inspection and Repair
• Rack Piston Group Inspection and Repair
• Valve and Adjuster Group Inspection and Repair
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Adjustment
• Adjustment (Cont)
• Chapter 12. FRAME MAINTENANCE
• SPLASH SHIELD SUPPORT BRACKET REPLACEMENT
• SPRING SEAT REPLACEMENT
• FRONT SUSPENSION BRACE REPLACEMENT
• Installation
• FRONT SUSPENSION BRACE REPLACEMENT (SERIAL NUMBERS 100,000 AND ABOVE )
• Installation
• LEFT AIRLIFT BRACKET AND FRONT UPPER CONTROL ARM BRACKETS REPLACEMENT
• Installation
• RIGHT AIRLIFT BRACKET AND FRONT UPPER CONTROL ARM BRACKETS REPLACEMENT
• Installation
• RIGHT ENGINE MOUNT BRACKET REPLACEMENT
• Installation
• LEFT ENGINE MOUNT BRACKET REPLACEMENT
• Installation
• REAR UPPER CONTROL ARM BRACKET REPLACEMENT
• Installation
• REAR-REAR TIEDOWN BRACKET REPLACEMENT
• TRANSMISSION CROSSMEMBER SUPPORT BRACKET REPLACEMENT
• REAR-FRONT TIEDOWN BRACKET REPLACEMENT
• Installation
• DIFFERENTIAL SUPPORT BRACKET AND SIDE MOUNTING BRACKET REPLACEMENT
• Removal
• Installation
• Installation (cont)
• FRONT SUSPENSION FRONT CROSSMEMBER REPLACEMENT
• Installation
• FRONT SUSPENSION REAR CROSSMEMBER REPLACEMENT
• Removal
• Installation
• Installation (cont)
• REAR SUSPENSION FRONT CROSSMEMBER REPLACEMENT
• Removal
• Installation
• Installation (cont)
• REAR SUSPENSION REAR CROSSMEMBER REPLACEMENT
• Installation
• SUSPENSION CROSSMEMBER REPAIR
• Repair
• Chapter 13. BODY MAINTENANCE
• Chapter 14. SPECIAL PURPOSE BODIES MAINTENANCE
• ROOF REPLACEMENT
• Removal
• Installation
• Installation (cont)
• SUPPORT RING MAINTENANCE
• Removal
• Disassembly
• Assembly
• Installation
• Installation (cont)
• WINDSHIELD MAINTENANCE
• Removal
• Removal (cont)
• Removal (cont)
• Disassembly
• Assembly
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• CARGO SHELL REPLACEMENT
• Removal
• Removal (cont)
• Removal (cont)
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• BLAST SHIELD REPLACEMENT
• Installation
• CARGO SHELL REPAIR
• Repair
• Section II. AMBULANCE MAINTENANCE
• AMBULANCE HEATER REPAIR (MODEL 10530A)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Cleaning and Inspection
• Cleaning and Inspection (Cont)
• Cleaning and Inspection (Cont)
• Cleaning and Inspection (Cont)
• Cleaning and Inspection (Cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• AMBULANCE HEATER REPAIR (MODEL 10530B)
• Disassembly
• Disassembly (Cont)
• Disassembly (Cont)
• Disassembly (Cont)
• Disassembly (Cont)
• Disassembly (Cont)
• Cleaning and Inspection
• Cleaning and Inspection (cont)
• Cleaning and Inspection (cont)
• Cleaning and Inspection (cont)
• Cleaning and Inspection (cont)
• Assembly
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• AMBULANCE HEATER FUEL CONTROL VALVE TESTING AND ADJUSTMENT (MODEL 10530A)
• Testing and Adjustment
• Testing and Adjustment (cont)
• Testing and Adjustment (cont)
• Testing and Adjustment (cont)
• Testing and Adjustment (cont)
• AMBULANCE HEATER FUEL CONTROL VALVE TESTING AND ADJUSTMENT (MODEL 10530B)
• Testing and Adjustment
• Testing and Adjustment (cont)
• Testing and Adjustment (cont)
• HEATER/AIR-CONDITIONING CONTROL BOX REPLACEMENT
• Removal
• Installation
• Installation (cont)
• Installation (cont)
• Installation (cont)
• THERMOSTAT SWITCH REPLACEMENT
• Installation
• PRESSURE SWITCH REPLACEMENT
• AIR-CONDITIONING SYSTEM SERVICING (R-12)
• Manifold Gauge Set Installation
• Manifold Gauge Set Installation (Cont)
• Manifold Gauge Set Removal
• Discharging System
• Flushing System
• Flushing System (cont)
• Evacuating System
• Evacuating System
• Charging System
• Charging System (cont)
• Checking/Adding Lubricating Oil
• Checking/Adding Lubricating Oil (cont)
• AIR-CONDITIONING PRESSURE LINES REPLACEMENT (R-12)
• Removal
• Installation
• Installation (cont)
• DRYER BOTTLE REPLACEMENT (R-12)
• Installation
• AIR-CONDITIONING EVAPORATOR MAINTENANCE (R-12)
• Removal
• Disassembly
• Assembly
• Installation
• Installation (cont)
• EXPANSION VALVE REPLACEMENT (R-12)
• Installation
• EVAPORATOR DUCT REPLACEMENT (R-12)
• Installation
• CONDENSER ASSEMBLY REPLACEMENT (R-12)
• Installation
• AIR-CONDITIONING COMPRESSOR REPLACEMENT (R-12)
• Installation
• AIR-CONDITIONING SERVICE VALVE REPLACEMENT (R-12)
• COMPRESSOR MOUNTING AND AIR HORN BRACKET REPLACEMENT (R-12)
• AIR-CONDITIONING COMPRESSOR REPAIR (R-12)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• AIR-CONDITIONING SYSTEM SERVICING (R-134a)
• Manifold Gauge Set Installation
• Manifold Gauge Set Removal
• Discharging System
• Flushing System
• Flushing System (cont)
• Evacuating System
• Evacuating System (cont)
• Charging System
• Adding Lubricating Oil
• AIR-CONDITIONING PRESSURE LINES REPLACEMENT (R-134a)
• Removal
• Installation
• Installation (cont)
• DRYER BOTTLE REPLACEMENT (R-134a)
• Installation
• AIR-CONDITIONING EVAPORATOR MAINTENANCE (R-134a)
• Removal
• Disassembly
• Assembly
• Installation
• Installation (cont)
• EXPANSION VALVE REPLACEMENT (R-134a)
• Installation
• EVAPORATOR DUCT REPLACEMENT (R-134a)
• Installation
• CONDENSER ASSEMBLY REPLACEMENT (R-134a)
• Installation
• AIR-CONDITIONING COMPRESSOR REPLACEMENT (R-134a)
• Installation
• AIR-CONDITIONING SERVICE VALVE REPLACEMENT (R-134a)
• Installation
• COMPRESSOR MOUNTING AND AIR HORN BRACKET REPLACEMENT (R-134a)
• Installation
• AIR-CONDITIONING COMPRESSOR REPAIR (R-134a)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (Cont)
• Assembly
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• Assembly (Cont)
• AMBULANCE WINDSHIELD REPLACEMENT
• Removal
• Installation
• Installation (Cont)
• Installation (Cont)
• Installation (Cont)
• Chapter 15. WINCH MAINTENANCE
• 6,000 LB. ELECTRIC WINCH REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (cont)
• Inspection (cont)
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• 9,000 LB. ELECTRIC WINCH REPAIR
• Disassembly
• Disassembly (Cont)
• Cleaning
• Inspection
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• 10,500 LB HYDRAULIC WINCH REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (Cont)
• Inspection (Cont)
• Inspection (Cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Chapter 16. SPECIAL PURPOSE KITS MAINTENANCE
• ARCTIC HEATER COWL COVER REPLACEMENT
• Installation
• ARCTIC HEATER EXHAUST DIVERTER TO OIL PAN SHROUD TUBE REPLACEMENT
• ARCTIC HEATER EXHAUST PIPE REPLACEMENT
• ARCTIC HEATER ELBOW TO EXHAUST DIVERTER ELBOW REPLACEMENT
• ARCTIC HEATER EXHAUST DIVERTER TO FLEX TUBE ELBOW REPLACEMENT
• ARCTIC HEATER EXHAUST DIVERTER REPLACEMENT
• Installation
• ARCTIC HEATER BATTERY BOX TO PLENUM BRACKET REPLACEMENT
• ARCTIC HEATER ELECTRIC FUEL PUMP MOUNTING BRACKET REPLACEMENT
• AIR VENTILATOR AND LIGHT DIVERTER REPLACEMENT
• Chapter 17. TRANSMISSION REPAIR
• TRANSMISSION DISASSEMBLY INTO SUBASSEMBLIES (3L80)
• Holding Fixture
• Oil Pan
• Control Valve
• Front Servo
• Direct Clutch
• Manual Linkage
• Intermediate Clutch
• Center Support
• Rear Band
• TORQUE CONVERTER MAINTENANCE (3L80)
• Inspection
• TRANSMISSION CASE REPAIR (3L80)
• Inspection
• OIL PUMP REPAIR (3L80)
• Inspection
• Inspection (cont)
• Inspection (cont)
• Assembly
• Assembly (cont)
• FORWARD CLUTCH AND TURBINE SHAFT REPAIR (3L80)
• Inspection
• Assembly
• Assembly (cont)
• DIRECT CLUTCH AND INTERMEDIATE SPRAG REPAIR (3L80)
• Inspection
• Assembly
• Assembly (cont)
• CENTER SUPPORT REPAIR (3L80)
• Inspection
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• GEAR UNIT REPAIR (3L80)
• Cleaning
• Inspection
• Inspection (cont)
• Assembly
• Assembly (cont)
• REAR SERVO REPAIR (3L80)
• Assembly
• GOVERNOR REPAIR (3L80)
• Inspection
• TRANSMISSION ASSEMBLY FROM SUBASSEMBLIES (3L80)
• Rear Band
• Gear Unit and Center Support
• Establish Rear End Play
• Intermediate Clutch
• Front Band
• Direct Clutch
• Forward Clutch and Turbine Shaft
• Oil Pump
• Establish Front End Play
• Detent Solenoid
• Front Servo
• Rear Servo
• Rear Servo (cont)
• Control Valve
• Governor
• Holding Fixture
• TR ANSMISSION DISASSEMBLY INTO SUBASSEMBLIES (4L80-E)
• Holding Fixture
• Oil Pan and Filter Assembly
• Control Valve Assembly (1995-1996)
• Control Valve Assembly (1995-1996) (Cont)
• Control Valve Assembly (1997-1998)
• Control Valve Assembly (1997-1998) (cont)
• Front Servo
• Parking Lock Pawl and Actuator Assembly
• Front End Play Check (Measured)
• Rear Unit End Play Check (Measured)
• Pump Assembly
• Turbine Shaft and Overd rive Carrier Assembly
• Forward Clutch Assembly
• Direct Clutch Assembly
• Intermediate Clutch Assembly
• Center Support Assembly
• TORQUE CONVERTER MAINTENANCE (4L80-E)
• Inspection
• TRANSMISSION CASE R EPAIR (4 L80-E)
• Inspection
• PARKING LOCK PAWL AND ACTUATOR ASSEMBLY REPAIR (4L80-E)
• REAR BAND AND SELECTIVE T HRUST WASHER REPAIR (4L80-E)
• GEAR U NIT AND OUTPUT ASSEMBLIES REPAIR (4L80-E)
• Disassembly (1995-1996)
• Disassembly (1997-1998)
• Cleaning
• Inspection
• Inspection (cont)
• Assembly (1995-1996)
• Assembly (1995-1996) (cont)
• Assembly (1997-1998)
• Assembly (1997-1998) (cont)
• CENTER SUPPORT REPAIR (4L80-E)
• Inspection
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• DIRECT CLUTCH ASSEMBLY REPAIR (4L80-E)
• Inspection
• Assembly
• Direct Clutch Piston Movement Measurement
• FORWARD CLUTCH ASSEMBLY REPAIR (4L80-E)
• Inspection
• Assembly
• Assembly (Cont)
• FOURTH CLUTCH ASSEMBLY REPAIR (4L80-E)
• End Play Measurement
• TURBINE SHAFT AND OVERDRIVE CARRIER ASSEMBLY REPAIR (4L80-E)
• Overrun Clutch Inspection
• Overrun Clutch Assembly
• Overrun Clutch Assembly (cont)
• Overdrive Carrier Measurement
• Overdrive Carrier Inspection
• Turbine Shaft Inspection
• Overdrive Unit Assembly
• INTERMEDIATE CLUT CHASSEMBLY AND FRONT BAND REPAIR (4L80-E)
• FRONT SERVO REPAIR (4L80-E)
• REAR SERVO REPAIR (1995 - 4L80-E)
• Assembly
• REAR SERVO REPAIR (1996-1998 - 4L80-E)
• Assembly
• CONTROL VALVE AND ACCUMULATOR HOUSING REPAIR (4L80-E)
• Accumulator Housing Disassembly
• Control Valve Disassembly
• Control Valve Assembly
• Accumulator Housing Inspection
• Accumulator Housing Assembly
• OIL PUMP ASSEMBLY REPAIR (4L80-E)
• Cleaning
• Inspection
• Inspection (Cont)
• Assembly
• Assembly (Cont)
• TRANSMISSION ASSEMBLY FROM SUBASSEMBLIES (4L80-E)
• Parking Lock Pawl Actuator Assembly
• Gear Unit Assembly
• Gear Unit Assembly (cont)
• Rear Unit End Play Check
• Rear Unit End Play Check (Cont)
• Intermediate Clutch Assembly
• Direct Clutch Assembly
• Fourth Clutch, Turbine Shaft, and Overdrive Carrier Assembly
• Fourth Clutch, Turbine Shaft, and Overdrive Carrier Assembly (Cont)
• Pump Assembly
• Front Unit End Play Check
• Front Servo
• Band Apply Pin Check
• Rear Servo
• Control Valve Assembly (1995-1996)
• Control Valve Assembly (1997-1998)
• Control Valve Assembly (1997-1998) (cont)
• Oil Pan and Filter Assembly
• Holding Fixture
• TRANSMISSION TESTING TASK SUMMARY
• TRANSMISSION OIL PRESSURE TESTS (3l80)
• Oil Pressure Diagnostic Test
• Table 17-9. Oil Pressure Diagnosis
• Control Valve and Governor Line Pressure Test
• Chapter 18. TRANSFER CASE REPAIR
• TRANSFER CASE REPAIR (Model 218)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (cont)
• Inspection (cont)
• Inspection (cont)
• Inspection (cont)
• Inspection (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• TRANSFER CASE REPAIR (MODEL 242)
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection and Repair
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Inspection and Repair (cont)
• Assembly
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Chapter 19. DIFFERENTIAL REPAIR
• DIFFERENTIAL REPAIR
• Disassembly
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Disassembly (cont)
• Inspection
• Inspection (cont)
• Assembly
• Table 9-1. Pinion Variance Table Inches)
• ]
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Assembly (cont)
• Chapter 20. STEERING SYSTEM REPAIR
• STEERING ALIGNMENT
• Caster and Camber Adjustment
• Toe Check and Adjustment
• Chapter 21. FRAME REPAIR
• FRAME INSPECTION AND REPAIR
• Powertrain Lift Sling Installation
• Inspection
• Inspection (cont)
• Inspection (cont)
• Inspection (cont)
• Preparation and Materials
• Repair Procedures
• Powertrain Lift Sling Removal
• RIGHT FRONT BODY MOUNT BRACKET REPLACEMENT
• RIGHT INTERMEDIATE BODY MOUNT BRACKET REPLACEMENT
• LEFT INTERMEDIATE BODY MOUNT BRACKET REPLACEMENT
• REAR CROSSMEMBER BRACKET AND REAR BODY MOUNT BRACKET REPLACEMENT
• REAR BUMPER MOUNTING BRACKET AND TIEDOWN BRACKET REPLACEMENT
• CHAPTER 22. BODY REPAIR
• BODY MOUNT REPLACEMENT
• Installation
• Section II. BODY REPAIR
• GENERAL
• INSPECTION
• RIVET REPLACEMENT
• Table 22-1. Drill Sizes for Solid Shank Rivets
• Table 22-4. Minimum Sheet Gauge for 100°Machine Countersink
• ALUMINUM REPAIR
• ALUMINUM REPAIR (cont)
• Joint Designs.
• Table 22-5. Stop Drill Sizes for Negligible Cracks.
• Repair by Patching
• Repair by Insertion.
• FIBERGLASS REPAIR
• Repair
• FLOOR PANEL REPAIR
• LEFT FRONT FLOOR PANEL REPAIR
• Metal Strips Fabrication
• Metal Strips Fabrication (cont)
• Metal Strips Fabrication (cont)
• Metal Strips Fabrication (cont)
• Left Front Floor Panel Removal
• Left Front Floor Panel Removal (Cont)
• Metal Strip A and Insert Panel Assembly
• Metal Strip A and Insert Panel Assembly (Cont)
• Metal Strip C and Insert Panel Assembly
• Metal Strip D and Insert panel Assembly
• Metal Strip B and Insert Panel Assembly
• Metal Strip B and Insert Panel Assembly (cont)
• Left Front Floor Panel and Insert Panel Drilling
• Left Front Floor Panel and Insert Panel Drilling (cont)
• Left Front Floor Panel and Insert Panel Drilling (cont)
• Left Front Floor Panel and Insert Panel Drilling (cont)
• Insert Panel and Left Front Floor Panel Installation
• Insert Panel and Left Front Floor Panel Installation (cont)
• '11523.doc' by LOGSA - Page 1 of 1304
• LEFT REAR FLOOR PANEL REPAIR
• Left Rear Insert Panel Fabrication
• Left Rear Insert Panel Fabrication (cont)
• Reinforcement Strips Fabrication
• Reinforcement Strips Fabrication (Cont)
• Metal Strips Fabrication
• Metal Strips Fabrication (Cont)
• Metal Strips Fabrication (Cont)
• Left Rear Floor Panel Removal
• Left Rear Floor Panel Removal (cont)
• Left Rear Floor Panel Removal (cont)
• Reinforcement Strip Aand Insert Panel Assembly
• Reinforcement Strip Aand Insert Panel Assembly (Cont)
• Reinforcement Strip B and Insert Panel Assembly
• Reinforcement Strip B and Insert Panel Assembly (cont)
• Metal Strip C and Insert Panel Assembly
• Metal Strip C and Insert Panel Assembly (cont)
• Metal Strip D and Insert Panel Assembly
• Metal Strip D and Insert Panel Assembly (cont)
• Metal Strip E and Insert Panel Assembly
• Metal Strip E and Insert Panel Assembly (cont)
• Metal Strip Fand Insert Panel Assembly
• Metal Strip Fand Insert Panel Assembly (Cont)
• Left Rear Floor Panel and Insert Panel Drilling
• Left Rear Floor Panel and Insert Panel Drilling (Cont)
• Insert Panel and Left Rear Floor Panel Installation
• Insert Panel and Left Rear Floor Panel Installation (Cont)
• Insert Panel and Left Rear Floor Panel Installation (Cont)
• Insert Panel and Left Rear Floor Panel Installation (Cont)
• RIGHT FRONT FLOOR PANEL REPAIR
• Right Front Insert Panel Fabrication
• Metal Strips Fabrication
• Metal Strips Fabrication (Cont)
• Right Front FloorPanel Removal
• Right Front FloorPanel Removal (cont)
• Metal Strip Aand Insert Panel Assembly
• Metal Strip Aand Insert Panel Assembly (Cont)
• Metal Strip B and Insert Panel Assembly
• Metal Strip B and Insert Panel Assembly (Cont)
• Metal Strip C and Insert Panel Assembly
• Metal Strip C and Insert Panel Assembly (Cont)
• Right Front Floor Panel and Battery Tray Drilling
• Right Front Floor Panel and Battery Tray Drilling (Cont)
• Right Front Floor Panel and Insert Panel Drilling
• Right Front Floor Panel and Insert Panel Drilling (Cont)
• Battery Tray Panel and Right Front Floor Panel Installation
• Battery Tray Panel and Right Front Floor Panel Installation (Cont)
• Insert Panel and Right Front FloorPanel Installation
• Insert Panel and Right Front FloorPanel Installation (cont)
• RIGHT REAR FLOOR PANEL REPAIR
• Right Rear Insert Panel Fabrication
• Reinforcement Strips Fabrication
• Reinforcement Strips Fabrication (cont)
• Metal Strips Fabrication
• Metal Strips Fabrication (cont)
• Right Rear Floor Panel Removal
• Right Rear Floor Panel Removal (Cont)
• Right Rear Floor Panel Removal (Cont)
• Reinforcement Strip A and Insert Panel Assembly
• Reinforcement Strip B and Insert Panel Assembly
• Metal Strip C and Insert Panel Assembly
• Metal Strip E and Insert Panel Assembly
• Metal Strip D and Insert Panel Assembly
• Right Rear Floor Panel and Insert Panel Drilling
• Right Rear Floor Panel and Insert Panel Drilling (Cont)
• Insert Panel and Right Rear Floor Panel Installation
• Insert Panel and Right Rear Floor Panel Installation (cont)
• Insert Panel and Right Rear Floor Panel Installation (cont)
• Insert Panel and Right Rear Floor Panel Installation (cont)
• Insert Panel and Right Rear Floor Panel Installation (cont)
• Insert Panel and Right Rear Floor Panel Installation (cont)
• AMBULANCE EXTERIOR BODY REPAIR
• Left Nose Cap Repair
• Left Side Outer Roof Panel Repair
• Left Side Outer Roof Panel Repair (cont)
• Left Front Nose Panel Repair
• Left Front Nose Panel Repair (cont)
• Rear Roof Panel Repair
• Rear Roof Panel Repair (cont)
• Left Rear Corner Roof Panel Repair
• Left Rear Lower/Upper Body Panel Repair
• Left Lower Body Panel Repair
• Left Lower Body Panel Repair (cont)
• Left Rear Side Corner body Panel Repair
• Left Rear Side Corner body Panel Repair (Cont)
• Right Front Nose Panel Repair
• Right Front Nose Panel Repair (cont)
• Right Front Nose Panel Repair (cont)
• Right Front Nose Panel Repair (cont)
• right Side Outer Roof Panel Repair
• right Side Outer Roof Panel Repair (Cont)
• Right Rear Side Corner body Panel Repair
• Right Rear Side Corner body Panel Repair (Cont)
• Right Lower Body Panel Repair
• Right Lower Body Panel Repair (cont)
• Right Rear/Lower/Upper body Panel Repair
• Appendix A: REFERENCES
• TECHNICAL MANUALS
• APPENDIX B: EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
• APPENDIX C: ILLUSTRATED LIST OF MANUFACTURED ITEMS
• Figure C-1. Differential Guide Pin, 5992390
• Figure C-3. Core Shaft Nut Tool, 5992392
• Figure C-4. Transfer Case Support Stand, 5992393
• Figure C-5. 100 Ampere Alternator Seal Sleeve Tool, 5992394
• Figure C-7. Lift Sling Beam, 5992396
• Figure C-8. Lift Hook, 5992397
• Figure C-11. Right Side Bracket Reinforcement 5992400
• Figure C-14. Powertrain Lift Sling, 5992403
• Figure C-16. Front Bumper Tow Pintle Plate Assembly (Front), 5992405
• Figure C-17. Front Bumper Low Pintle Plate Assembly (Back), 5992406
• Figure C-18. Modified Box Wrench
• Figure C-19. Power Steering Pump and Steering Gear Test Stand
• Figure C-20. Light Diverter, QQS698
• Figure C-21. Support Hook, QQS634
• Figure C-22. Brace QQ-A-200118
• Figure C-24. Bottom Support Sling
• Figure C-25. Bottom Support
• OVERHEAD SUPPORT SUNG
• Figure C-27. Engine Bracket, QQS634
• Figure C-30. A-Frame Brace, QQS630
• Figure C-33. Outer Floor Support, QQS741
• ASSEMBLY INSTRUCTIONS
• ASSEMBLY INSTRUCTIONS (Cont'd)
• Figure C-37. Overhead Support Sling For Transmission
• INSTALLATION INSTRUCTIONS:
• Figure C-39. Overhead Support Sling Transmission.
• Figure C-41. Hex Wrench.
• Figure C-42. Open End Wrench.
• Figure C-43. Parking Brake Spring Tool.
• ASSEMBLY INSTRUCTIONS
• Figure C-45. Alternator Bracket Spacer.
• Figure C-46. Drill Fixture.
• INSTALLATION INSTRUCTIONS (Cont)
• Figure C-47. Bars For Cylinder Head Lifting Device.
• Appendix D: TORQUE LIMITS
• Table D-1. Torque Limits for Dry Fasteners
• Table D-2. Torque Limits for Wet Fasteners
• Appendix E: MANDATORY REPLACEMENT PARTS
• Section II. MANDATORY REPLACEMENT PARTS
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• Section II. MANDATORY REPLACEMENT PARTS (Cont)
• APPENDIX F BODY REPAIR MATERIALS
• Table F-3. AN3 and AN4 Series Bolts
• Appendix G: TOOL IDENTIFICATION LIST
• Section II. TOOL IDE NTIFICATION LIST
• Section II. TOOL IDE NTIFICATION LIST (Cont'd)
• Section II. TOOL IDE NTIFICATION LIST (Cont'd)
• Section II. TOOL IDE NTIFICATION LIST (Cont'd)
• Section II. TOOL IDE NTIFICATION LIST (Cont'd)
• Section II. TOOL IDE NTIFICATION LIST (Cont'd)
• INDEX
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• INDEX (Cont)
• THE METRIC SYSTEM AND EQUIVALENTS
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